2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf¶
3207 excerpts.
FLUID CAPACITIES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3 · Applies to: 450, 451, 452, 454
Fluid Type Application Standard Metric Fluid Spec Note S/H Air Cond Refrigerant N/A N/A R-134a refrigerant and a special PAG lubricant oil (never R-12) S Brake Fluid 1.05 QTS. 1 L DOT 4 Brake Fluid S Engine Coolant 4.50 QTS. 4.3 L Anticorrosion/Antifreeze Meeting specification MB 325.0 S Engine Oil 3.50 QTS. 3.3 L Approved Engine Oil must meet specification MB 229.5 Mobil Formula M 5W-40, Mobil 1 0W-40, Labco MB 229.5 5W-30, Total Quartz 229.5 5W-30, Elf Excellium 0W-30, Shell Helix Ultra AB 5W-30 S Fuel Tank 8.72 GALS. 33 L Including a reserve of 1.32 gal. S Windshield Washer Fluid 4.00 QTS. 3.8 L Windshield washer concentrate Use a windshield washer concentrate labeled for summer and water for temperatures above freezing point or a windshield washer concentrate labeled for winter and water for temperatures below freezing point. S
MAINTENANCE SERVICE INTERVAL >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4 · Applies to: 450, 451, 452, 454
1 tips Tip: Recommended oil - 2008 smart car NOTE: Only vehicles listed in this index have a Maintenance Counter reset. MAINTENANCE COUNTER RESET INDEX Model & Year Reset Procedure Fortwo 2008-12 TPMS Reset - Procedure 1 MAINTENANCE SERVICE INTERVAL > MAINTENANCE COUNTER RESET - PROCEDURE 1 > 1 tips Tip: Oil Service Interval Reset - 2006 Smart Diesel NOTE: Some models (not all) may be equipped with one or more resettable maintenance reminder lights indicating maintenance is required. Once required maintenance services are performed, resetting of lights may be required. Information is provided to reset these lights where applicable. NOTE: Most vehicles are equipped with a Malfunction Indicator Light (MIL) or check engine light. If light comes on and remains on while driving, the vehicle requires some type of repair. See appropriate service and repair information. After repairing fault(s) and clearing fault code(s), the Malfunction Indicator Light (MIL) or check engine light should go out. After performing required service, reset indicator light. MAINTENANCE SERVICE INTERVAL > MAINTENANCE COUNTER RESET - PROCEDURE 1 > METHOD 1 >
1. Switch ignition on.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 5 · Applies to: 450, 451, 452, 454
- Locate the left instrument cluster button (service interval button). See Figure. Press (tap) the button twice, within 4 seconds of switching on the ignition.
- Switch ignition off, within 4 seconds of tapping the button. NOTE: Although the OEM claims that 4 seconds is the appropriate time interval in steps 2 and 3, aftermarket information indicates that performing the procedure as quickly as possible (2 sec.) will be more successful.
- Push and hold in the left instrument cluster button (service interval button) and switch ignition on.
- Hold the left instrument cluster button for another 10 seconds.
- When the wrench symbol flashes, the system has been reset. MAINTENANCE SERVICE INTERVAL > MAINTENANCE COUNTER RESET - PROCEDURE 1 > METHOD 2 >
- Switch ignition on.
- Locate the left instrument cluster button (service interval button). See Fig 1. Press the button twice, within 4 seconds of switching on the ignition.
- Keep holding the button down on the second press.
- Switch ignition off, within 4 seconds of tapping the button. NOTE: Although the OEM claims that 4 seconds is the appropriate time interval in steps 2 and 3, aftermarket information indicates that performing the procedure as quickly as possible (2 sec.) will be more successful.
- Switch ignition on.
- Hold the left instrument cluster button for another 10 seconds.
- When the wrench symbol flashes, the system has been reset.
TIRE PRESSURE MONITOR SYSTEM (TPMS) >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 6 · Applies to: 450, 451, 452, 454
NOTE: Only vehicles listed in this index have a TPMS reset. TPMS RESET INDEX Model & Year Reset Procedure Fortwo 2008-12 TPMS Reset - Procedure 1 TIRE PRESSURE MONITOR SYSTEM (TPMS) > TPMS RESET - PROCEDURE 1 > The TPMS must be restarted when you have adjusted the tire inflation pressure to a new level (e.g. because of different load or driving conditions). The TPMS sets new reference values for each tire. The TPMS is then recalibrated to the current tire inflation pressures. Press the Restarting TPMS button. See Fig 1. The combination low tire pressure/TPMS malfunction telltale in the instrument cluster flashes for approximately 5 seconds and then goes out. After driving a few minutes the system verifies that the current tire inflation pressures are within the systems specified range. Afterwards the Fig 1: Identifying Left Instrument Cluster Button (Service Interval Button) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
current tire inflation pre¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 7 · Applies to: 450, 451, 452, 454
ure are accepted a reference pre ure and then monitored Fig 1: Identifying TPMS Button Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > NOTES ON REPAIRS TO BRAKE SYSTEM - AH42.00-P-0003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 8 · Applies to: 450, 451, 452, 454
01A > When performing maintenance and repair work on the brake system, it must be ensured that no mineral oil, lubricating grease or similar substances enter the brake system. New brake fluid must be used as a flushing and cleaning agent for the cylinders, lines and the expansion reservoir of the hydraulic braking system. If mineral oil is found in the brake system, or if the presence of mineral oil in the brake system is suspected, the procedure below must be followed: 1. Replace tandem master brake cylinder or brake operating unit and expansion reservoir for brake fluid. 2. Thoroughly flush the entire brake system with new brake fluid. 3. All brake components with parts made of rubber, such as brake calipers, brake hoses, the SBC, ABS, ETS, ASR or ESP hydraulic unit, pressure reservoir, charging piston unit and charging pump, which may have come into contact with mineral oil, must be replaced. 4. Bleed brake system. Handling of SBC, ABS, ETS, ASR and ESP components in accident vehicles: If, because of the extent of the damage to the vehicle or the position and external appearance of the hydraulic unit, it is obvious that the hydraulic unit has sustained a severe shock, the hydraulic unit must be replaced. Indications of this are e.g.: Hydraulic lines kinked Connections on hydraulic unit leaking Cables or plug connections damaged Metal block of hydraulic unit shows signs of damage Hydraulic unit detached from its bracket and cannot be reinstalled without applying excessive force If this does not apply, the system must be subjected to a rigorous function test and the test steps for the solenoid valves and pump must be performed. Brake calipers must not be scratched, and the lacquer on lacquered brake calipers must not be damaged, not be removed/installed with hammers, levers, pliers or other tools, not be machined,
not be put down on the lacquered side,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 9 · Applies to: 450, 451, 452, 454
only be put down on a clean surface. To prevent damage to the brake calipers, particular care must be taken when: detaching/attaching the wheels, removing/installing the brake pads, removing/installing the brake calipers, performing any work in the area of the wheel wells, e.g. removing/installing suspension struts, transverse control arms, torsion bars etc., lowering the vehicle with detached wheels. Lacquered brake calipers are especially sensitive. GENERAL INFORMATION > BRAKE FLUID NOTES - AH42.50-P-0001-01A > All models Do not allow brake fluid to come into contact with vehicle paintwork, as it contains ingredients that act as solvents on the paint. Should brake fluid come into contact with the paint despite all precautions, the moistened surface must be flushed immediately with a lot of water (do not rub off brake fluid). Brake fluid is highly hygroscopic, i.e. it absorbs humidity which reduces its boiling point. Brake fluid must therefore only be stored in properly sealed reservoirs (original container) in order to avoid moisture absorption via the air humidity. A boiling point which is reduced as a result can lead to problems up to the total failure of the brake system at high operating temperatures. Used brake fluid must not be re-used. Brake fluid is colorless to yellow colored and is therefore easily confused with mineral oil products. Therefore only remove brake fluids from original containers and store separately from mineral oils and other fluids. For disposal notes for the location area Federal Republic of Germany see: "Environmental Manual for Motor Vehicle Repair Operations" Publisher: Association of the German Automotive Industry e.V. (VDA) 60625 Frankfurt am Main, Westendstraβe 61 RETROFITTING & CONVERSION > INSTALL BRABUS HAND BRAKE LEVER - AN42.20-P- 0003MCC > MODEL 451.3 /4 (except 451.391 /491) Shown on model 451.3 up to vehicle identification number (VIN) WME4513312K143823
Shown on model 451.3 as of VIN WME4513312K143824¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 10 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Hand Brake Handle, Snap Fasteners & Expansion Clip Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Hand Brake Handle, Snap Fasteners & Hand Brake Lever Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 11 · Applies to: 450, 451, 452, 454
1 Adjust seats rearwards and pull on hand brake lever (5)
2 Protect seats and center console against damage and dirt using a suitable cover On vehicles as of VIN WME4513312K143824
3 Unscrew and remove push button (2)
4.1 Remove expansion clip (3) and pull off hand brake handle (1) forwards On vehicles up to VIN WME4513312K143823
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 1.6
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)
Fig 3: Identifying Hand Brake Lever Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Replace¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 13 · Applies to: 450, 451, 452, 454
Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake Only pour brake fluid into suitable and appropriately marked containers. Wear fluid coming into contact with skin and eyes. 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 maintenance flap
2 Unscrew cap of brake fluid reservoir (1)
3 Connect brake fluid changer to brake fluid reservoir (1) and apply the specified pressure to the brake system Observe the operator's manual for the brake fluid changer.Brake fluid change unit
General brake fluid Sheet 330.1 BB00.40- P-0330- 01A Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40- P-0331- 00A 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 4 Raise vehicle with vehicle lift Position the front support plates of the vehicle lift as far as possible upwards, position the rear support plates as far as possible downwards and secure the vehicle to prevent it from slipping or toppling.
5 Remove dust caps from the brake bleeder valves
6 Connect hose of brake fluid receptacle to brake bleeder valve of the wheel brake cylinder (3) and open brake bleeder valve Close the brake bleeder valve only after the brake fluid escapes free of bubbles and without contamination (bright color of brake fluid).
*BA42.10- P-1001- 08C Observe correct sequence.
Checking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 15 · Applies to: 450, 451, 452, 454
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 1 Open brake fluid reservoir
2 Fold up folding cover (1) on brake fluid measuring device (4) Brake fluid meter Fig 3 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 Fig 2 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
Fig 1: Identifying Hinged Lid, Pipette, Prism Surface, Brake Fluid Meter And Eyepiece Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 21 · Applies to: 450, 451, 452, 454
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: Identifying Brake Shoes, Dust Boot, Wheel Brake Cylinder And Automatic Adjuster Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install, remove automatic brake adjuster¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 22 · Applies to: 450, 451, 452, 454
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 GENERAL INDEX - 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 MODEL 451.3 /4 AR42.20- P-
installation¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 23 · Applies to: 450, 451, 452, 454
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 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 AR42.10-
Remove/install brake hose to front axle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 24 · Applies to: 450, 451, 452, 454
MODEL 451.3 /4 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 (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 AR42.10-
Remove/install front axle brake caliper¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 25 · Applies to: 450, 451, 452, 454
MODEL 451.3 /4 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 AR42.30-
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 27 · Applies to: 450, 451, 452, 454
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 wheels Position the front support plates of the vehicle lift as far as possible upwards, position the rear support plates as far as possible downwards and secure the vehicle to prevent it from slipping or toppling. AR40.10- P- 1100MCU 2 Remove dust caps from the brake bleeder valves
3 Lower vehicle with vehicle lift
4 Remove maintenance flap
5 Unscrew cap of brake fluid reservoir (1)
Fig 1: Identifying Brake Fluid Reservoir, Brake Caliper And Wheel Brake Cylinder Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connect brake fluid¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 28 · Applies to: 450, 451, 452, 454
6 Connect brake fluid changer to brake fluid reservoir (1) and apply the specified pressure to the brake system Observe the operator's manual for the brake fluid changer.Brake fluid change unit
General brake fluid Sheet 330.1 BB00.40- P-0330- 01A Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40- P-0331- 00A
Bleed primary circuit
7 Connect hose of the brake fluid receptacle to the brake bleeder valve of the right wheel brake cylinder (3) and open the brake bleeder valve Only close the brake bleeder valve when the brake fluid escapes free of bubbles and without contaminants (light color of brake fluid).A second person is needed who assists the brake fluid changer by slowly pumping on the brake pedal.
*BA42.10- P-1001- 08C 8 Carry out the bleeding process on the left wheel brake cylinder (3), on the right brake caliper (2) and on the left brake caliper (2) in the same manner Observe correct sequence.
BA42.10- P-1001- 08C BA42.10- P-1002- 10A 9 Check brake pedal travel In the event of a soft pedal feel or long pedal travel, bleed the secondary circuit of the brake system.
Bleed secondary circuit
10 Connect STAR DIAGNOSIS and bleed the secondary circuit of the brake system The instructions for secondary circuit bleeding are specified by STAR DIAGNOSIS. A second person is needed who assists the brake fluid changer by slowly pumping on the brake pedal.
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC 11 Disconnect brake fluid changer
12 Check brake fluid level and correct if necessary
Figure¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 30 · Applies to: 450, 451, 452, 454
item, etc. Work instructions
1 Brake line From the ESP hydraulic unit to the left front brake hose.
Remove/install left front brake line AR42.10-P- 0032MCU 2 Brake line From the ESP hydraulic unit to the right front brake hose.
Remove/install right front brake line AR42.10-P- 0033MCU 3 Brake lines From the master brake cylinder to the ESP hydraulic unit.
Remove/install brake line from the master brake cylinder to the ESP hydraulic unit AR42.10-P- 0034MCU 4 Brake lines From the ESP hydraulic unit to the brake hose on the rear axle.
Remove/install brake line from the ESP hydraulic unit to the rear axle AR42.10-P- 0035MCU 5 Brake line From the brake hose on the rear axle to the left wheel brake cylinder.
Remove/install left rear brake line AR42.10-P- 0036MCU Fig 1: Locating Brake Lines Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Brake line¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 31 · Applies to: 450, 451, 452, 454
6 Brake line From the brake hose on the rear axle to the right wheel brake cylinder.
Remove/install right rear brake line AR42.10-P- 0037MCU TESTING & REPAIR > REMOVE/INSTALL BRAKE HOSE AT REAR AXLE - AR42.10-P- 0023MCU > MODEL 451.3 /4 Shown on left rear brake hose (1)
Remove/install
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 Risk of death caused by vehicle slipping or toppling off of Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by AS00.00- Z-0010- Fig 1: Identifying Brake Hose, Folding Clamp, Brake And Electrical Lines Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
the lifting platform.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 32 · Applies to: 450, 451, 452, 454
vehicle manufacturer. 01A 1 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
2 Remove bulkhead wall On model 451.431 AR61.25- P- 6600MCU 3 Unscrew plastic nut (2), open folding clamp (3) using a suitable tool and take off Observe installation position of brake line (4) and electrical lines (5, 6)
4 Hang up electrical lines (5, 6) to one side
5 Check bolted connections of brake lines (4, 7) with brake hose (1) for color coding Installation: Identify brake lines (4, 7) accordingly. AR42.10- P-0013- 05MCC 6 Loosen bolted connections of the brake lines (4, 7) with the brake hose (1) and separate Mark brake hose (1) relative to the brake lines (4, 7). Collect brake fluid in a suitable container. Seal brake lines (4, 7) and brake hose (1) with suitable plugs.
*BA42.10- P-1002- 04E Fig 2 7 Detach retaining clamps (8) and remove brake hose (1)
8 Replace brake line (4) or brake line (7) Only if brake line (4) or brake line (7) with red color coding has been detached.
Remove/install brake line from the ESP hydraulic unit to the rear axle AR42.10- P- 0035MCU Remove/install left rear brake line AR42.10- P- 0036MCU Remove/install right rear brake line AR42.10- P- 0037MCU 9 Install in the reverse order
10 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 33 · Applies to: 450, 451, 452, 454
Designation Model 451.3/4 BA42.10-P-1002-04E Brake pipe to brake hose Nm 16 TESTING & REPAIR > REMOVE/INSTALL BRAKE HOSE TO FRONT AXLE - AR42.10-P- 0026MCU > MODEL 451.3 /4 Shown on left side of vehicle
Remove/install
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 Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Hose, Line, Retaining Clamp And Caliper Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on repairs to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 34 · Applies to: 450, 451, 452, 454
brake system
AH42.00- P-0003- 01A 1 Remove left or right front wheel
AR40.10- P- 1100MCU 2 Detach retaining clip (3)
3 Check bolted connection of brake line (2) with brake hose (1) for color coding Installation: Identify the brake line (2) accordingly. AR42.10- P-0013- 05MCC 4 Loosen bolted connection of brake line (2) with the brake hose (1) and unhook brake hose (1) Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: The brake hose (1) must free to move at each steering angle and jounce condition. The brake hose (1) must not be mounted twisted otherwise the brake hose (1) may be damaged.
*BA42.10- P-1002- 04E Figure 5 Unscrew brake hose (1) from brake caliper (4) and remove Collect brake fluid in a suitable container. Seal the connections using suitable plugs.
*BA42.10- P-1001- 04E 6 Replace brake line (2). Only if the brake line (2) with the red color coding has been detached.
Remove/install left front brake line AR42.10- P- 0032MCU Remove/install right front brake line AR42.10- P- 0033MCU 7 Install in the reverse order
8 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1001-04E Brake hose to front floating caliper Nm 18
BA42.10-P-1002-04E¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 35 · Applies to: 450, 451, 452, 454
Brake pipe to brake hose Nm 16 TESTING & REPAIR > REMOVE/INSTALL LEFT FRONT BRAKE LINE - AR42.10-P- 0032MCU > MODEL 451.3 /4 Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Fluid Expansion Reservoir Cap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 36 · Applies to: 450, 451, 452, 454
Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when AS42.50- Z-0001- Fig 2: Identifying Brake Line & Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Brake Line & Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
fluid coming into contact¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 37 · Applies to: 450, 451, 452, 454
with skin and eyes. handling brake fluid. 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 Unscrew cap (2) of brake fluid expansion reservoir and suction off brake fluid
3 Remove left front wheel
AR40.10- P- 1100MCU 4 Remove underfloor panels Rechargeable drill / screwdriver
5 Remove diagonal struts On model 451.431 AR61.10- P- 5138MCU 6 Remove left diagonal strut On model 451.491 AR61.10- P- 5138MEV 7 Unclip brake line (3) from the bracket (4)
8 Loosen nuts (5), unscrew bolts (6) and remove bracket (7) Installation: Move guide pin (9) on the hydraulic unit (8) into the bracket (7).
*BA42.45- P-1008- 01F 9 Support hydraulic unit (8) using transmission jack and removal fixture Transmission jack Fig 4 10 Check bolted connections of brake lines (10) with the hydraulic unit (8) for color coding Installation: Identify brake lines (10) accordingly. AR42.10- P-0013- 05MCC Loosen bolted connections of brake Collect brake fluid in a suitable container. Seal connections using suitable plugs.
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (10), pay *BA42.10-
lines (10) with the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 38 · Applies to: 450, 451, 452, 454
11 lines (10) with the hydraulic unit (8) and separate ATTENTION to routing, leaktightness and clearance.If a brake line (10) with red color coding has been detached, this brake line (10) must be replaced.Refer to: ↓ P-1010- 04E Remove/install brake line from the master brake cylinder to the ESP hydraulic unit AR42.10- P- 0034MCU 12 Lower the hydraulic unit (8) carefully until the brake line (1) is accessible
13 Unclip retaining clips (11), RPM sensor connector (L6/1x1) and electrical lines (12, 13) on brake line (1)
14 Check bolted connections of brake line (1) with the hydraulic unit (8) and the brake hose (14) for color coding Installation: Identify the brake line (1) accordingly. AR42.10- P-0013- 05MCC 15 Loosen bolted connections of the brake line (1) with the hydraulic unit (8) and the brake hose (14) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation: Do not bend brake line (1), pay ATTENTION to routing, leaktightness and clearance.
BA42.10- P-1002- 04E BA42.10- P-1010- 04E Figure Fig 6 16 Remove brake line (1)
17 Replace brake line (1). Only if the brake line (1) with the red color coding has been detached.
18 Install in the reverse order
19 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4
BA42.10-P-1002-04E¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 39 · Applies to: 450, 451, 452, 454
Brake pipe to brake hose 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 Fig 4: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL RIGHT FRONT BRAKE LINE - AR42.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 40 · Applies to: 450, 451, 452, 454
0033MCU > MODEL 451.3 /4
Remove/install
Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact 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 Fig 1: Identifying Brake Fluid Expansion Reservoir Cap Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Right Front Brake Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
with skin and eyes.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 41 · Applies to: 450, 451, 452, 454
Brake fluid notes
AH42.50- P-0001- 01A Notes on repairs to brake system
AH42.00- P-0003- 01A 1 Remove maintenance flap
2 Unscrew cap (2) of brake fluid expansion reservoir and suction off brake fluid
3 Remove right front wheel
AR40.10- P- 1100MCU 4 Remove underfloor panels Rechargeable drill / screwdriver
5 Remove diagonal struts On model 451.431 AR61.10- P- 5138MCU 6 Remove left diagonal strut On model 451.491 AR61.10- P- 5138MEV 7 Remove support for front axle carrier On model 451.391/491 AR33.10- P- 0002MEV 8 Loosen nuts (3), unscrew bolts (4) and remove bracket (5) Installation: Move guide pin (7) on the hydraulic unit (6) into the bracket (5).
*BA42.45- P-1008- 01F 9 Support hydraulic unit (6) using transmission jack and removal fixture Transmission jack Figure 10 Check bolted connections of brake lines (8) with the hydraulic unit (6) for color coding Installation: Identify brake lines (8) accordingly. AR42.10- P-0013- 05MCC 11 Loosen bolted connections of brake lines (8) with the hydraulic unit (6) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs.
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (8), pay ATTENTION to routing, leaktightness and clearance.If a brake line (8) with red color coding has been loosened, this brake line (8) must be replaced.Refer to: ↓ *BA42.10- P-1010- 04E
Remove/install brake line from the master brake¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 42 · Applies to: 450, 451, 452, 454
cylinder to the ESP hydraulic unit AR42.10- P- 0034MCU 12 Lower the hydraulic unit (6) carefully until the brake line (1) is accessible
13 Unclip the retaining clips (9) and RPM sensor connector (L6/2x1) from the brake line (1) and unclip brake line (1) from the brackets (10)
14 Check bolted connections of brake line (1) with the hydraulic unit (6) and the brake hose (11) for color coding Installation: Identify the brake line (1) accordingly. AR42.10- P-0013- 05MCC 15 Loosen bolted connections of the brake line (1) with the hydraulic unit (6) and the brake hose (11) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation: Do not bend brake line (1), pay ATTENTION to routing, leaktightness and clearance.
BA42.10- P-1002- 04E BA42.10- P-1010- 04E Figure Figure 16 Remove brake line (1)
17 Replace brake line (1). Only if the brake line (1) with the red color coding has been detached.
18 Install in the reverse order
19 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002-04E Brake pipe to brake hose Nm 16 BA42.10-P-1010-04E Brake line to ESP hydraulic unit Nm 16
MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 44 · Applies to: 450, 451, 452, 454
Remove/install
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 maintenance flap
2 Unscrew cap of brake fluid expansion reservoir and drain brake fluid
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 3 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
Fig 1: Identifying Brake Lines, Hydraulic Unit, Master Brake Cylinder, Retaining Clip And Nuts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove diagonal struts¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 45 · Applies to: 450, 451, 452, 454
4 Remove diagonal struts On model 451.431 AR61.10- P- 5138MCU 5 Remove left diagonal strut On model 451.491 AR61.10- P- 5138MEV 6 Loosen nuts (2), unscrew bolts (3) and remove bracket (4) Installation: Move guide pin (6) on the hydraulic unit (5) into the bracket (4).
*BA42.45- P-1008- 01F 7 Support hydraulic unit (5) using transmission jack and removal fixture and lower carefully until the brake lines (1) are accessible Transmission jack Figure 8 Unclip retaining clip (7) of the electrical line (8)
9 Check bolted connections of brake lines (1) with the hydraulic unit (5) and the master brake cylinder (9) for color coding Installation: Identify brake lines (1) accordingly. AR42.10- P-0013- 05MCC 10 Loosen bolted connections of brake lines (1) with the hydraulic unit (5) and the master brake cylinder (9) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (1), pay ATTENTION to routing, leaktightness and clearance.
BA42.10- P-1005- 04E BA42.10- P-1010- 04E 11 Remove brake lines (1)
12 Install new brake lines (1) Only if the brake lines (1) with the red color coding have been detached.
13 Install in the reverse order
14 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES
Illustrated on model 451.30¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 47 · Applies to: 450, 451, 452, 454
Model 451.391/491 Fig 2: Identifying ESP Hydraulic Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying ESP Hydraulic Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.30¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 48 · Applies to: 450, 451, 452, 454
Remove/install
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 maintenance flap
2 Unscrew cap (2) of brake fluid expansion reservoir and suction off brake fluid
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 3 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
4 Remove diagonal struts On model 451.431 AR61.10- P- 5138MCU 5 Remove bulkhead wall On model 451.431 AR61.25- P- 6600MCU Fig 4: Identifying Brake Lines, Hydraulic Unit And Brake Hoses Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove high-voltage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 49 · Applies to: 450, 451, 452, 454
6 Remove high-voltage battery On model 451.391/491 AR54.10- P- 1140MEV 7 Unclip retaining clips (5) of electrical line (17) on upper brake line (1) On model 451.391/491
8 Unscrew plastic nut (3), open folding clamp (4) using a suitable tool and take off Observe installation position of brake lines (1) and electrical lines.
9 Unclip retaining clips (5) of electrical line (6), RPM sensor connector (L6/3x1) and RPM sensor connector (L6/4x1) on the brake lines (1)
10 Unclip brake lines (1) from the bracket (7)
11 Unclip brake line (8) from the bracket (9)
12 Loosen nuts (10), unscrew bolts (11) and remove bracket (12) Installation: Move guide pin (13) on the hydraulic unit (14) into the bracket (12).
*BA42.45- P-1008- 01F 13 Support hydraulic unit (14) using transmission jack and removal fixture Transmission jack Figure 14 Check bolted connections of brake lines (15) with the hydraulic unit (14) for color coding Installation: Identify brake lines (15) accordingly. AR42.10- P-0013- 05MCC 15 Loosen bolted connections of brake lines (15) with the hydraulic unit (14) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs.
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (15), pay ATTENTION to routing, leaktightness and clearance.If a brake line (15) with red color coding has been loosened, this brake line (15) must be replaced.Refer to: ↓ *BA42.10- P-1010- 04E Remove/install brake line from the master brake cylinder to the ESP hydraulic unit AR42.10- P- 0034MCU 16 Lower the hydraulic unit (14) carefully until the brake lines (1) are
accessible¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 50 · Applies to: 450, 451, 452, 454
17 Check bolted connections of brake lines (1) with the hydraulic unit (14) and the master brake cylinder (16) for color coding Installation: Identify brake lines (1) accordingly. AR42.10- P-0013- 05MCC 18 Loosen bolted connections of brake lines (1) with the hydraulic unit (14) and loosen the brake hoses (16) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation Do not bend brake lines (1), pay ATTENTION to routing, leaktightness and clearance.
BA42.10- P-1002- 04E BA42.10- P-1010- 04E Figure Figure 19 Remove brake lines (1)
20 Install new brake lines (1) Only if the brake lines (1) with the red color coding have been detached.
21 Install in the reverse order
22 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002-04E Brake pipe to brake hose 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
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 52 · Applies to: 450, 451, 452, 454
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 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
2 Check bolted connection of brake line (1) with brake hose (2) and wheel brake cylinder (3) for color codings Installation: Identify the brake line (1) accordingly. AR42.10- P-0013- 05MCC Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: Do not bend brake line (1), pay attention to routing,
Fig 1: Identifying Left Rear Brake Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Loosen bolted connections of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 53 · Applies to: 450, 451, 452, 454
3 Loosen bolted connections of the brake line (1) with the hydraulic unit (2) and the brake hose (3) and separate leaktightness and clearance. BA42.10- P-1002- 04E BA42.10- P-1003- 04E Figure 4 Unclip retaining clips (4) of electrical line (5) on brake line (1)
5 Unclip brake line (1) from bracket (6) on the axle tube (7)
6 Remove brake line (1)
7 Replace brake line (1). Only if the brake line (1) with the red color coding has been detached.
8 Install in the reverse order
9 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002-04E Brake pipe to brake hose Nm 16 BA42.10-P-1003-04E Brake line to rear wheel brake cylinder Nm 16 TESTING & REPAIR > REMOVE/INSTALL RIGHT REAR BRAKE LINE - AR42.10-P- 0037MCU > MODEL 451.3 /4 Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown with right rear wheel removed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 54 · Applies to: 450, 451, 452, 454
Remove/install
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 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 using the vehicle lift and remove rear underfloor paneling Rechargeable drill / screwdriver
2 Remove bulkhead wall On model 451.4 AR61.25- P- Fig 1: Identifying Right Rear Brake Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6600MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 55 · Applies to: 450, 451, 452, 454
3 Check bolted connections of brake line (1) with brake hose (2) and wheel brake cylinder (3) for color coding Installation: Identify the brake line (1) accordingly. AR42.10- P-0013- 05MCC 4 Loosen bolted connections of the brake line (1) with the hydraulic unit (2) and the brake hose (3) and separate Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: Do not bend brake line (1), pay attention to routing, leaktightness and clearance.
BA42.10- P-1002- 04E BA42.10- P-1003- 04E Figure 5 Unclip retaining clips (4) of electrical line (5) on brake line (1)
6 Unclip brake line (1) from brackets (6) on axle tube (7)
7 Remove brake line (1)
8 Replace brake line (1). Only if the brake line (1) with the red color coding has been detached.
9 Install in the reverse order
10 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002-04E Brake pipe to brake hose Nm 16 BA42.10-P-1003-04E Brake line to rear wheel brake cylinder Nm 16
TESTING & REPAIR > REMOVE/INSTALL MECHANICAL STOP LAMP SWITCH - AR42.10-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 56 · Applies to: 450, 451, 452, 454
P-0040MCC > MODEL 451.3 /4 MODEL 450.3/ 4 Illustrated on model 451 MODIFICATION NOTES 22.9.10 Work procedure completely revised owing to new self-adjusting brake light switch (S9/1) Operation steps 1 to 12 Remove
Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Stop Lamp Switch, Brake Pedal, Bracket And Electrical Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove brake pedal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 57 · Applies to: 450, 451, 452, 454
1 Remove brake pedal module cover The brake pedal module cover removed is no longer fitted
Type 450 AR29.10- P- 0330SM Model 451 AR29.10- P- 0330MCC 2 Disconnect electrical connector (3) on brake light switch (S9/1)
3 Turn brake light switch (S9/1) 90° counterclockwise and remove from bracket (2)
Checking
4 Check that punch holes are present in boot on brake pedal (1); make punch holes if necessary and install boot Only on model 450 If the boot of the brake pedal (1) is not already punched, the boot must be punched and an additional pedal assembly seal must be retrofitted.The new brake pedal module cover will be installed at a later stage.
Left-hand drive vehicles AR29.10- P- 0340SM Right-hand drive vehicles AR29.10- P- 0340SN 5 Check whether catch hooks of pedal assembly seal are all engaged correctly Engage the catch hooks of the pedal assembly seal if necessary.
Install
6 Insert brake light switch (S9/1) into bracket (2) and turn 90° clockwise as far as end stop Before installing the new self-adjusting brake light switch (S9/1), make sure that the plunger is pulled out fully.
7 Contact electrical connector (3) on brake light switch (S9/1)
8 Install brake pedal module cover Use the new brake pedal module cover.
Type 450 AR29.10- P- 0330SM Model 451 AR29.10- P-
Shown on left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 59 · Applies to: 450, 451, 452, 454
Remove/install
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 Although replacement of the brake caliper (1) as a pair is not specified by DaimlerChrysler, it is recommended
1 Remove brake pads on the left or right brake caliper (1)
AR42.10- P- 1600MCU 2 Check bolted connection of brake line (2) with brake hose (3) for color coding Installation: Identify the brake line (2) accordingly. AR42.10- P-0013- 05MCC Loosen bolted Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: The brake hose (3) must be clear at
Fig 1: Identifying Brake Caliper, Line, Hose And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
connection of brake¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 60 · Applies to: 450, 451, 452, 454
3 connection of brake line (2) with brake hose (3), separate, remove retaining clip and unhook brake hose (3) every steering angle and wheel compression position, and it must not be mounted when twisted, as otherwise the brake hose (3) may be damaged. *BA42.10- P-1002- 04E Figure 4 Unscrew brake hose (3) from brake caliper (1) When replacing the brake caliper (1). Collect brake fluid in a suitable container. Seal the connections using suitable plugs.
BA42.10- P-1001- 04E 5 Unscrew bolt (4) BA42.10- P-1001- 10A 6 Remove brake caliper (1)
7 Replace brake line (2). Only if the brake line (2) with the red color coding has been detached.
Remove/install left front brake line AR42.10- P- 0032MCU Remove/install right front brake line AR42.10- P- 0033MCU 8 Install in the reverse order
9 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1001-04E Brake hose to front floating caliper Nm 18 BA42.10-P-1002-04E Brake pipe to brake hose Nm 16 FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1001-10A Bolt, brake caliper to brake caliper support Nm 30
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 62 · Applies to: 450, 451, 452, 454
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) Fig 2 3 Remove wheel bearing
AR35.20- P- 0302MCU 4 Remove brake carrier plate (1)
5 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL BRAKE SHOES AT REAR AXLE - AR42.10-P- 0165MCU > MODEL 451.3 /4 Fig 2: Identifying Sleeve (451 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 63 · Applies to: 450, 451, 452, 454
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 left or right brake drum
AR42.10- P- 1010MCU 2 Support pliers on brake anchor plate (2) and unhook spring (3) Replace spring (3), a damaged or overstretched spring (3) can lead to impairment of the braking effect. Installation: Measure brake shoes (1) diagonally with universal vernier caliper and adjust to the dimension (A) of 202.6 mm, measured at the top side of the linings.
Fig 1: Identifying Brake Shoes Of Rear Axle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Universal vernier gauge set¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 64 · Applies to: 450, 451, 452, 454
Fig 2 3 Remove retaining washers (4) using the removal and installation tool and remove together with the springs (5) located underneath. Subsequently remove the retaining pins (6) from brake anchor plate (2) Replace retaining washers (4), springs (5) and retaining pins (6), damaged or overstretched springs (5) can lead to impairment of the braking effect.
Fig 3 4 Press back spring (7) on hand brake cable (8) and unhook hand brake cable (8) at hand brake lever (9) Twist wheel hub (10) until a threaded hole is located in the lower position.
5 Tilt brake shoes (1) upward by 90° over wheel hub (10)
6 Compress brake piston of wheel brake cylinder (11) and guide out brake shoes (1) upwards Ensure that the dust boots of the brake pistons of the wheel brake cylinder (11) are not damaged otherwise leakages can lead to failure of the brake system. Installation: The brake lining of the brake shoes (1) must be absolutely grease-free otherwise the braking effect will be impaired.
7 Clean brake carrier plate (2) Installation: Smear the contact surfaces (arrows) of the brake carrier plate (2) at the brake shoes (1) with a thin coating of brake paste.
Brake paste *BR00.45- Z-1060- 06A 8 Check ease of movement and leakproofness of wheel brake cylinder (11) In the event of the slightest signs of brake fluid escape or sluggishness of the brake pistons of the wheel brake cylinder (11) this must be replaced, see: ↓
Remove/install wheel brake cylinder AR42.10- P- 0167MCU 9 Install in the reverse order
AUXILIARY REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 65 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1060-06A Brake paste Q0007414V000000000 TESTING & REPAIR > REMOVE/INSTALL WHEEL BRAKE CYLINDER - AR42.10-P- 0167MCU > MODEL 451.3 /4 Fig 2: Identifying Pliers (450 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3 Identifying Removal And In tallation Tool (450 589 18 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 66 · Applies to: 450, 451, 452, 454
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 left or right brake shoe at the rear axle
AR42.10- P- 0165MCU 2 Check bolted connection of brake line (2) with wheel brake cylinder (1) for color coding Installation: Identify the brake line (2) accordingly. AR42.10- P-0013- 05MCC 3 Loosen bolted connection of brake line (2) with the wheel brake cylinder (1) and separate Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: Do not bend the brake line (2), pay attention to routing, leaktightness and clearance to rear axle.
*BA42.10- P-1003- 04E Figure Fig 1: Identifying Wheel Brake Cylinder, Brake Line And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Replace brake line (2).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 67 · Applies to: 450, 451, 452, 454
4 Replace brake line (2). Only if the brake line (2) with the red color coding has been detached.
Remove/install left rear brake line AR42.10- P- 0036MCU Remove/install right rear brake line AR42.10- P- 0037MCU 5 Undo bolts (3) on wheel brake cylinder (1) and remove wheel brake cylinder (1) *BA42.10- P-1001- 16C 6 Clean brake carrier plate
7 Install in the reverse order
8 Bleed brake system
AR42.10- P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1003-04E Brake line to rear wheel brake cylinder Nm 16 DRUM BRAKE Number Designation Model 451.3/4 BA42.10-P-1001-16C Wheel brake cylinder to brake carrier plate Nm 8 TESTING & REPAIR > INSTALL, REMOVE AUTOMATIC BRAKE ADJUSTER - AR42.10-P- 0169MCU > MODEL 451.3 /4 Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 68 · Applies to: 450, 451, 452, 454
1 Remove left or right brake shoes (3) on the rear axle
AR42.10- P- 0165MCU 2 Unhook fastening spring (1) on brake adjuster (2) and on brake shoes (3)
3 Unhook return spring (4) on brake shoes (3)
4 Unhook spring (5) on brake shoes (3) Installation: Observe curvature of teeth on adjusting wheel (8). They must curve away in the direction of adjustment (arrow).
5 Pull threaded union (6), spring (5) and adjustment wheel (8) out of the angle (7) in the brake adjuster (2) The heat shield (9) must be located in the center of the angle cutout (7), as otherwise the drum brake function may be impaired. Installation: Check the direction of the brake adjustment, in the process pressing against the elbow (7) and relieving the load again.Observe the installation position of the brake adjuster (2): Right side = Left-hand thread on brake adjuster (2) Left side = Right-hand thread on brake adjuster (2) The designations on the brake adjusters (2) are invalid.
Fig 1: Identifying Automatic Brake Adjuster Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install in the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 69 · Applies to: 450, 451, 452, 454
6 Install in the reverse order
7 Adjust drum brake
AR42.10- P-1010- 11SM TESTING & REPAIR > REMOVE/INSTALL FRONT AXLE BRAKE DISK - AR42.10-P- 0230MCU > MODEL 451.3 /4
Remove/install
1 Remove left or right engine support
AR42.10- P- 0500MCU 2 Remove bolt (2) and remove brake disk (1) Installation: Brake disks (1) must only be replaced in pairs.Clean wheel hub (3) and grease lightly at the centering surface (A) using brake paste.
Brake paste *BR00.45- Z-1060- 06A Checking
3 Check wear, condition of brake pads and the brake disk (1) using a Brake pad thickness *BE42.10- P-1001- 05E Fig 1: Identifying Brake Disk, Wheel Hub, Centering Surface And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
vernier caliper¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 70 · Applies to: 450, 451, 452, 454
Brake disk thickness *BE42.10- P-1001- 08E Fig 2 4 Install in the reverse order
Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work Before starting engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system. AS42.50- Z-0002- 01A 5 Operate the brake pedal several times until brake pads make contact with the brake disks (1) A firm resistance must be noticeable at the brake pedal.
CHECK VALUES FOR FRONT BRAKE PAD Number Designation Model 451.3/4 BE42.10-P- 1001-05E Brake pad thickness New (with pad backing plate) mm 15 Wear limit (without pad backing plate) for maintenance service mm ≤ 2 Wear limit (with pad backing plate) for maintenance service mm ≤7,7 Response of wear indicator (with pad backing 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 REPAIR MATERIALS Fig 2: Identifying Vernier Caliper (450 589 01 19 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 71 · Applies to: 450, 451, 452, 454
Designation Order number BR00.45-Z-1060-06A Brake paste Q0007414V000000000 TESTING & REPAIR > REMOVE/INSTALL SPLASH SHIELD ON FRONT BRAKE - AR42.10- P-0233MCU > MODEL 451.3/4 Remove/install
1 Remove left or right brake disk
AR42.10-P- 0230MCU 2 Remove bolts (2)
3 Unscrew bolt (3). Turn hub (4) such that the bolt (3) can be accessed through a wheel bolt bore in the hub (4).
4 Remove splash shield (1)
5 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL BRAKE FLUID RESERVOIR - AR42.10-P- 0301MCU > MODEL 451.3/4 Fig 1: Identifying Splash Shield Of Front Brake, Bolts, Screw And Hub Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 72 · Applies to: 450, 451, 452, 454
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- Fig 1: Removing/Installing Brake Fluid Reservoir (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Removing/Installing Brake Fluid Reservoir (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove maintenance flap¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 73 · Applies to: 450, 451, 452, 454
01A 1 Remove maintenance flap
2 Unscrew cap of brake fluid reservoir (2) and extract brake fluid from the brake fluid reservoir
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 3 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
4 Remove retainer (6) from master brake cylinder (5)
5 Detach brake lines (8) from master brake cylinder (5) Collect brake fluid in a suitable container. Seal the connections using suitable plugs.
6 Release brake lines (8) from brackets (9) on underfloor
7 Cut through brake lines (8) at suitable position (arrow C) and remove loose sections of brake lines (8) Only when replacing brake fluid reservoir (2).
8 Lower vehicle with lifting platform
9 Remove right headlamp unit
AR82.10- P- 4730MCU 10 Disconnect electrical connector (4) from brake fluid reservoir (2)
11 Unclip brake fluid reservoir (2) from fresh-air intake (1) using a suitable screwdriver (3) (arrow A) and lift off
12 Release brake lines (8) of brake fluid reservoir (2) from bracket (arrow B) on firewall
13 Raise vehicle with vehicle lift Only if the brake fluid reservoir (2) is reused.
14 Lift out brake fluid reservoir (2) If the brake fluid reservoir (2) is to be reused, have a second person on a ladder lift it out and guide out the brake lines (8) from below.
Install
15 Raise vehicle with vehicle lift Only when replacing brake fluid reservoir (2).
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 75 · Applies to: 450, 451, 452, 454
Notes on repairs to brake system
AH42.00-P-0003- 01A 1 Remove brake pads on the left or right brake caliper (1)
AR42.10-P- 1600MCU 2 Unscrew bolt (4) *BA42.10-P-1001- 10A 3 Remove brake caliper (1) and place with attached brake hose (2) to one side
4 Unscrew bolts (3) and remove brake caliper support (5) *BA42.10-P-1003- 10A 5 Install in the reverse order
FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1001-10A Bolt, brake caliper to brake caliper support Nm 30 BA42.10-P-1003-10A Bolt, brake caliper support to steering knuckle Nm 115 TESTING & REPAIR > ADJUST DRUM BRAKE - AR42.10-P-1010-11SM > When the brake drum is assembled no manual adjustments may be performed at the automatic adjuster. 1. Operate hand brake once and release again. 2. Operate service brake, release, and wait for approx. 1 second. Apply hand brake with button pressed and release. Repeat the procedure until no "actuation clicks" can be heard in the brake drum. 3. Check the rear wheels rotate freely 4. When all work has been completed, check the vehicle brake on the brake test stand. Fig 1: Identifying Brake Caliper, Hose, Bolts, Caliper Support And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 77 · Applies to: 450, 451, 452, 454
Designation Order number BR00.45-Z-1060-06A Brake paste Q0007414V000000000 TESTING & REPAIR > REMOVE/CHECK/INSTALL FRONT AXLE BRAKE PADS - AR42.10- P-1600MCU > MODEL 451.3 /4
Remove/install
Risk of poisoning caused by swallowing Fig 1: Removing/Checking/Installing Front Axle Brake Pads (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Removing/Checking/Installing Front Axle Brake Pads (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
brake fluid. Risk of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 78 · Applies to: 450, 451, 452, 454
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 left or right front wheel
AR40.10- P- 1100MCU 2 Counterhold upper guide pin (4) using a suitable open end wrench and unscrew bolt (2) on brake caliper (1) *BA42.10- P-1001- 10A 3 Fold brake caliper (1) downwards and remove brake pads (6) After removing the brake pads (6) ensure that the brake pedal is no longer operated otherwise the brake piston (8) will be pressed out of the brake caliper (1). Observe installation position of brake pad (6) with wear indicator (9). Installation: When folding up the brake caliper (1) ensure that the springs (3) of the brake pads (6) are clamped under the brake caliper (1).
4 Press back the brake piston (8) using the brake piston pusher tool (10) When the brake piston (8) is pushed back the fluid level in the brake fluid reservoir rises. Ensure that the brake fluid reservoir does not overflow. It must be possible to move the brake piston (8) easily.
Fig 4 5 Clean contact surfaces (arrows) on the brake pads (6) and brake caliper support (5) and coat with grease Installation: No grease may come into contact with the friction surfaces of the brake pads (6) and brake disk, otherwise the braking effect will be impaired.
Molykote 111 grease *BR00.45- Z-1070- 06A Checking
6 Check dust boot (7) for leaktightness If dust boot (7) is damaged, the brake caliper (1) must be replaced.Refer to: ↓
Remove/install front axle brake caliper (1) AR42.10- P- 0070MCU
Check wear and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 79 · Applies to: 450, 451, 452, 454
7 Check wear and condition of brake pads (6) as well as the brake disks Brake pad thickness BE42.10- P-1001- 05E Brake disk thickness Figure BE42.10- P-1001- 08E 8 Check ease of movement of guide pins (4) If guide pins (4) are hooked up or sluggish the brake caliper (1) must be replaced.Refer to: ↓
Remove/install front axle brake caliper (1) AR42.10- P- 0070MCU 9 Check bellows (11) for damage Damaged bellows (11) should be replaced. Installation: Twist the respective boot (11) with the fingers in order to ensure that sealing lip (12) seats correctly in the slot on the corresponding guide pin (4).
10 Install in the reverse order
Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work Before starting engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system. AS42.50- Z-0002- 01A 11 Depress the brake pedal several times until the brake pads (6) contact the brake disk A firm resistance must be noticeable at the brake pedal.
12 Check brake system for leaks
AR42.10- P-0100- 01MCC CHECK VALUES FOR FRONT BRAKE PAD Number Designation Model 451.3/4 BE42.10-P- 1001-05E Brake pad thickness New (with pad backing plate) mm 15 Wear limit (without pad backing plate) for maintenance service mm ≤2 Wear limit (with pad backing plate) for maintenance service mm ≤ 7,7
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 81 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove cargo area floor cover
AR68.20- P- 4810MCU 2 Unclip retaining clip (3) of wiring harness
3 Detach electrical connector (4) from parking brake indicator switch (S12)
4 Remove bolts (5) Installation: Perform function test of hand brake lever (1).If the hand brake cannot be operated, push the clamping piece (2) upwards to enable it to engage in the pull rod's toothing (6).
*BA42.20- P-1002- 01D Remove hand The teeth on the pull rod (6) can be disengaged by completely releasing the hand brake lever (1). Should the pull rod (6) not release, the clamping piece (2) can be unlocked by pressing with a screwdriver. Installation: The Fig 1: Identifying Hand Brake Lever Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 85 · Applies to: 450, 451, 452, 454
1.1 Release rear drive module Not on model 451.391/491 AR01.00- P- 3050MCU 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 1.2 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 Installation: The catch hook (8) on the guide sleeve (5) must point crosswise to the direction of travel.
Fig 2: Removing/Installing Pull Rod (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(L6/1x1) or RPM sensor connector¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 87 · Applies to: 450, 451, 452, 454
4 (L6/1x1) or RPM sensor connector (L6/2x1)
5 Loosen electrical line (1) of left front RPM sensor (L6/1) or right front RPM sensor (L6/2) from the brackets (2) Observe correct routing of the electrical line (1) otherwise damage can occur to the electrical line (1) of the left front RPM sensor (L6/1) or right front RPM sensor (L6/2).
6 Unclip brackets (5) on brake line (4) Observe installation position of brackets (5) on brake line (4).The brackets (5) remain on the electrical line (1).
7 Pull the left front RPM sensor (L6/1) or right front RPM sensor (L6/2) out of the steering knuckle and remove Installation: The contact surface of the left front RPM sensor (L6/1) or right front RPM sensor (L6/2) must be clean and free from rust. Clean contact surface if necessary.
8 Unclip brackets (5) on the electrical wiring harness (1) and attach at exactly the same point on the electrical line (1) of the new left front RPM sensor (L6/1) or new right front RPM sensor (L6/2) When replacing the left front RPM sensor (L6/1) or right front RPM sensor (L6/2).
9 Install in the reverse order
10 Read out fault memory
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC TESTING & REPAIR > REMOVE/INSTALL REAR AXLE SPEED SENSOR - AR42.30-P- 0714MCU > MODEL 451.3 /4 Shown on model 451.3
Shown on left side of vehicle on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 88 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove left or right rear wheel
AR40.10- P- 1100MCU 2 Remove rear underbody paneling Rechargeable drill / screwdriver
3 Mark the position of the brackets (6) on the electrical line (1) and
Fig 1: Identifying Rear Axle Speed Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Axle Speed Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
on the brake line (4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 89 · Applies to: 450, 451, 452, 454
4 Mark the position of all further fastening points on the electrical line (1)
5 Separate the RPM sensor connector (L6/3x1) or RPM sensor connector (L6/4x1)
6 Unscrew plastic nut (2), open folding clamp (3) using a suitable tool and expose electrical line (1) of left rear RPM sensor (L6/3) or the right rear RPM sensor (L6/4) Observe installation position of brake line and of electrical lines (1).
7 Unscrew bolt (5) on left rear RPM sensor (L6/3) or on right rear RPM sensor (L6/4) and remove the nut from the back
8 Unclip brackets (6) on the brake line (4) Observe correct routing of the electrical line (1) otherwise damage can occur to the electrical line (1) of the left front RPM sensor (L6/3) or right front RPM sensor (L6/4). The brackets (6) remain on the electrical line (1).
9 Loosen electrical line (1) of left rear RPM sensor (L6/3) or right rear RPM sensor (L6/4) from all other fastening points Observe installation position of electrical line (1).
10 Pull the left rear RPM sensor (L6/3) or right rear right rear RPM sensor (L6/4) out of its guide and take off Installation: The contact surface (arrow) of the left rear RPM sensor (L6/3) or right rear RPM sensor (L6/4) must be clean and free from rust. Clean contact surface if necessary.
11 Unclip brackets (6) on the wiring harness (1) and attach at exactly the same point on the electrical line (1) of the new left rear RPM sensor (L6/3) or the new right rear sensor (L6/4) When replacing the left rear RPM sensor (L6/3) or right rear RPM sensor (L6/4).
12 Transfer all markings applied to the electrical line (1) to the electrical line (1) of the new left rear RPM sensor (L6/3) or the new right rear RPM sensor (L6/4) When replacing the left rear RPM sensor (L6/3) or right rear RPM sensor (L6/4).
13 Install in the reverse order
14 Read out fault memory, erase if necessary
Note on high-voltage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 91 · Applies to: 450, 451, 452, 454
system Model 451.391/491 AH54.00- P-0011- 01MEV Brake fluid notes
AH42.50- P-0001- 01A Notes on repairs to brake system
AH42.00- P-0003- 01A 1 Remove vehicle key and on-board electrical system plug Model 451.391/491
2 Carry out enable of high- voltage system Model 451.391/491 After completing the work initial startup event log, attach the vehicle file with the enable event log. AR54.10- P- 1160MEV 3 Remove maintenance flap
4 Unscrew cap of brake fluid expansion reservoir and extract brake fluid
Risk of death caused by vehicle lipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and po ition four upport plate at vehicle lift support points specified by vehicle manufacturer. AS00.00- Z-0010- 01A 5 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
6 Remove diagonal struts On model 451.431 AR61.10- P- 5138MCU 7 Remove high voltage battery Model 451.391/491 AR54.10- P- 1140MEV 8 Remove bulkhead wall On model 451.431 AR61.25- P- 6600MCU 9 Unscrew plastic nut (2) and remove folding clamp (3) from screw bolt Observe installation position of brake lines (4, 5) and electrical lines.
10 Unclip brake lines (4, 5) from the bracket (6)
11 Unclip brake line (7) from the bracket (8)
Installation: Move guide pin (12) on the
Loosen nuts (9), unscrew¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 92 · Applies to: 450, 451, 452, 454
12 Loosen nuts (9), unscrew bolts (10) and remove bracket (11) hydraulic unit (1) into the bracket (11).
*BA42.45- P-1008- 01F 13 Support hydraulic unit (1) using transmission jack and removal fixture Transmission jack Figure 14 Check bolted connections of brake lines (13) with the hydraulic unit (1) for color coding Installation: Identify brake lines (13) accordingly. AR42.10- P-0013- 05MCC 15 Loosen bolted connections of brake lines (13) with the hydraulic unit (1) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs.
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (13), pay attention to routing, leaktightness and clearance.If a brake line (13) with red marking has been released, this brake line (13) must be replaced.Refer to: ↓ *BA42.10- P-1010- 04E Remove/install brake line from the master brake cylinder to the ESP hydraulic unit AR42.10- P- 0034MCU 16 Carefully lower the hydraulic unit (1) until the brake lines (4, 5, 7, 14) are accessible
17 Check the bolted connections of the brake lines (4, 5, 7, 14) with the hydraulic unit (1) for color coding Installation: Identify brake lines (4, 5, 7, 14) correspondingly. AR42.10- P-0013- 05MCC 18 Loosen bolted connections of brake lines (4, 5, 7, 14) with the hydraulic unit (1) and separate Observe installation location of brake lines (4, 5, 7, 14). Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation: Do not bend brake lines (4, 5, 7, 14), pay attention to routing, leaktightness and clearance.
*BA42.10- P-1010- 04E Figure 19 Unlock and separate electrical connector (15) on ESP control unit (N47- 5)
Remove hydraulic unit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 93 · Applies to: 450, 451, 452, 454
20 Remove hydraulic unit (1)
21 Replace brake line (4, 5, 7, 14) Only if a brake line (4, 5, 7, 14) with red color coding has been released.
Remove/install left front brake line AR42.10- P- 0032MCU Remove/install right front brake line AR42.10- P- 0033MCU Remove/install brake line from the ESP hydraulic unit to the rear axle AR42.10- P- 0035MCU 22 Install in the reverse order
23 Bleed brake system
AR42.10- P- 0010MCU 24 Carry out transposition test
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 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 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ground line¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 95 · Applies to: 450, 451, 452, 454
0003MCC 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 2 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
3 Unclip the brake line to the rear axle from the bracket (1) In order to prevent the brake lines to the rear axle being permanently deformed when the hydraulic unit (2) is subsequently lowered.
4 Unclip brake line (3) from the bracket (4)
5 Loosen nuts (5), unscrew bolts (6) and remove bracket (7) Installation: Move guide pin (8) on the hydraulic unit (2) into the bracket (7).
*BA42.45- P-1008- 01F 6 Clean hydraulic unit (2) and ESP control unit (N47 5) Clean the hydraulic unit (2) and ESP control unit (N47-5) carefully in order to avoid damage due to contamination when eparating the component
7 Unlock retainer of electrical connector (9) and disconnect electrical connector (9) on ESP control unit (N47-5)
8 Carefully pull the hydraulic unit (2) downwards together with the ESP control unit ESP (N47-5) until the bolts (10) are accessible
9 Unscrew bolts (10) and remove ESP control unit (N47-5) carefully from the hydraulic unit (2) It is essential to pay attention to cleanliness. No dirt may enter the ESP control unit (2) and the hydraulic unit (N47-5), otherwise its function may be impaired. Installation: Clean sealing surfaces on the hydraulic unit (2) and on the ESP control unit (N47-5).Check gasket, replace if necessary.
*BA42.45- P-1003- 01F Fig 2
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 97 · Applies to: 450, 451, 452, 454
1 Remove driver seat (1)
AR91.10- P- 1010MCU 2 Reposition floor covering under the driver seat (1) in the rear area until the yaw rate, lateral and longitudinal acceleration sensor (B24/15) is accessible When repositioning the floor covering ensure that this is not damaged due to breaking or cracking.
3 Disconnect electrical connector (2) on yaw rate, lateral and longitudinal acceleration sensor (B24/15)
4 Unscrew nuts (3) on yaw rate, lateral and longitudinal acceleration sensor (B24/15) and remove yaw rate, lateral and longitudinal acceleration sensor (B24/15)
5 Install in the reverse order
6 Calibrate yaw rate, lateral and longitudinal acceleration sensor (B24/15) Follow the instructions in the diagnosis assistant system.
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC TESTING & REPAIR > NOTES ON REPAIRS TO BRAKE SYSTEM - AH42.00-P-0003-01A > When performing maintenance and repair work on the brake system, it must be ensured that no mineral oil, lubricating grease or similar substances enter the brake system. New brake fluid must be used as a flushing and cleaning agent for the cylinders, lines and the Fig 1: Identifying Yaw Rate, Lateral And Longitudinal Acceleration Sensor And Electrical Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
expansion reservoir of the hydraulic braking system.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 98 · Applies to: 450, 451, 452, 454
If mineral oil is found in the brake system, or if the presence of mineral oil in the brake system is suspected, the procedure below must be followed: 1. Replace tandem master brake cylinder or brake operating unit and expansion reservoir for brake fluid. 2. Thoroughly flush the entire brake system with new brake fluid. 3. All brake components with parts made of rubber, such as brake calipers, brake hoses, the SBC, ABS, ETS, ASR or ESP hydraulic unit, pressure reservoir, charging piston unit and charging pump, which may have come into contact with mineral oil, must be replaced. 4. Bleed brake system. Handling of SBC, ABS, ETS, ASR and ESP components in accident vehicles: If, because of the extent of the damage to the vehicle or the position and external appearance of the hydraulic unit, it is obvious that the hydraulic unit has sustained a severe shock, the hydraulic unit must be replaced. Indications of this are e.g.: Hydraulic lines kinked Connections on hydraulic unit leaking Cables or plug connections damaged Metal block of hydraulic unit shows signs of damage Hydraulic unit detached from its bracket and cannot be reinstalled without applying excessive force If this does not apply, the system must be subjected to a rigorous function test and the test steps for the solenoid valves and pump must be performed. Brake calipers must not be scratched, and the lacquer on lacquered brake calipers must not be damaged, not be removed/installed with hammers, levers, pliers or other tools, not be machined, not be put down on the lacquered side, only be put down on a clean surface. To prevent damage to the brake calipers, particular care must be taken when: detaching/attaching the wheels, removing/installing the brake pads, removing/installing the brake calipers, performing any work in the area of the wheel wells, e.g. removing/installing suspension struts, transverse control arms, torsion bars etc.,
lowering the vehicle with detached wheels.¶
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Lacquered brake calipers are especially sensitive. SAFETY PRECAUTIONS > RISK OF DEATH CAUSED BY LIMBS BEING CAUGHT OR CRUSHED BY ROTATING PARTS WHEN PERFORMING TESTS ON THE BRAKE TEST STAND - AS42.00-Z-0001-01A > Never leave the vehicle unattended on the rollers except in an emergency. Ensure that no one is under the vehicle or near rotating parts during testing. In case of emergency, use the EMERGENCY STOP switch to shut down test stand. Risk of death Life-threatening injuries may be caused by contact with rotating engine or drive train parts or by coming to close to the brake test stand rollers. Safety precautions/instructions The brake test stand is to be operated by trained personnel only. Before driving the vehicle onto the rollers, the driver must ensure that the test stand is ready for operation (main switch is on). For as long as the vehicle in on the rollers, no one is permitted under the vehicle or in the pit. For as long as the vehicle in on the brake test stand, the driver may only leave the driver seat in the event of an emergency. During the test, no one is allowed to go near the rotating rollers, wheels, or propeller shafts. In case of emergency, shut off brake test stand using the red EMERGENCY STOP switch. Observe the special considerations in the operating instructions for the brake test stand. SAFETY PRECAUTIONS > SAFETY INFORMATION: BRAKES - HYDRAULIC AND MECHANICAL SYSTEMS - AS42.00-Z-9999ZZ > MODEL all Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work. MODEL all AS42.50- Z-0002- 01A Risk of death caused by limbs being caught or crushed by rotating parts when performing tests on the brake test stand MODEL 124, 129, 140, 163, 164, 168, 169, 170, 171, 172, 197, 199, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 251, 374, 375, 405, 408, 418, 427, 437, 450, 451, 452, 454, 460, 461, 463, 901, 902, 903, 904, 905, 930, 932, 933, 934, 940, 942, 943, 944, 950, 952, 953, 954, 957, 958, 963, 964, 970, 972, 974, 975, 976... AS42.00- Z-0001- 01A
Risk of injury caused by¶
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body parts being jammed or crushed. Risk of injury to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system MODEL 211, 219 with Sensotronic Brake Control (SBC) MODEL 230 AS42.46- Z-0001- 01B Risk of injury caused by body parts being jammed or crushed. Risk of injury to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system MODEL 199, 230, 240 MODEL 211, 219 with Sensotronic Brake Control (SBC) AS42.46- Z-0001- 01A Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid MODEL all AS42.50- Z-0001- 01A SAFETY PRECAUTIONS > RISK OF POISONING FROM SWALLOWING BRAKE FLUID. RISK OF INJURY FROM SKIN AND EYE CONTACT WITH BRAKE FLUID - AS42.50-Z-0001- 01A > Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. Possible hazards Risk of poisoning Swallowing brake fluid can cause symptoms of poisoning such as headaches, dizziness, stomach pains, vomiting, diarrhea, cramps and unconsciousness. A dose of more than 100 cm can have fatal consequences. Risk of injury Contact with brake fluid can cause serious skin damage to unprotected skin. Procedural guidelines and safety precautions Ensure that brake fluid is only accessible to authorized personnel. Store brake fluid in original containers only. Only store brake fluid in suitable, appropriately marked containers. Never use beverage bottles such as those for mineral water, beer etc. Wear safety glasses and protective clothing such as rubber gloves. If rubber gloves cannot be worn, the following instructions must be observed: 3
Allow brake fluid to act on the skin for as short a time as possible; wash affected skin with soap and¶
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water. Change contaminated clothing as quickly as possible. First aid measures Wash affected skin with soap and water. Change contaminated clothing as quickly as possible. If brake fluid enters the eyes, flush immediately with plenty of clean water and seek medical attention if necessary. SAFETY PRECAUTIONS > RISK OF ACCIDENT WHEN COMMISSIONING THE VEHICLE DUE TO A LACK OF BRAKING EFFECT WHEN THE SERVICE BRAKE IS OPERATED FOR THE FIRST TIME AFTER REPAIR WORK. - AS42.50-Z-0002-01A > Before commissioning the vehicle, operate the brake pedal several times until the pressure in the brake system is built up and maintained. Danger of accident The first time that the brakes are used after having performed any work on the braking system's hydraulics area, the risk of an accident is increased due to an impaired braking effect. Safety guidelines/precautions After finishing the work on the braking system's hydraulics area and before startup of the vehicle, press the brake pedal several times to build up pressure in the brake system. Once pressure has been built up in the brake system, the brake pedal should be held in this position for approximately 30 s, whereby the pressure in the brake system should not drop. TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: WHEELS, CHASSIS ALIGNMENT CHECK - BA40.00-Z-9999CZ > MODEL all
Wheels MODEL 454.0 BA40.10-P-1000-01G
Wheels MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA40.10-P-1000-01E TORQUE SPECIFICATIONS > BRAKE LINES, BRAKE HOSES - BA42.10-P-1000-04E > Model 450, 451, 452 MODIFICATION NOTES 25.2.05 Brake hose to front floating caliper
BRAKE LINES, BRAKE HOSES Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA42.10-P-1001- Brake hose to front floating
caliper¶
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04E caliper Nm 18 18 18 BA42.10-P-1002- 04E Brake pipe to brake hose Nm 15 16 18 BA42.10-P-1003- 04E Brake line to rear wheel brake cylinder Nm 18 16 18 BA42.10-P-1004- 04E Brake line to ABS hydraulic unit Nm 14 - 14 BA42.10-P-1005- 04E Brake pipe to master brake cylinder Nm 14 16 14 BA42.10-P-1006- 04E Brake line to pressure reducer Nm 12 - 18 BA42.10-P-1008- 04E Brake line to T piece Nm 18 16 18 BA42.10-P-1009- 04E Brake hose to T-piece Nm 15 15 15 BA42.10-P-1010- 04E Brake line to ESP hydraulic unit Nm - 16 - TORQUE SPECIFICATIONS > BRAKE CYLINDER - BA42.10-P-1000-08C > Model 450, 451, 452 BRAKE CYLINDER Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA42.10-P- 1001-08C Brake bleed valve to rear axle wheel brake cylinder Nm 6,5 7 6,5 TORQUE SPECIFICATIONS > FRONT AXLE BRAKE CALIPER - BA42.10-P-1000-10A > Model 451, 454 FRONT AXLE FLOATING CALIPER Number Designation Model 454.0 Model 451.3/4 BA42.10-P-1001- 10A Bolt, brake caliper to brake caliper support Nm 30 30 BA42.10-P-1002- 10A Brake bleeder valve to brake caliper Nm 10 7 BA42.10-P-1003- 10A Bolt, brake caliper support to steering knuckle Nm 105 115 TORQUE SPECIFICATIONS > DRUM BRAKE - BA42.10-P-1000-16C > Model 450, 451, 452, 454
DRUM BRAKE¶
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Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 Model 454.0 without code 30Y BA42.10-P- 1001-16C Wheel brake cylinder to brake carrier plate Nm 8 8 8 15 BA42.10-P- 1002-16C Self-locking bolt securing brake drum to wheel hub Nm 6.5 7 6.5 - TORQUE SPECIFICATIONS > PARKING BRAKE - BA42.20-P-1000-01D > Model 450, 451, 452 MODIFICATION NOTES 8.2.07 Bolt, handbrake lever to bearing bracket Model 450.3/4Model 452.3/4
8.2.07 Bolt, hand brake lever to floor panel Model 451.3/4
PARKING BRAKE Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA42.20-P-1001- 01D Bolt, handbrake lever to bearing bracket Nm 21 - 21 BA42.20-P-1002- 01D Bolt, hand brake lever to floor panel Nm - 21 - 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
Brake pad thickness, wear limit (with pad backing plate) at¶
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10.8.05
Brake pad thickness, wear limit (with pad backing plate) at maintenance service Type 452.3/4 CHECK VALUES FOR FRONT BRAKE PAD Number Designation Models 450.3/4 Models 451.3/4 Models 452.3/4 BE42.10- P-1001- 05E Brake pad thickness New (with pad backing plate) mm 15 15 15 Wear limit (without pad backing plate) for maintenance service mm ≤2 ≤2 ≤2 Wear limit (with pad backing plate) for maintenance service mm ≤7,7 ≤7,7 ≤7,7 Response of wear indicator (with pad backing plate) mm ≈7,7 ≈7,7 ≈7,7 TEST & ADJUSTMENT VALUES > TEST VALUES FOR FRONT BRAKE DISKS - BE42.10- P-1000-08E > Model 450, 451, 452, 454 TEST VALUES FOR FRONT BRAKE DISKS Number Designation Model 450.3/4 Model 451.3/4 BE42.10-P-1001- 08E Brake disk thickness New mm 9 9,7 Wear limit mm 8 8 BE42.10-P-1002- 08E Minimum distance, outside of brake disk to brake carrier mm 0.5 - BE42.10-P-1003- 08E Minimum distance, inside of brake disk to brake carrier mm 0,85 - TEST VALUES FOR FRONT BRAKE DISKS Number Designation Model 452.3/4 Model 454.0 BE42.10-P-1001- 08E Brake disk thickness New mm 9 24 Wear limit mm 8 21,5 BE42.10-P-1002- 08E Minimum distance, outside of brake disk to brake carrier mm 0.5 - BE42.10-P-1003- 08E Minimum distance, inside of brake disk to brake carrier mm 0,85 - TEST & ADJUSTMENT VALUES > DRUM BRAKE - BE42.10-P-1000-12C > Model 450, 451, 452
TEST VALUES FOR DRUM BRAKE¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 106 · Applies to: 450, 451, 452, 454
Number Designation Model 450.3/4 Model 451.3/4 BE42.10-P- 1001-12C Brake drum diameter New mm 203,0 203,0 Wear limit for maintenance service mm 204,5 204,5 BE42.10-P- 1002-12C Brake lining thickness New (with carrier) mm 6,6 6,6 Wear limit for maintenance service (with carrier) mm 3 3 TEST VALUES FOR DRUM BRAKE Number Designation Model 452.3/4 BE42.10-P-1001- 12C Brake drum diameter New mm 203,0 Wear limit for maintenance service mm 204,5 BE42.10-P-1002- 12C Brake lining thickness New (with carrier) mm 6,6 Wear limit for maintenance service (with carrier) mm 3 BASIC KNOWLEDGE > BRAKE LIGHT SWITCH, COMPONENT DESCRIPTION - GF42.10-P- 2010MCC > MODEL 451.3/4 Location The brake light switch is located in the brake pedal module. Fig 1: Identifying Stop Lamp Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Task¶
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The brake light switch detects brake pedal actuation and transfers the information to the ESP control unit (N47-5) and to the SAM control unit (N10/10). Design The brake light switch consists of a normally closed contact and a normally open contact. Function The N.O. contact transfers the signal for actuation of the brake pedal to the SAM control unit. The N.C. contact transfers the signal for actuation of the brake pedal to the ESP control unit. BASIC KNOWLEDGE > ELECTRONIC STABILITY PROGRAM (ESP), LOCATION OF ELECTRONIC COMPONENTS - GF42.45-P-0001-03MCU > BASIC KNOWLEDGE > ELECTRONIC STABILITY PROGRAM (ESP) FUNCTION - GF42.45- P-0001MCU > MODEL 451.3 /4 Schematic representation Fig 1: Locating Electronic Stability Program (ESP) Electronic Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Example of understeering vehicle (A)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 108 · Applies to: 450, 451, 452, 454
A vehicle understeers on a left curve. The vehicle pushes outwards over the front wheels. Precisely calculated braking force is applied at the left rear wheel. Example of oversteering vehicle (B) A vehicle oversteers in a left curve. In the process the rear of the vehicle breaks away. Precisely calculated braking force is applied at the right front wheel. General The Electronic Stability Program (ESP) is an active safety system for improving vehicle stability in all driving situations. It operates individually at one or more wheels on the front or rear axle. The ESP stabilizes the vehicle, if when cornering, when braking or when rolling without drive, forces acting from outside on one side have an effect on the vehicle and keep it safely on course. It supplements the familiar functions of the antilock brake system (ABS), acceleration slip regulation (ASR), engine braking regulation (EBR) and electronic brake force distribution (EBD). ESP regulates when: cornering (vehicle understeers or oversteers) driving straight ahead (vehicle deviates from its course on account of uneven road conditions) The function of the ESP control system overrides the ABS and ASR control systems. Apart from active intervention by the brake system through the ESP there is also an effect on the engine/transmission management. Advantages of ESP: Improvement in the starting-off and acceleration capability due to increased traction, particularly on a road with different adhesion and on curves Reduction in the risk of skidding under all road surface conditions by automatic stabilization when Fig 1: Example Of Understeering And Oversteering Vehicle Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
braking, accelerating or rolling¶
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Automatic adaptation of the engine torque depending on the traction condition of the wheels Improvement in the lane stability of the vehicle when cornering, also up to the critical limits Increase in active driving dynamics safety, as only one wheel which is not spinning permits the optimum traction without loss of lateral stability The ESP contains the following systems: Antilock brake system (ABS) Prevents blocking of the individual wheels by reducing the brake pressure at the wheels affected Acceleration slip regulation (ASR) Prevents a too high slip of the drive wheels when starting off and accelerating by torque reduction Electronic brake force distribution (EBV) Assists the driver in the partial braking range. It prevents overbraking of the rear axle and when braking in the curve increases the vehicle stability, while, if necessary, the pressure at the rear wheel on the inside of the curve reduces or is increased at the front wheel on the outside of the curve Engine braking regulation (MSR) Reduces the wheel slip of the drive wheels in deceleration mode by slightly increasing the torque and as a result improved driving stability The clutch can be disengaged as additional assistance.
Function overview¶
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Brake forces, drive forces and side forces acting on one side, which act on the vehicle from outside endeavor to turn the vehicle about its vertical axis. The ESP acquires the vehicle characteristics and for correction selectively brakes individual wheels. It regulates when cornering (vehicle understeers or oversteers) and when driving straight ahead (vehicle deviates from course due to dissimilar road conditions). Sensor system A distinction is made between sensors which detect the driver's requirement (e.g. the steering angle sensor), and sensors which record the actual vehicle characteristics. These include: Yaw rate, lateral and longitudinal acceleration sensor RPM sensor The ESP control unit is constantly supplied with the current data on engine torque and rotational speed by the motor electronics control unit via CAN. Via the turn rate, lateral and longitudinal acceleration sensor the brake forces, drive forces and side forces are recorded which want to turn the vehicle about the vertical axis (yaw rate). This information is transferred to the ESP control unit via CAN. The torque acting on the vehicle is calculated based on this information. If this torque exceeds defined thresholds then the corresponding wheels are braked by the ESP control unit to neutralize the torque which is acting. Simultaneously requests for drive torque reduction are passed on to the motor electronics control unit via Fig 2: Electronic Stability Program (ESP) Function Communication Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
CAN.¶
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Active brake intervention and drive torque reduction by the ESP ensure optimum vehicle stability. The following processes are performed: ESP braking torque control circuit ABS control EBD control ASR control ESP drive torque control circuit ASR control MSR control ESP braking torque control circuit ABS control If one wheel tends to lock the brake pressure at this wheel is reduced. The brake pressure is controlled via the ESP control unit. The various wheel speeds are transmitted to the ESP control unit by the RPM sensors. The ESP control unit compares the speeds against each other and reduces the brake pressure at the wheel which is tending to lock up. Visual status indication: Information on the status of the ABS control system is provided by the ABS indicator lamp. Actuation possibilities: ABS indicator lamp permanently on ABS has a malfunction EBD control The mass of the vehicle shifts during each brake application. The wheels are subjected to different loads depending on the direction of travel (straight-ahead driving or cornering). To achieve optimal braking effect, the brake pressure is increased at the wheels subjected to heavier loads and reduced at the wheels subjected to lesser loads. The ESP control unit computes the required brake interventions based on the information from the yaw rate and lateral acceleration sensor. This also has the simultaneous effect of preventing the wheels subjected to lesser loads from locking up. ASR control To brake the spinning wheel the brake pressure at the spinning wheel is increased via the ESP control unit. 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¶
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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 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 GF42.45-P-
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 115 · Applies to: 450, 451, 452, 454
The ESP control unit is located on the hydraulic unit on the vehicle underfloor. Task The ESP control unit controls the following systems: Electronic Stability Program (ESP) Acceleration Slip Regulation (ASR) Engine braking regulation (EBR) Antilock brake system (ABS) Electronic brake force distribution (EBV) Communication and influence of ESP control unit on other systems in the vehicle: The ESP control unit influences the engine management and power transmission in the case of an ESP control. For driver information the control unit actuates the instrument cluster via the Controller Area Network (data bus/CAN bus) (CAN)A1), the instrument cluster actuates the ABS indicator lamp (A1e17) and ESP warning lamp (A1e41). Direct entries Tml. 15 Circuit 30 Circuit 31 Left front RPM sensor (L6/1) Right front RPM sensor (L6/2) Left rear RPM sensor (L6/3) Right rear RPM sensor (L6/4) Stop light switch (S9/1) Brake fluid indicator switch (S11) Parking brake switch (S12) Voltage supply Yaw rate, lateral and longitudinal acceleration sensor (B24/15) Steering angle sensor (N49) CAN signals The ESP control unit is a CAN subscriber and receives signals from the following sensors: Yaw rate, lateral and longitudinal acceleration sensor
Steering angle sensor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 116 · Applies to: 450, 451, 452, 454
BASIC KNOWLEDGE > WHEEL RPM SENSOR, COMPONENT DESCRIPTION - GF42.45-P- 5134MCC > MODEL 451.3 /4 Location The left front RPM sensor and right front RPM sensor are mounted on the steering knuckles of the front axle. The left rear RPM sensor and right rear RPM sensor are mounted on the wheel carriers of the rear axle. Task The RPM sensors generate a square wave signal which the ESP control unit (N47-5) uses to detect the current wheel speed and other additional information. Design The RPM sensor consists of the RPM sensor head and an electrical line. Fig 1: Identifying Wheel RPM Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Function diagram¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 119 · Applies to: 450, 451, 452, 454
Functional principle The switching components for ABS, ASR, ESP and EBV are combined in the hydraulic unit. Fig 2: Identifying ESP Control And Hydraulic Units With Inlet And Outlet Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Traction System Hydraulic Unit Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
N10/10f18¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 121 · Applies to: 450, 451, 452, 454
Fuse 18 5L N10/10f34 Fuse 34 3L N10/10f38 Fuse 38 6L N47-5 ESP control unit 4A12A20A28A N49 Steering angle sensor 16L S9/1 Stop lamp switch 9L S11 Brake fluid indicator switch 23L S12 Parking brake indicator switch 25L W7 Ground (right wheelhouse in luggage compartment) 25G W9 Ground (left front, at lamp unit) 16G W10 Ground (battery) 7E10G W14 Left floor interior compartment ground 22G W43 Ground (outside left fire wall) 24G Z3/17 Circuit 15 (fused) connector sleeve 5G18G Z37/2 CAN engine bus (low) connector sleeve 13G16E Z37/3 CAN engine bus (high) connector sleeve 12G17E Z37/41 CAN databus (high) connector sleeve 12E19E Z37/42 CAN bus (low) connector sleeve 13E20E Z40 Stop lamp signal connector sleeve 9G WIRING DIAGRAMS > WIRING DIAGRAM OF ELECTRONIC STABILITY PROGRAM (ESP) - PE42.45-P-2000-97MCU > Code: Designation: Position: A1 Instrument cluster 13L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20L L6/1 Left front wheel speed sensor 26L L6/1x1 Wheel speed sensor connector
L6/2 Right front wheel speed sensor 28L L6/2x1 Wheel speed sensor connector
L6/3 Left rear wheel speed sensor 29L L6/3x1 Wheel speed sensor connector
L6/4 Right rear wheel speed sensor 31L L6/4x1 Wheel speed sensor connector
N10/10 SAM control unit 4L
N10/10f11¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 122 · Applies to: 450, 451, 452, 454
Fuse 11 2L N10/10f18 Fuse 18 5L N10/10f34 Fuse 34 3L N10/10f38 Fuse 38 7L N47-5 ESP control module 28A N47-5 ESP control module 12A N47-5 ESP control module 20A N47-5 ESP control module 4A N49 Steering angle sensor 17L S11 Brake fluid indicator switch 23L S12 Parking brake indicator switch 25L S9/1 Stop lamp switch (4-pin) 9L W10 Ground (battery) 11G W10 Ground (battery) 7E W14 Left floor interior compartment ground 22G W43 Ground (outside left fire wall) 24G W7 Ground (right wheelhousing in trunk) 25G W9 Ground (at left headlamp unit) 16G Z3/17 Circuit 15 (fused) connector sleeve 18G Z3/17 Circuit 15 (fused) connector sleeve 5G Z37/2 CAN engine bus (low) connector sleeve 14G Z37/2 CAN engine bus (low) connector sleeve 16E Z37/3 CAN engine bus (high) connector sleeve 12G Z37/3 CAN engine bus (high) connector sleeve 17E Z37/41 CAN databus (high) connector sleeve 12E Z37/41 CAN databus (high) connector sleeve 19E Z37/42 CAN bus (low) connector sleeve 14E Z37/42 CAN bus (low) connector sleeve 21E Z40 Stop lamp signal connector sleeve 9G
Fig 1: Electronic Stability Program (ESP) - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 123 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
OV00.01-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 125 · Applies to: 450, 451, 452, 454
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 WIRING DIAGRAMS > WIRING DIAGRAM OF ELECTRONIC STABILITY PROGRAM (ESP) - PE42.45-P-2000-99MCU > Code: Designation: Position: A1 Instrument cluster 13 L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20 L L6/1 Left front wheel speed sensor 26 L L6/1x1 Wheel speed sensor connector 25 H L6/2 Right front wheel speed sensor 28 L L6/2x1 Wheel speed sensor connector 27 H L6/3 Left rear wheel speed sensor 29 L L6/3x1 Wheel speed sensor connector 29 H L6/4 Right rear wheel speed sensor 31 L L6/4x1 Wheel speed sensor connector 30 H N10/10 SAM control unit 4 L N10/10f11 Fuse 11 2 L N10/10f18 Fuse 18 5 L N10/10f34 Fuse 34 3 L N10/10f38 Fuse 38 6 L N47-5 ESP control module 4 A N47-5 ESP control module 12 A N47-5 ESP control module 20 A N47-5 ESP control module 28 A N49 Steering angle sensor 16 L S11 Brake fluid indicator switch 23 L S12 Parking brake indicator switch 25 L
S9/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 126 · Applies to: 450, 451, 452, 454
Stop lamp switch (4-pin) 9 L W10 Ground (battery) 6 E W10 Ground (battery) 10 G W14 Left floor interior compartment ground 22 G W43 Ground (outside left fire wall) 23 G W7 Ground (right wheelhousing in trunk) 25 G W9 Ground (at left headlamp unit) 16 G Z3/17 Circuit 15 (fused) connector sleeve 5 H Z3/17 Circuit 15 (fused) connector sleeve 18 H Z37/2 CAN engine bus (low) connector sleeve 13 H Z37/2 CAN engine bus (low) connector sleeve 16 E Z37/3 CAN engine bus (high) connector sleeve 12 H Z37/3 CAN engine bus (high) connector sleeve 17 E Z37/41 CAN databus (high) connector sleeve 12 E Z37/41 CAN databus (high) connector sleeve 19 E Z37/42 CAN bus (low) connector sleeve 13 E Z37/42 CAN bus (low) connector sleeve 20 E Z40 Stop lamp signal connector sleeve 9 H
Fig 1: Electronic Stability Program (ESP) - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 127 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > LEGEND OF FUNCTION DIAGRAM FOR ELECTRICAL SYSTEM OF¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 128 · Applies to: 450, 451, 452, 454
ELECTRONIC STABILITY PROGRAM (ESP) - PE42.45-P-2050-60MCU > MODEL 451 Code Designation Coordinates A1 Instrument cluster 21L A1e7 Brake fluid and parking brake warning lamp 23J A1e41 ESP warning lamp 23K A1p8 Electronic speedometer 23K B24/15 Yaw rate, lateral and longitudinal acceleration sensor 7D E3e4 Left stop light 13H E4e4 Right stop light 13H Fig 2: Electronic Stability Program (ESP) - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3000MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 130 · Applies to: 450, 451, 452, 454
(line connectors in wiring harness) 3000MCU PE07.00-P- 1100MCU
Further wiring diagrams PE07.00-P- 1100MCU PE42.00-P- 1100MCU
Further wiring diagrams PE42.00-P- 1100MCU PE46.00-P- 1100MCU
Further wiring diagrams PE46.00-P- 1100MCU PE54.00-P- 1100MCU
Further wiring diagrams PE54.00-P- 1100MCU WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR ELECTRONIC STABILITY PROGRAM (ESP) - PE42.45-P-2050-99MCU > Code: Designation: Position: A1 Instrument cluster 13 L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20 L L6/1 Left front wheel speed sensor 26 L L6/1x1 Wheel speed sensor connector 25 H L6/2 Right front wheel speed sensor 28 L L6/2x1 Wheel speed sensor connector 27 H L6/3 Left rear wheel speed sensor 29 L L6/3x1 Wheel speed sensor connector 29 H L6/4 Right rear wheel speed sensor 31 L L6/4x1 Wheel speed sensor connector 30 H N10/10 SAM control unit 4 L N10/10f11 Fuse 11 2 L N10/10f18 Fuse 18 5 L N10/10f34 Fuse 34 3 L N10/10f38 Fuse 38 6 L N47-5 ESP control module 4 A N47-5 ESP control module 12 A N47-5 ESP control module 20 A N47-5 ESP control module 28 A N49 Steering angle sensor 16 L
Brake fluid indicator switch¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 131 · Applies to: 450, 451, 452, 454
S11 Brake fluid indicator switch 23 L S12 Parking brake indicator switch 25 L S9/1 Stop lamp switch (4-pin) 9 L W10 Ground (battery) 6 E W10 Ground (battery) 10 G W14 Left floor interior compartment ground 22 G W43 Ground (outside left fire wall) 23 G W7 Ground (right wheelhousing in trunk) 25 G W9 Ground (at left headlamp unit) 16 G Z3/17 Circuit 15 (fused) connector sleeve 5 H Z3/17 Circuit 15 (fused) connector sleeve 18 H Z37/2 CAN engine bus (low) connector sleeve 13 H Z37/2 CAN engine bus (low) connector sleeve 16 E Z37/3 CAN engine bus (high) connector sleeve 12 H Z37/3 CAN engine bus (high) connector sleeve 17 E Z37/41 CAN databus (high) connector sleeve 12 E Z37/41 CAN databus (high) connector sleeve 19 E Z37/42 CAN bus (low) connector sleeve 13 E Z37/42 CAN bus (low) connector sleeve 20 E Z40 Stop lamp signal connector sleeve 9 H
Fig 1: Electronic Stability Program (ESP) - Electrical Function Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 132 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 000 589 52 43 00 RESETTING DEVICE - WS42.00-P-0009A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 133 · Applies to: 450, 451, 452, 454
FG 42/Set A MODEL 450, 451, 452, 107, 123, 124, 126, 129, 140, 163, 164, 168, 169.0 /3, 170, 171, 172, 197, 199, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 251, 414, 460, 461, 463.2 /3
Further use FG42/Set A WS42.00-N- 0009A 15.10.10 Replacement for 450 589 02 37 00 brake piston pusher tool FG42/Set A WS42.00-P- 0062A Use: Resetting device for brake piston.
Fig 2: Electronic Stability Program (ESP) - Electrical Function Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 140 589 00 19 00 CALIPER GAUGE - WS42.00-P-0028A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 134 · Applies to: 450, 451, 452, 454
FG 42/Set A MODEL all MODIFICATION NOTES 10.12.92 Replacement for: 124 589 05 19 00 124 589 05 19 00 Caliper gage WS42.00-N- 3001B 1.7.08 Replacement for: 450 589 01 19 00 vernier caliper
WS42.00-P- 0063A Use: Vernier caliper for measurement of brake disk thickness. (measuring range 50 mm, leg length 75 mm).
SPECIAL TOOLS > 450 589 00 37 00 PLIERS - WS42.00-P-0060A > Fig 1: Identifying Resetting Device (000 589 52 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Caliper Gauge (140 589 00 19 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 42/Set A¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 135 · Applies to: 450, 451, 452, 454
MODEL 450,451,452 Use: Pliers for hooking in and unhooking brake springs at the brake shoes of the drum brake. NOTE: Brake spring pliersSmart no. 0004997. SPECIAL TOOLS > 450 589 02 37 00 BRAKE PISTON PUSHER TOOL - WS42.00-P-0062A > FG 42/Set A MODEL 450, 451, 452 15.10.10 Replaced by 000 589 52 43 00 Pusher tool WS42.00-P-0009A Use: Brake piston pusher tool for pushing brake piston back on front-axle brake caliper. NOTE: Brake piston resetting deviceSmart No. 0004999. Fig 1: Identifying Pliers (450 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 01 19 00 VERNIER CALIPER - WS42.00-P-0063A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 136 · Applies to: 450, 451, 452, 454
FG 42/Set A MODEL 450, 451, 452, 454 MODIFICATION NOTES 1.7.08 Replaced by 140 589 00 19 00 vernier caliper WS42.00-P-0028A Use: Vernier caliper for measuring brake disk thickness. NOTE: Vernier caliper for brake disksSmart No. 0005087. SPECIAL TOOLS > 450 589 03 09 00 TORX BIT INSERT - WS42.00-P-0064B > Fig 1: Identifying Brake Piston Pusher Tool (450 589 02 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Vernier Caliper (450 589 01 19 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 42/SET B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 137 · Applies to: 450, 451, 452, 454
MODEL 450, 451, 452 Use: Torx bit insert for loosening mounting screws on brake pedal head and Sedrive unit. NOTE: TORX bit insert IPR 30, 14/4" socketSmart no. 0005179. SPECIAL TOOLS > 452 589 00 68 00 SCRAPER - WS42.00-P-0066B > FG 42/Set B MODEL 450, 451, 452 Use: Removal of seal from ABS/ESP housing. NOTE: Smart no.: 001 5806 V000 0000 00 Fig 1: Identifying Torx Bit Insert (450 589 03 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 452 589 00 21 01 PIPETTE - WS42.00-P-0067-01A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 138 · Applies to: 450, 451, 452, 454
FG42/Set A MODEL 450, 451, 452, 454 Use: Pipette for sampling brake fluid. NOTE: CAUTION: The pipette may only be used once!Pipette: Smart no. 001 5955 V000 0000 00.Available in packs of 100 ea. Replacement part for caseW 452 589 00 21 00 / Smart no. 001 5798 V000 0000 00. SPECIAL TOOLS > 452 589 00 21 00 BRAKE FLUID METER - WS42.00-P-0067A > Fig 1: Identifying Scraper (452 589 00 68 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Pipette (452 589 00 21 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 42/Set A¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 139 · Applies to: 450, 451, 452, 454
MODEL 450, 451, 452, 454 Single part 452 589 00 21 01 Pipette FG 42/Set A WS42.00-P-0067-01A Use: Brake fluid meter for determining the condition of the brake fluid. NOTE: For DOT 4 and DOT 4+ brake fluids, device features temperature compensation, display scales for boiling point (°C) and water content (%), supplied in a plastic case with sampling pipette W 452 589 00 21 01 / 001 5955 V000 0000 00.Case: Smart no. 001 5798 V000 0. SPECIAL TOOLS > 450 589 09 99 04 BOX WRENCH BIT - WS42.00-P-0070-04B > FG29/42/Set B MODEL 450, 451, 452 Use: Open ring wrench socket for loosening and tightening the union nut on the brake lines. NOTE: Ring wrench socketsmart no. 001 9570 V001 0000 00. Fig 1: Identifying Brake Fluid Meter (452 589 00 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 452 589 03 99 01 TORQUE WRENCH - WS42.00-P-0071-01B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 140 · Applies to: 450, 451, 452, 454
FG42/Set B MODEL 450, 451, 452, 454 Use: Torque wrench for loosening and tightening the mounting screws of the ESP control unit on the hydraulic assembly to the specified torque. NOTE: Special size of torque wrench with permanently adjusted release torque of 3 Nm,smart-N. 001 9572 V001 0000 00. SPECIAL TOOLS > 452 589 03 99 02 PLUG-IN REVERSIBLE RATCHET - WS42.00-P-0071- Fig 1: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Torque Wrench (452 589 03 99 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
02B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 141 · Applies to: 450, 451, 452, 454
FG42/Set B MODEL 450, 451, 452 Use: Plug-in reversible ratchet with 9x12 mm plug-in square for 1/4" hexagon bit inserts (6.3 mm). NOTE: Plug-in reversible ratchetsmart no. 001 9573 V001 0000 00. SPECIAL TOOLS > 452 589 03 99 03 TORX PLUG-IN BIT - WS42.00-P-0071-03B > FG42/Set B MODEL 450, 451, 452 Use: Torx plug-in bit for loosening and tightening the mounting screws of the ESP control unit and hydraulic assembly. NOTE: Special length of Torx plug-in bit T20smart no. 001 9574 V001 0000 00. Fig 1: Identifying Plug-In Reversible Ratchet (452 589 03 99 02) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 452 589 03 99 00 SET OF TORQUE TOOLS - WS42.00-P-0071B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 142 · Applies to: 450, 451, 452, 454
FG 42/Set B MODEL 450, 451, 452 Single part 452 589 03 99 01 Torque wrench FG42/Set B WS42.00-P-0071-01B Single part 452 589 03 99 02 Plug-in reversible ratchet FG42/Set B WS42.00-P-0071-02B Single part 452 589 03 99 03 Torx plug-in bit FG42/Set B WS42.00-P-0071-03B Use: Set of torque tools for exchanging the ESP control unit on the hydraulic assembly without removing the major assembly. NOTE: Set of torque toolssmart no. 001 9571 V001 0000 00. Fig 1: Identifying Torx Plug-In Bit (452 589 03 99 03) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 15 37 00 PLIERS - WS42.00-P-0082B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 143 · Applies to: 450, 451, 452, 454
FG 42/Set B MODEL 450, 451, 452, 454 Use: Special pliers for assembling the low-pressure lines on ESP 8.0 SPECIAL TOOLS > 451 589 00 14 00 SLEEVE - WS42.00-P-0083C > FG 42/Set C MODEL 451 Use: Sleeve for installing/removing hand brake cables. Fig 1: Identifying Set Of Torque Tools (452 589 03 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Pliers (450 589 15 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 00 03 00 SOCKET WRENCH SET - WS42.00-P-0086B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 144 · Applies to: 450, 451, 452, 454 · AR: WS42.00-Z-9999CZ
FG 42/Set B MODEL 451 Use: Socket wrench set for loosening and tightening union nut on brake lines on ESP/ABS hydraulic assembly. SPECIAL TOOLS > SPECIAL TOOLS: SMART: BRAKES - HYDRAULIC AND MECHANICAL SYSTEMS - WS42.00-Z-9999CZ > MODEL all 000 589 52 43 00 Resetting device FG 42/Set A WS42.00-P-0009A 129 589 00 21 00 126-pin socket box FG 00/42/54/91 / Set B WS54.00-P-0008B Fig 1: Identifying Sleeve (451 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
140 589 00 19 00 Caliper gauge¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 145 · Applies to: 450, 451, 452, 454
FG 42/Set A WS42.00-P-0028A 168 589 00 37 00 Pliers FG 42/Set B WS42.00-P-0040B 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 450 589 00 37 00 Pliers FG 42/Set A WS42.00-P-0060A 450 589 01 19 00 Vernier caliper FG 42/Set A WS42.00-P-0063A 450 589 01 37 00 Pliers FG 42/Set A WS42.00-P-0061A 450 589 02 37 00 Brake piston pusher tool FG 42/Set A WS42.00-P-0062A 450 589 03 09 00 Torx bit insert FG 42/Set B WS42.00-P-0064B 450 589 09 99 00 Set of brake line wrenches FG 42/Set B WS42.00-P-0070B 450 589 09 99 01 Torque wrench FG42/Set B WS42.00-P-0070-01B 450 589 09 99 02 Socket wrench bit FG42/Set B WS42.00-P-0070-02B 450 589 09 99 03 Socket wrench bit FG42/Set B WS42.00-P-0070-03B 450 589 09 99 04 Box wrench bit FG29/42/Set B WS42.00-P-0070-04B 450 589 15 37 00 Pliers FG 42/Set B WS42.00-P-0082B 451 589 00 03 00 Socket wrench set FG 42/Set B WS42.00-P-0086B 451 589 00 14 00 Sleeve FG 42/Set C WS42.00-P-0083C 452 589 00 21 00 Brake fluid meter FG 42/Set A WS42.00-P-0067A 452 589 00 21 01 Pipette FG42/Set A WS42.00-P-0067-01A 452 589 00 68 00 Scraper FG 42/Set B WS42.00-P-0066B 452 589 02 09 00 Socket wrench bit FG 42/Set B WS42.00-P-0065B 452 589 03 99 00 Set of torque tools FG 42/Set B WS42.00-P-0071B 452 589 03 99 01 Torque wrench FG42/Set B WS42.00-P-0071-01B 452 589 03 99 02 Plug-in reversible ratchet FG42/Set B WS42.00-P-0071-02B 452 589 03 99 03 Torx plug-in bit FG42/Set B WS42.00-P-0071-03B 454 589 00 43 00 Resetting device FG 42/Set A WS42.00-P-0068A 454 589 01 91 00 Adapter FG 42/25/26/Set A WS42.00-P-0069A
GENERAL INFORMATION > NOTES ON REPAIRS TO BRAKE SYSTEM - AH42.00-P-0003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 146 · Applies to: 450, 451, 452, 454
01A > All models During maintenance and repair work on the brake system ensure that no mineral oil, grease or similar substances enter the brake system New brake fluid must be used as washing and cleaning medium for cylinders, lines and expansion containers in the hydraulic braking system. If mineral oil is found in the brake system or mineral oil is suspected of being in the brake system, the following procedure must be carried out: 1. Replace the tandem master brake cylinder or brake operating unit and expansion reservoir for brake fluid. 2. Flush out entire brake system thoroughly with fresh brake fluid. 3. All brake parts with components made from rubber, such as brake calipers, brake hoses, SBC/ABS/ETS/ASR or ESP hydraulic unit, pressure reservoir, charge plunger unit and charging pump, which may have come into contact with mineral oil, must be replaced. 4. Bleed the braking system. Handling SBC/ABS/ETS/ASR and ESP parts on vehicles involved in accidents: If, due to the extent of the damage to the vehicle, or from the position and external appearance of the hydraulic unit it can be recognized that the hydraulic unit has received a heavy blow, the hydraulic unit should be replaced. Indications of this are e.g.: Hydraulic lines kinked Connections on hydraulic unit leaking Cables or plug connections damaged The metal block of the hydraulic unit has signs of damage The hydraulic unit has sprung out of the bracket and cannot be inserted again without a lot of force. If the above conditions do not apply, the system must nevertheless be subjected to a thorough function test and the steps for testing the solenoid valves and pump must be carried out. GENERAL INFORMATION > BRAKE FLUID NOTES - AH42.50-P-0001-01A > All models Do not allow brake fluid to come into contact with vehicle paintwork, as it contains ingredients that
act as solvents on the paint. Should brake fluid come into contact with the paint despite all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 147 · Applies to: 450, 451, 452, 454
precautions, the moistened surface must be flushed immediately with a lot of water (do not rub off brake fluid). Brake fluid is highly hygroscopic, i.e. it absorbs humidity which reduces its boiling point. Brake fluid must therefore only be stored in properly sealed reservoirs (original container) in order to avoid moisture absorption via the air humidity. A boiling point which is reduced as a result can lead to problems up to the total failure of the brake system at high operating temperatures. Used brake fluid must not be re-used. Brake fluid is colorless to yellow colored and is therefore easily confused with mineral oil products. Therefore only remove brake fluids from original containers and store separately from mineral oils and other fluids. For disposal notes for the location area Federal Republic of Germany see: "Environmental Manual for Motor Vehicle Repair Operations" Publisher: Association of the German Automotive Industry e.V. (VDA) 60625 Frankfurt am Main, Westendstraβe 61 RETROFITTING & CONVERSION > INSTALL BRABUS HAND BRAKE LEVER - AN42.20-P- 0003MCC > MODEL 451.3/4 (except 451.391 /491) Shown on model 451.3 up to vehicle identification number (VIN) WME4513312K143823 Shown on model 451.3 as of VIN WME4513312K143824 Fig 1: Identifying Hand Brake Handle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 148 · Applies to: 450, 451, 452, 454
1 Adjust seats rearwards and pull on hand brake lever (5)
2 Protect seats and center console against damage and dirt using a suitable cover On vehicles as of VIN WME4513312K143824
3 Unscrew and remove push button (2)
4.1 Remove expansion clip (3) and pull off hand brake handle (1) On vehicles up to VIN WME4513312K143823
Fig 2: Identifying Hand Brake Handle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Brabus Hand Brake Lever Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Replace¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 150 · Applies to: 450, 451, 452, 454
Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake Only pour brake fluid into suitable and appropriately marked containers. Wear fluid coming into contact with skin and eyes. 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 maintenance flap
2 Unscrew cap of brake fluid reservoir (1)
3 Connect brake fluid changer to brake fluid reservoir (1) and apply the specified pressure to the brake system Observe the operator's manual for the brake fluid changer.Brake fluid change unithttp://gotis.aftersales.mercedes- benz.com
General brake fluid Sheet 330.1 BB00.40-P-0330- 01A Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331- 00A Fig 1: Identifying Brake Fluid Reservoir, Brake Caliper And Wheel Brake Cylinder Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of death¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 151 · Applies to: 450, 451, 452, 454
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 4 Raise vehicle with vehicle lift Position the front support plates of the vehicle lift as far as possible upwards, position the rear support plates as far as possible downwards and secure the vehicle to prevent it from slipping or toppling.
5 Remove dust caps from the brake bleeder valves
6 Connect hose of brake fluid receptacle to brake bleeder valve of the wheel brake cylinder (3) and open brake bleeder valve Close the brake bleeder valve only after the brake fluid escapes free of bubbles and without contamination (bright color of brake fluid).
*BA42.10-P-1001- 08C 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 Observe correct sequence.
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
caused by swallowing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 163 · Applies to: 450, 451, 452, 454
brake fluid. Risk of 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. 01A Brake fluid notes
AH42.50-P-0001- 01A Notes on repairs to brake system
AH42.00-P-0003- 01A 1 Remove wheels Position the front support plates of the vehicle lift as far as possible upwards, position the rear support plates as far as possible downwards and secure the vehicle to prevent it from slipping or toppling. AR40.10-P- 1100MCU 2 Remove dust caps from the brake bleeder valves
3 Lower vehicle with vehicle lift
4 Remove maintenance flap
5 Unscrew cap of brake fluid reservoir (1)
6 Connect brake fluid changer to brake fluid reservoir (1) and apply the specified pressure to the brake system Observe the operator's manual for the brake fluid changer.Brake fluid change unithttp://gotis.aftersales.mercedes- benz.com
General brake fluid Sheet 330.1 BB00.40-P-0330- 01A Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331- 00A
Bleed primary circuit
7 Connect hose of the brake fluid receptacle to the brake bleeder valve of the right wheel brake cylinder (3) and open the brake bleeder valve Only close the brake bleeder valve when the brake fluid escapes free of bubbles and without contaminants (light color of brake fluid).A second person is needed who assists the brake fluid changer by slowly pumping on the brake pedal.
*BA42.10-P-1001- 08C 8 Carry out the bleeding Observe correct sequence.
process on the left¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 164 · Applies to: 450, 451, 452, 454
wheel brake cylinder (3), on the right brake caliper (2) and on the left brake caliper (2) in the same manner BA42.10-P-1001- 08C BA42.10-P-1002- 10A 9 Check brake pedal travel In the event of a soft pedal feel or long pedal travel, bleed the secondary circuit of the brake system.
Bleed secondary circuit
10 Connect STAR DIAGNOSIS and bleed the secondary circuit of the brake system The instructions for secondary circuit bleeding are specified by STAR DIAGNOSIS. A second person is needed who assists the brake fluid changer by slowly pumping on the brake pedal.
Connect STAR DIAGNOSIS and read out fault memory
AD00.00-P-2000- 04MCC 11 Disconnect brake fluid changer
12 Check brake fluid level and correct if necessary
Brake system - inspect fluid 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
Figure item,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 166 · Applies to: 450, 451, 452, 454
etc. Work instructions
1 Brake line From the ESP hydraulic unit to the left front brake hose.
Remove/install left front brake line AR42.10-P- 0032MCU 2 Brake line From the ESP hydraulic unit to the right front brake hose.
Remove/install right front brake line AR42.10-P- 0033MCU 3 Brake lines From the master brake cylinder to the ESP hydraulic unit.
Remove/install brake line from the master brake cylinder to the ESP hydraulic unit AR42.10-P- 0034MCU 4 Brake lines From the ESP hydraulic unit to the brake hose on the rear axle.
Remove/install brake line from the ESP hydraulic unit to the rear axle AR42.10-P- 0035MCU 5 Brake line From the brake hose on the rear axle to the left wheel brake cylinder.
Fig 1: Brake Line Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install left rear brake line¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 167 · Applies to: 450, 451, 452, 454
AR42.10-P- 0036MCU 6 Brake line From the brake hose on the rear axle to the right wheel brake cylinder.
Remove/install right rear brake line AR42.10-P- 0037MCU TESTING & REPAIR > REMOVE/INSTALL BRAKE HOSE AT REAR AXLE - AR42.10-P- 0023MCU > MODEL 451.3/4 Shown on left rear brake hose (1)
Remove/install
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 Align vehicle between columns of Fig 1: Identifying Rear Axle Brake Hose Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of death caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 168 · Applies to: 450, 451, 452, 454
vehicle slipping or toppling off of the lifting platform. vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z- 0010-01A 1 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriverGOTIS://G_58.0_01.1
2 Remove bulkhead wall On model 451.431 AR61.25-P- 6600MCU 3 Unscrew plastic nut (2), open folding clamp (3) using a suitable tool and take off Observe installation position of brake line (4) and electrical lines (5, 6)
4 Hang up electrical lines (5, 6) to one side
5 Check bolted connections of brake lines (4, 7) with brake hose (1) for color coding Installation: Identify brake lines (4, 7) accordingly. AR42.10-P- 0013-05MCC 6 Loosen bolted connections of the brake lines (4, 7) with the brake hose (1) and separate Mark brake hose (1) relative to the brake lines (4, 7). Collect brake fluid in a suitable container. Seal brake lines (4, 7) and brake hose (1) with suitable plugs.
BA42.10-P- 1002-04E 450589099904 7 Detach retaining clamps (8) and remove brake hose (1)
8 Replace brake line (4) or brake line (7) Only if brake line (4) or brake line (7) with red color coding has been detached.
Remove/install brake line from the ESP hydraulic unit to the rear axle AR42.10-P- 0035MCU Remove/install left rear brake line AR42.10-P- 0036MCU Remove/install right rear brake line AR42.10-P- 0037MCU 9 Install in the reverse order
10 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002- 04E Brake pipe to brake hose Nm 16
TESTING & REPAIR > REMOVE/INSTALL BRAKE HOSE TO FRONT AXLE - AR42.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 169 · Applies to: 450, 451, 452, 454
0026MCU > MODEL 451.3/4 Shown on left side of vehicle
Remove/install
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 left or right front wheel
AR40.10-P- 1100MCU Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Axle Brake Hose Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Detach retaining clip¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 170 · Applies to: 450, 451, 452, 454
2 Detach retaining clip (3)
3 Check bolted connection of brake line (2) with brake hose (1) for color coding Installation: Identify the brake line (2) accordingly. AR42.10-P- 0013-05MCC 4 Loosen bolted connection of brake line (2) with the brake hose (1) and unhook brake hose (1) Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: The brake hose (1) must free to move at each steering angle and jounce condition. The brake hose (1) must not be mounted twisted otherwise the brake hose (1) may be damaged.
BA42.10-P- 1002-04E 450589099904 5 Unscrew brake hose (1) from brake caliper (4) and remove Collect brake fluid in a suitable container. Seal the connections using suitable plugs.
*BA42.10-P- 1001-04E 6 Replace brake line (2). Only if the brake line (2) with the red color coding has been detached.
Remove/install left front brake line AR42.10-P- 0032MCU Remove/install right front brake line AR42.10-P- 0033MCU 7 Install in the reverse order
8 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1001- 04E Brake hose to front floating caliper Nm 18 BA42.10-P-1002- 04E Brake pipe to brake hose Nm 16
TESTING & REPAIR > REMOVE/INSTALL LEFT FRONT BRAKE LINE - AR42.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 171 · Applies to: 450, 451, 452, 454
0032MCU > MODEL 451.3/4 Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Brake Fluid Expansion Reservoir Cap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 172 · Applies to: 450, 451, 452, 454
Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by Only pour brake fluid into suitable and appropriately marked containers. Wear AS42.50-Z- Fig 2: Identifying Left Front Brake Line Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Left Front Brake Line Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
brake fluid coming into¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 173 · Applies to: 450, 451, 452, 454
contact with skin and eyes. protective clothing and eye protection when handling brake fluid. 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 Unscrew cap (2) of brake fluid expansion reservoir and suction off brake fluid
3 Remove left front wheel
AR40.10-P- 1100MCU 4 Remove underfloor panels Rechargeable drill / screwdriverGOTIS://G_58.0_01.1
5 Remove diagonal struts On model 451.431 AR61.10-P- 5138MCU 6 Remove left diagonal strut On model 451.491 AR61.10-P- 5138MEV 7 Unclip brake line (3) from the bracket (4)
8 Loosen nuts (5), unscrew bolts (6) and remove bracket (7) Installation: Move guide pin (9) on the hydraulic unit (8) into the bracket (7).
BA42.45-P- 1008-01F 9 Support hydraulic unit (8) using transmission jack and removal fixture Transmission jackGOTIS://H_00.10_01.0 450589026200 10 Check bolted connections of brake lines (10) with the hydraulic unit (8) for color coding Installation: Identify brake lines (10) accordingly. AR42.10-P- 0013-05MCC 11 Loosen bolted connections of brake lines (10) with the hydraulic unit (8) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs.
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (10), pay ATTENTION to routing, leaktightness and clearance.If a brake line (10) with red color coding has been detached, this brake line (10) must be replaced.Refer to: ↓ *BA42.10-P- 1010-04E
Remove/install brake line from the master¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 174 · Applies to: 450, 451, 452, 454
brake cylinder to the ESP hydraulic unit AR42.10-P- 0034MCU 12 Lower the hydraulic unit (8) carefully until the brake line (1) is accessible
13 Unclip retaining clips (11), RPM sensor connector (L6/1x1) and electrical lines (12, 13) on brake line (1)
14 Check bolted connections of brake line (1) with the hydraulic unit (8) and the brake hose (14) for color coding Installation: Identify the brake line (1) accordingly. AR42.10-P- 0013-05MCC 15 Loosen bolted connections of the brake line (1) with the hydraulic unit (8) and the brake hose (14) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation: Do not bend brake line (1), pay ATTENTION to routing, leaktightness and clearance.
BA42.10-P- 1002 04E BA42.10-P- 1010-04E 450589099904 451589000300 16 Remove brake line (1)
17 Replace brake line (1). Only if the brake line (1) with the red color coding has been detached.
18 Install in the reverse order
19 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002- 04E Brake pipe to brake hose Nm 16 BA42.10-P-1010- 04E Brake line to ESP hydraulic unit Nm 16 ELECTRONIC STABILITY PROGRAM (ESP)
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 175 · Applies to: 450, 451, 452, 454
Designation Model 451.3/4 BA42.45-P-1008- 01F Bolt, ESP hydraulic unit bracket to floor panel Nm 25 TESTING & REPAIR > REMOVE/INSTALL RIGHT FRONT BRAKE LINE - AR42.10-P- 0033MCU > MODEL 451.3/4 Fig 4: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 176 · Applies to: 450, 451, 452, 454
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 Fig 1: Locating Brake Fluid Expansion Reservoir Cap Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Right Front Brake Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on repairs to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 177 · Applies to: 450, 451, 452, 454
brake system
AH42.00-P- 0003-01A 1 Remove maintenance flap
2 Unscrew cap (2) of brake fluid expansion reservoir and suction off brake fluid
3 Remove right front wheel
AR40.10-P- 1100MCU 4 Remove underfloor panels Rechargeable drill / screwdriverGOTIS://G_58.0_01.1
5 Remove diagonal struts On model 451.431 AR61.10-P- 5138MCU 6 Remove left diagonal strut On model 451.491 AR61.10-P- 5138MEV 7 Remove support for front axle carrier On model 451.391/491 AR33.10-P- 0002MEV 8 Loosen nuts (3), unscrew bolts (4) and remove bracket (5) Installation: Move guide pin (7) on the hydraulic unit (6) into the bracket (5).
BA42.45-P- 1008-01F 9 Support hydraulic unit (6) using transmission jack and removal fixture Transmission jackGOTIS://H_00.10_01.0 450589026200 10 Check bolted connections of brake lines (8) with the hydraulic unit (6) for color coding Installation: Identify brake lines (8) accordingly. AR42.10-P- 0013-05MCC 11 Loosen bolted connections of brake lines (8) with the hydraulic unit (6) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs.
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (8), pay ATTENTION to routing, leaktightness and clearance.If a brake line (8) with red color coding has been loosened, this brake line (8) must be replaced.Refer to: ↓ *BA42.10-P- 1010-04E Remove/install brake line from the master brake cylinder to the ESP hydraulic unit AR42.10-P- 0034MCU 12 Lower the hydraulic unit (6) carefully until the brake line (1) is accessible
Unclip the retaining¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 178 · Applies to: 450, 451, 452, 454
13 Unclip the retaining clips (9) and RPM sensor connector (L6/2x1) from the brake line (1) and unclip brake line (1) from the brackets (10)
14 Check bolted connections of brake line (1) with the hydraulic unit (6) and the brake hose (11) for color coding Installation: Identify the brake line (1) accordingly. AR42.10-P- 0013-05MCC 15 Loosen bolted connections of the brake line (1) with the hydraulic unit (6) and the brake hose (11) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation: Do not bend brake line (1), pay ATTENTION to routing, leaktightness and clearance.
BA42.10-P- 1002-04E BA42.10-P- 1010-04E 450589099904 451589000300 16 Remove brake line (1)
17 Replace brake line (1). Only if the brake line (1) with the red color coding has been detached.
18 Install in the reverse order
19 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002- 04E Brake pipe to brake hose 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
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 180 · Applies to: 450, 451, 452, 454
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 maintenance flap
2 Unscrew cap of brake fluid expansion reservoir and drain brake fluid
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 3 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriverGOTIS://G_58.0_01.1
4 Remove diagonal struts On model 451.431 AR61.10-P- 5138MCU Fig 1: Identifying Brake Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove left diagonal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 181 · Applies to: 450, 451, 452, 454
5 Remove left diagonal strut On model 451.491 AR61.10-P- 5138MEV 6 Loosen nuts (2), unscrew bolts (3) and remove bracket (4) Installation: Move guide pin (6) on the hydraulic unit (5) into the bracket (4).
BA42.45-P- 1008-01F 7 Support hydraulic unit (5) using transmission jack and removal fixture and lower carefully until the brake lines (1) are accessible Transmission jackGOTIS://H_00.10_01.0 450589026200 8 Unclip retaining clip (7) of the electrical line (8)
9 Check bolted connections of brake lines (1) with the hydraulic unit (5) and the master brake cylinder (9) for color coding Installation: Identify brake lines (1) accordingly. AR42.10-P- 0013-05MCC 10 Loosen bolted connections of brake lines (1) with the hydraulic unit (5) and the master brake cylinder (9) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (1), pay ATTENTION to routing, leaktightness and clearance.
BA42.10-P- 1005-04E BA42.10-P- 1010-04E 11 Remove brake lines (1)
12 Install new brake lines (1) Only if the brake lines (1) with the red color coding have been detached.
13 Install in the reverse order
14 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1005- 04E Brake pipe to master brake cylinder Nm 16 BA42.10-P-1010- Brake line to ESP hydraulic unit Nm 16
Illustrated on model 451.30¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 183 · Applies to: 450, 451, 452, 454
Model 451.391/491 Fig 2: Identifying ESP Hydraulic Unit Components (Model 451.30) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying ESP Hydraulic Unit Components (Model 451.391/491) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.30¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 184 · Applies to: 450, 451, 452, 454
Remove/install
Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eye 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 maintenance flap
2 Unscrew cap (2) of brake fluid expansion reservoir and suction off brake fluid
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 3 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriverGOTIS://G_58.0_01.1
4 Remove diagonal struts On model 451.431 AR61.10-P- 5138MCU 5 Remove bulkhead wall On model 451.431 AR61.25-P- 6600MCU Fig 4: Identifying Brake Lines, Hydraulic Unit And Brake Hoses (Model 451.30) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove high-voltage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 185 · Applies to: 450, 451, 452, 454
6 Remove high-voltage battery On model 451.391/491 AR54.10-P- 1140MEV 7 Unclip retaining clips (5) of electrical line (17) on upper brake line (1) On model 451.391/491
8 Unscrew plastic nut (3), open folding clamp (4) using a suitable tool and take off Observe installation position of brake lines (1) and electrical lines.
9 Unclip retaining clips (5) of electrical line (6), RPM sensor connector (L6/3x1) and RPM sensor connector (L6/4x1) on the brake lines (1)
10 Unclip brake lines (1) from the bracket (7)
11 Unclip brake line (8) from the bracket (9)
12 Loosen nuts (10), unscrew bolts (11) and remove bracket (12) Installation: Move guide pin (13) on the hydraulic unit (14) into the bracket (12).
BA42.45-P- 1008-01F 13 Support hydraulic unit (14) using transmission jack and removal fixture Transmission jackGOTIS://H_00.10_01.0 450589026200 14 Check bolted connections of brake lines (15) with the hydraulic unit (14) for color coding Installation: Identify brake lines (15) accordingly. AR42.10-P- 0013-05MCC 15 Loosen bolted connections of brake lines (15) with the hydraulic unit (14) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs.
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (15), pay ATTENTION to routing, leaktightness and clearance.If a brake line (15) with red color coding has been loosened, this brake line (15) must be replaced.Refer to: ↓ *BA42.10-P- 1010-04E Remove/install brake line from the master brake cylinder to the ESP hydraulic unit AR42.10-P- 0034MCU 16 Lower the hydraulic unit (14) carefully until the brake lines (1) are
accessible¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 186 · Applies to: 450, 451, 452, 454
17 Check bolted connections of brake lines (1) with the hydraulic unit (14) and the master brake cylinder (16) for color coding Installation: Identify brake lines (1) accordingly. AR42.10-P- 0013-05MCC 18 Loosen bolted connections of brake lines (1) with the hydraulic unit (14) and loosen the brake hoses (16) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation Do not bend brake lines (1), pay ATTENTION to routing, leaktightness and clearance.
BA42.10-P- 1002-04E BA42.10-P- 1010-04E 450589099904 451589000300 19 Remove brake lines (1)
20 Install new brake lines (1) Only if the brake lines (1) with the red color coding have been detached.
21 Install in the reverse order
22 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002- 04E Brake pipe to brake hose 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
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 188 · Applies to: 450, 451, 452, 454
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 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
2 Check bolted connection of brake line (1) with brake hose (2) and wheel brake cylinder (3) for color codings Installation: Identify the brake line (1) accordingly. AR42.10-P- 0013-05MCC 3 Loosen bolted connections of the brake line (1) with the Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: Do not bend brake line (1), pay attention to routing, leaktightness and clearance.
Fig 1: Identifying Left Rear Brake Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
hydraulic unit (2) and the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 189 · Applies to: 450, 451, 452, 454
brake hose (3) and separate BA42.10-P- 1002-04E BA42.10-P- 1003-04E *450589099904 4 Unclip retaining clips (4) of electrical line (5) on brake line (1)
5 Unclip brake line (1) from bracket (6) on the axle tube (7)
6 Remove brake line (1)
7 Replace brake line (1). Only if the brake line (1) with the red color coding has been detached.
8 Install in the reverse order
9 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002- 04E Brake pipe to brake hose Nm 16 BA42.10-P-1003- 04E Brake line to rear wheel brake cylinder Nm 16 TESTING & REPAIR > REMOVE/INSTALL RIGHT REAR BRAKE LINE - AR42.10-P- 0037MCU > MODEL 451.3/4 Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown with right rear wheel removed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 190 · Applies to: 450, 451, 452, 454
Remove/install
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 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 using the vehicle lift and remove rear underfloor paneling Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
Fig 1: Identifying Right Rear Brake Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove bulkhead¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 191 · Applies to: 450, 451, 452, 454
2 Remove bulkhead wall On model 451.4 AR61.25-P- 6600MCU 3 Check bolted connections of brake line (1) with brake hose (2) and wheel brake cylinder (3) for color coding Installation: Identify the brake line (1) accordingly. AR42.10-P- 0013-05MCC 4 Loosen bolted connections of the brake line (1) with the hydraulic unit (2) and the brake hose (3) and separate Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: Do not bend brake line (1), pay attention to routing, leaktightness and clearance.
BA42.10-P- 1002-04E BA42.10-P- 1003-04E *450589099904 5 Unclip retaining clips (4) of electrical line (5) on brake line (1)
6 Unclip brake line (1) from brackets (6) on axle tube (7)
7 Remove brake line (1)
8 Replace brake line (1). Only if the brake line (1) with the red color coding has been detached.
9 Install in the reverse order
10 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002- 04E Brake pipe to brake hose Nm 16 BA42.10-P-1003- 04E Brake line to rear wheel brake cylinder Nm 16
TESTING & REPAIR > REMOVE/INSTALL MECHANICAL STOP LAMP SWITCH - AR42.10-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 192 · Applies to: 450, 451, 452, 454
P-0040MCC > MODEL 451.3/4 MODEL 450.3/ 4 Illustrated on model 451 MODIFICATION NOTES 22.9.10 Work procedure completely revised owing to new self-adjusting brake light switch (S9/1) Operation steps 1 to 12 Remove
Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Stop Lamp Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove brake pedal module¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 193 · Applies to: 450, 451, 452, 454 · AR: AR29.10-P-0330SM, AR29.10-P-0330MCC, AR29.10-P-0340SM, AR29.10-P-0340SN
1 Remove brake pedal module cover The brake pedal module cover removed is no longer fitted
Type 450 AR29.10-P-0330SM Model 451 AR29.10-P-0330MCC 2 Disconnect electrical connector (3) on brake light switch (S9/1)
3 Turn brake light switch (S9/1) 90° counterclockwise and remove from bracket (2)
Checking
4 Check that punch holes are present in boot on brake pedal (1); make punch holes if necessary and install boot Only on model 450 If the boot of the brake pedal (1) is not already punched, the boot must be punched and an additional pedal assembly seal must be retrofitted.The new brake pedal module cover will be installed at a later stage.
Left-hand drive vehicles AR29.10-P-0340SM Right-hand drive vehicles AR29.10-P-0340SN 5 Check whether catch hooks of pedal assembly seal are all engaged correctly Engage the catch hooks of the pedal assembly seal if necessary.
Install
6 Insert brake light switch (S9/1) into bracket (2) and turn 90° clockwise as far as end stop Before installing the new self-adjusting brake light switch (S9/1), make sure that the plunger is pulled out fully
7 Contact electrical connector (3) on brake light switch (S9/1)
8 Install brake pedal module cover Use the new brake pedal module cover.
Type 450 AR29.10-P-0330SM Model 451 AR29.10-P-0330MCC
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
Shown on left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 195 · Applies to: 450, 451, 452, 454
Remove/install
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 Although replacement of the brake caliper (1) as a pair is not specified by DaimlerChrysler, it is recommended
1 Remove brake pads on the left or right brake caliper (1)
AR42.10-P- 1600MCU 2 Check bolted connection of brake line (2) with brake hose (3) for color coding Installation: Identify the brake line (2) accordingly. AR42.10-P- 0013-05MCC 3 Loosen bolted connection of brake line (2) with brake hose (3), separate, remove retaining clip and unhook brake hose (3) Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: The brake hose (3) must be clear at every steering angle and wheel compression position, and it must not be mounted when twisted, as otherwise the brake hose (3) may be damaged.
BA42.10-P- 1002-04E 450589099904 4 Unscrew brake hose (3) from brake caliper (1) When replacing the brake caliper (1). Collect brake fluid in a suitable container. Seal the connections using suitable plugs.
BA42.10-P- 1001-04E 5 Unscrew bolt (4) BA42.10-P- 1001-10A 6 Remove brake caliper
Replace brake line¶
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(1) 7 Replace brake line (2). Only if the brake line (2) with the red color coding has been detached.
Remove/install left front brake line AR42.10-P- 0032MCU Remove/install right front brake line AR42.10-P- 0033MCU 8 Install in the reverse order
9 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1001- 04E Brake hose to front floating caliper Nm 18 BA42.10-P-1002- 04E Brake pipe to brake hose Nm 16 FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1001- 10A Bolt, brake caliper to brake caliper support Nm 30 TESTING & REPAIR > CHECK BRAKE SYSTEM FOR LEAKS - AR42.10-P-0100-01MCC > 1. 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 Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL BRAKE SHOES AT REAR AXLE - AR42.10-P-¶
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0165MCU > MODEL 451.3/4
Remove/install
Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when AS42.50-Z- 0001-01A Fig 2: Identifying Sleeve (451 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Rear Axle Brake Shoe Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
fluid coming into contact¶
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with skin and eyes. handling brake fluid. Brake fluid notes
AH42.50-P- 0001-01A Notes on repairs to brake system
AH42.00-P- 0003-01A 1 Remove left or right brake drum
AR42.10-P- 1010MCU 2 Support pliers on brake anchor plate (2) and unhook spring (3) Replace spring (3), a damaged or overstretched spring (3) can lead to impairment of the braking effect. Installation: Measure brake shoes (1) diagonally with universal vernier caliper and adjust to the dimension (A) of 202.6 mm, measured at the top side of the linings.
Universal vernier gauge sethttp://gotis.aftersales.mercedes- benz.com *450589003700 3 Remove retaining washers (4) using the removal and installation tool and remove together with the springs (5) located underneath. Subsequently remove the retaining pins (6) from brake anchor plate (2) Replace retaining washers (4), springs (5) and retaining pins (6), damaged or overstretched springs (5) can lead to impairment of the braking effect.
*450589186300 4 Press back spring (7) on hand brake cable (8) and unhook hand brake cable (8) at hand brake lever (9) Twist wheel hub (10) until a threaded hole is located in the lower position.
5 Tilt brake shoes (1) upward by 90° over wheel hub (10)
6 Compress brake piston of wheel brake cylinder (11) and guide out brake shoes (1) upwards Ensure that the dust boots of the brake pistons of the wheel brake cylinder (11) are not damaged otherwise leakages can lead to failure of the brake system. Installation: The brake lining of the brake shoes (1) must be absolutely grease-free otherwise the braking effect will be impaired.
7 Clean brake carrier plate (2) Installation: Smear the contact surfaces (arrows) of the brake carrier plate (2) at the brake shoes (1) with a thin coating of brake paste.
Brake paste¶
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*BR00.45-Z- 1060-06A 8 Check ease of movement and leakproofness of wheel brake cylinder (11) In the event of the slightest signs of brake fluid escape or sluggishness of the brake pistons of the wheel brake cylinder (11) this must be replaced, see: ↓
Remove/install wheel brake cylinder AR42.10-P- 0167MCU 9 Install in the reverse order
AUXILIARY REPAIR MATERIALS Number Designation Order number BR00.45-Z-1060-06A Brake paste Q0007414V000000000 TESTING & REPAIR > REMOVE/INSTALL WHEEL BRAKE CYLINDER - AR42.10-P- 0167MCU > MODEL 451.3/4 Fig 2: Identifying Pliers (450 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Removal And Installation Tool (450 589 18 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
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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 left or right brake shoe at the rear axle
AR42.10-P- 0165MCU 2 Check bolted connection of brake line (2) with wheel brake cylinder (1) for color coding Installation: Identify the brake line (2) accordingly. AR42.10-P- 0013-05MCC 3 Loosen bolted connection of brake line (2) with the wheel brake cylinder (1) and separate Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: Do not bend the brake line (2), pay attention to routing, leaktightness and clearance to rear axle.
BA42.10-P- 1003-04E 450589099904 Only if the brake line (2) with the red
Fig 1: Identifying Wheel Brake Cylinder, Brake Line And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Replace brake line (2).¶
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4 Replace brake line (2). color coding has been detached. Remove/install left rear brake line AR42.10-P- 0036MCU Remove/install right rear brake line AR42.10-P- 0037MCU 5 Undo bolts (3) on wheel brake cylinder (1) and remove wheel brake cylinder (1) *BA42.10-P- 1001-16C 6 Clean brake carrier plate
7 Install in the reverse order
8 Bleed brake system
AR42.10-P- 0010MCU BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1003- 04E Brake line to rear wheel brake cylinder Nm 16 DRUM BRAKE Number Designation Model 451.3/4 BA42.10-P-1001- 16C Wheel brake cylinder to brake carrier plate Nm 8 TESTING & REPAIR > INSTALL, REMOVE AUTOMATIC BRAKE ADJUSTER - AR42.10-P- 0169MCU > MODEL 451.3/4 Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
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1 Remove left or right brake shoes (3) on the rear axle
AR42.10- P- 0165MCU 2 Unhook fastening spring (1) on brake adjuster (2) and on brake shoes (3)
3 Unhook return spring (4) on brake shoes (3)
4 Unhook spring (5) on brake shoes (3) Installation: Observe curvature of teeth on adjusting wheel (8). They must curve away in the direction of adjustment (arrow).
5 Pull threaded union (6), spring (5) and adjustment wheel (8) out of the angle (7) in the brake adjuster (2) The heat shield (9) must be located in the center of the angle cutout (7), as otherwise the drum brake function may be impaired. Installation: Check the direction of the brake adjustment, in the process pressing against the elbow (7) and relieving the load again.Observe the installation position of the brake adjuster (2): Right side = Left-hand thread on brake adjuster (2) Left side = Right-hand thread on brake adjuster (2) The designations on the brake adjusters (2) are invalid.
Fig 1: Identifying Automatic Brake Adjuster Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install in the¶
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6 Install in the reverse order
7 Adjust drum brake
AR42.10- P-1010- 11SM TESTING & REPAIR > REMOVE/INSTALL FRONT AXLE BRAKE DISK - AR42.10-P- 0230MCU > MODEL 451.3/4
Remove/install
1 Remove left or right engine support
AR42.10-P- 0500MCU 2 Remove bolt (2) and remove brake disk (1) Installation: Brake disks (1) must only be replaced in pairs.Clean wheel hub (3) and grease lightly at the centering surface (A) using brake paste.
Brake paste *BR00.45-Z- 1060-06A Checking
3 Check wear, condition of brake pads and the brake disk (1) using a vernier caliper Brake pad thickness BE42.10-P- 1001-05E Brake disk thickness BE42.10-P- 1001-08E *450589011900 Fig 1: Identifying Brake Disk, Wheel Hub And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install in the reverse order¶
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4 Install in the reverse order
Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work Before starting engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system. AS42.50-Z- 0002-01A 5 Operate the brake pedal several times until brake pads make contact with the brake disks (1) A firm resistance must be noticeable at the brake pedal.
CHECK VALUES FOR FRONT BRAKE PAD Number Designation Model 451.3/4 BE42.10-P-1001- 05E Brake pad thickness New (with pad backing plate) mm 15 Wear limit (without pad backing plate) for maintenance service mm ≤ 2 Wear limit (with pad backing plate) for maintenance service mm ≤7,7 Response of wear indicator (with pad backing 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 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1060-06A Brake paste Q0007414V000000000 TESTING & REPAIR > REMOVE/INSTALL SPLASH SHIELD ON FRONT BRAKE - AR42.10- Fig 2: Identifying Vernier Caliper (450 589 01 19 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
P-0233MCU >¶
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MODEL 451.3/4 Remove/install
1 Remove left or right brake disk
AR42.10-P- 0230MCU 2 Remove bolts (2)
3 Unscrew bolt (3). Turn hub (4) such that the bolt (3) can be accessed through a wheel bolt bore in the hub (4).
4 Remove splash shield (1)
5 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL BRAKE FLUID RESERVOIR - AR42.10-P- 0301MCU > MODEL 451.3/4 Fig 1: Identifying Front Brake Splash Shield Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removal¶
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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- Fig 1: Identifying Brake Fluid Reservoir Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Brake Fluid Reservoir Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on repairs¶
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01A Notes on repairs to brake system
AH42.00-P-0003- 01A 1 Remove maintenance flap
2 Unscrew cap of brake fluid reservoir (2) and extract brake fluid from the brake fluid reservoir
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 3 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
4 Remove retainer (6) from master brake cylinder (5)
5 Detach brake lines (8) from master brake cylinder (5) Collect brake fluid in a suitable container. Seal the connections using suitable plugs.
6 Release brake lines (8) from brackets (9) on underfloor
7 Cut through brake lines (8) at suitable position (arrow C) and remove loose sections of brake lines (8) Only when replacing brake fluid reservoir (2).
8 Lower vehicle with lifting platform
9 Remove right
AR82.10-P-
headlamp unit¶
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4730MCU 10 Disconnect electrical connector (4) from brake fluid reservoir (2)
11 Unclip brake fluid reservoir (2) from fresh-air intake (1) using a suitable screwdriver (3) (arrow A) and lift off
12 Release brake lines (8) of brake fluid reservoir (2) from bracket (arrow B) on firewall
13 Raise vehicle with vehicle lift Only if the brake fluid reservoir (2) is reused.
14 Lift out brake fluid reservoir (2) If the brake fluid reservoir (2) is to be reused, have a second person on a ladder lift it out and guide out the brake lines (8) from below.
Install
15 Raise vehicle with vehicle lift Only when replacing brake fluid reservoir (2).
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.
*450589153700 19 Install retainer (6) on brake lines (8)
20 Install underfloor
Remove/install¶
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Notes on repairs to brake system
AH42.00-P-0003- 01A 1 Remove brake pads on the left or right brake caliper (1)
AR42.10-P- 1600MCU 2 Unscrew bolt (4) *BA42.10-P-1001- 10A 3 Remove brake caliper (1) and place with attached brake hose (2) to one side
4 Unscrew bolts (3) and remove brake caliper support (5) *BA42.10-P-1003- 10A 5 Install in the reverse order
FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1001- 10A Bolt, brake caliper to brake caliper support Nm 30 BA42.10-P-1003- 10A Bolt, brake caliper support to steering knuckle Nm 115 TESTING & REPAIR > ADJUST DRUM BRAKE - AR42.10-P-1010-11SM > When the brake drum is assembled no manual adjustments may be performed at the automatic adjuster. 1. Operate hand brake once and release again. 2. Operate service brake, release, and wait for approx. 1 second. Apply hand brake with button pressed and release. Repeat the procedure until no "actuation clicks" can be heard in the brake drum. 3. Check the rear wheels rotate freely Fig 1: Identifying Brake Caliper, Hose, Bolts, Caliper Support And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
AUXILIARY REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 213 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1060-06A Brake paste Q0007414V000000000 TESTING & REPAIR > REMOVE/CHECK/INSTALL FRONT AXLE BRAKE PADS - AR42.10- P-1600MCU > MODEL 451.3/4
Remove/install
Fig 1: Removing/Checking/Installing Front Axle Brake Pads (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Removing/Checking/Installing Front Axle Brake Pads (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of poisoning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 214 · Applies to: 450, 451, 452, 454
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 left or right front wheel
AR40.10-P- 1100MCU 2 Counterhold upper guide pin (4) using a suitable open end wrench and unscrew bolt (2) on brake caliper (1) *BA42.10-P- 1001-10A 3 Fold brake caliper (1) downwards and remove brake pads (6) After removing the brake pads (6) ensure that the brake pedal is no longer operated otherwise the brake piston (8) will be pressed out of the brake caliper (1). Observe in tallation po ition of brake pad (6) with wear indicator (9). Installation: When folding up the brake caliper (1) ensure that the springs (3) of the brake pads (6) are clamped under the brake caliper (1).
4 Press back the brake piston (8) using the brake piston pusher tool (10) When the brake piston (8) is pushed back the fluid level in the brake fluid reservoir rises. Ensure that the brake fluid reservoir does not overflow. It must be possible to move the brake piston (8) easily.
*450589023700 5 Clean contact surfaces (arrows) on the brake pads (6) and brake caliper support (5) and coat with grease Installation: No grease may come into contact with the friction surfaces of the brake pads (6) and brake disk, otherwise the braking effect will be impaired.
Molykote 111 grease *BR00.45-Z- 1070-06A Checking
6 Check dust boot (7) for leaktightness If dust boot (7) is damaged, the brake caliper (1) must be replaced.Refer to: ↓
Remove/install front axle brake caliper (1) AR42.10-P- 0070MCU
Check wear and¶
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7 Check wear and condition of brake pads (6) as well as the brake disks Brake pad thickness BE42.10-P- 1001-05E Brake disk thickness 450589011900 *BE42.10-P- 1001-08E 8 Check ease of movement of guide pins (4) If guide pins (4) are hooked up or sluggish the brake caliper (1) must be replaced.Refer to: ↓
Remove/install front axle brake caliper (1) AR42.10-P- 0070MCU 9 Check bellows (11) for damage Damaged bellows (11) should be replaced. Installation: Twist the respective boot (11) with the fingers in order to ensure that sealing lip (12) seats correctly in the slot on the corresponding guide pin (4).
10 Install in the reverse order
Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work Before starting engine, actuate brake pedal several times until the pressure is built up and maintained in the brake system. AS42.50-Z- 0002-01A 11 Depress the brake pedal several times until the brake pads (6) contact the brake disk A firm resistance must be noticeable at the brake pedal.
12 Check brake system for leaks
AR42.10-P- 0100-01MCC CHECK VALUES FOR FRONT BRAKE PAD Number Designation Model 451.3/4 BE42.10-P-1001- 05E Brake pad thickness New (with pad backing plate) mm 15 Wear limit (without pad backing plate) for maintenance service mm ≤2 Wear limit (with pad backing plate) for maintenance service mm ≤ 7,7 Response of wear indicator (with pad backing plate) mm ≈7,7 TEST VALUES FOR FRONT BRAKE DISKS
Remove/install¶
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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 / screwdriverhttp://gotis.aftersales.mercedes- benz.com
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).
4 Separate RPM sensor connector (L6/1x1) or RPM sensor connector (L6/2x1)
5 Loosen electrical line (1) of left front RPM sensor (L6/1) or right front RPM sensor (L6/2) from the brackets (2) Observe correct routing of the electrical line (1) otherwise damage can occur to the electrical line (1) of the left front RPM sensor (L6/1) or right front RPM sensor (L6/2).
Fig 1: Identifying Front RPM Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unclip brackets (5) on¶
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6 Unclip brackets (5) on brake line (4) Observe installation position of brackets (5) on brake line (4).The brackets (5) remain on the electrical line (1).
7 Pull the left front RPM sensor (L6/1) or right front RPM sensor (L6/2) out of the steering knuckle and remove Installation: The contact surface of the left front RPM sensor (L6/1) or right front RPM sensor (L6/2) must be clean and free from rust. Clean contact surface if necessary.
8 Unclip brackets (5) on the electrical wiring harness (1) and attach at exactly the same point on the electrical line (1) of the new left front RPM sensor (L6/1) or new right front RPM sensor (L6/2) When replacing the left front RPM sensor (L6/1) or right front RPM sensor (L6/2).
9 Install in the reverse order
10 Read out fault memory
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC TESTING & REPAIR > REMOVE/INSTALL REAR AXLE SPEED SENSOR - AR42.30-P- 0714MCU > MODEL 451.3/4 Shown on model 451.3 Fig 1: Identifying Rear Axle Speed Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on left side of vehicle on model 451.3¶
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Remove/install
1 Remove left or right rear wheel
AR40.10- P- 1100MCU 2 Remove rear underbody paneling Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
3 Mark the position of the brackets (6) on the electrical line (1) and on the brake line (4)
4 Mark the position of all further fastening points on the electrical line (1)
5 Separate the RPM sensor connector (L6/3x1) or RPM sensor connector (L6/4x1)
Unscrew plastic nut (2), open folding clamp (3) Fig 2: Identifying Rear Axle Speed Sensor Components (Left Side) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
using a suitable tool and¶
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6 using a suitable tool and expose electrical line (1) of left rear RPM sensor (L6/3) or the right rear RPM sensor (L6/4) Observe installation position of brake line and of electrical lines (1).
7 Unscrew bolt (5) on left rear RPM sensor (L6/3) or on right rear RPM sensor (L6/4) and remove the nut from the back
8 Unclip brackets (6) on the brake line (4) Observe correct routing of the electrical line (1) otherwise damage can occur to the electrical line (1) of the left front RPM sensor (L6/3) or right front RPM sensor (L6/4). The brackets (6) remain on the electrical line (1).
9 Loosen electrical line (1) of left rear RPM sensor (L6/3) or right rear RPM sensor (L6/4) from all other fastening points Observe installation position of electrical line (1).
10 Pull the left rear RPM sensor (L6/3) or right rear right rear RPM sensor (L6/4) out of its guide and take off Installation: The contact surface (arrow) of the left rear RPM sensor (L6/3) or right rear RPM sensor (L6/4) must be clean and free from rust. Clean contact surface if necessary.
11 Unclip brackets (6) on the wiring harness (1) and attach at exactly the same point on the electrical line (1) of the new left rear RPM sensor (L6/3) or the new right rear sensor (L6/4) When replacing the left rear RPM sensor (L6/3) or right rear RPM sensor (L6/4).
12 Transfer all markings applied to the electrical line (1) to the electrical line (1) of the new left rear RPM sensor (L6/3) or the new right rear RPM sensor (L6/4) When replacing the left rear RPM sensor (L6/3) or right rear RPM sensor (L6/4).
13 Install in the reverse order
14 Read out fault memory, erase if necessary
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC TESTING & REPAIR > REMOVE/INSTALL ELECTRONIC STABILITY PROGRAM (ESP)
Notes on repairs to¶
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brake system
AH42.00-P- 0003-01A 1 Remove vehicle key and on-board electrical system plug Model 451.391/491
2 Carry out enable of high-voltage system Model 451.391/491 After completing the work initial startup event log, attach the vehicle file with the enable event log. AR54.10-P- 1160MEV 3 Remove maintenance flap
4 Unscrew cap of brake fluid expansion reservoir and extract brake fluid
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 5 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdrivergotis://G_58.0_01.1
6 Remove diagonal struts On model 451.431 AR61.10-P- 5138MCU 7 Remove high-voltage battery Model 451.391/491 AR54.10-P- 1140MEV 8 Remove bulkhead wall On model 451.431 AR61.25-P- 6600MCU 9 Unscrew plastic nut (2) and remove folding clamp (3) from screw bolt Observe installation position of brake lines (4, 5) and electrical lines.
10 Unclip brake lines (4, 5) from the bracket (6)
11 Unclip brake line (7) from the bracket (8)
12 Loosen nuts (9), unscrew bolts (10) and remove bracket (11) Installation: Move guide pin (12) on the hydraulic unit (1) into the bracket (11).
BA42.45-P- 1008-01F 13 Support hydraulic unit (1) using transmission jack and removal fixture Transmission jackgotis://H_00.10_01.0 450589026200
Check bolted¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 227 · Applies to: 450, 451, 452, 454
14 Check bolted connections of brake lines (13) with the hydraulic unit (1) for color coding Installation: Identify brake lines (13) accordingly. AR42.10-P- 0013-05MCC 15 Loosen bolted connections of brake lines (13) with the hydraulic unit (1) and separate Collect brake fluid in a suitable container. Seal connections using suitable plugs.
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (13), pay attention to routing, leaktightness and clearance.If a brake line (13) with red marking has been released, this brake line (13) must be replaced.Refer to: ↓ *BA42.10-P- 1010-04E Remove/install brake line from the master brake cylinder to the ESP hydraulic unit AR42.10-P- 0034MCU 16 Carefully lower the hydraulic unit (1) until the brake lines (4, 5, 7, 14) are accessible
17 Check the bolted connections of the brake lines (4, 5, 7, 14) with the hydraulic unit (1) for color coding Installation: Identify brake lines (4, 5, 7, 14) correspondingly. AR42.10-P- 0013-05MCC 18 Loosen bolted connections of brake lines (4, 5, 7, 14) with the hydraulic unit (1) and separate Observe installation location of brake lines (4, 5, 7, 14). Collect brake fluid in a suitable container. Seal connections using suitable plugs. Installation: Do not bend brake lines (4, 5, 7, 14), pay attention to routing, leaktightness and clearance.
BA42.10-P- 1010-04E 451589000300 19 Unlock and separate electrical connector (15) on ESP control unit (N47-5)
20 Remove hydraulic unit (1)
21 Replace brake line (4, 5, 7, 14) Only if a brake line (4, 5, 7, 14) with red color coding has been released.
Remove/install left front brake line AR42.10-P- 0032MCU Remove/install right front brake line AR42.10-P-
0033MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 228 · Applies to: 450, 451, 452, 454
Remove/install brake line from the ESP hydraulic unit to the rear axle AR42.10-P- 0035MCU 22 Install in the reverse order
23 Bleed brake system
AR42.10-P- 0010MCU 24 Carry out transposition test
Connect STAR DIAGNOSIS and read out fault memory
AD00.00-P- 2000-04MCC BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 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 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Disconnect¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 230 · Applies to: 450, 451, 452, 454
1 Disconnect battery ground line
AR54.10-P- 0003MCC 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 2 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
3 Unclip the brake line to the rear axle from the bracket (1) In order to prevent the brake lines to the rear axle being permanently deformed when the hydraulic unit (2) is subsequently lowered.
4 Unclip brake line (3) from the bracket (4)
5 Loosen nuts (5), unscrew bolts (6) and remove bracket (7) Installation: Move guide pin (8) on the hydraulic unit (2) into the bracket (7).
*BA42.45-P- 1008-01F 6 Clean hydraulic unit (2) and ESP control unit (N47- 5) Clean the hydraulic unit (2) and ESP control unit (N47-5) carefully in order to avoid damage due to contamination when separating the components.
7 Unlock retainer of electrical connector (9) and disconnect electrical connector (9) on ESP control unit (N47-5)
8 Carefully pull the hydraulic unit (2) downwards together with the ESP control unit ESP (N47-5) until the bolts (10) are accessible
Unscrew bolts (10) and remove It is essential to pay attention to cleanliness. No dirt may enter the ESP control unit (2) and the hydraulic unit (N47-5), otherwise its function may be impaired. Installation: Clean sealing
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 232 · Applies to: 450, 451, 452, 454
1 Remove driver seat (1)
AR91.10- P- 1010MCU 2 Reposition floor covering under the driver seat (1) in the rear area until the yaw rate, lateral and longitudinal acceleration sensor (B24/15) is accessible When repositioning the floor covering ensure that this is not damaged due to breaking or cracking.
3 Disconnect electrical connector (2) on yaw rate, lateral and longitudinal acceleration sensor (B24/15)
4 Unscrew nuts (3) on yaw rate, lateral and longitudinal acceleration sensor (B24/15) and remove yaw rate, lateral and longitudinal acceleration sensor (B24/15)
5 Install in the reverse order
6 Calibrate yaw rate, lateral and longitudinal acceleration sensor (B24/15) Follow the instructions in the diagnosis assistant system.
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC SAFETY PRECAUTIONS > RISK OF DEATH CAUSED BY LIMBS BEING CAUGHT OR CRUSHED BY ROTATING PARTS WHEN PERFORMING TESTS ON THE BRAKE TEST STAND - AS42.00-Z-0001-01A > Never leave the vehicle unattended on the rollers except in an emergency. Ensure that no one is under the vehicle or near rotating parts during testing. In case of emergency, use the Fig 1: Locating Yaw Rate, Lateral And Longitudinal Acceleration Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
EMERGENCY STOP switch to shut down test stand.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 233 · Applies to: 450, 451, 452, 454 · AR: AS42.00-Z-9999ZZ
Risk of death Life-threatening injuries may be caused by contact with rotating engine or drive train parts or by coming to close to the brake test stand rollers. Safety precautions/instructions The brake test stand is to be operated by trained personnel only. Before driving the vehicle onto the rollers, the driver must ensure that the test stand is ready for operation (main switch is on) . For as long as the vehicle in on the rollers, no one is permitted under the vehicle or in the pit. For as long as the vehicle in on the brake test stand, the driver may only leave the driver seat in the event of an emergency. During the test, no one is allowed to go near the rotating rollers, wheels, or propeller shafts. In case of emergency, shut off brake test stand using the red EMERGENCY STOP switch. Observe the special considerations in the operating instructions for the brake test stand. SAFETY PRECAUTIONS > SAFETY INFORMATION: BRAKES - HYDRAULIC AND MECHANICAL SYSTEMS - AS42.00-Z-9999ZZ > MODEL all Risk of accident when commissioning the vehicle due to a lack of braking effect when the service brake is operated for the first time after repair work. MODEL all AS42.50-Z-0002- 01A Risk of death caused by limbs being caught or crushed by rotating parts when performing tests on the brake test stand MODEL 124, 129, 140, 163, 164, 168, 169, 170 171, 197, 199, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 219, 220, 221, 230, 240, 245, 251, 374, 375, 405, 408, 418, 427, 437, 450, 451, 452, 454, 460, 461, 463, 901, 902, 903, 904, 905, 930, 932, 933, 934, 940, 942, 943, 944, 950, 952, 953, 954, 957, 958, 970, 972, 974, 975, 976... AS42.00-Z-0001- 01A Risk of injury caused by body parts being jammed or crushed. Risk of injury to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system MODEL 211,219 mit Sensotronic Brake Control (SBC) MODEL 230 AS42.46-Z-0001- 01B
Risk of injury caused by body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 234 · Applies to: 450, 451, 452, 454
parts being jammed or crushed. Risk of injury to skin and eyes caused by brake fluid spraying out at high pressure when working on the SBC brake system MODEL 199, 230, 240 MODEL 211, 219 mit Sensotronic Brake Control (SBC) AS42.46-Z-0001- 01A Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid MODEL all AS42.50-Z-0001- 01A SAFETY PRECAUTIONS > RISK OF POISONING FROM SWALLOWING BRAKE FLUID. RISK OF INJURY FROM SKIN AND EYE CONTACT WITH BRAKE FLUID - AS42.50-Z-0001- 01A > Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. Possible hazards Risk of poisoning Swallowing brake fluid can cause symptoms of poisoning such as headaches, dizziness, stomach pains, vomiting, diarrhea, cramps and unconsciousness. A dose of more than 100 cm can have fatal consequences. Risk of injury Contact with brake fluid can cause serious skin damage to unprotected skin. Procedural guidelines and safety precautions Ensure that brake fluid is only accessible to authorized personnel. Store brake fluid in original containers only. Only store brake fluid in suitable, appropriately marked containers. Never use beverage bottles such as those for mineral water, beer etc. Wear safety glasses and protective clothing such as rubber gloves. If rubber gloves cannot be worn, the following instructions must be observed: Allow brake fluid to act on the skin for as short a time as possible; wash affected skin with soap and water. Change contaminated clothing as quickly as possible. First aid measures Wash affected skin with soap and water. Change contaminated clothing as quickly as possible. If brake fluid enters the eyes, flush immediately with plenty of clean water and seek medical attention if necessary. 3
SAFETY PRECAUTIONS > RISK OF ACCIDENT WHEN COMMISSIONING THE VEHICLE¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 235 · Applies to: 450, 451, 452, 454 · AR: BA42.00-Z-9999CZ
DUE TO A LACK OF BRAKING EFFECT WHEN THE SERVICE BRAKE IS OPERATED FOR THE FIRST TIME AFTER REPAIR WORK. - AS42.50-Z-0002-01A > Before commissioning the vehicle, operate the brake pedal several times until the pressure in the brake system is built up and maintained. Danger of accident The first time that the brakes are used after having performed any work on the braking system's hydraulics area, the risk of an accident is increased due to an impaired braking effect. Safety guidelines/precautions After finishing the work on the braking system's hydraulics area and before startup of the vehicle, press the brake pedal several times to build up pressure in the brake system. Once pressure has been built up in the brake system, the brake pedal should be held in this position for approximately 30 s, whereby the pressure in the brake system should not drop. TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: BRAKES - HYDRAULIC AND MECHANICAL SYSTEMS - BA42.00-Z-9999CZ > MODEL all Brake cylinder MODEL 454.0 except CODE (30Y) Scheibenbremse Hinterachse BA42.10-P-1000-08E Brake cylinder MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA42.10-P-1000- 08C Brake disks, brake cover plate MODEL 452.3 /4, 450.3 /4 BA42.10-P-1000-06D Brake lines, brake hoses MODEL 454.0 BA42.10-P-1000-04G Brake lines, brake hoses MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA42.10-P-1000- 04E Drum brake MODEL 450.3 /4, 451.3 /4, 452.3 /4 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle BA42.10-P-1000- 16C Electronic Stability Program (ESP) MODEL 454.0 BA42.45-P-1000-01G Electronic Stability Program (ESP) MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA42.45-P-1000- 01F Front axle brake caliper MODEL 451.3/4, 454.0 BA42.10-P-1000- 10A Front axle floating caliper MODEL 450.3 /4, 452.3 /4 BA42.10-P-1000-03C Front axle speed sensor MODEL 450.3 /4, 452.3 /4 BA42.30-P-1000-01D Front axle speed sensor MODEL 454.0 BA42.30-P-1000-01E Hydraulic unit MODEL 450.3 /4, 454.0 BA42.30-P-1000-03B
Master brake cylinder¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 236 · Applies to: 450, 451, 452, 454
MODEL 452.3 /4, 454.0 BA42.10-P-1000-05E Parking brake MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA42.20-P-1000- 01D Parking brake MODEL 454.0 BA42.20-P-1000-01E Rear axle brake caliper MODEL 454.0 with CODE (30Y) Scheibenbremse Hinterachse BA42.10-P-1000-12A Rear axle RPM sensor MODEL 454.0 BA42.30-P-1000-02E Rear axle VSS [GES] sensor MODEL 450.3 /4, 452.3 /4 BA42.30-P-1000-02C TORQUE SPECIFICATIONS > BRAKE LINES, BRAKE HOSES - BA42.10-P-1000-04E > Model 450, 451, 452 MODIFICATION NOTES 25.2.05 Brake hose to front floating caliper BRAKE LINES, BRAKE HOSES Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA42.10-P-1001- 04E Brake hose to front floating caliper Nm 18 18 18 BA42.10-P-1002- 04E Brake pipe to brake hose Nm 15 16 18 BA42.10-P-1003- 04E Brake line to rear wheel brake cylinder Nm 18 16 18 BA42.10-P-1004- 04E Brake line to ABS hydraulic unit Nm 14 - 14 BA42.10-P-1005- 04E Brake pipe to master brake cylinder Nm 14 16 14 BA42.10-P-1006- 04E Brake line to pressure reducer Nm 12 - 18 BA42.10-P-1008- 04E Brake line to T-piece Nm 18 16 18 BA42.10-P-1009- 04E Brake hose to T-piece Nm 15 15 15 BA42.10-P-1010- 04E Brake line to ESP hydraulic unit Nm - 16 - TORQUE SPECIFICATIONS > BRAKE CYLINDER - BA42.10-P-1000-08C > Model 450, 451, 452 BRAKE CYLINDER
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 237 · Applies to: 450, 451, 452, 454
Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA42.10-P-1001- 08C Brake bleed valve to rear axle wheel brake cylinder Nm 6,5 7 6,5 TORQUE SPECIFICATIONS > FRONT AXLE BRAKE CALIPER - BA42.10-P-1000-10A > Model 451, 454 FRONT AXLE FLOATING CALIPER Number Designation Model 454.0 Model 451.3/4 BA42.10-P-1001- 10A Bolt, brake caliper to brake caliper support Nm 30 30 BA42.10-P-1002- 10A Brake bleeder valve to brake caliper Nm 10 7 BA42.10-P-1003- 10A Bolt, brake caliper support to steering knuckle Nm 105 115 TORQUE SPECIFICATIONS > DRUM BRAKE - BA42.10-P-1000-16C > Model 450, 451, 452, 454 DRUM BRAKE Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 Model 454.0 without code 30Y BA42.10-P- 1001-16C Wheel brake cylinder to brake carrier plate Nm 8 8 8 15 BA42.10-P- 1002-16C Self-locking bolt securing brake drum to wheel hub Nm 6.5 7 6.5 - TORQUE SPECIFICATIONS > PARKING BRAKE - BA42.20-P-1000-01D > Model 450, 451, 452 MODIFICATION NOTES 8.2.07 Bolt, handbrake lever to bearing bracket Model 450.3/4Model 452.3/4 8.2.07 Bolt, hand brake lever to floor panel Model 451.3/4 PARKING BRAKE Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA42.20-P-1001- 01D Bolt, handbrake lever to bearing bracket Nm 21 - 21 BA42.20-P-1002- Bolt, hand brake lever to floor Nm - 21 -
Drum brake¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 239 · Applies to: 450, 451, 452, 454
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 10.8.05 Brake pad thickness, wear limit (with pad backing plate) at maintenance service Model 450.3/4 Brake pad thickness, wear limit (with pad backing plate) at maintenance service Type 452.3/4 CHECK VALUES FOR FRONT BRAKE PAD Number Designation Models 450.3/4 Models 451.3/4 Models 452.3/4 BE42.10- P-1001- 05E Brake pad thickness New (with pad backing plate) mm 15 15 15 Wear limit (without pad backing plate) for maintenance service mm ≤2 ≤2 ≤2 Wear limit (with pad backing plate) for maintenance service mm ≤7,7 ≤7,7 ≤7,7 Response of wear indicator (with pad backing plate) mm ≈7,7 ≈7,7 ≈7,7 TEST & ADJUSTMENT VALUES > TEST VALUES FOR FRONT BRAKE DISKS - BE42.10- P-1000-08E > Model 450, 451, 452, 454 TEST VALUES FOR FRONT BRAKE DISKS Model Model
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 240 · Applies to: 450, 451, 452, 454
Designation 450.3/4 451.3/4 BE42.10-P-1001- 08E Brake disk thickness New mm 9 9,7 Wear limit mm 8 8 BE42.10-P-1002- 08E Minimum distance, outside of brake disk to brake carrier mm 0.5 - BE42.10-P-1003- 08E Minimum distance, inside of brake disk to brake carrier mm 0,85 - TEST VALUES FOR FRONT BRAKE DISKS Number Designation Model 452.3/4 Model 454.0 BE42.10-P-1001- 08E Brake disk thickness New mm 9 24 Wear limit mm 8 21,5 BE42.10-P-1002- 08E Minimum distance, outside of brake disk to brake carrier mm 0.5 - BE42.10-P-1003- 08E Minimum distance, inside of brake disk to brake carrier mm 0,85 - TEST & ADJUSTMENT VALUES > DRUM BRAKE - BE42.10-P-1000-12C > Model 450, 451, 452 TEST VALUES FOR DRUM BRAKE Number Designation Model 450.3/4 Model 451.3/4 BE42.10-P- 1001-12C Brake drum diameter New mm 203,0 203,0 Wear limit for maintenance service mm 204,5 204,5 BE42.10-P- 1002-12C Brake lining thickness New (with carrier) mm 6,6 6,6 Wear limit for maintenance service (with carrier) mm 3 3 TEST VALUES FOR DRUM BRAKE Number Designation Model 452.3/4 BE42.10-P-1001- 12C Brake drum diameter New mm 203,0 Wear limit for maintenance service mm 204,5 BE42.10-P-1002- 12C Brake lining thickness New (with carrier) mm 6,6 Wear limit for maintenance service (with carrier) mm 3
BASIC KNOWLEDGE > BRAKE LIGHT SWITCH, COMPONENT DESCRIPTION - GF42.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 241 · Applies to: 450, 451, 452, 454
2010MCC > MODEL 451.3/4 Location The brake light switch is located in the brake pedal module. Task The brake light switch detects brake pedal actuation and transfers the information to the ESP control unit (N47-5) and to the SAM control unit (N10/10). Design The brake light switch consists of a normally closed contact and a normally open contact. Function The N.O. contact transfers the signal for actuation of the brake pedal to the SAM control unit. The N.C. contact transfers the signal for actuation of the brake pedal to the ESP control unit. BASIC KNOWLEDGE > ELECTRONIC STABILITY PROGRAM (ESP), LOCATION OF ELECTRONIC COMPONENTS - GF42.45-P-0001-03MCU > Fig 1: Locating Stop Lamp Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > ELECTRONIC STABILITY PROGRAM (ESP) FUNCTION - GF42.45-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 242 · Applies to: 450, 451, 452, 454
P-0001MCU > MODEL 451.3/4 Schematic representation Fig 1: Locating Electronic Stability Program (ESP) Electronic Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Understeering And Oversteering Vehicle Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Example of understeering vehicle (A)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 243 · Applies to: 450, 451, 452, 454
A vehicle understeers on a left curve. The vehicle pushes outwards over the front wheels. Precisely calculated braking force is applied at the left rear wheel. Example of oversteering vehicle (B) A vehicle oversteers in a left curve. In the process the rear of the vehicle breaks away. Precisely calculated braking force is applied at the right front wheel. General The Electronic Stability Program (ESP) is an active safety system for improving vehicle stability in all driving situations. It operates individually at one or more wheels on the front or rear axle. The ESP stabilizes the vehicle, if when cornering, when braking or when rolling without drive, forces acting from outside on one side have an effect on the vehicle and keep it safely on course. It supplements the familiar functions of the antilock brake system (ABS), acceleration slip regulation (ASR), engine braking regulation (EBR) and electronic brake force distribution (EBD). ESP regulates when: cornering (vehicle understeers or oversteers) driving straight ahead (vehicle deviates from its course on account of uneven road conditions) The function of the ESP control system overrides the ABS and ASR control systems. Apart from active intervention by the brake system through the ESP there is also an effect on the engine/transmission management. Advantages of ESP: Improvement in the starting-off and acceleration capability due to increased traction, particularly on a road with different adhesion and on curves Reduction in the risk of skidding under all road surface conditions by automatic stabilization when braking, accelerating or rolling Automatic adaptation of the engine torque depending on the traction condition of the wheels Improvement in the lane stability of the vehicle when cornering, also up to the critical limits Increase in active driving dynamics safety, as only one wheel which is not spinning permits the optimum traction without loss of lateral stability The ESP contains the following systems: Antilock brake system (ABS) Prevents blocking of the individual wheels by reducing the brake pressure at the wheels affected Acceleration slip regulation (ASR) Prevents a too high slip of the drive wheels when starting off and accelerating by torque reduction Electronic brake force distribution (EBV) Assists the driver in the partial braking range. It prevents overbraking of the rear axle and when braking in the curve increases the vehicle stability, while if necessary the pressure at the rear
wheel on the inside of the curve reduces or is increased at the front wheel on the outside of the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 244 · Applies to: 450, 451, 452, 454
curve Engine braking regulation (MSR) Reduces the wheel slip of the drive wheels in deceleration mode by slightly increasing the torque and as a result improved driving stability The clutch can be disengaged as additional assistance. Function overview Brake forces, drive forces and side forces acting on one side, which act on the vehicle from outside endeavor to turn the vehicle about its vertical axis. The ESP acquires the vehicle characteristics and for correction selectively brakes individual wheels. It regulates when cornering (vehicle understeers or oversteers) and when driving straight ahead (vehicle deviates from course due to dissimilar road conditions). Sensor system A distinction is made between sensors which detect the driver's requirement (e.g. the steering angle sensor), and sensors which record the actual vehicle characteristics. These include: Yaw rate, lateral and longitudinal acceleration sensor RPM sensor The ESP control unit is constantly supplied with the current data on engine torque and rotational speed by Fig 2: Electronic Stability Program (ESP) Function Can Communication Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
the motor electronics control unit via CAN.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 245 · Applies to: 450, 451, 452, 454
Via the turn rate, lateral and longitudinal acceleration sensor the brake forces, drive forces and side forces are recorded which want to turn the vehicle about the vertical axis (yaw rate). This information is transferred to the ESP control unit via CAN. The torque acting on the vehicle is calculated based on this information. If this torque exceeds defined thresholds then the corresponding wheels are braked by the ESP control unit to neutralize the torque which is acting. Simultaneously requests for drive torque reduction are passed on to the motor electronics control unit via CAN. Active brake intervention and drive torque reduction by the ESP ensure optimum vehicle stability. The following processes are performed: ESP braking torque control circuit ABS control EBD control ASR control ESP drive torque control circuit ASR control MSR control ESP braking torque control circuit ABS control If one wheel tends to lock the brake pressure at this wheel is reduced. The brake pressure is controlled via the ESP control unit. The various wheel speeds are transmitted to the ESP control unit by the RPM sensors. The ESP control unit compares the speeds against each other and reduces the brake pressure at the wheel which is tending to lock up. Visual status indication: Information on the status of the ABS control system is provided by the ABS indicator lamp. Actuation possibilities: ABS indicator lamp permanently on ABS has a malfunction EBD control The mass of the vehicle shifts during each brake application. The wheels are subjected to different loads depending on the direction of travel (straight-ahead driving or cornering). To achieve optimal braking effect, the brake pressure is increased at the wheels subjected to heavier loads and reduced at the wheels subjected to lesser loads. The ESP control unit computes the required brake interventions based on the information from the yaw rate and lateral acceleration sensor. This also has the simultaneous effect of preventing the wheels subjected to lesser loads from locking up. ASR control
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 249 · Applies to: 450, 451, 452, 454
The ESP control unit is located on the hydraulic unit on the vehicle underfloor. Task The ESP control unit controls the following systems: Electronic Stability Program (ESP) Acceleration Slip Regulation (ASR) Engine braking regulation (EBR) Antilock brake system (ABS) Electronic brake force distribution (EBV) Communication and influence of ESP control unit on other systems in the vehicle: The ESP control unit influences the engine management and power transmission in the case of an ESP control. For driver information the control unit actuates the instrument cluster via the Controller Area Network (data bus/CAN bus) (CAN)A1), the instrument cluster actuates the ABS indicator lamp (A1e17) and ESP warning lamp (A1e41). Direct entries Tml. 15 Circuit 30 Circuit 31 Left front RPM sensor (L6/1) Right front RPM sensor (L6/2) Left rear RPM sensor (L6/3) Right rear RPM sensor (L6/4) Stop light switch (S9/1) Fig 1: Locating ESP Control And Hydraulic Units Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Brake fluid indicator switch (S11)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 250 · Applies to: 450, 451, 452, 454
Parking brake switch (S12) Voltage supply Yaw rate, lateral and longitudinal acceleration sensor (B24/15) Steering angle sensor (N49) CAN signals The ESP control unit is a CAN subscriber and receives signals from the following sensors: Yaw rate, lateral and longitudinal acceleration sensor Steering angle sensor BASIC KNOWLEDGE > WHEEL RPM SENSOR, COMPONENT DESCRIPTION - GF42.45-P- 5134MCC > MODEL 451.3/4 Location The left front RPM sensor and right front RPM sensor are mounted on the steering knuckles of the front axle. The left rear RPM sensor and right rear RPM sensor are mounted on the wheel carriers of the rear axle. Task The RPM sensors generate a square wave signal which the ESP control unit (N47-5) uses to detect the current wheel speed and other additional information. Fig 1: Identifying Wheel RPM Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Design¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 251 · Applies to: 450, 451, 452, 454
The RPM sensor consists of the RPM sensor head and an electrical line. The display shows the current curve through the active RPM sensor during an acceleration phase. 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. Fig 2: Display Current Curve Of Active RPM Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Function diagram¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 253 · Applies to: 450, 451, 452, 454
Functional principle The switching components for ABS, ASR, ESP and EBV are combined in the hydraulic unit. Fig 2: Identifying ESP Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Traction System Hydraulic Unit Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
N10/10f18¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 255 · Applies to: 450, 451, 452, 454
Fuse 18 5L N10/10f34 Fuse 34 3L N10/10f38 Fuse 38 6L N47-5 ESP control unit 4A12A20A28A N49 Steering angle sensor 16L S9/1 Stop lamp switch 9L S11 Brake fluid indicator switch 23L S12 Parking brake indicator switch 25L W7 Ground (right wheelhouse in luggage compartment) 25G W9 Ground (left front, at lamp unit) 16G W10 Ground (battery) 7E10G W14 Left floor interior compartment ground 22G W43 Ground (outside left fire wall) 24G Z3/17 Circuit 15 (fused) connector sleeve 5G18G Z37/2 CAN engine bus (low) connector sleeve 13G16E Z37/3 CAN engine bus (high) connector sleeve 12G17E Z37/41 CAN databus (high) connector sleeve 12E19E Z37/42 CAN bus (low) connector sleeve 13E20E Z40 Stop lamp signal connector sleeve 9G WIRING DIAGRAMS > WIRING DIAGRAM OF ELECTRONIC STABILITY PROGRAM (ESP) - PE42.45-P-2000-97MCU > Code: Designation: Position: A1 Instrument cluster 13L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20L L6/1 Left front wheel speed sensor 26L L6/1x1 Wheel speed sensor connector
L6/2 Right front wheel speed sensor 28L L6/2x1 Wheel speed sensor connector
L6/3 Left rear wheel speed sensor 29L L6/3x1 Wheel speed sensor connector
L6/4 Right rear wheel speed sensor 31L L6/4x1 Wheel speed sensor connector
N10/10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 256 · Applies to: 450, 451, 452, 454
SAM control unit 4L N10/10f11 Fuse 11 2L N10/10f18 Fuse 18 5L N10/10f34 Fuse 34 3L N10/10f38 Fuse 38 7L N47-5 ESP control module 28A N47-5 ESP control module 12A N47-5 ESP control module 20A N47-5 ESP control module 4A N49 Steering angle sensor 17L S11 Brake fluid indicator switch 23L S12 Parking brake indicator switch 25L S9/1 Stop lamp switch (4-pin) 9L W10 Ground (battery) 11G W10 Ground (battery) 7E W14 Left floor interior compartment ground 22G W43 Ground (outside left fire wall) 24G W7 Ground (right wheelhousing in trunk) 25G W9 Ground (at left headlamp unit) 16G Z3/17 Circuit 15 (fused) connector sleeve 18G Z3/17 Circuit 15 (fused) connector sleeve 5G Z37/2 CAN engine bus (low) connector sleeve 14G Z37/2 CAN engine bus (low) connector sleeve 16E Z37/3 CAN engine bus (high) connector sleeve 12G Z37/3 CAN engine bus (high) connector sleeve 17E Z37/41 CAN databus (high) connector sleeve 12E Z37/41 CAN databus (high) connector sleeve 19E Z37/42 CAN bus (low) connector sleeve 14E Z37/42 CAN bus (low) connector sleeve 21E Z40 Stop lamp signal connector sleeve 9G
Fig 1: Electronic Stability Program (ESP) - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 257 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM OF ELECTRONIC STABILITY PROGRAM (ESP) -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 258 · Applies to: 450, 451, 452, 454
PE42.45-P-2000-99MCU > Code: Designation: Position: A1 Instrument cluster 13 L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20 L L6/1 Left front wheel speed sensor 26 L L6/1x1 Wheel speed sensor connector 25 H L6/2 Right front wheel speed sensor 28 L L6/2x1 Wheel speed sensor connector 27 H L6/3 Left rear wheel speed sensor 29 L Fig 2: Electronic Stability Program (ESP) - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
L6/3x1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 259 · Applies to: 450, 451, 452, 454
Wheel speed sensor connector 29 H L6/4 Right rear wheel speed sensor 31 L L6/4x1 Wheel speed sensor connector 30 H N10/10 SAM control unit 4 L N10/10f11 Fuse 11 2 L N10/10f18 Fuse 18 5 L N10/10f34 Fuse 34 3 L N10/10f38 Fuse 38 6 L N47-5 ESP control module 4 A N47-5 ESP control module 12 A N47-5 ESP control module 20 A N47-5 ESP control module 28 A N49 Steering angle sensor 16 L S11 Brake fluid indicator switch 23 L S12 Parking brake indicator switch 25 L S9/1 Stop lamp switch (4-pin) 9 L W10 Ground (battery) 6 E W10 Ground (battery) 10 G W14 Left floor interior compartment ground 22 G W43 Ground (outside left fire wall) 23 G W7 Ground (right wheelhousing in trunk) 25 G W9 Ground (at left headlamp unit) 16 G Z3/17 Circuit 15 (fused) connector sleeve 5 H Z3/17 Circuit 15 (fused) connector sleeve 18 H Z37/2 CAN engine bus (low) connector sleeve 13 H Z37/2 CAN engine bus (low) connector sleeve 16 E Z37/3 CAN engine bus (high) connector sleeve 12 H Z37/3 CAN engine bus (high) connector sleeve 17 E Z37/41 CAN databus (high) connector sleeve 12 E Z37/41 CAN databus (high) connector sleeve 19 E Z37/42 CAN bus (low) connector sleeve 13 E Z37/42 CAN bus (low) connector sleeve 20 E Z40 Stop lamp signal connector sleeve 9 H
Fig 1: Electronic Stability Program (ESP) - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 260 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Code:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 263 · Applies to: 450, 451, 452, 454
Designation: Position: A1 Instrument cluster 13 L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20 L L6/1 Left front wheel speed sensor 26 L L6/1x1 Wheel speed sensor connector 25 H L6/2 Right front wheel speed sensor 28 L L6/2x1 Wheel speed sensor connector 27 H L6/3 Left rear wheel speed sensor 29 L L6/3x1 Wheel speed sensor connector 29 H L6/4 Right rear wheel speed sensor 31 L L6/4x1 Wheel speed sensor connector 30 H N10/10 SAM control unit 4 L N10/10f11 Fuse 11 2 L N10/10f18 Fuse 18 5 L N10/10f34 Fuse 34 3 L N10/10f38 Fuse 38 6 L N47-5 ESP control module 4 A N47-5 ESP control module 12 A N47-5 ESP control module 20 A N47-5 ESP control module 28 A N49 Steering angle sensor 16 L S11 Brake fluid indicator switch 23 L S12 Parking brake indicator switch 25 L S9/1 Stop lamp switch (4-pin) 9 L W10 Ground (battery) 6 E W10 Ground (battery) 10 G W14 Left floor interior compartment ground 22 G W43 Ground (outside left fire wall) 23 G W7 Ground (right wheelhousing in trunk) 25 G W9 Ground (at left headlamp unit) 16 G Z3/17 Circuit 15 (fused) connector sleeve 5 H Z3/17 Circuit 15 (fused) connector sleeve 18 H Z37/2 CAN engine bus (low) connector sleeve 13 H
Z37/2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 264 · Applies to: 450, 451, 452, 454
CAN engine bus (low) connector sleeve 16 E Z37/3 CAN engine bus (high) connector sleeve 12 H Z37/3 CAN engine bus (high) connector sleeve 17 E Z37/41 CAN databus (high) connector sleeve 12 E Z37/41 CAN databus (high) connector sleeve 19 E Z37/42 CAN bus (low) connector sleeve 13 E Z37/42 CAN bus (low) connector sleeve 20 E Z40 Stop lamp signal connector sleeve 9 H Fig 1: Electronic Stability Program (ESP) - Wiring Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Caliper gage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 267 · Applies to: 450, 451, 452, 454
1.7.08 Replacement for: 450 589 01 19 00 vernier caliper
WS42.00-P- 0063A Use: Vernier caliper for measurement of brake disk thickness. (measuring range 50 mm, leg length 75 mm).
SPECIAL TOOLS > 450 589 00 37 00 PLIERS - WS42.00-P-0060A > FG 42/Set A MODEL 450,451,452 Use: Pliers for hooking in and unhooking brake springs at the brake shoes of the drum brake. NOTE: Brake spring pliersSmart no. 0004997. Fig 1: Identifying Caliper Gauge (140 589 00 19 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 02 37 00 BRAKE PISTON PUSHER TOOL - WS42.00-P-0062A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 268 · Applies to: 450, 451, 452, 454
FG 42/Set A MODEL 450, 451, 452 15.10.10 Replaced by 000 589 52 43 00 Pusher tool WS42.00-P-0009A Use: Brake piston pusher tool for pushing brake piston back on front-axle brake caliper. NOTE: Brake piston resetting deviceSmart No. 0004999. SPECIAL TOOLS > 450 589 01 19 00 VERNIER CALIPER - WS42.00-P-0063A > Fig 1: Identifying Pliers (450 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Piston Pusher Tool (450 589 02 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 42/Set A¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 269 · Applies to: 450, 451, 452, 454
MODEL 450, 451, 452, 454 MODIFICATION NOTES 1.7.08 Replaced by 140 589 00 19 00 vernier caliper WS42.00-P-0028A Use: Vernier caliper for measuring brake disk thickness. NOTE: Vernier caliper for brake disksSmart No. 0005087. SPECIAL TOOLS > 450 589 03 09 00 TORX BIT INSERT - WS42.00-P-0064B > FG 42/SET B MODEL 450, 451, 452 Use: Torx bit insert for loosening mounting screws on brake pedal head and Sedrive unit. NOTE: TORX bit insert IPR 30, 14/4" socketSmart no. 0005179. Fig 1: Identifying Vernier Caliper (450 589 01 19 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 452 589 00 68 00 SCRAPER - WS42.00-P-0066B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 270 · Applies to: 450, 451, 452, 454
FG 42/Set B MODEL 450, 451, 452 Use: Removal of seal from ABS/ESP housing. NOTE: Smart no.: 001 5806 V000 0000 00 SPECIAL TOOLS > 452 589 00 21 01 PIPETTE - WS42.00-P-0067-01A > FG42/Set A MODEL 450, 451, 452, 454 Fig 1: Identifying Torx Bit Insert (450 589 03 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Scraper (452 589 00 68 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 271 · Applies to: 450, 451, 452, 454
Pipette for sampling brake fluid. NOTE: CAUTION: The pipette may only be used once!Pipette: Smart no. 001 5955 V000 0000 00.Available in packs of 100 ea. Replacement part for caseW 452 589 00 21 00 / Smart no. 001 5798 V000 0000 00. SPECIAL TOOLS > 452 589 00 21 00 BRAKE FLUID METER - WS42.00-P-0067A > FG 42/Set A MODEL 450, 451, 452, 454 Single part 452 589 00 21 01 Pipette FG 42/Set A WS42.00-P-0067-01A Use: Brake fluid meter for determining the condition of the brake fluid. NOTE: For DOT 4 and DOT 4+ brake fluids, device features temperature compensation, display scales for boiling point (°C) and water content (%), supplied in a plastic case with sampling pipette W 452 589 00 21 01 / 001 5955 V000 0000 00.Case: Smart no. 001 5798 V000 0. Fig 1: Identifying Pipette (452 589 00 21 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 09 99 04 BOX WRENCH BIT - WS42.00-P-0070-04B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 272 · Applies to: 450, 451, 452, 454
FG29/42/Set B MODEL 450, 451, 452 Use: Open ring wrench socket for loosening and tightening the union nut on the brake lines. NOTE: Ring wrench socketsmart no. 001 9570 V001 0000 00. SPECIAL TOOLS > 452 589 03 99 01 TORQUE WRENCH - WS42.00-P-0071-01B > FG42/Set B MODEL 450, 451, 452, 454 Fig 1: Identifying Brake Fluid Meter (452 589 00 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 273 · Applies to: 450, 451, 452, 454
Torque wrench for loosening and tightening the mounting screws of the ESP control unit on the hydraulic assembly to the specified torque. NOTE: Special size of torque wrench with permanently adjusted release torque of 3 Nm,smart-N. 001 9572 V001 0000 00. SPECIAL TOOLS > 452 589 03 99 02 PLUG-IN REVERSIBLE RATCHET - WS42.00-P-0071- 02B > FG42/Set B MODEL 450, 451, 452 Use: Plug-in reversible ratchet with 9x12 mm plug-in square for 1/4" hexagon bit inserts (6.3 mm). NOTE: Plug-in reversible ratchetsmart no. 001 9573 V001 0000 00. Fig 1: Identifying Torque Wrench (452 589 03 99 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 452 589 03 99 03 TORX PLUG-IN BIT - WS42.00-P-0071-03B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 274 · Applies to: 450, 451, 452, 454
FG42/Set B MODEL 450, 451, 452 Use: Torx plug-in bit for loosening and tightening the mounting screws of the ESP control unit and hydraulic assembly. NOTE: Special length of Torx plug-in bit T20smart no. 001 9574 V001 0000 00. SPECIAL TOOLS > 452 589 03 99 00 SET OF TORQUE TOOLS - WS42.00-P-0071B > FG 42/Set B Fig 1: Identifying Plug-In Reversible Ratchet (452 589 03 99 02) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Torx Plug-In Bit (452 589 03 99 03) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 450, 451, 452¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 275 · Applies to: 450, 451, 452, 454
Single part 452 589 03 99 01 Torque wrench FG42/Set B WS42.00-P-0071-01B Single part 452 589 03 99 02 Plug-in reversible ratchet FG42/Set B WS42.00-P-0071-02B Single part 452 589 03 99 03 Torx plug-in bit FG42/Set B WS42.00-P-0071-03B Use: Set of torque tools for exchanging the ESP control unit on the hydraulic assembly without removing the major assembly. NOTE: Set of torque toolssmart no. 001 9571 V001 0000 00. SPECIAL TOOLS > 450 589 15 37 00 PLIERS - WS42.00-P-0082B > FG 42/Set B MODEL 450, 451, 452, 454 Use: Special pliers for assembling the low-pressure lines on ESP 8.0 Fig 1: Identifying Set Of Torque Tools (452 589 03 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 00 14 00 SLEEVE - WS42.00-P-0083C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 276 · Applies to: 450, 451, 452, 454
FG 42/Set C MODEL 451 Use: Sleeve for installing/removing hand brake cables. SPECIAL TOOLS > 451 589 00 03 00 SOCKET WRENCH SET - WS42.00-P-0086B > FG 42/Set B MODEL 451 Use: Socket wrench set for loosening and tightening union nut on brake lines on ESP/ABS hydraulic assembly. Fig 1: Identifying Pliers (450 589 15 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Sleeve (451 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: BRAKES - HYDRAULIC AND MECHANICAL¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 277 · Applies to: 450, 451, 452, 454 · AR: WS42.00-Z-9999CZ
SYSTEMS - WS42.00-Z-9999CZ > MODEL all 000 589 52 43 00 Resetting device FG 42/Set A WS42.00-P-0009A 129 589 00 21 00 126-pin socket box FG 00/42/54/91 / Set B WS54.00-P-0008B 140 589 00 19 00 Caliper gauge FG 42/Set A WS42.00-P-0028A 168 589 00 37 00 Pliers FG 42/Set B WS42.00-P-0040B 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 450 589 00 37 00 Pliers FG 42/Set A WS42.00-P-0060A 450 589 01 19 00 Vernier caliper FG 42/Set A WS42.00-P-0063A 450 589 01 37 00 Pliers FG 42/Set A WS42.00-P-0061A 450 589 02 37 00 Brake piston pusher tool FG 42/Set A WS42.00-P-0062A 450 589 03 09 00 Torx bit insert FG 42/Set B WS42.00-P-0064B 450 589 09 99 00 Set of brake line wrenches FG 42/Set B WS42.00-P-0070B 450 589 09 99 01 Torque wrench FG42/Set B WS42.00-P-0070- 01B 450 589 09 99 02 Socket wrench bit FG42/Set B WS42.00-P-0070- 02B 450 589 09 99 03 Socket wrench bit FG42/Set B WS42.00-P-0070- 03B 450 589 09 99 04 Box wrench bit FG29/42/Set B WS42.00-P-0070- 04B Fig 1: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
450 589 15 37 00 Pliers¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 278 · Applies to: 450, 451, 452, 454
FG 42/Set B WS42.00-P-0082B 451 589 00 03 00 Socket wrench set FG 42/Set B WS42.00-P-0086B 451 589 00 14 00 Sleeve FG 42/Set C WS42.00-P-0083C 452 589 00 21 00 Brake fluid meter FG 42/Set A WS42.00-P-0067A 452 589 00 21 01 Pipette FG42/Set A WS42.00-P-0067- 01A 452 589 00 68 00 Scraper FG 42/Set B WS42.00-P-0066B 452 589 02 09 00 Socket wrench bit FG 42/Set B WS42.00-P-0065B 452 589 03 99 00 Set of torque tools FG 42/Set B WS42.00-P-0071B 452 589 03 99 01 Torque wrench FG42/Set B WS42.00-P-0071- 01B 452 589 03 99 02 Plug-in reversible ratchet FG42/Set B WS42.00-P-0071- 02B 452 589 03 99 03 Torx plug-in bit FG42/Set B WS42.00-P-0071- 03B 454 589 00 43 00 Resetting device FG 42/Set A WS42.00-P-0068A 454 589 01 91 00 Adapter FG 42/25/26/Set A WS42.00-P-0069A
TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: BRAKES - PNEUMATIC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 279 · Applies to: 450, 451, 452, 454 · AR: AR43.00-Z-9451CA, AR43.05-P-1325MCD, AR43.10-P-0355MCC, AR43.10-P-0355MCD, AR43.10-P-0355MEV (+3 more)
SYSTEM AND AUXILIARY BRAKES - AR43.00-Z-9451CA > MODEL 451 Check vacuum pump MODEL 451.3/4 with ENGINE 660.9 AR43.05-P-1325MCD Remove/install brake booster vacuum line MODEL 451.3/4 with ENGINE 132.9 AR43.10-P-0355MCC Remove/install brake booster vacuum line MODEL 451.3/4 with ENGINE 660.9 AR43.10-P-0355MCD Remove/install brake booster vacuum line MODEL 451.3/4 with ENGINE 132.910 AR43.10-P- 0355MCU Remove/install brake booster vacuum line MODEL 451.391/ 491 AR43.10-P-0355MEV Remove/install vacuum pump MODEL 451.3/4 with ENGINE 660.9 AR43.05-P-1320MCD Remove/install vacuum pump MODEL 451.391/491 with ENGINE 780.009 AR43.05-P-1320MEV Remove/install vacuum pump control unit MODEL 451.391/491 with ENGINE 780.009 AR43.05-P-1323MEV TESTING & REPAIR > REMOVE/INSTALL BRAKE BOOSTER VACUUM LINE - AR43.10-P- 0355MCU > MODEL 451.3/4 with ENGINE 132.910
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 280 · Applies to: 450, 451, 452, 454
1 Push down brake pedal several times To reduce any vacuum.
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 2 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver http://gotis.aftersales.mercedes-benz.com
3 Remove bulkhead wall On model 451.4 AR61.25- P- 6600MCU 4 Compress retainer (2) and pull vacuum line of brake booster (1) off intake manifold (3) Installation: Check sealing rings, replace if necessary.
5 Unclip vacuum line of brake booster (1) from the bracket (4) on the underfloor
Fig 1: Identifying Brake Booster Vacuum Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Pull vacuum line of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 281 · Applies to: 450, 451, 452, 454 · AR: AS43.00-Z-9999ZZ, BA43.00-Z-9999CZ, BE43.00-Z-9999CZ, WS43.00-Z-9999CZ
6 Pull vacuum line of brake booster (1) out of brake booster (5) Installation: Check grommet (6) and replace if necessary.
7 Pull out vacuum line of brake booster (1) between the frame-type integral support (7) and the underfloor towards the engine and remove Do not kink vacuum line of brake booster (1) otherwise it may be damaged. Observe installation position of chafe protection (8) and routing of vacuum line of brake booster (1). Installation: Pay attention to kink-free and chafe- free routing of vacuum line of brake booster (1).
8 Install in the reverse order
SAFETY PRECAUTIONS > SAFETY INFORMATION: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY BRAKES - AS43.00-Z-9999ZZ > MODEL all Risk of injury caused by touching hot retarder and by scalding from hot retarder oil. Risk of injury to skin or eyes caused by retarder oil escaping under high pressure MODEL 000, 374, 375, 613, 671, 930, 932, 933, 934, 940, 942, 943, 944, 950, 952, 953, 954, 958... AS43.30-Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY BRAKES - BA43.00-Z-9999CZ > MODEL all Pneumatic brake booster MODEL 452.3 /4 BA43.10-P-1000- 01D Pneumatic brake booster MODEL 454.0 with ENGINE 639.939, 122.950, 134.910 /911, 135.930 /950 BA43.10-P-1000- 01E Vacuum pump ENGINE 639.939, 660.950 /951 BA43.05-P-1000- 01G Vacuum pump MODEL 450.3 /4, 451.391 /491 BA43.05-P-1000- 01E TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY BRAKES - BE43.00-Z-9999CZ > MODEL all Test values for pneumatic brake servo MODEL 450.3 /4 BE43.10-P-1000- 01C Test values for vacuum pump MODEL 450.3 /4 MODEL 451.3/4 with ENGINE 660.9 BE43.05-P-1000- 01A SPECIAL TOOLS > SPECIAL TOOLS: SMART: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY BRAKES - WS43.00-Z-9999CZ >
MODEL all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 282 · Applies to: 450, 451, 452, 454
220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P- 0050B
TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: BRAKES - PNEUMATIC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 283 · Applies to: 450, 451, 452, 454 · AR: AR43.00-Z-9451CA, AR43.05-P-1325MCD, AR43.10-P-0355MCC, AR43.10-P-0355MCD, AR43.10-P-0355MCU (+4 more)
SYSTEM AND AUXILIARY BRAKES - AR43.00-Z-9451CA > MODEL 451 Check vacuum pump MODEL 451.3/4 with ENGINE 660.9 AR43.05-P-1325MCD Remove/install brake booster vacuum line MODEL 451.3 /4 with ENGINE 132.9 AR43.10-P-0355MCC Remove/install brake booster vacuum line MODEL 451.3 /4 with ENGINE 660.9 AR43.10-P-0355MCD Remove/install brake booster vacuum line MODEL 451.3 /4 with ENGINE 132.910 AR43.10-P-0355MCU Remove/install brake booster vacuum line MODEL 451.391/ 491 AR43.10-P-0355MEV Remove/install vacuum pump MODEL 451.3 /4 with ENGINE 660.9 AR43.05-P-1320MCD Remove/install vacuum pump MODEL 451.391 /491 with ENGINE 780.009 AR43.05-P-1320MEV Remove/install vacuum pump control unit MODEL 451.391 /491 with ENGINE 780.009 AR43.05-P-1323MEV TESTING & REPAIR > REMOVE/INSTALL BRAKE BOOSTER VACUUM LINE - AR43.10-P- 0355MCU > MODEL 451.3 /4 with ENGINE 132.910
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 284 · Applies to: 450, 451, 452, 454
1 Push down brake pedal several times To reduce any vacuum.
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 2 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
3 Remove bulkhead wall On model 451.4 AR61.25- P- 6600MCU 4 Compress retainer (2) and pull vacuum line of brake booster (1) off intake manifold (3) Installation: Check sealing rings, replace if necessary.
5 Unclip vacuum line of brake booster (1) from the brackets (4) on the underfloor
Fig 1: Identifying Brake Booster Vacuum Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Pull vacuum line of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 285 · Applies to: 450, 451, 452, 454 · AR: AS43.00-Z-9999ZZ, BA43.00-Z-9999CZ, BE43.00-Z-9999CZ, WS43.00-Z-9999CZ
6 Pull vacuum line of brake booster (1) out of brake booster (5) Installation: Check grommet (6) and replace if necessary.
7 Pull out vacuum line of brake booster (1) between the frame-type integral support (7) and the underfloor towards the engine and remove Do not kink vacuum line of brake booster (1) otherwise it may be damaged. Observe installation position of chafe protection (8) and routing of vacuum line of brake booster (1). Installation: Pay attention to kink-free and chafe-free routing of vacuum line of brake booster (1).
8 Install in the reverse order
SAFETY PRECAUTIONS > SAFETY INFORMATION: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY BRAKES - AS43.00-Z-9999ZZ > MODEL all Risk of injury caused by touching hot retarder and by scalding from hot retarder oil. Risk of injury to skin or eyes caused by retarder oil escaping under high pressure MODEL 000, 374, 375, 613, 671, 930, 932, 933, 934, 940, 942, 943, 944, 950, 952, 953, 954, 958... AS43.30- Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY BRAKES - BA43.00-Z-9999CZ > MODEL all Pneumatic brake booster MODEL 452.3 /4 BA43.10-P-1000- 01D Pneumatic brake booster MODEL 454.0 with ENGINE 639.939, 122.950, 134.910 /911, 135.930 /950 BA43.10-P-1000-01E Vacuum pump ENGINE 639.939, 660.950 /951 BA43.05-P-1000- 01G Vacuum pump MODEL 450.3 /4, 451.391 /491 BA43.05-P-1000-01E TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY BRAKES - BE43.00-Z-9999CZ > MODEL all Test values for pneumatic brake servo MODEL 450.3 /4 BE43.10-P-1000-01C Test values for vacuum pump MODEL 450.3 /4 MODEL 451.3 /4 with ENGINE 660.9 BE43.05-P-1000-01A SPECIAL TOOLS > SPECIAL TOOLS: SMART: BRAKES - PNEUMATIC SYSTEM AND AUXILIARY BRAKES - WS43.00-Z-9999CZ >
MODEL all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 286 · Applies to: 450, 451, 452, 454
220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B
ENGINES 132.910 in MODEL 451.3/4 with CODE (494) USA version¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 290 · Applies to: 450, 451, 452, 454
ENGINES 132.910 in MODEL 451.3/4 as of 31.8.10 except CODE (494) USA version Shown on vehicle with code (494) USA version Remove/install
1 Remove interior flap above engine
AR88.40- P-1100- 03MCC 2 Remove O2 sensor downstream of CAT [KAT] * not for USA AR07.04- P- 0080MCF 3 Unclip vacuum hose (2) from brackets (3) on resonator (1)
4 Remove clamp (8) on crank case vent hose (4) on resonator (1) Retrofit clamp (8) on vehicles where not installed. Installation: Replace clamp (8). Install clamp (8) as near as possible to resonator (1).Clamping pliers with side bladegotis://G_58.3_06.2
5 Detach crankcase vent hose (4) on resonator (1)
6 Loosen screw clamps (5) and detach resonator (1) from air filter housing upper section (6) and from throttle valve actuator (M16/6)
7 Unscrew bolt (7) and remove resonator (1)
Fig 1: Identifying Resonance Chamber Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Lower rear drive module¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 292 · Applies to: 450, 451, 452, 454
3 Lower rear drive module
P- 3050MCU 4 Lower vehicle with vehicle lift
5 Detach charge current line (2) on intake manifold (1)
6 Detach engine wiring harness (3) on intake manifold (1)
AR15.18- P-1000- 01MCV 7 Unclip and interrupt separation point (arrow) for the line coming out of the mount on the intake manifold (1) from the tank vent valve (Y58/1)
8 Detach clamp (4) and remove fuel line (5) from fuel distributor (7) Then unclip fuel line (6) from mounts on intake manifold (1) Seal fuel line (5) and fuel distributor (7) using suitable stop plugs. Installation: Replace clamp (4).
9 Detach brake booster vacuum line (8) from intake manifold (1)
10 Detach vacuum hose (9) from intake manifold (1)
11 Remove bolts (10) and intake manifold (1) from cylinder head (11) Ensure that the spacer sleeves in the intake manifold (1) do not fall into the cylinder head (11) otherwise this can lead to engine damage. Installation: Replace profiled rubber seals between the intake manifold (1) and the cylinder head (11.
*BA09.20- P-1001- 01J 12 Remove throttle flap actuator (M16/6) from intake manifold (1) When replacing the intake pipe (1). AR07.61- P- 1401MCU 13 Remove intake manifold pressure sensor (B28) from intake manifold (1) When replacing the intake pipe (1). AR07.04- P- 0100MCU 14 Remove fuel distributor (7) from intake manifold (1) When replacing the intake pipe (1). AR07.03- P- 1450MCU 15 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating AS00.00- Z-0005-
during starting procedure or¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 293 · Applies to: 450, 451, 452, 454 · AR: BA09.00-Z-9999CZ
when working near the engine as it is running parts. 01A 16 Conduct engine test run and check for leaktightness in the area of the intake manifold (1) and fuel distributor (7)
INTAKE MANIFOLD, INTAKE MANIFOLD PREHEATER Number Designation Engine 132.910 BA09.20-P-1001- 01J Bolt, intake manifold to cylinder head Initial torque Nm 20 Retightening torque Nm 20 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: AIR INTAKE, SUPERCHARGING - BA09.00-Z-9999CZ > MODEL all Air filter ENGINE 660.940 BA09.10-P-1000-01D Air filter ENGINE 132.9 in MODEL 451.3/4 BA09.10-P-1000-01J Boost pressure sensor ENGINE 660.940 BA09.41-P-1000-04A Charge air cooler ENGINE 160.923 in MODEL 452.3 /4 BA09.41-P-1000-03B Charge air duct ENGINE 660.940 /950 /951 BA09.41-P-1000-02C Charge air pipe/charge air cooling ENGINE 122.9 in MODEL 454.0 BA09.41-P-1000-01L Charge air pipe/charge air cooling ENGINE 639.939 BA09.41-P-1000-01K Charge air pipe/charge air cooling ENGINE 660.940 BA09.41-P-1000-01F Charge air pipe/charge air cooling ENGINE 132.930, 160.910 /920 /921 /922 /923 BA09.41-P-1000-01E Intake manifold ENGINE 134.910 /911, 135.930 /950 BA09.20-P-1000-01M Intake manifold ENGINE 132.910, 160.910 /920 /921 /922 /923 BA09.20-P-1000-01J Turbocharger ENGINE 122.9 BA09.40-P-1000-01L Turbocharger ENGINE 639.939 BA09.40-P-1000-01I Turbocharger ENGINE 660.940 /950 /951 BA09.40-P-1000-01G Turbocharger ENGINE 132.9 BA09.40-P-1000-01O Turbocharger ENGINE 160.910 /920 /921 /922 /923 BA09.40-P-1000-01F TORQUE SPECIFICATIONS > AIR FILTER - BA09.10-P-1000-01J >
Engine 132.9¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 294 · Applies to: 450, 451, 452, 454
AIR FILTER, AIR DUCTING Number Designation Engine 132.9 BA09.10-P-1001-01J Bolt, air filter to transmission Nm 10 TORQUE SPECIFICATIONS > INTAKE MANIFOLD - BA09.20-P-1000-01J > Engines 132, 160 INTAKE MANIFOLD, INTAKE MANIFOLD PREHEATER Number Designation Engine 132.910 Engine 160.910 Engine 160.920 BA09.20-P- 1001-01J Bolt, intake manifold to cylinder head Initial torque Nm 20 12 12 Continued torque Nm 20 10 10 BA09.20-P- 1002-01J Bolt, bracket of air line to transmission Initial torque Nm - 12 12 Continued torque Nm - 9 9 INTAKE MANIFOLD, INTAKE MANIFOLD PREHEATER Number Designation Engine 160.921 Engine 160.922 Engine 160.923 BA09.20-P- 1001-01J Bolt, intake manifold to cylinder head Initial torque Nm 12 12 12 Continued torque Nm 10 10 10 BA09.20-P- 1002-01J Bolt, bracket of air line to transmission Initial torque Nm 12 12 12 Continued torque Nm 9 9 9 TORQUE SPECIFICATIONS > TURBOCHARGER - BA09.40-P-1000-01O > Engine 132.9 TURBOCHARGER Number Designation Engine 132.930 BA09.40-P-1001- 01O Nut of turbocharger to exhaust manifold Nm 30 BA09.40-P-1002- 01O Bolt, exhaust pipe to turbocharger Nm 50 BA09.40-P-1003- 01O Banjo bolt, oil pressure line to turbocharger Nm 17
001 589 01 16 03 box wrench¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 297 · Applies to: 450, 451, 452, 454
FG22/09/28/Set B WS22.00-P-0008- 03B 001 589 01 16 09 Box wrench bit FG22/09/28/Set B WS22.00-P-0008- 09B 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P-0111B 450 589 07 21 00 Pressure pump FG 01/09/20/Set B WS01.00-P-0074B 450 589 11 21 00 Base FG 09/Set B WS09.00-P-0005B 611 589 02 21 00 Leaktightness tester FG 09/Set B WS09.00-P-0006B
ENGINES 132.910 in MODEL 451.3 /4 with CODE (494) USA version¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 301 · Applies to: 450, 451, 452, 454
ENGINES 132.910 in MODEL 451.3 /4 as of 31.8.10 except CODE (494) USA version Shown on vehicle with code (494) USA version Remove/install
1 Remove interior flap above engine
AR88.40- P-1100- 03MCC 2 Remove O2 sensor downstream of CAT [KAT] * not for USA AR07.04- P- 0080MCF 3 Unclip vacuum hose (2) from brackets (3) on resonator (1)
4 Remove clamp (8) on crank case vent hose (4) on resonator (1) Retrofit clamp (8) on vehicles where not installed. Installation: Replace clamp (8). Install clamp (8) as near as possible to resonator (1).Clamping pliers with side blade
5 Detach crankcase vent hose (4) on resonator (1)
6 Loosen screw clamps (5) and detach resonator (1) from air filter housing upper section (6) and from throttle valve actuator (M16/6)
7 Unscrew bolt (7) and remove resonator (1)
Remove bracket (3) from Fig 1: Identifying Resonance Chamber Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3050MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 303 · Applies to: 450, 451, 452, 454
4 Lower vehicle with vehicle lift
5 Detach charge current line (2) on intake manifold (1)
6 Detach engine wiring harness (3) on intake manifold (1)
AR15.18- P-1000- 01MCV 7 Unclip and interrupt separation point (arrow) for the line coming out of the mount on the intake manifold (1) from the tank vent valve (Y58/1)
8 Detach clamp (4) and remove fuel line (5) from fuel distributor (7) Then unclip fuel line (6) from mounts on intake manifold (1) Seal fuel line (5) and fuel distributor (7) using suitable stop plugs. Installation: Replace clamp (4).
9 Detach brake booster vacuum line (8) from intake manifold (1)
10 Detach vacuum hose (9) from intake manifold (1)
11 Remove bolts (10) and intake manifold (1) from cylinder head (11) Ensure that the spacer sleeves in the intake manifold (1) do not fall into the cylinder head (11) otherwise this can lead to engine damage. Installation: Replace profiled rubber seals between the intake manifold (1) and the cylinder head (11.
*BA09.20- P-1001- 01J 12 Remove throttle flap actuator (M16/6) from intake manifold (1) When replacing the intake pipe (1). AR07.61- P- 1401MCU 13 Remove intake manifold pressure sensor (B28) from intake manifold (1) When replacing the intake pipe (1). AR07.04- P- 0100MCU 14 Remove fuel distributor (7) from intake manifold (1) When replacing the intake pipe (1). AR07.03- P- 1450MCU 15 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A
when working near the engine as¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 304 · Applies to: 450, 451, 452, 454 · AR: BA09.00-Z-9999CZ
it is running 16 Conduct engine test run and check for leaktightness in the area of the intake manifold (1) and fuel distributor (7)
INTAKE MANIFOLD, INTAKE MANIFOLD PREHEATER Number Designation Engine 132.910 BA09.20-P-1001- 01J Bolt, intake manifold to cylinder head Initial torque Nm 20 Retightening torque Nm 20 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: AIR INTAKE, SUPERCHARGING - BA09.00-Z-9999CZ > MODEL all
Air filter ENGINE 660.940 BA09.10-P-1000- 01D
Air filter ENGINE 132.9 in MODEL 451.3 /4 BA09.10-P-1000- 01J
Boost pressure sensor ENGINE 660.940 BA09.41-P-1000- 04A
Charge air cooler ENGINE 160.923 in MODEL 452.3 /4 BA09.41-P-1000- 03B
Charge air duct ENGINE 660.940 /950 /951 BA09.41-P-1000- 02C
Charge air pipe/charge air cooling ENGINE 122.9 in MODEL 454.0 BA09.41-P-1000- 01L
Charge air pipe/charge air cooling ENGINE 639.939 BA09.41-P-1000- 01K
Charge air pipe/charge air cooling ENGINE 660.940 BA09.41-P-1000- 01F
Charge air pipe/charge air cooling ENGINE 132.930, 160.910 /920 /921 /922 /923 BA09.41-P-1000- 01E
Intake manifold ENGINE 134.910 /911, 135.930 /950 BA09.20-P-1000- 01M
Intake manifold ENGINE 132.910, 160.910 /920 /921 /922 /923 BA09.20-P-1000- 01J
Turbocharger ENGINE 122.9 BA09.40-P-1000- 01L
Turbocharger¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 305 · Applies to: 450, 451, 452, 454
ENGINE 639.939 BA09.40-P-1000- 01I
Turbocharger ENGINE 660.940 /950 /951 BA09.40-P-1000- 01G
Turbocharger ENGINE 132.9 BA09.40-P-1000- 01O
Turbocharger ENGINE 160.910 /920 /921 /922 /923 BA09.40-P-1000- 01F TORQUE SPECIFICATIONS > AIR FILTER - BA09.10-P-1000-01J > Engine 132.9 AIR FILTER, AIR DUCTING Number Designation Engine 132.9 BA09.10-P-1001-01J Bolt, air filter to transmission Nm 10 TORQUE SPECIFICATIONS > INTAKE MANIFOLD - BA09.20-P-1000-01J > Engines 132, 160 INTAKE MANIFOLD, INTAKE MANIFOLD PREHEATER Number Designation Engine 132.910 Engine 160.910 Engine 160.920 BA09.20-P- 1001-01J Bolt, intake manifold to cylinder head Initial torque Nm 20 12 12 Continued torque Nm 20 10 10 BA09.20-P- 1002-01J Bolt, bracket of air line to transmission Initial torque Nm - 12 12 Continued torque Nm - 9 9 INTAKE MANIFOLD, INTAKE MANIFOLD PREHEATER Number Designation Engine 160.921 Engine 160.922 Engine 160.923 BA09.20-P- 1001-01J Bolt, intake manifold to cylinder head Initial torque Nm 12 12 12 Continued torque Nm 10 10 10 BA09.20-P- 1002-01J Bolt, bracket of air line to transmission Initial torque Nm 12 12 12 Continued torque Nm 9 9 9
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 308 · Applies to: 450, 451, 452, 454
The intake air resonator is located on the upper side of the engine on the air line coming from the air filter. Task The intake air resonator serves as a pulsation damper. This reduces intake noise and minimizes the fluctuations which occur in the air flow during load changes. SPECIAL TOOLS > SPECIAL TOOLS: SMART: AIR INTAKE, SUPERCHARGING - WS09.00- Z-9999CZ > MODEL all 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B 001 589 01 16 03 box wrench FG22/09/28/Set B WS22.00-P-0008-03B 001 589 01 16 09 Box wrench bit FG22/09/28/Set B WS22.00-P-0008-09B 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P-0111B 450 589 07 21 00 Pressure pump FG 01/09/20/Set B WS01.00-P-0074B 450 589 11 21 00 Base FG 09/Set B WS09.00-P-0005B 611 589 02 21 00 Leaktightness tester FG 09/Set B WS09.00-P-0006B Fig 1: Identifying Intake Air Resonator Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > NOTES FOR EVALUATION OF A CYLINDER BARREL -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 309 · Applies to: 450, 451, 452, 454
AH01.40-P-0001-03SM > Engine 132.9, 660.9 in Model 451.3/4 Engine 160.9 in model 450.3/4, 452.3/4 If condition of cylinder barrels cannot be assessed with sufficient certainty by means of visual inspection using an inspection light then the cylinder head must be removed. The following information should be helpful in assessing the cylinder barrel and in making a correct decision concerning the condition and further use of a crankcase. The following illustrated damage profiles are only an excerpt of possible forms of damage to the cylinder barrel. The surface quality of the piston and piston ring must always be taken into account in diagnosing the type of damage. Normal condition Matt gray surface, honing pattern visible, dry cylinder barrel, without oil residues, without polished places or reflective smooth areas. The cylinder barrels must not have any scorch streaks. Individual slight scores are not critical. The honing pattern is more or less clearly recognizable over the cylinder barrel. The honing pattern may be partially worn away at the reversal point of the first piston ring. The crankcase can be reused.
Carbon deposits on the cylinder barrel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 310 · Applies to: 450, 451, 452, 454
Check top land unit of crankcase for carbon deposits (arrow). In the case of carbon deposits (arrow) on the top land unit: clean top land unit and crankcase. Fig 1: Identifying Normal Cylinder Barrel Condition Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: View Of Carbon Deposits On Cylinder Barrel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Individual continuous traces of scratches or score marks¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 311 · Applies to: 450, 451, 452, 454
Check area of contact surface in crankcase for traces of scratches (arrows). The crankcase can be reused if there are light traces of scratches (arrows) or score marks on it. Pressure gloss marks, smooth spots Check at individual blank locations (arrow) e.g. in the middle of the cylinder barrel or an all-round impression on the piston ring reversal point above and below. The crankcase be used again if there are isolated blank areas (arrow). Fig 3: Identifying Individual Continuous Traces Of Scratches Or Score Marks On Cylinder Barrel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Piston seizure or roughened streaks, signs of seizure¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 312 · Applies to: 450, 451, 452, 454
The cylinder barrel is usually roughened over the whole length. Material deposits and perceptible seizure marks on cylinder barrel and also on piston skirt. The crankcase is unusable and must be replaced. Fig 4: Locating Pressure Gloss Marks, Smooth Spots On Cylinder Barrel Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Signs Of Seizure On Cylinder Barrel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > NOTES ON SEALANT PATH FOR TIMING CASE COVER -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 313 · Applies to: 450, 451, 452, 454
AH01.40-P-1000-01MCC > Model 451.3/4 with engine 132.9 Application of sealant to timing case cover The sealing surface on the timing case cover must be absolutely clean and grease-free. The sealant muss must be applied in the form of a bead with a height and width of about 2.0 0.5 mm along the line shown with a gap of about 3 mm to the inner edge of the timing case cover. In crossover areas (arrows) of the cylinder crankcase to the cylinder head two additional beads of sealant must be applied with a length of 8 mm with the same height and width. The timing case cover must be installed within 10 minutes. The applied sealant must not be spread. Use only the sealant listed in the Repair Products. TESTING & REPAIR > INSPECT CYLINDERS WITH A LIGHT PROBE - AR01.00-P- 0200MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 1: Locating Sealant Application Areas On Timing Case Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 314 · Applies to: 450, 451, 452, 454
Risk of death caused by vehicle slipping or toppling off the lifting Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points AS00.00- Z-0010- Fig 1: Identifying Expansion Clip, Crankshaft Belt Pulley, Cover And Center Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: View Of Spark Plugs Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 316 · Applies to: 450, 451, 452, 454
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z- 0005-01A 1 Bring engine to its operating temperature of about 144°C and switch off ignition Only test compression pressure when engine is at normal operating temperature.
2 Remove spark plugs
Replace spark plugs
AP15.10-P- 1580MCU Checking
3 Route electrical line (2) for compression recorder (1) between air filter housing (3) and throttle valve actuator (M16/6) to the starter (M1) *001589762100 Risk of death caused by vehicle slipping or toppling off the lifting Align vehicle between columns of vehicle lift and position four support plates AS00.00-Z- Fig 1: Testing Compression Pressure Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
platform¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 317 · Applies to: 450, 451, 452, 454
at vehicle lift upport point specified by vehicle manufacturer. 0010 01A 4 Raise vehicle with vehicle lift
5 Detach connector (4) from starter (M1)
6 Attach clamping device (5, 6) to starter (M1) *001589762100 7 Lower vehicle with lifting platform
8 Allow engine to turn using contact switch on compression recorder (1) for about 5 seconds In order to remove combustion residues from the cylinders.
001589762100 9 Insert compression recorder (1) with appropriate connecting piece into spark plug bore 001589762100 10 Crank engine with contact switch at the compression recorder (1) until an increase in pressure is no longer indicated on the compression recorder (1) *001589762100 11 Carry out test procedure at remaining cylinders in the same way
12 Compare measurements obtained with the specified pressures Compression pressure new value BE01.00-P- 1001-01G Compression pressure wear limit or limit value If the wear limit is not reached, cylinder leakage must be checked on the respective cylinder.See: ↓ BE01.00-P- 1002-01G Inspect cylinders for leaks AR01.00-P- 1300MCU 13 Install in the reverse order
14 Read out fault memory, erase if necessary
Connect STAR DIAGNOSIS and read out fault memory
AD00.00-P- 2000-04MCC CHECK VALUES FOR COMPRESSION PRESSURE Number Designation Engine 132.910 BE01.00-P-1001- 01G Compression pressure new value bar 15 BE01.00-P-1002- Compression pressure wear limit or limit value bar ≈11
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 319 · Applies to: 450, 451, 452, 454
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z- 0005-01A 1 Warm up engine to operating temperature of approximately 144°C
2 Remove right rear wheel
AR40.10-P- 1100MCU 3 Remove expansion clips (1) and remove cover (2)
4 Lower vehicle with lifting platform
5 Remove maintenance flap
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective glove , protective clothing and safety glasses. AS20.00-Z- 0001-01A Fig 2: View Of Spark Plugs Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Turn cooling y tem cap on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 320 · Applies to: 450, 451, 452, 454
6 Turn cooling y tem cap on radiator counterclockwise through half a revolution, release overpressure, then unscrew cap on cooling system expansion reservoir
7 Remove spark plugs (R4)
Replace spark plugs
AP15.10-P- 1580MCU 8 Unscrew cap on oil filler neck
Check
9 Screw adapter into spark plug bore on cylinder 1 and connect up top dead center finder Insert for cylinder 1 and 2 of adapter from the left.Insert for cylinder 3 of adapter from the right.
451589009100 450589172100 10 Raise vehicle with vehicle lift
11 Turn engine in direction of engine rotation at the center bolt (4) of the crankshaft belt pulley (3) and set piston on cylinder 1 with the aid of the top dead center locator to ignition TDC Turn combustion engine until the ball in the inspection glass on the top dead center locator falls suddenly.
*450589172100 12 Lower vehicle with lifting platform
13 Apply hand brake and select gear
14 Disconnect top dead center locator on adapter 451589009100 450589172100 15 Connect compressed air hose to pressure loss tester *450589172100 16 Attach pressure loss tester to adapter Calibrate pressure loss tester. Observe operating instructions for the pressure loss tester.
451589009100 450589172100 17 Pressurize cylinder 1 with compressed air and read off the pressure loss on pressure loss tester If there is increased pressure loss determine the cause.
Cylinder leaktightness: permissible loss total indication BE01.00-P- 1001-02Z 450589172100
Place tran mi¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 321 · Applies to: 450, 451, 452, 454
18 Place tran mi ion in neutral and release hand brake
19 Inspect other cylinders in the same way
20 Install in the reverse order
CYLINDER LEAKAGE Number Designation All engines BE01.00-P-1001- 02Z Cylinder leaktightness: permissible loss total indication % ≤25 TESTING & REPAIR > DETACHING AND ATTACHING ENGINE WIRING HARNESS ON ENGINE - AR01.00-P-2420-01MCU > 1. Disconnect electrical connector (2) on adjustable camshaft timing solenoid (Y49) 2. Unclip retaining clamps (3) for engine wiring harness (1) from brackets on cylinder head cover (4). 3. Disconnect connector for O2 sensor upstream of TWC (G3/2x1) and unclip on bracket (5). Fig 3: Identifying Adapter (451 589 00 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Pressure Loss Tester (450 589 17 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Remove bolts (6) and lay holder (5) to the side together with engine wiring harness (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 322 · Applies to: 450, 451, 452, 454
- Connect in reverse order. TESTING & REPAIR > RELEASE AND POSITION REAR DRIVE MODULE - AR01.00-P- 3050MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 1: Identifying Connectors & Clamps For Engine Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying Thrust Bearing, Park Pawl Cable, Fuel Tank Vent Valve And Bracket¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 323 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Drive Module Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on vehicles up to production date 2.6.08 with code (I01) Plus air conditioning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 324 · Applies to: 450, 451, 452, 454
MODIFICATION NOTES 28.3.08 Repair method revised Steps 8, 9, 11 and 13 Remove/install
1 Remove interior flap above engine
AR88.40-P- 1100-03MCC 2 Unhook tank vent valve (Y58) on holder (1)
3 Remove air filter housing
AR09.10-P- 1150MCU 4 Unhook thrust bearing (2) for park pawl cable (3) on transmission
5 Remove the rear wheels
AR40.10-P- 1100MCU 6 Remove expansion clip (4) on fender liner (5) of left and right rear fender
7 Remove rear underbody paneling Rechargeable drill / screwdriver http://gotis.aftersales.mercedes-benz.com
8 Detach diagonal struts For model 451.4 with code (I01) Air Conditioning Plus AR61.10-P- 5138-02MCU BA61.25-P- 1002-01B 9 Remove bracket for the diagonal struts For model 451.4 with code (I01) Air Conditioning Plus AR61.10-P- 5138-01MCC BA61.25-P- 1003-01B 10 Remove bulkhead wall On model 451.4 AR61.25-P- 6600MCU On vehicles with code (I01) Air conditioning Plus Installation: Note routing of refrigerant lines (14). There must have a minimum distance of about 5 mm to the body, fuel tank or other components, otherwise noises or damage may be caused by impacts or AR47.10-P- 4100-03MCU
Lower fuel tank¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 325 · Applies to: 450, 451, 452, 454
11 Lower fuel tank chafing. BA47.10-P- 1001-01F Transmission jack http://gotis.aftersales.mercedes-benz.com 450589026200 12 Unscrew plastic nut (6) and remove folding clamp (7) from screw bolt
13 Unclip refrigerant lines (14) from bracket (15) and remove bracket (15) For vehicles with code (I01) Air Conditioning Plus, for which the holder (15) is still installed. Installation: The bracket (15) may no longer be installed.
14 Unhook ground line (8) from holder (9)
15 Remove rear apron
AR88.30-P- 0502MCC
Lower, position
16 Position major assembly lifting table with universal main assembly mount and fix in place with the mount on the engine
AR01.10-P- 2400-06MCU Major assembly lifting platform and universal main assembly mount http://gotis.aftersales.mercedes- benz.com *451589006200 17 Replace bolts (10) by drain screws (11) and bolts (12) by drain screws (13) Observe installation location of bolts (10, 12). Position: Screw in bolts (10, 12) all the way and then tighten.
BA35.10-P- 1001-01F 221589006200 18 Lower rear- wheel drive module carefully When lowering, check for unobstructed movement of electrical lines and hoses in order to avoid causing any damage.For vehicles with code (I01) Air Conditioning Plus, ensure that the refrigerant lines (14) are not bent since these must be replaced otherwise. Positioning: For vehicles with code (I01) Air Conditioning Plus, ensure that the refrigerant lines (14) have unobstructed movement relative to each other and are not damaged due to impacts, chafing, bending or crushing. Position: Ensure that torque strut is correctly introduced into the sleeve.
Remove mount¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 326 · Applies to: 450, 451, 452, 454
19 Remove mount on engine and main assembly lifting table with universal main assembly mount
AR01.10-P- 2400-06MCU *451589006200 20 Install in the reverse order
REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1001- 01F Bolt, frame-type integral support to body Nm 125 FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001- 01F Bolt, fuel tank to body Nm 13 UNDERBODY FRAME Number Designation Model 451.4 except 451.491 BA61.25-P-1002- 01B Bolt, diagonal strut to underbody Nm 65 BA61.25-P-1003- 01B Bolt, console to underbody Nm 26 Fig 3: Identifying Set Of Spacer Bolts (221 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL REAR-WHEEL DRIVE MODULE - AR01.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 327 · Applies to: 450, 451, 452, 454
3060MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 4: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Mount (451 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on vehicles up to production date 2.6.08 with code (I01) Plus air conditioning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 328 · Applies to: 450, 451, 452, 454
MODIFICATION NOTES Fig 1: Identifying Rear-Wheel Drive Module Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear-Wheel Drive Module Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Repair method revised¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 329 · Applies to: 450, 451, 452, 454
31.3.08 Repair method revised Steps 13, 14, 16 and 18
Remove/install
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00-Z- 0001-01A 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 explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking.Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00-Z- 0001-01A Notes on coolant
AH20.00-N- 2080-01A 1 Remove right side paneling in trunk
AR68.30-P- 4800MCU 2 Remove interior flap above engine
AR88.40-P- 1100-03MCC 3 Disconnect ground line of battery
AR54.10-P- 0003MCC 4 Remove tank vent line (1) on tank vent valve (Y58)
5 Detach clamp (2), disconnect fuel line (3) on fuel distributor (4) and expose Seal fuel line (3) and fuel distributor (4) using suitable stop plugs. Installation: Replace clamp (2).
6 Remove air filter housing
AR09.10-P- 1150MCU
Unlock and detach¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 330 · Applies to: 450, 451, 452, 454
7 Unlock and detach brake booster vacuum line (5) on intake manifold (6)
8 Unhook thrust bearing (7) for park pawl cable (8) on transmission
9 Disconnect engine wiring harness on vehicle side
AR15.18-P- 1000-02MCU 10 Remove fender liner in the left and right rear fender
AR88.10-P- 1400MCU 11 Lower vehicle with vehicle lift
12 Drain coolant
AR20.00-P- 1142MCU 13 Detach diagonal struts For model 451.4 with code (I01) Air Conditioning Plus AR61.10-P- 5138-02MCU
*BA61.25-P- 1002-01B 14 Remove bracket for the diagonal struts For model 451.4 with code (I01) Air Conditioning Plus AR61.10-P- 5138-01MCC
*BA61.25-P- 1003-01B 15 Remove bulkhead wall On model 451.4 AR61.25-P- 6600MCU 16 Lower fuel tank and position On vehicles with code (I01) Air conditioning Plus Installation: Note routing of refrigerant lines (18). There must have a minimum distance of about 5 mm to the body, fuel tank or other components, otherwise noises or damage may be caused by impacts or chafing. AR47.10-P- 4100-03MCU
*BA47.10-P- 1001-01F
Transmission jack http://gotis.aftersales.mercedes-benz.com *450589026200 17 Detach clamps (9) and disconnect coolant return flow line (10), coolant line feed line (11) as well as heater coolant line (12) Installation: Replace clamps (9).
from the respective¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 331 · Applies to: 450, 451, 452, 454
coolant pipe 18 Unclip refrigerant lines (18) from bracket (19) and remove bracket (19) For vehicles with code (I01) Air Conditioning Plus, for which the holder (19) is still installed. Installation: The bracket (19) may no longer be installed.
19 Detach electric wiring harness at transmission
AR26.19-P- 0001-05MCU 20 Unscrew plastic nut (13), open folding clamp (14) using a suitable tool and take off Observe installation position of brake lines (15) and electrical lines for RPM sensor connector (L6/3x1, L6/4x1).
21 Expose RPM sensor connector (L6/3x1, L6/4x1) and disconnect
22 Check bolted connection of brake lines (15) for color coding Installation: Identify brake lines (15) accordingly. AR42.10-P- 0013-05MCC 23 Loosen and disconnect bolted connections of brake lines (15) with brake hoses for rear axle (16) Collect brake fluid in a suitable container. Seal connections with suitable stop plugs. *BA42.10-P- 1002-04E
Installation: If a brake line (15) with red color coding has been detached, this brake line (15) must be replaced. Refer to: ↓Remove/install brake line from the ESP hydraulic unit to the rear axle AR42.10-P- 0035MCU 24 Position major assembly lifting table with universal main assembly mount and fix in place with the mount on the engine
AR01.10-P- 2400-06MCU
Major assembly lifting platform and universal main assembly mount http://gotis.aftersales.mercedes-benz.com 451589006200 25 Remove bolts (17) Pay attention to different bolt lengths (17). BA35.10-P- 1001-01F Lower rear-wheel During lowering and positioning ensure that no electrical lines and hoses get pinched. Installation: For vehicles with code (I01) Air
drive module¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 332 · Applies to: 450, 451, 452, 454
26 drive module carefully until the charge current line is accessible Conditioning Plus, ensure that the refrigerant lines (18) have unobstructed movement relative to each other and are not damaged due to impacts, chafing, bending or crushing. Installation: Ensure that torque strut is correctly introduced into the sleeve.
27 Detach charging current line on the engine side
AR15.18-P- 2000-01MCU
*BA15.30-P- 1002-01E
*BA15.40-P- 1002-01G 28 Remove poly-V belt for supercharger On vehicles with code (I01) Air conditioning Plus AR13.21-P- 1202MCU 29 Remove refrigerant compressor and fix at a suitable location using a cable tie On vehicles with code (I01) Air conditioning Plus AR83.55-P- 5300-04MCU
*BA83.55-P- 1001-01V
*BA83.55-P- 1002-01V 30 Lower rear-wheel drive module carefully complete During lowering and positioning ensure that no electrical lines and hoses get pinched.
31 Lift vehicle using the vehicle lift until the rear-wheel drive module can be pulled forward under the vehicle
32 Install in the reverse order
33 Bleed brake system
AR42.10-P- 0010MCU STARTER Number Designation Engine 132.9 BA15.30-P-1002- 01E Cable on starter circuit 30 Nm 10 ALTERNATOR
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 333 · Applies to: 450, 451, 452, 454
Designation Engine 132.9 BA15.40-P-1002- 01G Cable to alternator terminal B+ Nm 10 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1001- 01F Bolt, frame-type integral support to body Nm 125 BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002- 04E Brake pipe on brake hose Nm 16 FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001- 01F Bolt, fuel tank to body Nm 13 UNDERBODY FRAME Number Designation Model 451.4 except 451.491 BA61.25-P-1002- 01B Bolt, diagonal strut to underbody Nm 65 BA61.25-P-1003- 01B Bolt, console to underbody Nm 26 REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001- 01V Bolt, refrigerant compressor to cylinder crankcase Nm 20 BA83.55-P-1002- 01V Bolt, AC compressor to oil pan Nm 20
1. Remove expansion clips (1) and remove cover (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 336 · Applies to: 450, 451, 452, 454
- Transfer marking (arrow A) on crankshaft belt pulley (3) to the front side using a suitable colored pencil. If necessary turn engine at the center bolt (4) of the crankshaft belt pulley (3) in the direction of engine rotation.
- Rotate engine at crankshaft in direction of engine rotation until marking (arrow A) on crankshaft belt pulley (3) coincides with the TDC marking (arrow B) on the timing case cover (5).
- Position cover (2) and install expansion clip (1) If no further turning of engine is required. TESTING & REPAIR > ATTACHING/REMOVING ENGINE SUPPORT FIXTURE - AR01.10-P- 2400-06MCU > Fig 1: Turning Engine To Top Dead Center Position Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Attaching¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 337 · Applies to: 450, 451, 452, 454
- Position main assembly lifting table with universal main assembly mount (1) under engine and transmission. Main assembly lifting table and universal main assembly mount http://gotis.aftersales.mercedes-benz.com
- Fasten mount (2) on timing case cover (3).
- Position mounting plate (4) under the oil pan position mounting plate (5) under the transmission. Then adjust height of the mount (2) and mounting plates (4, 5) appropriately. Fig 1: Identifying Mount (451 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Attaching Engine Support Fixture Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 338 · Applies to: 450, 451, 452, 454
- Lower main assembly lifting table with universal main assembly mount (1) and pull to the front under the vehicle.
- Remove mount (2) from timing case cover (3). TESTING & REPAIR > REMOVE/INSTALL ENGINE WITH TRANSMISSION - AR01.10-P- 2401MCU > ENGINES 132.910 in MODEL 451.3/4 Fig 1: Identifying Engine Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 339 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00-Z- 0001-01A Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00-Z- 0001-01A Notes on coolant
AH20.00-N- 2080-01A 1 Remove maintenance flap
2 Turn cap on engine coolant expansion reservoir a half turn counterclockwise, relieve pressure and then unscrew the cap
3 Remove right side paneling in trunk
AR68.30-P- 4800MCU Fig 2: Identifying Coolant System Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove interior flap above¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 340 · Applies to: 450, 451, 452, 454
4 Remove interior flap above engine
AR88 40 P 1100-03MCC 5 Disconnect ground line of battery
AR54.10-P- 0003MCC 6 Disconnect engine wiring harness on vehicle side
AR15.18-P- 1000-02MCU 7 Detach tank vent valve (Y58/1) from holder (1) on right engine mount (2) and unlock tank vent line (3) on tank vent valve (Y58/1) and detach
8 Detach molded hose (4) on valve for secondary air injection (5)
9 Detach bolts (6) for engine mount on the right (2) on timing case cover *BA22.10-P- 1007-01M 10 Remove air filter housing
AR09.10-P- 1150MCU 11 Detach vacuum line for brake booster (7) at intake manifold (8)
12 Unhook thrust bearing (9) for park pawl cable (10) on transmission and unclip park pawl cable (10) on lever (11)
13 Detach bolts (12) for transmission mounting bearing (13) on transmission *BA26.00-P- 1002-01D 14 Detach clamp (14), disconnect fuel line (15) on fuel distributor (16) and expose Seal fuel line (15) and fuel distributor (16) using suitable stop plugs. Installation: Replace clamp (14).
15 Remove fender liner in the left and right rear fender
AR88.10-P- 1400MCU 16 Remove complete exhaust system
AR49.10-P- 7000MCU 17 Remove rear axle crossmember together with bar links
AR35.15-P- 0250MCC 18 Drain coolant
AR20.00-P- 1142MCU 19 Detach electric wiring harness at transmission
AR26.19-P- 0001-05MCU
Remove bulkhead wall¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 341 · Applies to: 450, 451, 452, 454
20 Remove bulkhead wall On model 451.4 AR61.25-P- 6600MCU 21 Detach clamps (17) and disconnect coolant return flow line (18), coolant line feed line (19) as well as heater coolant line (20) from the respective coolant pipe Installation: Replace clamps (17).
22 Remove expansion clips (21) and remove cover (22)
23 Detach left and right rear axle shaft outboard and fix at a suitable location with a cable ties
AR35.30-P- 0620MCU 24 Remove coolant compressor poly-V belt On vehicles with code (I01) Air conditioning Plus AR13.21-P- 1202MCU 25 Position major assembly lifting table with universal main assembly mount and fix in place with the mount on the engine
AR01.10-P- 2400-06MCU SupportMajor assembly lifting platform and universal lifting platform gotis://A_01_07.1 451589006200 26 Remove bolt (23) to torque support (24) BA22.10-P- 1010-01M 27 Remove bolts (12) for transmission mounting bearing (13) on transmission The bolts (12) are accessible over the left wheel well.
28 Remove bolts (6) for engine mount on the right (2) on timing case cover The bolts (6) are accessible over the right wheel well.
29 Lower engine with transmission carefully until the charge current line is accessible During lowering and positioning, ensure that no electrical lines and hoses are pinched to prevent damage.
30 Remove refrigerant compressor and fix at a suitable location using a cable tie On vehicles with code (I01) Air conditioning Plus AR83.55-P- 5300-04MCU BA83.55-P- 1001-01V BA83.55-P- 1002-01V 31 Detach charging current line on the engine side
AR15.18-P- 2000-01MCU BA15.30-P- 1002-01E BA15.40-P-
1002 01G¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 342 · Applies to: 450, 451, 452, 454
32 Carefully lower combustion engine with transmission During lowering and positioning ensure that no electrical lines and hoses get pinched. Aid of helper required.
33 Lift vehicle using the vehicle lift until the engine with transmission can be pulled forward under the vehicle
34 Install in the reverse order
STARTER Number Designation Engine 132.9 BA15.30-P-1002- 01E Cable to starter circuit 30 Nm 10 ALTERNATOR Number Designation Engine 132.9 BA15.40-P-1002- 01G Cable on alternator terminal B+ Nm 10 ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 BA22.10-P-1007- 01M Bolt, right engine mount to timing case cover Nm 80 BA22.10-P-1010- 01M Bolt, torque support to frame-type integral support Nm 115 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.48 BA26.00-P-1002- 01D Bolt, transmission mount to transmission Nm 80 REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001- 01V Bolt, refrigerant compressor to cylinder crankcase Nm 20 BA83.55-P-1002- 01V Bolt, AC compressor to oil pan Nm 20
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 345 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1053-01A Sealant Q0000282V000000000 TESTING & REPAIR > BOLT TIGHTENING PROCEDURE FOR CYLINDER HEAD COVER - AR01.20-P-5014-03MCC > CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 132.9 BA01.20-P-1002- 01I Bolt, cylinder head cover to cylinder head Nm 10 1. Screw in bolts (1 to 10) for cylinder head cover in a number of stages according to the represented sequence all the way and tighten using the prescribed torque. Loosen bolts for the cylinder head cover in reverse order of the tightening procedure. Fig 2: Identifying Knife (122 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 347 · Applies to: 450, 451, 452, 454
27.1.09 Remove/install clamp on vent hose for crankcase of cylinder head cover added Step 2
Remove/install
1 Remove ignition coils
AR15.12- P- 2003MCU For vehicles, on which the clamp (11) is not Fig 1: Identifying Cylinder Head Cover Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Cylinder Head Cover, Vent Hose For Crankcase And Clip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove clamp (11) of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 348 · Applies to: 450, 451, 452, 454
2 Remove clamp (11) of crankcase vent hose (2) on cylinder head cover (1) yet installed, it must then be retrofitted during installation. Installation: Replace clip (11). The clamp (11) must be fitted as close as possible to the cylinder head cover (1).Clamp pliers with side cutter gotis://G_58.3_06.2
3 Detach crankcase vent hose (2) to the cylinder head cover (1)
4 Remove oil dipstick (3) from cylinder head cover (1)
5 Disconnect engine wiring harness (4) on engine
AR01.00- P-2420- 01MCU 6 Detach vacuum hose (5) and supply line (7) on secondary air injection valve (6)
7 Remove complete exhaust system
AR49.10- P- 7000MCU 8 Remove bolts for secondary air injection pipe (8) on cylinder head The secondary air injection pipe (8) is attached to cylinder head by three bolts.
*BA14.30- P-1002- 03C 9 Remove bolts (9) for secondary air injection valve (6) on cylinder head and remove together with secondary air injection pipe (8)
10 Remove bolts on cylinder head cover (1) The cylinder head cover (1) is fastened with ten bolts. Loosen bolts for cylinder head cover (1) in reverse order of the tightening procedure. Installation: Observe prescribed tightening sequence of bolts for the cylinder head cover (1). AR01.20- P-5014- 03MCC *BA01.20- P-1002- 01I Detach and remove Check seal on cylinder head cover (1) for damage; replace cylinder head cover (1) if necessary. Remove sealant residue in the area of the joint edge of the cylinder head and timing case cover. Installation: Check seals for spark plug shafts for damage, replace if necessary. Apply sealant in the area of the joint
cylinder head cover (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 349 · Applies to: 450, 451, 452, 454
11 cylinder head cover (1) from cylinder head edge of the cylinder head and timing case cover. Sealing compound *BR00.45- Z-1053- 01A 12 Remove bracket (10) for engine wiring harness (4) on cylinder head cover (1) When replacing the cylinder head cover (1).
13 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 14 Conduct engine test run and check engine for leaks in the area of the cylinder head cover (1)
CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 132.9 BA01.20-P-1002- 01I Bolt, cylinder head cover to cylinder head Nm 10 COMBINATION VALVE Number Designation Engine 132.910 BA14.30-P-1002- 03C Bolt, pipe for secondary air injection to cylinder head Nm 8 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1053-01A Sealing compound Q0000282V000000000 TESTING & REPAIR > TIGHTENING PROCEDURE FOR CYLINDER HEAD BOLTS - AR01.30-P-5800-01MCC > CYLINDER HEAD Number Designation Engine 132.9 BA01.30-P-1001- Bolt, cylinder head to crankcase Stage 1 Nm 25
Illustrated on removed engine¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 351 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Cylinder Head Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Engine 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. 352 · Applies to: 450, 451, 452, 454
1 Check basic position of camshafts
AR05.20-P- 6010MCU 2 Remove timing case cover
AR01.40-P- 8000MCU 3 Support rear axle crossmember (2) in the middle with a transmission jack, remove bolts (3) and lower rear axle crossmember (2) Use a suitable base.
Transmission jack http://gotis.aftersales.mercedes-benz.com *BA35.10-P- 1003-01F 4 Disconnect electrical connector (4) on coolant temperature sensor (B11/4) and unclip retaining clip (5) from electrical wiring harness on holder (6)
In order to lock the chain tensioner (8), place a Fig 3: Identifying Engine Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Turn back ratchet¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 353 · Applies to: 450, 451, 452, 454
5 Turn back ratchet (7) on chain tensioner (8) using a suitable screwdriver and lock chain tensioner (8) via the bore (arrow A) pin with a diameter of 1.5 mm into the bore (arrow A) in the chain tensioner (8). Installation: Attach adapter to crankshaft, remove retaining lock on starter ring gear and turn engine in direction of engine rotation through about two revolutions until the markings on the crankshaft sprocket and on the cylinder crankcase stand opposite each other. Then check whether the marking (arrow B) on the camshaft sprocket (14) and the marking (arrow C) on the camshaft adjuster (15) stand opposite each other; remove timing chain (13) if necessary and mount again anew.
Attach/disassemble retaining lock for engine AR03.30-P- 1600-06MCE 451589014000 If the cylinder head (1) was replaced the valve clearance must be checked and adjusted if necessary.Refer to: ↓ 451589016300 Set valve clearance AP05.30-P- 0560MCU 6 Unscrew bolts (9) and remove slide rail (10) BA05.10-P- 1002-01P BA05.10-P- 1003-01P 7 Unscrew bolt (11) and remove tensioning rail (12) *BA05.10-P- 1001-01P 8 Take off timing chain (13) Installation: Before mounting the timing chain (13) check whether the marking (arrow B) on the camshaft sprocket (14) and the marking (arrow C) on the camshaft adjuster (15) are standing opposite each other. If this is not the case, the intake camshaft and the exhaust camshaft must be turned appropriately.
9 Lower vehicle with lifting platform
10 Remove bolt (16) and pull adjustable camshaft timing solenoid (Y49) out of cylinder head (1) Cover oil holes on adjustable camshaft timing solenoid (Y49) to protect against ingress of foreign objects. Ingress of foreign objects can cause engine damage.
*BA05.20-P- 1006-01M 11 Remove intake camshaft and The camshaft sprocket (14) remains on the exhaust camshaft. AR05.20-P- 6992MCU
exhaust camshaft¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 354 · Applies to: 450, 451, 452, 454
12 Loosen clamp (17) and detach coolant hose (18) from connection fitting on cylinder head (1) Installation: Replace clamp (17).
13 Remove bolt (19) and pull camshaft Hall sensor (B6/1) out of cylinder head (1) BA15.12-P- 1004-01G 14 Remove bolt (20) for coolant pipe (21) on cylinder head (1) BA20.10-P- 1011-01J 15 Detach holder (22) for electrical wiring harness (23) on intake manifold (24)
16 Remove bolts (25) and detach air intake manifold (24) from intake manifold (1) Installation: Replace seals on intake manifold (24).
BA09.20-P- 1001-01J 17 Loosen cylinder head bolts (26) in stages Loosen cylinder head bolts (26) in reverse order of tightening procedure. Installation: Replace cylinder head bolts (26) and wet on thread and on bolt head contact surfaces with engine oil. AR01.30-P- 5800-01MCC BA01.30-P- 1001-01K 18 Support engine on carrier for front engine mount using a hand-operated hydraulic floor jack Use a suitable base.Hand-operated hydraulic floor jack http://gotis.aftersales.mercedes- benz.com
19 Unhook chain for engine-lifting device on retaining plate (30) *451589026300 Remove cylinder head bolts (26)
and cylinder head¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 355 · Applies to: 450, 451, 452, 454
20 and cylinder head (1) from cylinder crankcase
21 Take cylinder head gasket (27) off crankcase Installation: Replace cylinder head gasket (27).
22 Remove valve tappet (28) from basic bores in cylinder head (1) Do not use magnets. Gathering of the smallest metal shavings can occur due to magnetization of the valve tappets (28) which can lead to damage of valve tappets (28) and intake camshaft or exhaust camshaft. Installation: The valve tappet (28) must be installed again at the same location.
23 Clean separating surfaces on cylinder head (1) and crankcase then check for visible damage and flatness Replace cylinder head (1) if necessary.Straightedge http://gotis.aftersales.mercedes-benz.com
24 Clean threaded hole for cylinder head bolts (26) in crankcase
25 Unscrew bolt (29) and remove retaining plate (30) from cylinder head (1) When replacing the cylinder head (1).
*451589026300 26 Remove coolant temperature sensor (B11/4) from cylinder head (1) When replacing the cylinder head (1).
*BA15.60-P- 1002-01B 27 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z- 0005-01A
Conduct engine¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 356 · Applies to: 450, 451, 452, 454
28 Conduct engine test run and check engine for leaks in area of the cylinder head (1) CYLINDER HEAD Number Designation Engine 132.9 BA01.30-P-1001- 01K Bolt, cylinder head to crankcase Stage 1 Nm 25 Stage 2 ∠° 90 Stage 3 ∠° 90 Stage 4 ∠° - TIMING CHAIN DRIVE Number Designation Engine 132.9 BA05.10-P-1001- 01P Bolt, timing chain tensioning rail to cylinder head Nm 23 BA05.10-P-1002- 01P Bolt, timing chain slide rail to cylinder head Nm 10 BA05.10-P-1003- 01P Bolt, timing chain slide rail to crankcase Nm 10 CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1006- 01M Bolt, camshaft solenoid to cylinder head Nm 11 INTAKE MANIFOLD, INTAKE MANIFOLD PREHEATER Number Designation Engine 132.910 BA09.20-P-1001- 01J Bolt, intake manifold to cylinder head Initial torque Nm 20 Retightening torque Nm 20 ECI IGNITION SYSTEM Number Designation Engine 132.9 BA15.12-P-1004- 01G Bolt, camshaft position sensor to cylinder head Nm 11 TEMPERATURE SENSOR
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 357 · Applies to: 450, 451, 452, 454
Designation Engine 132.9 BA15.60-P-1002- 01B Coolant temperature sensor to cylinder head Nm 30 COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1011- 01J Bolt connecting coolant line to cylinder head Nm 24 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1003- 01F Bolt, crossmember to frame-type integral support Nm 65 Fig 4: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Adapter (451 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying Carrier For Front Engine Mount, Torque Support And Frame-Type Integral Support¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 359 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Timing Case Cover 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. 360 · Applies to: 450, 451, 452, 454
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00-Z- 0001-01A Notes on coolant
AH20.00-N- 2080-01A 1 Remove service flap
2 Turn cap for coolant expansion reservoir half a revolution counterclockwise, release excess pressure, and take off the cooling system cap
3 Remove interior flap above engine
AR88.40-P- 1100-03MCC 4 Disconnect ground line of battery
AR54.10-P- 0003MCC Remove fender liner in AR88.10-P- Fig 3: Identifying Timing Case Cover Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
right rear fender¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 361 · Applies to: 450, 451, 452, 454
5 right rear fender
1400MCU 6 Release rear drive module
AR01.00-P- 3050MCU 7 Drain coolant
AR20.00-P- 1142MCU 8 Remove poly-V-belt tensioning device
AR13.25-P- 3200MCU 9 Remove belt pulley for crankshaft
AR03.30-P- 1700MCU 10 Remove oil pan Remove front engine mount carrier (2) together with torque support (3). For this, unscrew the bolt of the torque support (3) on the frame-type integral support (4). AR01.45-P- 7500MCU *BA22.10-P- 1010-01M 11 Reinstall front engine mount carrier (2) together with the torque support (3). On order to support the engine during the work procedure.
12 Remove cylinder head cover
AR01.20-P- 5014MCU 13 Lower vehicle with lifting platform
14 Undo bolts (5) and remove bracket (6)
15 Fix retaining plate in place on cylinder head (7) using a bolt (5), attach support braces to engine using an engine lifting device and support engine using an engine lifting device and appropriate chain via the retaining plate on the cylinder head (7) 451589016200 Engine lifting device http://gotis.aftersales.mercedes- benz.com 451589026300 16 Remove bolts (8, 9) and right engine mount (10) BA22.10-P- 1006-01M BA22.10-P- 1007-01M 17 Remove bolts (11) and loosen alternator (G2) from timing case cover (1) and fix in place at a *BA15.40-P- 1008-01G
suitable location using¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 362 · Applies to: 450, 451, 452, 454
a cable tie 18 Raise vehicle with vehicle lift
19 Disconnect electrical connector (12) at oil pressure switch (S41/1)
20 Remove bolt (13) as well as ground (14) line for engine ground
21 Unscrew bolt (15)
22 Remove bolts (16) and lay electrical wiring harness (17) to the side BA01.40-P- 1007-01M 23 Remove refrigerant compressor and fix at a suitable location using a cable tie On vehicles with code (I01) Air conditioning Plus Installation: Only attach refrigerant compressor after installing the oil pan. AR83.55-P- 5300-04MCU BA83.55-P- 1001-01V BA83.55-P- 1002-01V 24 Remove bolts (18, 19), detach timing case cover (1) using a tool from cylinder crankcase and remove downwards Installation: Clean sealing surface on timing case cover (1) and on cylinder crankcase, replace seal ring (20) on timing case cover (1) and seal ring on coolant feed line. Before installing the timing case cover (1), screw guide for crankshaft radial sealing ring (21) into the threaded hole for crankshaft and align the drive for oil pump in timing case cover (1) according the position of the crankshaft. Pay attention to different bolt lengths (18, 19). AR01.40-P- 8000-01MCC BA01.40-P- 1007-01M 451589036300 Sealing compound BR00.45-Z- 1053-01A Notes on sealant path for timing case cover AH01.40-P- 1000-01MCC 25 Lever crankshaft radial sealant ring (21) out of timing case cover (1) using a suitable tool Ensure that timing case cover (1) is not damage otherwise it must be replaced. Installation: The crankshaft radial sealing ring (21) must be installed dry and lock flush with the timing case cover (1).
Remove cooling pump¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 363 · Applies to: 450, 451, 452, 454
*711589131500 26 Remove cooling pump (22) from timing case cover (1) When replacing timing case cover (1). Installation: Replace gasket of coolant pump (22).
*BA20.10-P- 1007-01J 27 Remove oil pressure switch (S41/1) from timing case cover (1) When replacing timing case cover (1).
*BA18.40-P- 1002-01G 28 Install in the reverse order
CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 BA01.40-P-1007- 01M Bolt, timing case cover to crankcase/cylinder head M6 Nm 10 M8 Nm 23 BELT TENSIONING DEVICE Number Designation Engine 132.9 BA13.25-P-1003- 01K Bolt, poly-V belt tensioning device to timing case cover Nm 49 ALTERNATOR Number Designation Engine 132.9 BA15.40-P-1008- 01G Bolt, alternator to timing case cover Nm 23 OIL LEVEL/OIL PRESSURE SENSOR Number Designation Engine 132.9 BA18.40-P-1002- 01G Oil pressure sensor to timing case cover Nm 10 COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1007- 01J Bolt, coolant pump to timing case cover M6 Nm 10 M8 Nm 23 ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9
BA22.10-P-1006-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 364 · Applies to: 450, 451, 452, 454
01M Bolt, right engine mount to frame-type integral support Nm 56 BA22.10-P-1007- 01M Bolt, right engine mount to timing case cover Nm 80 BA22.10-P-1010- 01M Bolt, torque support to frame-type integral support Nm 115 REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001- 01V Bolt, AC compressor to crankcase Nm 20 BA83.55-P-1002- 01V Bolt, AC compressor to oil pan Nm 20 Fig 4: Identifying Support Braces (451 589 01 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Retaining Plates (451 589 02 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 366 · Applies to: 450, 451, 452, 454
1 Remove oil pan Remove front engine mount carrier (2) together with torque support (3). To do this remove bolt for torque support (3) on frame-type integral support (4). AR01.45- P- 7500MCU 2 Reinstall front engine mount carrier (2) together with the torque support (3). On order to support the engine during the work procedure.
3 Remove flywheel
AR03.30- P- 8002MCU 4 Remove bolts (5) *BA01.40- P-1006- 01M 5 Detach and remove end cover together with radial shaft seal (1) on crankcase (6) Make sure that surfaces are completely clean to prevent leaks around the end cover with radial shaft sealing ring (1). Installation: Clean sealing surface on crankcase (6) (e.g. with acetone), clean contact surface to crankshaft with a clean rag without using cleaning agent.Apply sealant to cylinder crankcase (6).
Sealant *BR00.45- Z-1053- 01A Notes on Fig 1: Identifying End Cover With Shaft Seal Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Drain engine oil¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 369 · Applies to: 450, 451, 452, 454
1 Drain engine oil
Engine oil and filter change
AP18.00-P- 0101MCU 2 Remove fender liner in right rear fender On vehicles with code (I01) Air conditioning Plus AR88.10-P- 1400MCU 3 Remove poly-V belt for refrigerant compressor On vehicles with code (I01) Air conditioning Plus AR13.21-P- 1202MCU 4 Detach refrigerant compressor to oil pan (1)
AR83.55-P- 5300-04MCU BA83.55-P- 1001-01V BA83.55-P- 1002-01V 5 Remove carrier for front engine mount (2)
AR22.10-P- 1001MCU 6 Remove bolt (3) for coolant pipe (4) to oil pan (1) *BA20.10-P- 1010-01J 7 Remove bolt (5) for bracket (6) to oil pan (1)
8 Remove oil pan bolts (1) on cylinder crankcase and on timing case cover The oil pan (1) is fixed using eight bolts on the cylinder crankcase and with four bolts on the timing case cover.
*BA01.45-P- 1001-01J 9 Detach and remove oil pan (1) using a blade on the cylinder crankcase as well as on the timing case cover
Installation: Clean sealing surfaces. Coat sealing surface to oil pan (1) with sealant. Replace seal ring on timing case cover. 122589002800 Sealant BR00.45-Z- 1053-01A Information on application of sealant to oil pan AH01.45-P- 0001-01MCC 10 Install in the reverse order
OIL PAN Number Designation Engine 132.9 BA01.45-P-1001- 01J Bolt, oil pan to crankcase and timing case cover Initial torque Nm 10 Retightening torque Nm 10 COOLANT PUMP, COOLANT THERMOSTAT
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 370 · Applies to: 450, 451, 452, 454 · AR: BA01.00-Z-9999CZ
Designation Engine 132.9 BA20.10-P-1010- 01J Bolt, coolant pipe to oil pan Nm 10 REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001- 01V Bolt, AC compressor to crankcase Nm 20 BA83.55-P-1002- 01V Bolt, AC compressor to oil pan Nm 20 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1053-01A Sealant Q0000282V000000000 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - BA01.00-Z-9999CZ > MODEL all Crankcase, timing case cover, end cover ENGINE 134.910 /911, 135.930 /950 BA01.40-P-1000-01O Crankcase, timing case cover, end cover ENGINE 660.940 /950 BA01.40-P-1000-01N Crankcase, timing case cover, end cover ENGINE 132.9, 160.910 /920 /921 /922 /923 BA01.40-P-1000- 01M Crankcase, timing case cover, end cover ENGINE 639.9 in MODEL 454.0 BA01.40-P-1000-01V Crankcase, timing case cover, end cover ENGINE 122.9 in MODEL 454.0 BA01.40-P-1000-01U Crankcase ventilation, cylinder ENGINE 122.950, 134.910 /911, BA01.20-P-1000-01K Fig 2: Identifying Knife (122 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
head cover¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 371 · Applies to: 450, 451, 452, 454
135.930/950 Crankcase ventilation, cylinder head cover ENGINE 660.940 /950 /951 BA01.20-P-1000-01J Crankcase ventilation, cylinder head cover ENGINE 132.9, 160.910 /920 /921 /922 /923 BA01.20-P-1000-01I Crankcase ventilation, cylinder head cover ENGINE 639.939 BA01.20-P-1000-01O Cylinder head ENGINE 122.950 BA01.30-P-1000-01T Cylinder head ENGINE 639.939 BA01.30-P-1000-01R Cylinder head ENGINE 134.910 /911, 135.930 /950 BA01.30-P-1000-01N Cylinder head ENGINE 660.940 /950 /951 BA01.30-P-1000-01L Cylinder head ENGINE 132.9, 160.910 /920 /921 /922 /923 BA01.30-P-1000-01K Oil pan ENGINE 122.950, 134.910 /911, 135.930/950 BA01.45-P-1000-01L Oil pan ENGINE 660.940 /950 /951 BA01.45-P-1000-01K Oil pan ENGINE 132.9, 160.910 /920 /921 /922 /923 BA01.45-P-1000-01J Oil pan ENGINE 639.939 BA01.45-P-1000-01P TORQUE SPECIFICATIONS > CRANKCASE VENTILATION, CYLINDER HEAD COVER - BA01.20-P-1000-01I > Engine 132, 160 CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 132.9 Engine 160.910 BA01.20-P- 1001-01I Bolt, cylinder head cover to cylinder head Initial torque Nm 10 12 Continued torque Nm 10 9.5 BA01.20-P- 1002-01I Bolt, cylinder head cover to cylinder head Nm 10 - BA01.20-P- 1003-01I Bolt, partial load bleed plate to crankcase Nm 10 - CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 160.920 Engine 160.921 BA01.20-P-1001- 01I Bolt, cylinder head cover to cylinder Initial torque Nm 12 12
head¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 372 · Applies to: 450, 451, 452, 454
Continued torque Nm 9.5 9.5 BA01.20-P-1002- 01I Bolt, cylinder head cover to cylinder head Nm - - BA01.20-P-1003- 01I Bolt, partial load bleed plate to crankcase Nm - - CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 160.922 Engine 160.923 BA01.20-P-1001- 01I Bolt, cylinder head cover to cylinder head Initial torque Nm 12 12 Continued torque Nm 9.5 9.5 BA01.20-P-1002- 01I Bolt, cylinder head cover to cylinder head Nm - - BA01.20-P-1003- 01I Bolt, partial load bleed plate to crankcase Nm - - TORQUE SPECIFICATIONS > CYLINDER HEAD - BA01.30-P-1000-01K > Engine 132, 160 CYLINDER HEAD Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 Engine 160.922 BA01.30-P- 1001-01K Bolt, cylinder head to crankcase Stage 1 Nm 25 21 21 21 21 Stage 2 ∠° 90 90 90 90 90 Stage 3 ∠° 90 90 90 90 90 Stage 4 ∠° - 10 10 10 10 BA01.30-P- 1002-01K Bolt, cylinder head to timing case cover Nm - - 27 27 27 CYLINDER HEAD Number Designation Engine 160.923 BA01.30-P-1001- 01K Bolt, cylinder head to crankcase Stage 1 Nm 21 Stage 2 ∠° 90 Stage 3 ∠° 90 Stage 4 ∠° 10
BA01.30-P-1002-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 373 · Applies to: 450, 451, 452, 454
01K Bolt, cylinder head to timing case cover Nm 27 TORQUE SPECIFICATIONS > CRANKCASE, TIMING CASE COVER, END COVER - BA01.40-P-1000-01M > Engine 132, 160 CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 Engine 160.910 BA01.40-P- 1001-01M Coolant drain plug to crankcase Nm - 12 BA01.40-P- 1002-01M Bolt, timing case cover to crankcase Initial torque Nm - 12 Continued torque Nm - 9,5 BA01.40-P- 1003-01M Screw plug, oil duct to crankcase Nm - 30 BA01.40-P- 1004-01M Cylinder head to timing case Nm - 27 BA01.40-P- 1005-01M Bolt, crankcase bottom section 8 mm Stage 1 Nm - - Stage 2 ∠° - - 6 mm Nm - - BA01.40-P- 1006-01M Bolt connecting end cover to radial shaft sealing ring to crankcase Nm 10 - BA01.40-P- 1007-01M Bolt, timing case cover to crankcase/cylinder head M6 Nm 10 - M8 Nm 23 - BA01.40-P- 1008-01M Screw plug at timing case cover Nm 50 - CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 160.920 Engine 160.921 BA01.40-P- 1001-01M Coolant drain plug to crankcase Nm 12 12 BA01.40-P- 1002-01M Bolt, timing case cover to crankcase Initial torque Nm 12 12 Continued torque Nm 9,5 9,5 BA01.40-P- 1003-01M Screw plug, oil duct to crankcase Nm 30 30 BA01.40-P- Cylinder head to timing case Nm 27 27
1004-01M¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 374 · Applies to: 450, 451, 452, 454
BA01.40-P- 1005-01M Bolt, crankcase bottom section 8 mm Stage 1 Nm 21 21 Stage 2 ∠° 90 90 6 mm Nm 9,5 9,5 BA01.40-P- 1006-01M Bolt connecting end cover to radial shaft sealing ring to crankcase Nm - - BA01.40-P- 1007-01M Bolt, timing case cover to crankcase/cylinder head M6 Nm - - M8 Nm - - BA01.40-P- 1008-01M Screw plug at timing case cover Nm - - CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 160.922 Engine 160.923 BA01.40-P- 1001-01M Coolant drain plug to crankcase Nm 12 12 BA01.40-P- 1002-01M Bolt, timing case cover to crankcase Initial torque Nm 12 12 Continued torque Nm 9,5 9,5 BA01.40-P- 1003-01M Screw plug, oil duct to crankcase Nm 30 30 BA01.40-P- 1004-01M Cylinder head to timing case Nm 27 27 BA01.40-P- 1005-01M Bolt, crankcase bottom section 8 mm Stage 1 Nm 21 21 Stage 2 ∠° 90 90 6 mm Nm 9,5 9,5 BA01.40-P- 1006-01M Bolt connecting end cover to radial shaft sealing ring to crankcase Nm - - BA01.40-P- 1007-01M Bolt, timing case cover to crankcase/cylinder head M6 Nm - - M8 Nm - - BA01.40-P- 1008-01M Screw plug at timing case cover Nm - - TORQUE SPECIFICATIONS > OIL PAN - BA01.45-P-1000-01J > Engine 132, 160 MODIFICATION NOTES 29.8.05 Bolt connecting oil dipstick guide tube to crankcase, retightening torque Engine 160.921
Bolt connecting oil dipstick guide tube to crankcase,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 375 · Applies to: 450, 451, 452, 454
retightening torque Engine 160.922 Bolt connecting oil dipstick guide tube to crankcase, retightening torque Engine 160.923 OIL PAN Number Designation Engine 132.9 Engine 160.910 Engine 160.920 BA01.45-P- 1001-01J Bolt, oil pan to crankcase and timing case cover Initial torque Nm 10 12 12 Continued torque Nm 10 9 9 BA01.45-P- 1002-01J Bolt, dipstick guide tube to crankcase Initial torque Nm - 12 12 Continued torque Nm - 9 9 BA01.45-P- 1003-01J Oil drain screw to oil pan Nm 65 - - OIL PAN Number Designation Engine 160.921 Engine 160.922 Engine 160.923 BA01.45-P- 1001-01J Bolt, oil pan to crankcase and timing case cover Initial torque Nm 12 12 12 Continued torque Nm 9 9 9 BA01.45-P- 1002-01J Bolt, dipstick guide tube to crankcase Initial torque Nm 12 12 12 Continued torque Nm 9 9 9 BA01.45-P- 1003-01J Oil drain screw to oil pan Nm - - - TEST & ADJUSTMENT VALUES > COMPRESSION PRESSURE - BE01.00-P-1000-01G > Engine 122, 132, 134, 135, 639, 660 CHECK VALUES FOR COMPRESSION PRESSURE Number Designation Engine 122 Engine 132.910 Engine 132.930 Engine 134 BE01.00-P- 1001-01G Compression pressure new value bar 12.1 15 14 13.2 BE01.00-P- 1002-01G Compression pressure wear limit or limit value bar ≈8.3 ≈11 ≈10 ≈9 BE01.00-P- 1003-01G Compression pressure: permissible difference bar ≤0.98 - - ≤0.98
Check values for cylinder¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 377 · Applies to: 450, 451, 452, 454
bore ENGINE 122, 134, 135, 160, 639... BE01.40-P-1000-01L Compression pressure ENGINE 160.910 /920 /921 /922 BE01.00-P-1000-01H Compression pressure ENGINE 122, 132.910 /930, 134, 135.930 /950, 639, 660.940 /950 /951 BE01.00-P-1000- 01G Cylinder head/cylinder head bolts ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 in MODEL 454.0 BE01.30-P-1000-04F Cylinder leaktightness ENGINE all BE01.00-P-1000- 02Z Inspection data for cylinder head ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 in MODEL 454.0 BE01.30-P-1000-02F Test specifications for cylinder bore ENGINE 132.9 in MODEL 451.3/4 BE01.40-P-1000- 01P TEST & ADJUSTMENT VALUES > TEST SPECIFICATIONS FOR CYLINDER BORE - BE01.40-P-1000-01P > Engine 132 TEST SPECIFICATIONS FOR CYLINDER BORE Number Designation Engine 132.910/930 BE01.40-P-1001- 01P Ø of cylinder bore Standard size mm 72.010 to 72.025 Out-of-roundness (in a new condition) mm 0.01 Wear limit in longitudinal and transverse direction mm 0.15 BASIC KNOWLEDGE > MECHANICAL ENGINE COMPONENTS, FUNCTION - GF01.10-P- 0001MCU > ENGINES 132.9 in MODEL 451.3/4 The three-cylinder engine was newly developed from scratch. It is raked to the rear by 45° and installed transversely in front of the rear axle. The engine is characterized by a weight-conscious full aluminum construction from the oil pan to the cylinder head cover. The crankcases are equipped with gray cast iron bushes for the cylinder barrel. Four valves per cylinder control the gas exchange in the cylinder heads. These are controlled by intake and exhaust camshafts which are driven via a maintenance free timing chain by the crankshaft. Cup tappets serve as transmission elements for cam contours in the valve movement. It was possible to dispense with a balance shaft for the three-cylinder typical vibrations (free mass moment) because of the low moved masses. Significant reduction in the tendency to knock was also achieved through optimization of combustion chambers.
ENGINE 112, 271, 272, 642, 646, 651, 132¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 380 · Applies to: 450, 451, 452, 454
Use: Engine lifting device for lifting engine.
SPECIAL TOOLS > 001 589 76 21 00 COMPRESSION TESTER - WS01.00-P-0004A > FG 01/13/Set A ENGINE all Part 001 589 76 21 13 Diagram charts FG 01/Set A WS01.00-P-0004-01A Part 001 589 76 21 21 Graph sheets FG 01/Set A WS01.00-P-0004-02A Part 001 589 76 21 23 Connectors FG 01/Set A WS01.00-P-0004-03A Use: Compression recorder complete for gasoline engines 3.5 - 17.5 bar and diesel engines 10 - 40 bar NOTE: Connectors M22 x 1.5 mm/R1/4" for injection nozzle hole, see 602 589 00 63 00, 604 589 00 63 00
Fig 1: Identifying Engine Lifting Device (639 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 00 10 00 SOCKET WRENCH - WS01.00-P-0070B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 381 · Applies to: 450, 451, 452, 454
FG 01/Set B MODEL 450, 451, 452 Use: Socket wrench for tightening the cylinder head bolts. NOTE: Internal Torx T 70Smart No. 0005084. SPECIAL TOOLS > 450 589 05 21 00 COMPRESSION TESTER SET - WS01.00-P-0072A > FG 01/Set A ENGINE 122, 132, 134, 135, 160, 639, 660 Fig 1: Identifying Compression Tester (001 589 76 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Socket Wrench (450 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Single part¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 382 · Applies to: 450, 451, 452, 454
450 589 05 21 06 Screw piece FG01/Set A WS01.00-P-0072-06A Use: Compression tester set for testing the compression pressure, mechanical leaktightness of the pistons, cylinders, valves, head gasket. NOTE: Compression tester set, smart no.: 000 5152 V001 0000 00. SPECIAL TOOLS > 450 589 07 21 00 PRESSURE PUMP - WS01.00-P-0074B > FG 01/09/20/Set B MODEL 450, 452, 454 MODEL 451 with ENGINE 132, 660.9, 780.009 Separate part 450 589 07 21 07 Adapter FG01/20/Set B WS01.00-P-0074-07B Use: Pressure pump for testing pressure/vacuum values at drive. NOTE: Pressure pump with fine adjustment, smart no. 0005166. Fig 1: Identifying Compression Tester Set (450 589 05 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 01 91 00 ADAPTATION - WS01.00-P-0078A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 383 · Applies to: 450, 451, 452, 454
FG 01/Set A MODEL 450, 451, 452, 454 Use: Adaptation for testing the compression pressure on gasoline engines. For engines M 160, M132, M134, M135. NOTE: For engines M 160/1 and 454, the screw piece Q0005159V001000000 / W 450 589 05 21 06 is required. SPECIAL TOOLS > 450 589 03 91 00 ADAPTER - WS01.00-P-0081A > Fig 1: Identifying Pressure Pump (450 589 07 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Adaptation (450 589 01 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 01/Set A¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 384 · Applies to: 450, 451, 452, 454
ENGINE 122, 132, 160, 660 Use: Adapter for compression pressure tester for connecting a motor meter. NOTE: Adapter for compression pressure testerSmart No. 0009377. SPECIAL TOOLS > 450 589 17 21 00 PRESSURE LOSS TESTER - WS01.00-P-0082B > FG 01/Set B ENGINE 122, 132, 134, 135, 160, 639, 660 Use: Pressure loss tester for testing in percent the pressure loss of the cylinder. NOTE: Pressure loss tester, smart no.: 001 2133 V001 0000 00. Fig 1: Identifying Adapter (450 589 03 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 452 589 01 99 00 REPAIR TOOLS FOR VALVES - WS01.00-P-0108C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 385 · Applies to: 450, 451, 452, 454
FG 01/set C MODEL 450, 452 with ENGINE 160 MODEL 454 MODEL 451 with ENGINE 132 Single part 452 589 01 99 04 Assembly cartridge FG01/Set C WS01.00-P-0108-04C Single part 452 589 01 99 09 Drift FG01/Set C WS01.00-P-0108-09C Single part 452 589 01 99 10 Drift FG01/Set C WS01.00-P-0108-10C Single part 452 589 01 99 15 Valve seat refacer FG01/Set C WS01.00-P-0108-15C Single part 452 589 01 99 16 Valve seat refacer FG01/Set C WS01.00-P-0108-16C Single part 452 589 01 99 17 Valve seat refacer FG01/Set C WS01.00-P-0108-17C Single part 452 589 01 99 18 Valve seat refacer FG01/Set C WS01.00-P-0108-18C Single part 452 589 01 99 19 Valve seat refacer FG01/Set C WS01.00-P-0108-19C Single part 452 589 01 99 20 Valve seat refacer FG01/Set C WS01.00-P-0108-20C Single part 452 589 01 99 21 T-handle FG01/Set C WS01.00-P-0108-21C Single part 452 589 01 99 22 Guide FG01/Set C WS01.00-P-0108-22C Single part 452 589 01 99 23 Guide FG01/Set C WS01.00-P-0108-23C Single part 452 589 01 99 24 Straightedge FG01/Set C WS01.00-P-0108-24C Fig 1: Identifying Pressure Loss Tester (450 589 17 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Single part¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 386 · Applies to: 450, 451, 452, 454
452 589 01 99 26 Roll pin FG01/Set C WS01.00-P-0108-26C Single part 452 589 01 99 28 Adapter FG01/Set C WS01.00-P-0108-28C Use: Valve repair tools: toolkit for removing and installing the valves and for valve machining. NOTE: smart no.: 001 7001 V001 0000 00. SPECIAL TOOLS > 001 589 00 91 00 SET OF PROTECTIVE CAPS - WS01.00-P-0110B > FG 01/Set B ENGINE all Use: Set of protective caps, set (5 pieces) of protective caps, D=25 mm, L=75 mm to close openings at engine during repair work.
Fig 1: Identifying Repair Tools For Valves (452 589 01 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 001 589 01 91 00 SET OF PROTECTIVE COVERS - WS01.00-P-0111B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 387 · Applies to: 450, 451, 452, 454
FG 01/08/09/14/15/54/83/ Set B ENGINES all Use: Set of protective covers, set (5 pcs) protective covers, 40 mm dia., length 100 mm for closing of openings during repair work.
SPECIAL TOOLS > 001 589 02 91 00 SET OF PROTECTIVE CAPS - WS01.00-P-0112B > FG 01/Set B ENGINE all Use: Set of protective caps, set (5 pieces) of protective caps, D=60 mm, L=60 mm to close openings at engine Fig 1: Identifying Set Of Protective Caps (001 589 00 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Set Of Protective Covers (001 589 01 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
during repair work.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 388 · Applies to: 450, 451, 452, 454
SPECIAL TOOLS > 003 589 03 37 00 HOSE CLAMP PLIERS - WS01.00-P-0113B > FG 01/Set B ENGINE all Use: Pliers with reinforced Bowden cable and multiple lock for actuation of self-tensioning spring band and compact clamps in particular in areas which are difficult to access.
SPECIAL TOOLS > 122 589 00 28 00 BLADE - WS01.00-P-0138B > FG 01/Set B ENGINE 122, 132, 134, 135, 660.950 Fig 1: Identifying Set Of Protective Caps (001 589 02 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Hose Clamp Pliers (003 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 389 · Applies to: 450, 451, 452, 454
Blade to loosen oil pan gasket. SPECIAL TOOLS > 451 589 01 63 00 ADAPTER - WS01.00-P-0143B > FG 01/03/05/Set B ENGINE 132 Use: Adapter for turning crankshaft for a removed belt pulley or timing case cover. SPECIAL TOOLS > 451 589 02 63 00 RETAINING PLATES - WS01.00-P-0144B > FG 01/Set B ENGINE 132 Fig 1: Identifying Blade (122 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Adapter (451 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 390 · Applies to: 450, 451, 452, 454
Retaining plate for mounting engine in a removed condition. SPECIAL TOOLS > 451 589 01 62 00 SUPPORT BRACES - WS01.00-P-0145C > FG 01/03/Set C MODEL 451 Use: Support brace for mounting various engine lifting devices. NOTE: Only in combination with 240 589 00 61 00 or 639 589 00 61 00 or M30 use engine lifting device. Fig 1: Identifying Retaining Plates (451 589 02 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Support Braces (451 589 01 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 00 91 00 ADAPTER - WS01.00-P-0146B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 391 · Applies to: 450, 451, 452, 454 · AR: WS01.00-Z-9999CZ
FG 01/Set B ENGINE 132 Use: Adapter for checking pressure loss at the gasoline engine. NOTE: Use in combination with 450 589 17 21 00 pressure loss test. SPECIAL TOOLS > SPECIAL TOOLS: SMART: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - WS01.00-Z-9999CZ > MODEL all 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P- 0006Z 001 589 00 91 00 Set of protective caps FG 01/Set B WS01.00-P- 0110B 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P- 0111B 001 589 02 91 00 Set of protective caps FG 01/Set B WS01.00-P- 0112B 001 589 76 21 00 Compression tester FG 01/13/Set A WS01.00-P- 0004A 003 589 03 37 00 Hose clamp pliers FG 01/Set B WS01.00-P- 0113B Fig 1: Identifying Adapter (451 589 00 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
110 589 03 59 00 Mounting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 392 · Applies to: 450, 451, 452, 454
wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P- 0274K 112 589 00 25 00 Application gun FG 00/01 WS00.00-P- 0052Z 122 589 00 28 00 Blade FG 01/Set B WS01.00-P- 0138B 129 589 01 21 00 Retainer device FG 40/01/Set B WS40.00-P- 0025B 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P- 0050B 450 589 00 10 00 Socket wrench FG 01/Set B WS01.00-P- 0070B 450 589 01 40 00 Adaptation FG 01/Set B WS01.00-P- 0079B 450 589 01 62 00 Removal fixture FG 01/Set B WS01.00-P- 0071B 450 589 01 91 00 Adaptation FG 01/Set A WS01.00-P- 0078A 450 589 02 91 00 Adapter FG 01/Set A WS01.00-P- 0080A 450 589 03 91 00 Adapter FG 01/Set A WS01.00-P- 0081A 450 589 05 21 00 Compression tester set FG 01/Set A WS01.00-P- 0072A 450 589 05 21 06 Screw piece FG01/Set A WS01.00-P-0072- 06A 450 589 07 21 00 Pressure pump FG 01/09/20/Set B WS01.00-P- 0074B 450 589 07 21 07 Adapter FG 01/20/54/Set B WS01.00-P-0074- 07B 450 589 07 63 00 Stethoscope FG 01/Set A WS01.00-P- 0073A 450 589 14 21 00 Adaptation FG 01/Set B WS01.00-P- 0075B 450 589 17 21 00 Pressure loss tester FG 01/Set B WS01.00-P- 0082B 450 589 29 63 00 Retainer FG 01/Set B WS01.00-P- 0132B 451 589 00 91 00 Adapter FG 01/Set B WS01.00-P- 0146B 451 589 01 62 00 Support braces FG 01/03/Set C WS01.00-P- 0145C
451 589 01 63 00 Adapter¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 393 · Applies to: 450, 451, 452, 454
FG 01/03/05/Set B WS01.00-P- 0143B 451 589 02 63 00 Retaining plates FG 01/Set B WS01.00-P- 0144B 451 589 05 63 00 Screw-in fitting FG 01/Set A WS01.00-P- 0155A 452 589 01 99 00 Repair tools for valves FG 01/set C WS01.00-P- 0108C 452 589 01 99 04 Assembly cartridge FG01/05/Set C WS01.00-P-0108- 04C 452 589 01 99 09 Drift FG01/05/Set C WS01.00-P-0108- 09C 452 589 01 99 10 Drift FG01/05/Set C WS01.00-P-0108- 10C 452 589 01 99 15 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 15C 452 589 01 99 16 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 16C 452 589 01 99 17 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 17C 452 589 01 99 18 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 18C 452 589 01 99 19 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 19C 452 589 01 99 20 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 20C 452 589 01 99 21 T-handle FG01/05/Set C WS01.00-P-0108- 21C 452 589 01 99 22 Guide FG01/05/Set C WS01.00-P-0108- 22C 452 589 01 99 23 Guide FG01/05/Set C WS01.00-P-0108- 23C 452 589 01 99 24 Straightedge FG01/05/Set C WS01.00-P-0108- 24C 452 589 01 99 26 Roll pin FG01/05/Set C WS01.00-P-0108- 26C 452 589 01 99 28 Adapter FG01/05/Set C WS01.00-P-0108- 28C 454 589 00 61 00 Motor crossmember FG 01/set C WS01.00-P- 0114C 454 589 00 62 00 Support fixture FG 01/Set C WS01.00-P- 0126C
454 589 01 62 00 Adaptation¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 394 · Applies to: 450, 451, 452, 454
FG 01/Set C WS01.00-P- 0127C 454 589 02 62 00 Engine lifting device FG 01/Set C WS01.00-P- 0128C 454 589 03 63 00 Adapter FG 01/Set B WS01.00-P- 0136B 454 589 04 09 00 Set of socket wrench bits FG 22/26/01 Set B WS22.00-P- 0007B 454 589 05 15 00 Insertion drift FG 01/Set B WS01.00-P- 0140B 611 589 00 63 00 Connector FG 01/05/Set B WS01.00-P- 0057B 639 589 00 61 00 Engine lifting device FG 01/33/Set C WS01.00-N- 3106C
GENERAL INFORMATION > NOTES FOR EVALUATION OF A CYLINDER BARREL -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 395 · Applies to: 450, 451, 452, 454
AH01.40-P-0001-03SM > Engine 132.9, 660.9 in Model 451.3/4 Engine 160.9 in model 450.3/4, 452.3/4 If condition of cylinder barrels cannot be assessed with sufficient certainty by means of visual inspection using an inspection light then the cylinder head must be removed. The following information should be helpful in assessing the cylinder barrel and in making a correct decision concerning the condition and further use of a crankcase. The following illustrated damage profiles are only an excerpt of possible forms of damage to the cylinder barrel. The surface quality of the piston and piston ring must always be taken into account in diagnosing the type of damage. Normal condition Matt gray surface, honing pattern visible, dry cylinder barrel, without oil residues, without polished places or reflective smooth areas. The cylinder barrels must not have any scorch streaks. Individual slight scores are not critical. The honing pattern is more or less clearly recognizable over the cylinder barrel. The honing pattern may be partially worn away at the reversal point of the first piston ring. The crankcase can be reused.
Carbon deposits on the cylinder barrel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 396 · Applies to: 450, 451, 452, 454
Check top land unit of crankcase for carbon deposits (arrow). In the case of carbon deposits (arrow) on the top land unit: clean top land unit and crankcase. Fig 1: View Of Cylinder Barrel With Normal Condition Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: View Of Carbon Deposits On Cylinder Barrel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Individual continuous traces of scratches or score marks¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 397 · Applies to: 450, 451, 452, 454
Check area of contact surface in crankcase for traces of scratches (arrows). The crankcase can be reused if there are light traces of scratches (arrows) or score marks on it. Pressure gloss marks, smooth spots Check at individual blank locations (arrow) e.g. in the middle of the cylinder barrel or an all-round impression on the piston ring reversal point above and below. The crankcase be used again if there are isolated blank areas (arrow). Fig 3: Locating Individual Continuous Traces Of Scratches Or Score Marks On Cylinder Barrel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Piston seizure or roughened streaks, signs of seizure¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 398 · Applies to: 450, 451, 452, 454
The cylinder barrel is usually roughened over the whole length. Material deposits and perceptible seizure marks on cylinder barrel and also on piston skirt. The crankcase is unusable and must be replaced. Fig 4: Locating Pressure Gloss Marks, Smooth Spots On Cylinder Barrel Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: View Of Seizure Marks On Cylinder Barrel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > NOTES ON SEALANT PATH FOR TIMING CASE COVER -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 399 · Applies to: 450, 451, 452, 454
AH01.40-P-1000-01MCC > Model 451.3/4 with engine 132.9 Application of sealant to timing case cover The sealing surface on the timing case cover must be absolutely clean and grease-free. The sealant muss must be applied in the form of a bead with a height and width of about 2.0 0.5 mm along the line shown with a gap of about 3 mm to the inner edge of the timing case cover. In crossover areas (arrows) of the cylinder crankcase to the cylinder head two additional beads of sealant must be applied with a length of 8 mm with the same height and width. The timing case cover must be installed within 10 minutes. The applied sealant must not be spread. Use only the sealant listed in the Repair Products. GENERAL INFORMATION > NOTES APPLICATION OF SEALANT TO END COVER WITH RADIAL SHAFT SEAL - AH01.40-P-1000-06MCC > Model 451.3/4 with engine 132.9 Application of sealant to crankcase The sealing surface must be cleaned. The sealant must only be applied to the specified surface in the form of a bead and a height and width of 2.5 mm ±0.5 mm. The sealant must be applied within 10 minutes. The sealant bead must not be spread. Only sealant listed in the Repair Products may be used. Fig 1: Locating Sealant Application Areas On Timing Case Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > NOTES ON SEALANT PATH FOR OIL PAN - AH01.45-P-0001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 400 · Applies to: 450, 451, 452, 454
01MCC > Model 451.3/4 with engine 132.9 The sealing surface must be cleaned. The sealant must only be applied to the specified surface in the form of a bead and a height and width of 2.5 mm ±0.5 mm. The sealant bead must not be spread. Only the approved sealant may be used. The oil pan must be fitted within 10 minutes. Fig 1: View Of Sealing Surface Of Crankcase Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSPECT CYLINDERS WITH A LIGHT PROBE - AR01.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 401 · Applies to: 450, 451, 452, 454
0200MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 1: View Of Oil Pan Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Expansion Clip, Crankshaft Belt Pulley, Cover And Center Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 402 · Applies to: 450, 451, 452, 454
Risk of death caused by vehicle slipping or toppling off 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 using the vehicle lift until the rear wheels can be turned freely
2 Remove expansion clips (1) and remove cover (2)
3 Remove spark plugs (R4)
Replace spark plugs
AP15.10- P- 1580MCU 4 Lead a suitable hose through the spark plug threaded hole in the respective cylinder and turn engine at the center bolt (3) of the crankshaft belt pulley (4) in the direction of engine rotation until the piston stands at the bottom dead center of the cylinder to be checked
5 Attach inspection light to endoscope and lead inspection light through the spark plug threaded hole in the cylinder to be checked Endoscope (cold light)
Fig 2: Identifying Spark Plugs Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
running. Risk of injury caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 404 · Applies to: 450, 451, 452, 454
contusions and burns during starting procedure or when working near the engine as it is running from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 1 Bring engine to its operating temperature of about 144°C and switch off ignition Only test compression pressure when engine is at normal operating temperature.
2 Remove spark plugs
Replace spark plugs
AP15.10- P- 1580MCU Checking
3 Route electrical line (2) for compression recorder (1) between air filter housing (3) and throttle valve actuator (M16/6) to the starter (M1) Fig 2 Risk of death caused by vehicle slipping or toppling off 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 4 Raise vehicle with vehicle lift
5 Detach connector (4) from starter (M1)
6 Attach clamping device (5, 6) to starter (M1) Fig 2 7 Lower vehicle with lifting platform
8 Allow engine to turn using contact switch on compression recorder (1) for about 5 seconds In order to remove combustion residues from the cylinders.
Fig 2 9 Insert compression recorder (1) with appropriate connecting piece into spark plug bore Fig 2 10 Crank engine with contact switch at the compression recorder (1) until an increase in pressure is no longer indicated on the compression recorder (1) Fig 2 11 Carry out test procedure at remaining cylinders in the same way
Compression pressure new value *BE01.00- P-1001- 01G Compression pressure wear
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 406 · Applies to: 450, 451, 452, 454
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury Secure vehicle to prevent it from moving by itself.Wear closed and AS00.00- Fig 1: Identifying Expansion Clip, Crankshaft Belt Pulley, Cover And Center Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Spark Plugs Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
caused by contusions and burns¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 407 · Applies to: 450, 451, 452, 454
during starting procedure or when working near the engine as it is running snug-fitting work clothes.Do not touch hot or rotating parts. Z-0005- 01A 1 Warm up engine to operating temperature of approximately 144°C
2 Remove right rear wheel
AR40.10- P- 1100MCU 3 Remove expansion clips (1) and remove cover (2)
4 Lower vehicle with lifting platform
5 Remove maintenance flap
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. AS20.00- Z-0001- 01A 6 Turn cooling system cap on radiator counterclockwise through half a revolution, release overpressure, then unscrew cap on cooling system expansion reservoir
7 Remove spark plugs (R4)
Replace spark plugs
AP15.10- P- 1580MCU 8 Unscrew cap on oil filler neck
Check
9 Screw adapter into spark plug bore on cylinder 1 and connect up top dead center finder Insert for cylinder 1 and 2 of adapter from the left.Insert for cylinder 3 of adapter from the right.
Fig 3 Fig 4 10 Raise vehicle with vehicle lift
11 Turn engine in direction of engine rotation at the center bolt (4) of the crankshaft belt pulley (3) and set piston on cylinder 1 with the aid of the top dead center locator to ignition TDC Turn combustion engine until the ball in the inspection glass on the top dead center locator falls suddenly.
Fig 4
Lower vehicle with lifting platform¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 408 · Applies to: 450, 451, 452, 454
12 Lower vehicle with lifting platform
13 Apply hand brake and select gear
14 Disconnect top dead center locator on adapter Fig 3 Fig 4 15 Connect compressed air hose to pressure loss tester Fig 4 16 Attach pressure loss tester to adapter Calibrate pressure loss tester. Observe operating instructions for the pressure loss tester.
Fig 3 Fig 4 17 Pressurize cylinder 1 with compressed air and read off the pressure loss on pressure loss tester If there is increased pressure loss determine the cause.
Cylinder leaktightness: permissible loss total indication *BE01.00- P-1001- 02Z Fig 4 18 Place transmission in neutral and release hand brake
19 Inspect other cylinders in the same way
20 Install in the reverse order
CYLINDER LEAKAGE Number Designation All engines BE01.00-P-1001-02Z Cylinder leaktightness: permissible loss total indication % ≤25 Fig 3: Identifying Adapter (451 589 00 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > DETACHING AND ATTACHING ENGINE WIRING HARNESS ON¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 409 · Applies to: 450, 451, 452, 454
ENGINE - AR01.00-P-2420-01MCU > 1. Disconnect electrical connector (2) on adjustable camshaft timing solenoid (Y49) 2. Unclip retaining clamps (3) for engine wiring harness (1) from brackets on cylinder head cover (4). 3. Disconnect connector for O2 sensor upstream of TWC (G3/2x1) and unclip on bracket (5). 4. Remove bolts (6) and lay holder (5) to the side together with engine wiring harness (1). Fig 4: Identifying Pressure Loss Tester (450 589 17 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Engine Wiring Harness Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Connect in reverse order.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 410 · Applies to: 450, 451, 452, 454
TESTING & REPAIR > RELEASE AND POSITION REAR DRIVE MODULE - AR01.00-P- 3050MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 1: Identifying Thrust Bearing, Park Pawl Cable, Fuel Tank Vent Valve And Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on vehicles up to production date 2.6.08 with code (I01) Plus air conditioning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 411 · Applies to: 450, 451, 452, 454
MODIFICATION NOTES 28.3.08 Repair method revised Steps 8, 9, 11 and 13 Remove/install
1 Remove interior flap above engine
AR88.40- P-1100- 03MCC 2 Unhook tank vent valve (Y58) on holder (1)
3 Remove air filter housing
AR09.10- P- 1150MCU 4 Unhook thrust bearing (2) for park pawl cable (3) on
Fig 2: Identifying Rear Drive Module Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
tran mi¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 412 · Applies to: 450, 451, 452, 454
ion 5 Remove the rear wheels
AR40.10- P- 1100MCU 6 Remove expansion clip (4) on fender liner (5) of left and right rear fender
7 Remove rear underbody paneling Rechargeable drill / screwdriver
8 Detach diagonal struts For model 451.4 with code (I01) Air Conditioning Plus AR61.10- P-5138- 02MCU BA61.25- P-1002- 01B 9 Remove bracket for the diagonal struts For model 451.4 with code (I01) Air Conditioning Plus AR61.10- P-5138- 01MCC BA61.25- P-1003- 01B 10 Remove bulkhead wall On model 451.4 AR61.25- P- 6600MCU 11 Lower fuel tank On vehicles with code (I01) Air conditioning Plus Installation: Note routing of refrigerant lines (14). There must have a minimum distance of about 5 mm to the body, fuel tank or other components, otherwise noises or damage may be caused by impacts or chafing. AR47.10- P-4100- 03MCU *BA47.10- P-1001- 01F Transmission jack Fig 4 12 Unscrew plastic nut (6) and remove folding clamp (7) from screw bolt
13 Unclip refrigerant lines (14) from bracket (15) and remove bracket (15) For vehicles with code (I01) Air Conditioning Plus, for which the holder (15) is still installed. Installation: The bracket (15) may no longer be installed.
Unhook ground¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 413 · Applies to: 450, 451, 452, 454
14 Unhook ground line (8) from holder (9)
15 Remove rear apron
AR88.30- P- 0502MCC
Lower, position
16 Position major assembly lifting table with universal main assembly mount and fix in place with the mount on the engine
AR01.10- P-2400- 06MCU Major assembly lifting platform and universal main assembly mount Fig 5 17 Replace bolts (10) by drain screws (11) and bolts (12) by drain screws (13) Observe installation location of bolts (10, 12). Position: Screw in bolts (10, 12) all the way and then tighten.
*BA35.10- P-1001- 01F Fig 3 18 Lower rear- wheel drive module carefully When lowering, check for unobstructed movement of electrical lines and hoses in order to avoid causing any damage.For vehicles with code (I01) Air Conditioning Plus, ensure that the refrigerant lines (14) are not bent since these must be replaced otherwise. Positioning: For vehicles with code (I01) Air Conditioning Plus, ensure that the refrigerant lines (14) have unobstructed movement relative to each other and are not damaged due to impacts, chafing, bending or crushing. Position: Ensure that torque strut is correctly introduced into the sleeve.
19 Remove mount on engine and main assembly lifting table with universal main assembly mount
AR01.10- P-2400- 06MCU Fig 5 20 Install in the reverse order
REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1001-01F Bolt, frame-type integral support to body Nm 125 FUEL TANK
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 414 · Applies to: 450, 451, 452, 454
Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 UNDERBODY FRAME Number Designation Model 451.4 except 451.491 BA61.25-P-1002-01B Bolt, diagonal strut to underbody Nm 65 BA61.25-P-1003-01B Bolt, console to underbody Nm 26 Fig 3: Identifying Set Of Spacer Bolts (221 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Position cover (2) and install expansion clip (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 418 · Applies to: 450, 451, 452, 454
If no further turning of engine is required. TESTING & REPAIR > ATTACHING/REMOVING ENGINE SUPPORT FIXTURE - AR01.10-P- 2400-06MCU > Attaching 1. Position main assembly lifting table with universal main assembly mount (1) under engine and transmission. Main assembly lifting table and universal main assembly mount 2. Fasten mount (2) on timing case cover (3). 3. Position mounting plate (4) under the oil pan position mounting plate (5) under the transmission. Then adjust height of the mount (2) and mounting plates (4, 5) appropriately. Fig 1: Identifying Mount (451 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 419 · Applies to: 450, 451, 452, 454
- Lower main assembly lifting table with universal main assembly mount (1) and pull to the front under the vehicle.
- Remove mount (2) from timing case cover (3). TESTING & REPAIR > REMOVE/INSTALL ENGINE WITH TRANSMISSION - AR01.10-P- 2401MCU > ENGINES 132.910 in MODEL 451.3 /4 Fig 2: Attaching Engine Support Fixture Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 420 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Engine Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Coolant System Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of explosion caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 421 · Applies to: 450, 451, 452, 454
fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00- Z-0001- 01A Notes on coolant
AH20.00- N-2080- 01A 1 Remove maintenance flap
2 Turn cap on engine coolant expansion reservoir a half turn counterclockwise, relieve pressure and then unscrew the cap
3 Remove right side paneling in trunk
AR68.30- P- 4800MCU 4 Remove interior flap above engine
AR88.40- P-1100- 03MCC 5 Disconnect ground line of battery
AR54.10- P- 0003MCC 6 Disconnect engine wiring harness on vehicle side
AR15.18- P-1000- 02MCU 7 Detach tank vent valve (Y58/1) from holder (1) on right engine mount (2) and unlock tank vent line (3) on tank vent valve (Y58/1) and detach
8 Detach molded hose (4) on valve for secondary air injection (5)
9 Detach bolts (6) for engine mount on the right (2) on timing case cover *BA22.10- P-1007- 01M 10 Remove air filter housing
AR09.10- P- 1150MCU
Detach vacuum line for brake¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 422 · Applies to: 450, 451, 452, 454
11 Detach vacuum line for brake booster (7) at intake manifold (8)
12 Unhook thrust bearing (9) for park pawl cable (10) on transmission and unclip park pawl cable (10) on lever (11)
13 Detach bolts (12) for transmission mounting bearing (13) on transmission *BA26.00- P-1002- 01D 14 Detach clamp (14), disconnect fuel line (15) on fuel distributor (16) and expose Seal fuel line (15) and fuel distributor (16) using suitable stop plugs. Installation: Replace clamp (14).
15 Remove fender liner in the left and right rear fender
AR88.10- P- 1400MCU 16 Remove complete exhaust system
AR49.10- P- 7000MCU 17 Remove rear axle crossmember together with bar links
AR35.15- P- 0250MCC 18 Drain coolant
AR20.00- P- 1142MCU 19 Detach electric wiring harness at transmission
AR26.19- P-0001- 05MCU 20 Remove bulkhead wall On model 451.4 AR61.25- P- 6600MCU 21 Detach clamps (17) and disconnect coolant return flow line (18), coolant line feed line (19) as well as heater coolant line (20) from the respective coolant pipe Installation: Replace clamps (17).
22 Remove expansion clips (21) and remove cover (22)
23 Detach left and right rear axle shaft outboard and fix at a suitable location with a cable ties
AR35.30- P- 0620MCU 24 Remove coolant compressor poly-V belt On vehicles with code (I01) Air conditioning Plus AR13.21- P- 1202MCU
Position major assembly lifting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 423 · Applies to: 450, 451, 452, 454
25 Position major assembly lifting table with universal main assembly mount and fix in place with the mount on the engine
AR01.10- P-2400- 06MCU SupportMajor assembly lifting platform and universal lifting platform Figure 26 Remove bolt (23) to torque support (24) *BA22.10- P-1010- 01M 27 Remove bolts (12) for transmission mounting bearing (13) on transmission The bolts (12) are accessible over the left wheel well.
28 Remove bolts (6) for engine mount on the right (2) on timing case cover The bolts (6) are accessible over the right wheel well.
29 Lower engine with transmission carefully until the charge current line is accessible During lowering and positioning, ensure that no electrical lines and hoses are pinched to prevent damage.
30 Remove refrigerant compressor and fix at a suitable location using a cable tie On vehicles with code (I01) Air conditioning Plus AR83.55- P-5300- 04MCU BA83.55- P-1001- 01V BA83.55- P-1002- 01V 31 Detach charging current line on the engine side
AR15.18- P-2000- 01MCU BA15.30- P-1002- 01E BA15.40- P-1002- 01G 32 Carefully lower combustion engine with transmission During lowering and positioning ensure that no electrical lines and hoses get pinched. Aid of helper required.
33 Lift vehicle using the vehicle lift until the engine with transmission can be pulled forward under the vehicle
34 Install in the reverse order
STARTER
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 426 · Applies to: 450, 451, 452, 454
1 Remove intake manifold (2)
AR09.20- P- 1310MCU 2 Remove crankcase ventilation valve (3) from grommet (4) on partial load vent plate (1)
3 Remove bolts (5) *BA01.20- P-1003- 01I 4 Detach partial load venting plate (1) from the crankcase using the knife and take off
Installation: Clean sealing surfaces to partial load venting plate (1) and on crankcase. Apply sealant to cylinder crankcase. Fig 2 Sealant *BR00.45- Z-1053- 01A 5 Install in the reverse order
CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 132.9 BA01.20-P-1003-01I Bolt, partial load venting plate to crankcase Nm 10 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1053-01A Sealant Q0000282V000000000 TESTING & REPAIR > BOLT TIGHTENING PROCEDURE FOR CYLINDER HEAD COVER - AR01.20-P-5014-03MCC > Fig 2: Identifying Knife (122 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 428 · Applies to: 450, 451, 452, 454
27.1.09 Remove/install clamp on vent hose for crankcase of cylinder head cover added Step 2
Remove/install
1 Remove ignition coils
AR15.12- P- 2003MCU For vehicles, on which the clamp (11) is not Fig 1: Identifying Cylinder Head Cover Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Cylinder Head Cover, Vent Hose For Crankcase And Clip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove clamp (11) of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 429 · Applies to: 450, 451, 452, 454
2 Remove clamp (11) of crankcase vent hose (2) on cylinder head cover (1) yet installed, it must then be retrofitted during installation. Installation: Replace clip (11). The clamp (11) must be fitted as close as possible to the cylinder head cover (1).Clamp pliers with side cutter
3 Detach crankcase vent hose (2) to the cylinder head cover (1)
4 Remove oil dipstick (3) from cylinder head cover (1)
5 Disconnect engine wiring harness (4) on engine
AR01.00- P-2420- 01MCU 6 Detach vacuum hose (5) and supply line (7) on secondary air injection valve (6)
7 Remove complete exhaust system
AR49.10- P- 7000MCU 8 Remove bolts for secondary air injection pipe (8) on cylinder head The secondary air injection pipe (8) is attached to cylinder head by three bolts.
*BA14.30- P-1002- 03C 9 Remove bolts (9) for secondary air injection valve (6) on cylinder head and remove together with secondary air injection pipe (8)
10 Remove bolts on cylinder head cover (1) The cylinder head cover (1) is fastened with ten bolts. Loosen bolts for cylinder head cover (1) in reverse order of the tightening procedure. Installation: Observe prescribed tightening sequence of bolts for the cylinder head cover (1). AR01.20- P-5014- 03MCC *BA01.20- P-1002- 01I Detach and remove Check seal on cylinder head cover (1) for damage; replace cylinder head cover (1) if necessary. Remove sealant residue in the area of the joint edge of the cylinder head and timing case cover. Installation: Check seals for spark plug shafts for damage, replace if necessary. Apply sealant in the area of the
cylinder head cover (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 430 · Applies to: 450, 451, 452, 454
11 cylinder head cover (1) from cylinder head joint edge of the cylinder head and timing case cover. Sealing compound *BR00.45- Z-1053- 01A 12 Remove bracket (10) for engine wiring harness (4) on cylinder head cover (1) When replacing the cylinder head cover (1).
13 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 14 Conduct engine test run and check engine for leaks in the area of the cylinder head cover (1)
CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 132.9 BA01.20-P-1002-01I Bolt, cylinder head cover to cylinder head Nm 10 COMBINATION VALVE Number Designation Engine 132.910 BA14.30-P-1002- 03C Bolt, pipe for secondary air injection to cylinder head Nm 8 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1053-01A Sealing compound Q0000282V000000000 TESTING & REPAIR > TIGHTENING PROCEDURE FOR CYLINDER HEAD BOLTS - AR01.30-P-5800-01MCC > CYLINDER HEAD Number Designation Engine 132.9 Stage 1 Nm 25
Illustrated on removed engine¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 432 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Cylinder Head Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Engine 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. 433 · Applies to: 450, 451, 452, 454
1 Check basic position of camshafts
AR05.20-P- 6010MCU 2 Remove timing case cover
AR01.40-P- 8000MCU 3 Support rear axle crossmember (2) in the middle with a transmission jack, remove bolts (3) and lower rear axle crossmember (2) Use a suitable base.
Transmission jack *BA35.10-P-1003- 01F 4 Disconnect electrical connector (4) on coolant temperature sensor (B11/4) and unclip retaining clip (5) from electrical wiring harness on holder (6)
5 Turn back ratchet (7) on chain tensioner (8) using a suitable screwdriver and lock chain tensioner (8) via the bore (arrow A) In order to lock the chain tensioner (8), place a pin with a diameter of 1.5 mm into the bore (arrow A) in the chain tensioner (8). Installation: Attach
Fig 3: Identifying Engine Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Lower vehicle with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 435 · Applies to: 450, 451, 452, 454
9 Lower vehicle with lifting platform
10 Remove bolt (16) and pull adjustable camshaft timing solenoid (Y49) out of cylinder head (1) Cover oil holes on adjustable camshaft timing solenoid (Y49) to protect against ingress of foreign objects. Ingress of foreign objects can cause engine damage.
*BA05.20-P-1006- 01M 11 Remove intake camshaft and exhaust camshaft The camshaft sprocket (14) remains on the exhaust camshaft. AR05.20-P- 6992MCU 12 Loosen clamp (17) and detach coolant hose (18) from connection fitting on cylinder head (1) Installation: Replace clamp (17).
13 Remove bolt (19) and pull camshaft Hall sensor (B6/1) out of cylinder head (1) BA15.12-P-1004- 01G 14 Remove bolt (20) for coolant pipe (21) on cylinder head (1) BA20.10-P-1011- 01J 15 Detach holder (22) for electrical wiring harness (23) on intake manifold (24)
16 Remove bolts (25) and detach air intake manifold (24) from intake manifold (1) Installation: Replace seals on intake manifold (24).
BA09.20-P-1001- 01J 17 Loosen cylinder head bolts (26) in stages Loosen cylinder head bolts (26) in reverse order of tightening procedure. Installation: Replace cylinder head bolts (26) and wet on thread and on bolt head contact surfaces with engine oil. AR01.30-P-5800- 01MCC BA01.30-P-1001- 01K
Support engine on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 436 · Applies to: 450, 451, 452, 454
18 Support engine on carrier for front engine mount using a hand- operated hydraulic floor jack Use a suitable base.Hand-operated hydraulic floor jack
19 Unhook chain for engine-lifting device on retaining plate (30) Fig 6 20 Remove cylinder head bolts (26) and cylinder head (1) from cylinder crankcase
21 Take cylinder head gasket (27) off crankcase Installation: Replace cylinder head gasket (27).
22 Remove valve tappet (28) from basic bores in cylinder head (1) Do not use magnets. Gathering of the smallest metal shavings can occur due to magnetization of the valve tappets (28) which can lead to damage of valve tappets (28) and intake camshaft or exhaust camshaft. Installation: The valve tappet (28) must be installed again at the same location.
23 Clean separating surfaces on cylinder head (1) and crankcase then check for visible damage and flatness Replace cylinder head (1) if necessary.Straightedge
24 Clean threaded hole for cylinder head bolts (26) in crankcase
25 Unscrew bolt (29) and remove retaining plate (30) from cylinder head (1) When replacing the cylinder head (1).
Fig 6 26 Remove coolant temperature sensor (B11/4) from cylinder head (1) When replacing the cylinder head (1).
*BA15.60-P-1002- 01B 27 Install in the reverse order
Risk of accident¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 437 · Applies to: 450, 451, 452, 454
caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A 28 Conduct engine test run and check engine for leaks in area of the cylinder head (1) CYLINDER HEAD Number Designation Engine 132.9 BA01.30-P-1001-01K Bolt, cylinder head to crankcase Stage 1 Nm 25 Stage 2 ∠° 90 Stage 3 ∠° 90 Stage 4 ∠° - TIMING CHAIN DRIVE Number Designation Engine 132.9 BA05.10-P-1001-01P Bolt, timing chain tensioning rail to cylinder head Nm 23 BA05.10-P-1002-01P Bolt, timing chain slide rail to cylinder head Nm 10 BA05.10-P-1003-01P Bolt, timing chain slide rail to crankcase Nm 10 CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1006-01M Bolt, camshaft solenoid to cylinder head Nm 11 INTAKE MANIFOLD, INTAKE MANIFOLD PREHEATER Number Designation Engine 132.910 BA09.20-P-1001- 01J Bolt, intake manifold to cylinder head Initial torque Nm 20 Retightening torque Nm 20 ECI IGNITION SYSTEM Number Designation Engine 132.9
BA15.12-P-1004-01G¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 438 · Applies to: 450, 451, 452, 454
Bolt, camshaft position sensor to cylinder head Nm 11 TEMPERATURE SENSOR Number Designation Engine 132.9 BA15.60-P-1002-01B Coolant temperature sensor to cylinder head Nm 30 COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1011-01J Bolt connecting coolant line to cylinder head Nm 24 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1003-01F Bolt, crossmember to frame-type integral support Nm 65 Fig 4: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Adapter (451 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying Carrier For Front Engine Mount, Torque Support And Frame-Type Integral Support¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 440 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Timing Case Cover 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. 441 · Applies to: 450, 451, 452, 454
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00- Z-0001- 01A Notes on coolant
AH20.00- N-2080- 01A 1 Remove service flap
2 Turn cap for coolant expansion reservoir half a revolution counterclockwise, release excess pressure, and take off the cooling system cap
3 Remove interior flap above engine
AR88.40- P-1100- 03MCC 4 Disconnect ground line of battery
AR54.10- P- 0003MCC Fig 3: Identifying Timing Case Cover Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove fender liner in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 442 · Applies to: 450, 451, 452, 454
5 Remove fender liner in right rear fender
AR88.10- P- 1400MCU 6 Release rear drive module
AR01.00- P- 3050MCU 7 Drain coolant
AR20.00- P- 1142MCU 8 Remove poly-V-belt tensioning device
AR13.25- P- 3200MCU 9 Remove belt pulley for crankshaft
AR03.30- P- 1700MCU 10 Remove oil pan Remove front engine mount carrier (2) together with torque support (3). For this, unscrew the bolt of the torque support (3) on the frame-type integral support (4). AR01.45- P- 7500MCU *BA22.10- P-1010- 01M 11 Reinstall front engine mount carrier (2) together with the torque support (3). On order to support the engine during the work procedure.
12 Remove cylinder head cover
AR01.20- P- 5014MCU 13 Lower vehicle with lifting platform
14 Undo bolts (5) and remove bracket (6)
15 Fix retaining plate in place on cylinder head (7) using a bolt (5), attach support braces to engine using an engine lifting device and support engine using an engine lifting device and appropriate chain via the retaining plate on the cylinder head (7) Fig 4 Engine lifting device Figure 16 Remove bolts (8, 9) and right engine mount (10) BA22.10- P-1006- 01M BA22.10-
P-1007-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 443 · Applies to: 450, 451, 452, 454
01M 17 Remove bolts (11) and loosen alternator (G2) from timing case cover (1) and fix in place at a suitable location using a cable tie *BA15.40- P-1008- 01G 18 Raise vehicle with vehicle lift
19 Disconnect electrical connector (12) at oil pressure switch (S41/1)
20 Remove bolt (13) as well as ground (14) line for engine ground
21 Unscrew bolt (15)
22 Remove bolts (16) and lay electrical wiring harness (17) to the side BA01.40- P-1007- 01M 23 Remove refrigerant compressor and fix at a suitable location using a cable tie On vehicles with code (I01) Air conditioning Plus Installation: Only attach refrigerant compressor after installing the oil pan. AR83.55- P-5300- 04MCU BA83.55- P-1001- 01V BA83.55- P-1002- 01V 24 Remove bolts (18, 19), detach timing case cover (1) using a tool from cylinder crankcase and remove downwards Installation: Clean sealing surface on timing case cover (1) and on cylinder crankcase, replace seal ring (20) on timing case cover (1) and seal ring on coolant feed line. Before installing the timing case cover (1), screw guide for crankshaft radial sealing ring (21) into the threaded hole for crankshaft and align the drive for oil pump in timing case cover (1) according the position of the crankshaft. Pay attention to different bolt lengths (18, 19). AR01.40- P-8000- 01MCC BA01.40- P-1007- 01M Fig 6 Sealing compound *BR00.45- Z-1053- 01A
Notes on sealant path for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 444 · Applies to: 450, 451, 452, 454
timing case cover AH01.40- P-1000- 01MCC 25 Lever crankshaft radial sealant ring (21) out of timing case cover (1) using a suitable tool Ensure that timing case cover (1) is not damage otherwise it must be replaced. Installation: The crankshaft radial sealing ring (21) must be installed dry and lock flush with the timing case cover (1).
Fig 7 26 Remove cooling pump (22) from timing case cover (1) When replacing timing case cover (1). Installation: Replace gasket of coolant pump (22).
*BA20.10- P-1007- 01J 27 Remove oil pressure switch (S41/1) from timing case cover (1) When replacing timing case cover (1).
*BA18.40- P-1002- 01G 28 Install in the reverse order
CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 BA01.40-P-1007- 01M Bolt, timing case cover to crankcase/cylinder head M6 Nm 10 M8 Nm 23 BELT TENSIONING DEVICE Number Designation Engine 132.9 BA13.25-P-1003- 01K Bolt, poly-V belt tensioning device to timing case cover Nm 49 ALTERNATOR Number Designation Engine 132.9 BA15.40-P-1008-01G Bolt, alternator to timing case cover Nm 23 OIL LEVEL/OIL PRESSURE SENSOR Number Designation Engine 132.9 BA18.40-P-1002-01G Oil pressure sensor to timing case cover Nm 10 COOLANT PUMP, COOLANT THERMOSTAT Designation
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 445 · Applies to: 450, 451, 452, 454
Engine 132.9 BA20.10-P-1007-01J Bolt, coolant pump to timing case cover M6 Nm 10 M8 Nm 23 ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 BA22.10-P-1006- 01M Bolt, right engine mount to frame-type integral support Nm 56 BA22.10-P-1007- 01M Bolt, right engine mount to timing case cover Nm 80 BA22.10-P-1010- 01M Bolt, torque support to frame-type integral support Nm 115 REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001-01V Bolt, AC compressor to crankcase Nm 20 BA83.55-P-1002-01V Bolt, AC compressor to oil pan Nm 20 Fig 4: Identifying Support Braces (451 589 01 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINE 132.910 in MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 447 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove oil pan Remove front engine mount carrier (2) together with torque support (3). To do this remove bolt for torque support (3) on frame-type integral support (4). AR01.45- P- 7500MCU 2 Reinstall front engine mount carrier (2) together with the torque support (3). On order to support the engine during the work procedure.
3 Remove flywheel
AR03.30- P- 8002MCU 4 Remove bolts (5) *BA01.40- P-1006- 01M 5 Detach and remove end cover together with radial shaft seal (1) on crankcase (6) Make sure that surfaces are completely clean to prevent leaks around the end cover with radial shaft sealing ring (1). Installation: Clean sealing surface on crankcase (6) (e.g. with acetone), clean contact surface to crankshaft with a clean rag without using cleaning agent.Apply sealant to cylinder crankcase (6).
*BR00.45- Z-1053- 01A Fig 1: Identifying End Cover Together With Shaft Seal Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 450 · Applies to: 450, 451, 452, 454
1 Drain engine oil
Engine oil and filter change
AP18.00- P- 0101MCU 2 Remove fender liner in right rear fender On vehicles with code (I01) Air conditioning Plus AR88.10- P- 1400MCU 3 Remove poly-V belt for refrigerant compressor On vehicles with code (I01) Air conditioning Plus AR13.21- P- 1202MCU 4 Detach refrigerant compressor to oil pan (1)
AR83.55- P-5300- 04MCU BA83.55- P-1001- 01V BA83.55- P-1002- 01V 5 Remove carrier for front engine mount (2)
AR22.10- P- 1001MCU 6 Remove bolt (3) for coolant pipe (4) to oil pan (1) *BA20.10- P-1010- 01J 7 Remove bolt (5) for bracket (6) to oil pan (1)
8 Remove oil pan bolts (1) on cylinder crankcase and on timing case cover The oil pan (1) is fixed using eight bolts on the cylinder crankcase and with four bolts on the timing case cover.
*BA01.45- P-1001- 01J 9 Detach and remove oil pan (1) using a blade on the cylinder crankcase as well as on the timing case cover
Installation: Clean sealing surfaces. Coat sealing surface to oil pan (1) with sealant. Replace seal ring on timing case cover. Figure Sealant *BR00.45- Z-1053- 01A Information on application of sealant to oil pan AH01.45- P-0001- 01MCC
Install in the reverse order¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 451 · Applies to: 450, 451, 452, 454 · AR: BA01.00-Z-9999CZ
10 Install in the reverse order
OIL PAN Number Designation Engine 132.9 BA01.45-P-1001- 01J Bolt, oil pan to crankcase and timing case cover Initial torque Nm 10 Retightening torque Nm 10 COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1010-01J Bolt, coolant pipe to oil pan Nm 10 REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001-01V Bolt, AC compressor to crankcase Nm 20 BA83.55-P-1002-01V Bolt, AC compressor to oil pan Nm 20 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1053-01A Sealant Q0000282V000000000 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - BA01.00-Z-9999CZ > MODEL all Crankcase, timing case cover, end cover ENGINE 134.910 /911, 135.930 /950 BA01.40-P-1000-01O Fig 2: Identifying Knife (122 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Crankcase, timing case cover,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 452 · Applies to: 450, 451, 452, 454
end cover ENGINE 660.940 /950 BA01.40-P-1000-01N Crankcase, timing case cover, end cover ENGINE 132.9, 160.910 /920 /921 /922 /923 BA01.40-P-1000-01M Crankcase, timing case cover, end cover ENGINE 639.9 in MODEL 454.0 BA01.40-P-1000-01V Crankcase, timing case cover, end cover ENGINE 122.9 in MODEL 454.0 BA01.40-P-1000-01U Crankcase ventilation, cylinder head cover ENGINE 122.950, 134.910 /911, 135.930/950 BA01.20-P-1000-01K Crankcase ventilation, cylinder head cover ENGINE 660.940 /950 /951 BA01.20-P-1000-01J Crankcase ventilation, cylinder head cover ENGINE 132.9, 160.910 /920 /921 /922 /923 BA01.20-P-1000-01I Crankcase ventilation, cylinder head cover ENGINE 639.939 BA01.20-P-1000-01O Cylinder head ENGINE 122.950 BA01.30-P-1000-01T Cylinder head ENGINE 639.939 BA01.30-P-1000-01R Cylinder head ENGINE 134.910 /911, 135.930 /950 BA01.30-P-1000-01N Cylinder head ENGINE 660.940 /950 /951 BA01.30-P-1000-01L Cylinder head ENGINE 132.9, 160.910 /920 /921 /922 /923 BA01.30-P-1000-01K Oil pan ENGINE 122.950, 134.910 /911, 135.930/950 BA01.45-P-1000-01L Oil pan ENGINE 660.940 /950 /951 BA01.45-P-1000-01K Oil pan ENGINE 132.9, 160.910 /920 /921 /922 /923 BA01.45-P-1000-01J Oil pan ENGINE 639.939 BA01.45-P-1000-01P TORQUE SPECIFICATIONS > CRANKCASE VENTILATION, CYLINDER HEAD COVER - BA01.20-P-1000-01I > Engine 132, 160 CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 132.9 Engine 160.910 BA01.20-P- 1001-01I Bolt, cylinder head cover to cylinder head Initial torque Nm 10 12 Continued torque Nm 10 9.5 BA01.20-P- Bolt, cylinder head cover to cylinder Nm 10 -
1002-01I¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 453 · Applies to: 450, 451, 452, 454
head BA01.20-P- 1003-01I Bolt, partial load bleed plate to crankcase Nm 10 - CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 160.920 Engine 160.921 BA01.20-P- 1001-01I Bolt, cylinder head cover to cylinder head Initial torque Nm 12 12 Continued torque Nm 9.5 9.5 BA01.20-P- 1002-01I Bolt, cylinder head cover to cylinder head Nm - - BA01.20-P- 1003-01I Bolt, partial load bleed plate to crankcase Nm - - CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 160.922 Engine 160.923 BA01.20-P- 1001-01I Bolt, cylinder head cover to cylinder head Initial torque Nm 12 12 Continued torque Nm 9.5 9.5 BA01.20-P- 1002-01I Bolt, cylinder head cover to cylinder head Nm - - BA01.20-P- 1003-01I Bolt, partial load bleed plate to crankcase Nm - - TORQUE SPECIFICATIONS > CYLINDER HEAD - BA01.30-P-1000-01K > Engine 132, 160 CYLINDER HEAD Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 Engine 160.922 BA01.30-P- 1001-01K Bolt, cylinder head to crankcase Stage 1 Nm 25 21 21 21 21 Stage 2 ∠° 90 90 90 90 90 Stage 3 ∠° 90 90 90 90 90 Stage 4 ∠° - 10 10 10 10 BA01.30-P- Bolt, cylinder head to timing
1002-01K¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 454 · Applies to: 450, 451, 452, 454
case cover Nm - - 27 27 27 CYLINDER HEAD Number Designation Engine 160.923 BA01.30-P-1001-01K Bolt, cylinder head to crankcase Stage 1 Nm 21 Stage 2 ∠° 90 Stage 3 ∠° 90 Stage 4 ∠° 10 BA01.30-P-1002-01K Bolt, cylinder head to timing case cover Nm 27 TORQUE SPECIFICATIONS > CRANKCASE, TIMING CASE COVER, END COVER - BA01.40-P-1000-01M > Engine 132, 160 CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 Engine 160.910 BA01.40-P- 1001-01M Coolant drain plug to crankcase Nm - 12 BA01.40-P- 1002-01M Bolt, timing case cover to crankcase Initial torque Nm - 12 Continued torque Nm - 9,5 BA01.40-P- 1003-01M Screw plug, oil duct to crankcase Nm - 30 BA01.40-P- 1004-01M Cylinder head to timing case Nm - 27 BA01.40-P- 1005-01M Bolt, crankcase bottom section 8 mm Stage 1 Nm - - Stage 2 ∠° - - 6 mm Nm - - BA01.40-P- 1006-01M Bolt connecting end cover to radial shaft sealing ring to crankcase Nm 10 - BA01.40-P- 1007-01M Bolt, timing case cover to crankcase/cylinder head M6 Nm 10 - M8 Nm 23 - BA01.40-P- 1008-01M Screw plug at timing case cover Nm 50 - CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 160.920 Engine 160.921
BA01.40-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 455 · Applies to: 450, 451, 452, 454
1001-01M Coolant drain plug to crankcase Nm 12 12 BA01.40-P- 1002-01M Bolt, timing case cover to crankcase Initial torque Nm 12 12 Continued torque Nm 9,5 9,5 BA01.40-P- 1003-01M Screw plug, oil duct to crankcase Nm 30 30 BA01.40-P- 1004-01M Cylinder head to timing case Nm 27 27 BA01.40-P- 1005-01M Bolt, crankcase bottom section 8 mm Stage 1 Nm 21 21 Stage 2 ∠° 90 90 6 mm Nm 9,5 9,5 BA01.40-P- 1006-01M Bolt connecting end cover to radial shaft sealing ring to crankcase Nm - - BA01.40-P- 1007-01M Bolt, timing case cover to crankcase/cylinder head M6 Nm - - M8 Nm - - BA01.40-P- 1008-01M Screw plug at timing case cover Nm - - CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 160.922 Engine 160.923 BA01.40-P- 1001-01M Coolant drain plug to crankcase Nm 12 12 BA01.40-P- 1002-01M Bolt, timing case cover to crankcase Initial torque Nm 12 12 Continued torque Nm 9,5 9,5 BA01.40-P- 1003-01M Screw plug, oil duct to crankcase Nm 30 30 BA01.40-P- 1004-01M Cylinder head to timing case Nm 27 27 BA01.40-P- 1005-01M Bolt, crankcase bottom section 8 mm Stage 1 Nm 21 21 Stage 2 ∠° 90 90 6 mm Nm 9,5 9,5 BA01.40-P- 1006-01M Bolt connecting end cover to radial shaft sealing ring to crankcase Nm - - BA01.40-P- 1007-01M Bolt, timing case cover to crankcase/cylinder head M6 Nm - - M8 Nm - - BA01.40-P- Screw plug at timing case cover Nm - -
1008-01M¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 456 · Applies to: 450, 451, 452, 454
TORQUE SPECIFICATIONS > OIL PAN - BA01.45-P-1000-01J > Engine 132, 160 MODIFICATION NOTES 29.8.05 Bolt connecting oil dipstick guide tube to crankcase, retightening torque Engine 160.921 Bolt connecting oil dipstick guide tube to crankcase, retightening torque Engine 160.922 Bolt connecting oil dipstick guide tube to crankcase, retightening torque Engine 160.923 OIL PAN Number Designation Engine 132.9 Engine 160.910 Engine 160.920 BA01.45-P- 1001-01J Bolt, oil pan to crankcase and timing case cover Initial torque Nm 10 12 12 Continued torque Nm 10 9 9 BA01.45-P- 1002-01J Bolt, dipstick guide tube to crankcase Initial torque Nm - 12 12 Continued torque Nm - 9 9 BA01.45-P- 1003-01J Oil drain screw to oil pan Nm 65 - - OIL PAN Number Designation Engine 160.921 Engine 160.922 Engine 160.923 BA01.45-P- 1001-01J Bolt, oil pan to crankcase and timing case cover Initial torque Nm 12 12 12 Continued torque Nm 9 9 9 BA01.45-P- 1002-01J Bolt, dipstick guide tube to crankcase Initial torque Nm 12 12 12 Continued torque Nm 9 9 9 BA01.45-P- 1003-01J Oil drain screw to oil pan Nm - - - TEST & ADJUSTMENT VALUES > COMPRESSION PRESSURE - BE01.00-P-1000-01G > Engine 122, 132, 134, 135, 639, 660 CHECK VALUES FOR COMPRESSION PRESSURE
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 457 · Applies to: 450, 451, 452, 454
Designation Engine 122 Engine 132.910 Engine 132.930 Engine 134 BE01.00-P- 1001-01G Compression pressure new value bar 12.1 15 14 13.2 BE01.00-P- 1002-01G Compression pressure wear limit or limit value bar ≈8.3 ≈11 ≈10 ≈9 BE01.00-P- 1003-01G Compression pressure: permissible difference between individual cylinders bar ≤0.98 - - ≤0.98 CHECK VALUES FOR COMPRESSION PRESSURE Number Designation Engine 135.930 Engine 135.950 Engine 639 Engine 660.940 =18.5 BE01.00-P- 1001-01G Compression pressure new value bar 14.3 15.5 18 18.5 BE01.00-P- 1002-01G Compression pressure wear limit or limit value bar ≈10 ≈11 ≈10.5 - BE01.00-P- 1003-01G Compression pressure: permissible difference between individual cylinders bar ≤0.98 ≤0.98 ≤2.5 - CHECK VALUES FOR COMPRESSION PRESSURE Number Designation Engine 660.950 =19 Engine 660.951 BE01.00-P-1001- 01G Compression pressure new value bar 28 - BE01.00-P-1002- 01G Compression pressure wear limit or limit value bar 18 18 BE01.00-P-1003- 01G Compression pressure: permissible difference between individual cylinders bar 3 3 TEST & ADJUSTMENT VALUES > CYLINDER LEAKTIGHTNESS - BE01.00-P-1000-02Z > All engines CYLINDER LEAKTIGHTNESS Number Designation All engines BE01.00-P-1001- 02Z Cylinder leaktightness permissible loss total indication % ≤25 BE01.00-P-1002- 02Z Cylinder leaktightness permissible losses at valves and cylinder head gasket % ≤10
This reduces the resistance at the crankshaft and also prevents foaming of the engine oil.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 461 · Applies to: 450, 451, 452, 454
Furthermore, returning engine oil from the engine flows via the baffle plate into the oil pan. This causes calming of the engine oil. The whipped up engine oil for various driving conditions is held back by the baffle plate and therefore does not come into direct contact with the crankshaft. This also prevents air being sucked in by the die oil pump when the vehicle is tilted. SPECIAL TOOLS > 639 589 00 61 00 ENGINE LIFTING DEVICE - WS01.00-N-3106C > FG 01/33/Set C ENGINE 112, 271, 272, 642, 646, 651, 132 Use: Engine lifting device for lifting engine.
SPECIAL TOOLS > 001 589 76 21 00 COMPRESSION TESTER - WS01.00-P-0004A > FG 01/13/Set A ENGINE all Part 001 589 76 21 13 Diagram charts FG 01/Set A WS01.00-P-0004-01A Part 001 589 76 21 21 Graph sheets FG 01/Set A WS01.00-P-0004-02A Part 001 589 76 21 23 Connectors FG 01/Set A WS01.00-P-0004-03A Use: Compression recorder complete for gasoline engines 3.5 - 17.5 bar and diesel engines 10 - 40 bar NOTE: Fig 1: Identifying Engine Lifting Device (639 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connectors M22 x 1.5 mm/R1/4" for injection nozzle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 462 · Applies to: 450, 451, 452, 454
hole, see 602 589 00 63 00, 604 589 00 63 00
SPECIAL TOOLS > 450 589 00 10 00 SOCKET WRENCH - WS01.00-P-0070B > FG 01/Set B MODEL 450, 451, 452 Use: Socket wrench for tightening the cylinder head bolts. NOTE: Internal Torx T 70Smart No. 0005084. Fig 1: Identifying Compression Tester (001 589 76 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Socket Wrench (450 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 05 21 00 COMPRESSION TESTER SET - WS01.00-P-0072A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 463 · Applies to: 450, 451, 452, 454
FG 01/Set A ENGINE 122, 132, 134, 135, 160, 639, 660 Single part 450 589 05 21 06 Screw piece FG01/Set A WS01.00-P-0072-06A Use: Compression tester set for testing the compression pressure, mechanical leaktightness of the pistons, cylinders, valves, head gasket. NOTE: Compression tester set, smart no.: 000 5152 V001 0000 00. SPECIAL TOOLS > 450 589 07 21 00 PRESSURE PUMP - WS01.00-P-0074B > FG 01/09/20/Set B MODEL 450, 452, 454 MODEL 451 with ENGINE 132, 660.9, 780.009 Separate part 450 589 07 21 07 Adapter FG01/20/Set B WS01.00-P-0074-07B Use: Pressure pump for testing pressure/vacuum values at drive. NOTE: Pressure pump with fine adjustment, smart no. Fig 1: Identifying Compression Tester Set (450 589 05 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 01 91 00 ADAPTATION - WS01.00-P-0078A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 464 · Applies to: 450, 451, 452, 454
0005166. SPECIAL TOOLS > 450 589 01 91 00 ADAPTATION - WS01.00-P-0078A > FG 01/Set A MODEL 450, 451, 452, 454 Use: Adaptation for testing the compression pressure on gasoline engines. For engines M 160, M132, M134, M135. NOTE: For engines M 160/1 and 454, the screw piece Q0005159V001000000 / W 450 589 05 21 06 is required. Fig 1: Identifying Pressure Pump (450 589 07 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 03 91 00 ADAPTER - WS01.00-P-0081A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 465 · Applies to: 450, 451, 452, 454
FG 01/Set A ENGINE 122, 132, 160, 660 Use: Adapter for compression pressure tester for connecting a motor meter. NOTE: Adapter for compression pressure testerSmart No. 0009377. SPECIAL TOOLS > 450 589 15 37 00 PLIERS - WS42.00-P-0082B > FG 42/Set B Fig 1: Identifying Adaptation (450 589 01 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Adapter (450 589 03 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 450, 451, 452, 454¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 466 · Applies to: 450, 451, 452, 454
Use: Special pliers for assembling the low-pressure lines on ESP 8.0. SPECIAL TOOLS > 452 589 01 99 00 REPAIR TOOLS FOR VALVES - WS01.00-P-0108C > FG 01/set C MODEL 450, 452 with ENGINE 160 MODEL 454 MODEL 451 with ENGINE 132 Single part 452 589 01 99 04 Assembly cartridge FG01/Set C WS01.00-P-0108-04C Single part 452 589 01 99 09 Drift FG01/Set C WS01.00-P-0108-09C Single part 452 589 01 99 10 Drift FG01/Set C WS01.00-P-0108-10C Single part 452 589 01 99 15 Valve seat refacer FG01/Set C WS01.00-P-0108-15C Single part 452 589 01 99 16 Valve seat refacer FG01/Set C WS01.00-P-0108-16C Single part 452 589 01 99 17 Valve seat refacer FG01/Set C WS01.00-P-0108-17C Single part 452 589 01 99 18 Valve seat refacer FG01/Set C WS01.00-P-0108-18C Single part 452 589 01 99 19 Valve seat refacer FG01/Set C WS01.00-P-0108-19C Single part 452 589 01 99 20 Valve seat refacer FG01/Set C WS01.00-P-0108-20C Fig 1: Identifying Pliers (450 589 15 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Single part¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 467 · Applies to: 450, 451, 452, 454
452 589 01 99 21 T-handle FG01/Set C WS01.00-P-0108-21C Single part 452 589 01 99 22 Guide FG01/Set C WS01.00-P-0108-22C Single part 452 589 01 99 23 Guide FG01/Set C WS01.00-P-0108-23C Single part 452 589 01 99 24 Straightedge FG01/Set C WS01.00-P-0108-24C Single part 452 589 01 99 26 Roll pin FG01/Set C WS01.00-P-0108-26C Single part 452 589 01 99 28 Adapter FG01/Set C WS01.00-P-0108-28C Use: Valve repair tools: toolkit for removing and installing the valves and for valve machining. NOTE: smart no.: 001 7001 V001 0000 00. SPECIAL TOOLS > 001 589 00 91 00 SET OF PROTECTIVE CAPS - WS01.00-P-0110B > FG 01/Set B ENGINE all Use: Set of protective caps, set (5 pieces) of protective caps, D=25 mm, L=75 mm to close openings at engine during repair work.
Fig 1: Identifying Repair Tools For Valves (452 589 01 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 001 589 01 91 00 SET OF PROTECTIVE COVERS - WS01.00-P-0111B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 468 · Applies to: 450, 451, 452, 454
FG 01/08/09/14/15/54/83/ Set B ENGINES all Use: Set of protective covers, set (5 pcs) protective covers, 40 mm dia., length 100 mm for closing of openings during repair work.
SPECIAL TOOLS > 001 589 02 91 00 SET OF PROTECTIVE CAPS - WS01.00-P-0112B > FG 01/Set B ENGINE all Use: Set of protective caps, set (5 pieces) of protective caps, D=60 mm, L=60 mm to close openings at engine Fig 1: Identifying Set Of Protective Caps (001 589 00 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Set Of Protective Covers (001 589 01 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
during repair work.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 469 · Applies to: 450, 451, 452, 454
SPECIAL TOOLS > 003 589 03 37 00 HOSE CLAMP PLIERS - WS01.00-P-0113B > FG 01/Set B ENGINE all Use: Pliers with reinforced Bowden cable and multiple lock for actuation of self-tensioning spring band and compact clamps in particular in areas which are difficult to access.
SPECIAL TOOLS > 122 589 00 28 00 BLADE - WS01.00-P-0138B > FG 01/Set B ENGINE 122, 132, 134, 135, 660.950 Fig 1: Identifying Set Of Protective Covers (001 589 02 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Hose Clamp Pliers (003 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 470 · Applies to: 450, 451, 452, 454
Blade to loosen oil pan gasket. SPECIAL TOOLS > 451 589 01 63 00 ADAPTER - WS01.00-P-0143B > FG 01/03/05/Set B ENGINE 132 Use: Adapter for turning crankshaft for a removed belt pulley or timing case cover. SPECIAL TOOLS > 451 589 02 63 00 RETAINING PLATES - WS01.00-P-0144B > FG 01/Set B ENGINE 132 Fig 1: Identifying Blade (122 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Adapter (451 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 471 · Applies to: 450, 451, 452, 454
Retaining plate for mounting engine in a removed condition. SPECIAL TOOLS > 451 589 01 62 00 SUPPORT BRACES - WS01.00-P-0145C > FG 01/03/Set C MODEL 451 Use: Support brace for mounting various engine lifting devices. NOTE: Only in combination with 240 589 00 61 00 or 639 589 00 61 00 or M30 use engine lifting device. Fig 1: Identifying Retaining Plates (451 589 02 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Support Braces (451 589 01 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 00 91 00 ADAPTER - WS01.00-P-0146B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 472 · Applies to: 450, 451, 452, 454 · AR: WS01.00-Z-9999CZ
FG 01/Set B ENGINE 132 Use: Adapter for checking pressure loss at the gasoline engine. NOTE: Use in combination with 450 589 17 21 00 pressure loss test. SPECIAL TOOLS > SPECIAL TOOLS: SMART: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - WS01.00-Z-9999CZ > MODEL all 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P-0006Z 001 589 00 91 00 Set of protective caps FG 01/Set B WS01.00-P- 0110B 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P- 0111B 001 589 02 91 00 Set of protective caps FG 01/Set B WS01.00-P- 0112B 001 589 76 21 00 Compression tester FG 01/13/Set A WS01.00-P- 0004A 003 589 03 37 00 Hose clamp pliers FG 01/Set B WS01.00-P- 0113B Fig 1: Identifying Adapter (451 589 00 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
110 589 03 59 00 Mounting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 473 · Applies to: 450, 451, 452, 454
wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K 112 589 00 25 00 Application gun FG 00/01 WS00.00-P-0052Z 122 589 00 28 00 Blade FG 01/Set B WS01.00-P- 0138B 129 589 01 21 00 Retainer device FG 40/01/Set B WS40.00-P-0025B 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 450 589 00 10 00 Socket wrench FG 01/Set B WS01.00-P-0070B 450 589 01 40 00 Adaptation FG 01/Set B WS01.00-P-0079B 450 589 01 62 00 Removal fixture FG 01/Set B WS01.00-P-0071B 450 589 01 91 00 Adaptation FG 01/Set A WS01.00-P- 0078A 450 589 02 91 00 Adapter FG 01/Set A WS01.00-P-0080A 450 589 03 91 00 Adapter FG 01/Set A WS01.00-P- 0081A 450 589 05 21 00 Compression tester set FG 01/Set A WS01.00-P- 0072A 450 589 05 21 06 Screw piece FG01/Set A WS01.00-P-0072- 06A 450 589 07 21 00 Pressure pump FG 01/09/20/Set B WS01.00-P- 0074B 450 589 07 21 07 Adapter FG 01/20/54/Set B WS01.00-P-0074- 07B 450 589 07 63 00 Stethoscope FG 01/Set A WS01.00-P-0073A 450 589 14 21 00 Adaptation FG 01/Set B WS01.00-P-0075B 450 589 17 21 00 Pressure loss tester FG 01/Set B WS01.00-P-0082B 450 589 29 63 00 Retainer FG 01/Set B WS01.00-P-0132B 451 589 00 91 00 Adapter FG 01/Set B WS01.00-P- 0146B 451 589 01 62 00 Support braces FG 01/03/Set C WS01.00-P- 0145C 451 589 01 63 00 Adapter FG 01/03/05/Set B WS01.00-P- 0143B 451 589 02 63 00 Retaining plates FG 01/Set B WS01.00-P- 0144B
451 589 05 63 00 Screw-in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 474 · Applies to: 450, 451, 452, 454
fitting FG 01/Set A WS01.00-P-0155A 452 589 01 99 00 Repair tools for valves FG 01/set C WS01.00-P- 0108C 452 589 01 99 04 Assembly cartridge FG01/05/Set C WS01.00-P-0108- 04C 452 589 01 99 09 Drift FG01/05/Set C WS01.00-P-0108- 09C 452 589 01 99 10 Drift FG01/05/Set C WS01.00-P-0108- 10C 452 589 01 99 15 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 15C 452 589 01 99 16 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 16C 452 589 01 99 17 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 17C 452 589 01 99 18 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 18C 452 589 01 99 19 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 19C 452 589 01 99 20 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 20C 452 589 01 99 21 T-handle FG01/05/Set C WS01.00-P-0108- 21C 452 589 01 99 22 Guide FG01/05/Set C WS01.00-P-0108- 22C 452 589 01 99 23 Guide FG01/05/Set C WS01.00-P-0108- 23C 452 589 01 99 24 Straightedge FG01/05/Set C WS01.00-P-0108- 24C 452 589 01 99 26 Roll pin FG01/05/Set C WS01.00-P-0108- 26C 452 589 01 99 28 Adapter FG01/05/Set C WS01.00-P-0108- 28C 454 589 00 61 00 Motor crossmember FG 01/set C WS01.00-P-0114C 454 589 00 62 00 Support fixture FG 01/Set C WS01.00-P-0126C 454 589 01 62 00 Adaptation FG 01/Set C WS01.00-P-0127C 454 589 02 62 00 Engine lifting device FG 01/Set C WS01.00-P-0128C
454 589 03 63 00 Adapter¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 475 · Applies to: 450, 451, 452, 454
FG 01/Set B WS01.00-P-0136B 454 589 04 09 00 Set of socket wrench bits FG 22/26/01 Set B WS22.00-P-0007B 454 589 05 15 00 Insertion drift FG 01/Set B WS01.00-P-0140B 611 589 00 63 00 Connector FG 01/05/Set B WS01.00-P-0057B 639 589 00 61 00 Engine lifting device FG 01/33/Set C WS01.00-N- 3106C
Crankshaft¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 478 · Applies to: 450, 451, 452, 454
Connecting rod upper and lower 0 1 1 0 2 2 0 3 3 1 1 2 1 2 3 1 3 4 2 1 3 2 2 4 2 3 5 TESTING & REPAIR > REMOVE PISTONS - AR03.10-P-7021-07MCC > 1. Lay piston (1) on the basic body (5) and press piston pin (2) with the thrust piece (4) out of the connecting rod (3). 2. Remove thrust piece (4) out of the piston (1) and disconnect piston (1) and connecting rod (3). Fig 2: Identifying Connecting Rod Bearing Shell And Connecting Rod Number Mark Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Assembly Tool (132 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL PISTONS - AR03.10-P-7021-08MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 479 · Applies to: 450, 451, 452, 454
Lubricate all slide surfaces on piston (1), piston pin (2) and on connecting rod (3) with engine oil before assembly. 1. Assemble together piston (1) and connecting rod (3). The marking (arrow B) on the connecting rod (3) and the marking (arrow A) on the piston (1) must point upwards. Fig 2: Disconnecting Piston And Connecting Rod Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Assembly Tool (132 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert thrust piece (4) from below into the piston (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 480 · Applies to: 450, 451, 452, 454
- Insert thrust piece (4) from below into the piston (1).
- Insert piston pin (2) from above in the piston (1).
- Insert guide (5) into the piston pin (2) and screw into the thrust piece (4). The thrust piece (4) and guide (5) must be completely screwed down otherwise there can be false positioning of the piston pin (2) in the piston (1).
- Insert piston (1), piston pin (2) and connecting rod (3) together with the thrust piece (4) and the guide (5), as shown, in the basic body (6).
- Press piston pin (2) into the connecting rod (3) all the way.
- Unscrew and separate thrust piece (4) and guide (5).
- Check clearance of the piston pin (2) in piston (1); replace piston (1), piston pin (2) and connecting rod (3) if necessary in the case of sluggishness. Fig 2: Assembling Piston And Connecting Rod Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > POSITION PISTON RINGS AT THE PISTON - AR03.10-P-7311-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 486 · Applies to: 450, 451, 452, 454
03MCC > Position the plain compression ring, taper-faced ring and three-piece oil ring with reference to markings (1). 1. Position the plain compression ring with the piston ring end gap at "A". 2. Position the taper-faced ring with the piston ring end gap at "B". 3. Position the upper section of the three-piece oil ring with the piston ring end gap at "C". 4. Position the spring for the three-piece oil ring with the piston ring end gap at "A or B". 5. Position the lower section of the three-piece oil ring with the piston ring end gap at "D". Fig 3: Identifying Tensioning Strap (450 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Positioning Piston Rings At Piston Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > ATTACH/REMOVE RETAINING LOCK FOR ENGINE - AR03.30-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 487 · Applies to: 450, 451, 452, 454
1600-06MCC > Attaching 1. Remove bolts (3) and retaining lock (1) from retaining lock adapter (2). 2. Insert retaining lock (1) in toothing of flywheel (4). 3. Insert sleeve (5) between retaining lock (1) and cylinder crankcase (6) and fix in place with a suitable bolt and nut. Turn crankshaft just a little if necessary. 4. Remove in the reverse order. Fig 1: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Bolts, Retaining Lock And Retaining Lock Adapter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > ATTACH/DISASSEMBLE RETAINING LOCK FOR ENGINE -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 488 · Applies to: 450, 451, 452, 454
AR03.30-P-1600-06MCE > 1. Insert retaining lock (1) in toothing of the flywheel and screw in mounting screws (2) for the starter. 2. Remove in the reverse order. Fig 3: Inserting Sleeve Between Retaining Lock And Cylinder Crankcase Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove bolts (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 490 · Applies to: 450, 451, 452, 454 · AR: BA03.00-Z-9999CZ
2 Remove bolts (2) Install new self-locking bolts (2). Installation: To exclude any possibility of offset angle errors, a bending rod torquing angle wrench must not be used for tightening.If no torquing angle wrench is available, the bolts (2) can be torqued further by the specified angle in a single operation using a wrench and Tommy bar.
*BA03.30-P- 1002-01P 3 Detach retaining lock for engine
AR03.30-P- 1600-06MCC *451589014000 4 Remove flywheel (1) from crankshaft Observe installation position of flywheel (1). Installation: Check flywheel (1) for wear; replace if necessary.
5 Install in the reverse order
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR Number Designation Engine 132.9 BA03.30-P-1002- 01P Bolt, flywheel to crankshaft Stage 1 Nm 20 Stage 2 ∠° 90 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: CRANK ASSEMBLY - BA03.00-Z-9999CZ > MODEL all Balance shaft ENGINE 639.939 in MODEL 454.0 BA03.20-P-1000-02F Balancing shaft ENGINE 134.910 /911 in MODEL 454.0 BA03.20-P-1000-02E Connecting rod ENGINE 122.9, 134.910 /911, 135.930 /950 in MODEL 454.0 BA03.10-P-1000-01N Fig 2: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connecting rods¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 491 · Applies to: 450, 451, 452, 454
ENGINE 639.939 in MODEL 454.0 BA03.10-P-1000-01O Connecting rods ENGINE 132.9, 160.910 /920 /921 /922 /923 BA03.10-P-1000- 01K Crankshaft ENGINE 639.939 in MODEL 454.0 BA03.20-P-1000-01I Crankshaft ENGINE 132.9 in MODEL 451 ENGINE 122.9, 134.910 /911, 135.930 /950 in MODEL 454.0 BA03.20-P-1000- 01G Flywheel, driven plate, vibration damper, starter ring gear ENGINE 132.9 BA03.30-P-1000- 01P Flywheel, driven plate, vibration damper, starter ring gear ENGINE 122.950, 134.910 /911, 135.930/950 BA03.30-P-1000-01L Flywheel, driven plate, vibration damper, starter ring gear ENGINE 639.939, 660.940 /950 /951 BA03.30-P-1000-01K Flywheel, driven plate, vibration damper, starter ring gear ENGINE 160.910 /920 /921 /922 /923 BA03.30-P-1000-01J TORQUE SPECIFICATIONS > CONNECTING RODS - BA03.10-P-1000-01K > Engine 132, 160 CONNECTING RODS Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 BA03.10-P- 1001-01K Bolt, connecting rod cap to connecting rod Stage 1 Nm 15 15 15 15 Stage 2 ∠° 90 90 90 90 CONNECTING ROD Number Designation Engine 160.922 Engine 160.923 BA03.10-P-1001- 01K Bolt, connecting rod cap to connecting rod Stage 1 Nm 15 15 Stage 2 ∠° 90 90 TORQUE SPECIFICATIONS > CRANKSHAFT - BA03.20-P-1000-01G > Engine 122, 132, 134, 135 CRANKSHAFT BEARING CAP
Inspection data of piston rings¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 493 · Applies to: 450, 451, 452, 454
ENGINE 639.939 BE03.10-P-1000-05G Test specifications for crankshaft bearing cap bolts ENGINE 132.9 BE03.20-P-1000- 01G Test values for crankshaft ENGINE 122.9 in MODEL 454.0 BE03.20-P-1000-02G TEST & ADJUSTMENT VALUES > CHECK VALUES FOR PISTON RINGS - BE03.10-P- 1000-05H > Engines 122, 132, 134, 135 CHECK VALUES FOR PISTON RINGS Number Designation Engines 134.910/911, 135.930/950 Engine 122.9 BE03.10-P-1001- 05H Piston ring vertical clearance Groove 1 mm 0.03 to 0.07 0.03 to 0.07
Groove 2 mm 0.02 to 0.06 0.02 to 0.06
max. mm 0.1 - BE03.10-P-1002- 05H Piston ring end gap Groove 1 mm 0.15 to 0.30 0.15 to 0.30
Groove 2 mm 0.30 to 0.50 0.30 to 0.45
max. mm 0.8 0.8 BE03.10-P-1003- 05H Oil scraper ring end clearance Groove 3 mm - 0.20 to 0.50
max. mm - 1.0 BE03.10-P-1004- 05H End gap for upper and lower ring of the oil scraper ring Groove 3 mm - -
max. mm - - CHECK VALUES FOR PISTON RINGS Number Designation Engine 132.910/930 BE03.10-P-1001- 05H Piston ring vertical clearance Groove 1 mm 0.03 to 0.07
Groove 2 mm 0.02 to 0.06
max. mm 0.1 BE03.10-P-1002- 05H Piston ring end gap Groove 1 mm 0.15 to 0.30
Groove 2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 494 · Applies to: 450, 451, 452, 454
mm 0.15 to 0.30
max. mm 0.08 BE03.10-P-1003- 05H Oil scraper ring end clearance Groove 3 mm -
max. mm - BE03.10-P-1004- 05H End gap for upper and lower ring of the oil scraper ring Groove 3 mm 0.10 to 0.40
max. mm 1.0 TEST & ADJUSTMENT VALUES > TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CAP BOLTS - BE03.20-P-1000-01G > Engine 132 Number Designation Engine 132.910/930 BE03.20-P-1001- 01G Bolt for crankshaft bearing cap Max. length (L) mm 75,05 See picture
SPECIAL TOOLS > 450 589 00 14 00 TENSIONING STRAP - WS03.00-P-0091C > Group 03/Set C ENGINE 160 in MODEL 450, 452 ENGINE 122, 134, 135, 639 in MODEL 454 ENGINE 132 in MODEL 451 Use: Tensioning strap to press the piston rings together NOTE: Equivalent part to MB tool W000 589 04 14 00. smart no.: 0020933 V001 0000 00.
SPECIAL TOOLS > 450 589 14 37 00 PLIERS - WS03.00-P-0092C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 495 · Applies to: 450, 451, 452, 454
FG 03/Set C ENGINE 160 in MODEL 450, 452 ENGINE 122, 134.910 /911, 135.930 /950, 639.939 in MODEL 454 ENGINE 132 in MODEL 451 Use: Pliers for spreading apart piston rings. NOTE: smart no.: 0020924 V001 0000 00. SPECIAL TOOLS > 451 589 01 40 00 RETAINING LOCK - WS03.00-P-0103B > Fig 1: Identifying Tensioning Strap (450 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Pliers (450 589 14 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 03/Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 496 · Applies to: 450, 451, 452, 454
MODEL 451 with ENGINE 132 Use: Retaining lock for locking the flywheel when dismantling the belt pulley or flywheel. SPECIAL TOOLS > 451 589 00 40 00 COUNTERHOLDER - WS03.00-P-0104B > FG 03/Set B Use: Counterholder for firmly holding the belt pulley on the water pump. SPECIAL TOOLS > 451 589 03 63 00 GUIDE - WS03.00-P-0106B > FG 03/Set B Fig 1: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Counterholder (451 589 00 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 497 · Applies to: 450, 451, 452, 454
Use: For guiding the front radial shaft sealing ring when mounting the timing case cover. NOTE: Only use in connection with W711 589 13 15 00 for mounting the radial shaft sealing ring. SPECIAL TOOLS > 711 589 13 15 00 DRIFT - WS03.00-P-0107B > FG 03/Set B MODEL 451 Use: Drift for assembling the shaft seal (on the drive side), for assembling bearing shells for output shafts and for assembling the front radial shaft sealing ring. Fig 1: Identifying Guide (451 589 03 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 132 589 00 35 00 ASSEMBLY TOOL - WS03.00-P-0121C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 498 · Applies to: 450, 451, 452, 454 · AR: WS03.00-Z-9999CZ
FG 03/Set C Use: For assembling pistons, piston pins and connecting rods. SPECIAL TOOLS > SPECIAL TOOLS: SMART: CRANK ASSEMBLY - WS03.00-Z-9999CZ > MODEL all 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 122 589 00 15 00 Drift FG 03/Set B WS03.00-P-0099B 122 589 00 43 00 Assembly tool FG 03/Set C WS03.00-P-0098C 122 589 00 59 00 Piston repair FG 03/Set C WS03.00-P-0097C Fig 1: Identifying Drift (711 589 13 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Assembly Tool (132 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
132 589 00 35 00 Assembly¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 499 · Applies to: 450, 451, 452, 454
kit 132 589 00 35 00 Assembly tool FG 03/Set C WS03.00-P-0121C 450 589 00 14 00 Tensioning strap Group 03/Set C WS03.00-P-0091C 450 589 00 40 00 Catch FG 03/Set B WS03.00-P-0080B 450 589 02 33 00 Installation aid FG 03/Set B WS03.00-P-0081B 450 589 14 37 00 Pliers FG 03/Set C WS03.00-P-0092C 451 589 00 40 00 Counterholder FG 03/Set B WS03.00-P-0104B 451 589 01 40 00 Retaining lock FG 03/Set B WS03.00-P-0103B 451 589 01 62 00 Support braces FG 01/03/Set C WS01.00-P-0145C 451 589 01 63 00 Adapter FG 01/03/05/Set B WS01.00-P-0143B 451 589 02 40 00 Retaining lock FG 03/Set B WS03.00-P-0108B 451 589 03 63 00 Guide FG 03/Set B WS03.00-P-0106B 454 589 00 40 00 Retaining lock FG 03/Set B WS03.00-P-0084B 454 589 01 40 00 Counterholder FG 03/Set B WS03.00-P-0088B 454 589 02 14 00 Sleeve FG 03/Set B WS03.00-P-0100B 454 589 03 40 00 Counterholder FG 03/Set B WS03.00-P-0085B 454 589 04 15 00 Insertion drift FG 03/Set B WS03.00-P-0093B 454 589 11 09 00 Socket wrench bit FG 03/Set B WS03.00-P-0087B 602 589 00 98 00 Case FG 03/05/18/Set C WS05.00-P-0158C 711 589 13 15 00 Drift FG 03/Set B WS03.00-P-0107B
GENERAL INFORMATION > ASSIGNMENT OF PISTONS TO CYLINDER BORE - AH03.10-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 500 · Applies to: 450, 451, 452, 454
P-0001-02MCC > Model 451.3/4 with engine 132.9 The markings (arrows) on the pistons (1) must point towards the timing case. GENERAL INFORMATION > INTERFERENCE FIT OF CRANKSHAFT BEARING CAP - AH03.20-P-4351-02MCC > Model 451.3/4 with engine 132.9 The crankshaft bearing caps (1) are machined together with the crankcase (2) and must not be interchanged. The crankshaft bearing caps (1) are numbered consecutively, beginning at the first crankshaft bearing cap (1) on the timing case. The numbers are located on the right as seen from the output side. The crankshaft bearing cap (1) may only be mounted in this position. Fig 1: Locating Markings On Pistons Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > ASSIGN CONNECTING ROD BEARING SHELLS - AR03.10-P-6112-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 502 · Applies to: 450, 451, 452, 454
01MCC > 1. Assign connecting rod bearing shells for crankshaft (1) and the connecting rod (4). Selection of the connecting rod bearing shells takes place over the three numbers (3) on the cheek of the crankshaft (1) and the numbers (arrow) on the associated connecting rod (4). The first four numbers (2) are foreseen for the crankshaft bearing shells. The connecting rod bearing shells should be assigned to the connecting rods (4) according to the sequence of the numbers (3). The first bearing point is located opposite the output side of the engine. Assignment takes place over a number placed on the side on the connecting rod bearing shells and can be taken from the following list. Number on the Crankshaft Number on the marking (arrow) Connecting rod Connecting rod bearing shell (5) upper and lower 0 1 1 0 2 2 0 3 3 1 1 2 1 2 3 1 3 4 Fig 1: Identifying Numbers On Cheek Of Crankshaft And Associated Connecting Rod Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 503 · Applies to: 450, 451, 452, 454
2 1 3 2 2 4 2 3 5 TESTING & REPAIR > REMOVE PISTONS - AR03.10-P-7021-07MCC > 1. Lay piston (1) on the basic body (5) and press piston pin (2) with the thrust piece (4) out of the connecting rod (3). 2. Remove thrust piece (4) out of the piston (1) and disconnect piston (1) and connecting rod (3). Fig 2: Identifying Connecting Rod Bearing Shell And Connecting Rod Number Mark Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Assembly Tool (132 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL PISTONS - AR03.10-P-7021-08MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 504 · Applies to: 450, 451, 452, 454
Lubricate all slide surfaces on piston (1), piston pin (2) and on connecting rod (3) with engine oil before assembly. 1. Assemble together piston (1) and connecting rod (3). The marking (arrow B) on the connecting rod (3) and the marking (arrow A) on the piston (1) must point upwards. Fig 2: Removing Piston Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Assembly Tool (132 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert thrust piece (4) from below into the piston (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 505 · Applies to: 450, 451, 452, 454
- Insert thrust piece (4) from below into the piston (1).
- Insert piston pin (2) from above in the piston (1).
- Insert guide (5) into the piston pin (2) and screw into the thrust piece (4). The thrust piece (4) and guide (5) must be completely screwed down otherwise there can be false positioning of the piston pin (2) in the piston (1).
- Insert piston (1), piston pin (2) and connecting rod (3) together with the thrust piece (4) and the guide (5), as shown, in the basic body (6).
- Press piston pin (2) into the connecting rod (3) all the way.
- Unscrew and separate thrust piece (4) and guide (5).
- Check clearance of the piston pin (2) in piston (1); replace piston (1), piston pin (2) and connecting rod (3) if necessary in the case of sluggishness. Fig 2: Assembling Piston And Connecting Rod Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 507 · Applies to: 450, 451, 452, 454
1 Remove engine with transmission Only if the engine is removed and should be fixed onto an engine repair stand.
- not for USAEngine 132.910 AR01.10- P- 2401MCC
- not for USAEngine 132.930 AR01.10- P- 2401MCB
-
for USA only AR01.10- P- 2401MCU 2 Remove flywheel Only if the engine is removed and should be fixed onto an engine repair stand.
-
not for USA AR03.30- P- 8002MCC
- for USA only AR03.30- P- 8002MCU Fix engine onto an Only if the engine is removed and should be fixed Fig 1: Identifying Piston Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
engine repair tand¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 508 · Applies to: 450, 451, 452, 454
3 engine repair tand onto an engine repair tand Engine repair standUniversal mount
4 Remove cylinder head * not for USA AR01.30- P- 5800MCC * for USA only AR01.30- P- 5800MCU 5 Check markings on the piston (7), clean piston crown if necessary and make markings with a colored pencil In case of used pistons (7), the markings may no longer be visible due to carbonization.For this reason, remove carbon deposits from pistons (7).If the markings on the pistons (7) are no longer visible, the pistons (7) must be marked again.
6.1 Lower vehicle with vehicle lift If engine installed.
6.2 Turn engine at engine repair stand until the connecting rod bearing cap (3) is accessible For a removed engine.
7 Mark connecting rod (2) and connecting rod bearing cap (3) relative to each other The connecting rods (2) and connecting rod bearing caps (3) are cracked and must not be mixed up with each other.
8 Remove bolts (1)
9 Remove connecting rod bearing cap (3) and connecting rod bearing shells (5) from the crankshaft (6) If worn connecting rod bearing shells (5) are reused these must remain assigned to the respective connecting rod (2) or connecting rod bearing cap (3).
10 Remove piston (7) with connecting rod (2) and connecting rod bearing shell (4) from cylinder bore (9) If worn connecting rod bearing shells (4) are reused these must remain assigned to the respective connecting rod (2) or connecting rod bearing cap (3).
11 Remove plain compression ring (10), taper-faced ring (11) and three-piece oil ring (12) on piston (7)
AR03.10- P- 7311MCC 12 Remove piston (7) from connecting rod (2)
AR03.10- P-7021- 07MCC Assembly tool Figure Install
Attach piston (7) to
AR03.10- P-7021-
connecting rod (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 509 · Applies to: 450, 451, 452, 454
13 connecting rod (2) 08MCC Assembly tool Figure 14 Clean and lubricate cylinder bores (9), connecting rod bearing journals, connecting rod bearing shells (4, 5) and pistons (7)
15 Install plain compression ring (10), taper-faced ring (11) and three-piece oil ring (12) on piston (7)
AR03.10- P- 7311MCC 16 Position plain compression ring (10), taper-faced ring (11) and three-piece oil ring (12) on piston (7)
AR03.10- P-7311- 03MCC 17 Place tensioning strap (8) on the piston (7) and stretch Do not turn plain compression ring (10), taper- faced ring (11) and three-piece oil ring (12) anymore.
Tensioning strap Fig 3 18 Assign connecting rod bearing shells (4, 5) When using new connecting rod bearing shells (4, 5). AR03.10- P-6112- 01MCC 19 Insert connecting rod bearing shells (4, 5) into connecting rod (2) and into connecting rod bearing cap (3).
20.1 Turn engine at engine repair stand through 90° For a removed engine.
20.2 Raise vehicle with vehicle lift If engine installed.
21 Assign piston (7) to cylinder bore (9)
Assignment of pistons to cylinder bore
AH03.10- P-0001- 02MCC 22 Insert connecting rod (2) with piston (7) and connecting rod bearing shell (4) in the respective cylinder bore (9) If necessary turn the crankshaft (6) so that the connecting rod (2) is not touching the connecting rod journal before inserting the piston (7).Ensure that the connecting rod bearing shell (4) does not fall out.
Tensioning strap Fig 3 Place connecting rod
bearing cap (3) with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 510 · Applies to: 450, 451, 452, 454
23 bearing cap (3) with connecting rod bearing shell (5) in place Ob erve marking of connecting rod (2) relative to connecting rod bearing cap (3).
24 Lubricate bolts (1) and screw in Replace bolts (1).
*BA03.10- P-1001- 01K 25.2 Turn engine at engine repair stand through 90° For a removed engine.
25.1 Raise vehicle with vehicle lift If engine installed.
26 Rotate crankshaft (6) fully and inspect clearance
27 Install cylinder head * not for USA AR01.30- P- 5800MCC * for USA only AR01.30- P- 5800MCU 28 Remove engine from engine repair stand For a removed engine.
29 Install flywheel For a removed engine.
- not for USA AR03.30- P- 8002MCC
-
for USA only AR03.30- P- 8002MCU 30 Install engine with transmission For a removed engine.
-
not for USAEngine 132.910 AR01.10- P- 2401MCC
- not for USAEngine 132.930 AR01.10- P- 2401MCB
- for USA only AR01.10- P- 2401MCU CONNECTING ROD Number Designation Engine 132.9 BA03.10-P-1001- 01K Bolt, connecting rod bearing cap to connecting rod Stage 1 Nm 15
Stage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 511 · Applies to: 450, 451, 452, 454
2 ∠° 90 TESTING & REPAIR > MEASURE VERTICAL CLEARANCE OF PISTON RINGS - AR03.10- P-7311-01MCC > CHECK VALUES FOR PISTON RINGS Number Designation Engine 132.910/930 BE03.10-P-1001- 05H Piston ring vertical clearance Groove 1 mm 0.03 to 0.07 Groove 2 mm 0.02 to 0.06 max. mm 0.1 Shown on plain compression ring which has been removed 1. Measure the side clearance of the plain compression ring (1) in groove 1 and the taper-faced ring (2) in groove 2 using a suitable feeler gauge (4). There should be no combustion residues in the piston ring groove during measurement. The side clearance of the oil scraper ring in groove 3 cannot be checked due to its three-part Fig 2: Identifying Assembly Tool (132 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Tensioning Strap (450 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
structure.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 512 · Applies to: 450, 451, 452, 454
The plain compression ring (1), taper-faced ring (2), oil scraper ring must be replaced together with the piston (3) if wear is found. TESTING & REPAIR > MEASURE PISTON RING END GAP - AR03.10-P-7311-02MCC > CHECK VALUES FOR PISTON RINGS Number Designation Engine 132.910/930 BE03.10-P-1002- 05H Piston ring end gap Groove 1 mm 0.15 to 0.30 Groove 2 mm 0.15 to 0.30 max. mm 0.08 BE03.10-P-1004- 05H End gap for upper and lower ring of the oil scraper ring Groove 3 mm 0.10 to 0.40 max. mm 1.0 1. Clean cylinder barrel (1) 2. Insert plain compression ring (2), taper-faced ring and lower or upper ring of the oil scraper ring one after another into the cylinder barrel (1) and align with the piston (3) above the reversal point of the plain compression ring (2). Fig 1: Measuring Side Clearance Of Plain Compression Ring And Taper-Faced Ring Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Measure the end gap on the plain compression ring (2), taper-faced ring and the upper or lower¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 513 · Applies to: 450, 451, 452, 454
ring the oil scraper ring one after another in the cylinder barrel (1) using a feeler gauge (4). Replace piston ring set by set in the case of wear. TESTING & REPAIR > POSITION PISTON RINGS AT THE PISTON - AR03.10-P-7311- 03MCC > Position the plain compression ring, taper-faced ring and three-piece oil ring with reference to markings (1). 1. Position the plain compression ring with the piston ring end gap at "A". Fig 1: Identifying Cylinder Barrel, Compression Ring And Piston Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Measuring End Gap On Plain Compression Ring Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
of injury cau ed by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 519 · Applies to: 450, 451, 452, 454
contusions and burns during starting procedure or when working near the engine as it is running nug fitting work clothes.Do not touch hot or rotating parts. 9 Carry out engine test run and check engine for leaks in area of crankshaft radial sealing ring (1)
TESTING & REPAIR > TIGHTENING PROCEDURE FOR CRANKSHAFT BEARING CAPS - AR03.20-P-4351-02MCC > CRANKSHAFT BEARING CAP Number Designation Engine 132.9 BA03.20-P-1001- 01G Bolt for crankshaft bearing cap Stage 1 Nm 30 Stage 2 ∠° 60 Releasing 1. Loosen and remove bolts (1 to 8) for crankshaft bearing cap in a descending sequence. Fig 2: Identifying Guide (451 589 03 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Drift (711 589 13 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Actuating¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 520 · Applies to: 450, 451, 452, 454
-
Tighten bolts (1 to 8) of crankshaft bearing caps in an ascending sequence. TESTING & REPAIR > INSPECT CRANKSHAFT BEARING CAP BOLTS - AR03.20-P-4351- 03MCC > TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CAP BOLTS Number Designation Engine 132.910/930 BE03.20-P-1001- 01G Bolt for crankshaft bearing cap Max. length (L) mm 75,05 See figure
-
Measure length (L). If length (L) is greater than the maximum permissible dimension, use new bolts. Fig 1: Identifying Crankshaft Bearing Cap Bolt Removal & Tightening Sequence Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
connecting rod (4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 524 · Applies to: 450, 451, 452, 454
TEST SPECIFICATIONS FOR CRANKSHAFT BEARING CAP BOLTS Number Designation Engine 132.910/930 BE03.20-P-1001- 01G Bolt for crankshaft bearing cap Max. length (L) mm 75.05 See figure
CRANKSHAFT BEARING CAP Number Designation Engine 132.9 BA03.20-P-1001-01G Bolt for crankshaft bearing cap Stage 1 Nm 30 Stage 2 ∠° 60 TESTING & REPAIR > ASSIGN CRANKSHAFT BEARING SHELLS - AR03.20-P-4360- 01MCC > 1. Assign crankshaft bearing shell to the cylinder crankcase (1). Assignment of the bearing shell takes place over a number on the side of the crankshaft bearing shells and numbers (arrow) on the underside of the cylinder crankcase (1). The bearing shells are to be assigned to the bearing points in the crankcase (1) according to the sequence of the numbers (arrow). The first bearing point is located opposite the output side of the engine. The respective number on the cylinder crankcase (1) represents the number on the associated crankshaft bearing shell in the cylinder crankcase (1).
2. Assign crankshaft bearing shells to the crankshaft bearing caps¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 525 · Applies to: 450, 451, 452, 454
Assignment of the bearing shell takes place over a number on the side of the crankshaft bearing shells and the first four numbers (3) on the cheek of the crankshaft (2). The additional three numbers (4) are foreseen for the connecting rod bearing shells. The crankshaft bearing shell should be assigned to the crankshaft bearing caps according to the sequence of the numbers (3). The first bearing point is located opposite the output side of the engine. The respective number on the cheek of the crankshaft (2) represents the number on the associated crankshaft bearing shell in the crankshaft bearing cap. Fig 1: Assigning Crankshaft Bearing Shell To Cylinder Crankcase Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The number on the cylinder crankcase represents the number (arrow) on the associated¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 526 · Applies to: 450, 451, 452, 454
crankshaft bearing shell (5) in the cylinder crankcase. The number on the cheek of the crankshaft (arrow) represents the number on the associated crankshaft bearing shell (6) in the crankshaft bearing cap. The crankshaft bearing shells (5) in the cylinder crankcase are fitted with an oil duct; the crankshaft bearing shells (6) in the crankshaft bearing caps are smooth. Fig 2: Assigning Crankshaft Bearing Shells To Crankshaft Bearing Caps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > ATTACH/REMOVE RETAINING LOCK FOR ENGINE - AR03.30-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 527 · Applies to: 450, 451, 452, 454
1600-06MCC > Attaching 1. Remove bolts (3) and retaining lock (1) from retaining lock adapter (2). Fig 3: Locating Crankshaft Bearing Shell Number Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Insert retaining lock (1) in toothing of flywheel (4).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 528 · Applies to: 450, 451, 452, 454
- Insert retaining lock (1) in toothing of flywheel (4).
- Insert sleeve (5) between retaining lock (1) and cylinder crankcase (6) and fix in place with a suitable bolt and nut. Turn crankshaft just a little if necessary.
- Remove in the reverse order. Fig 2: Identifying Bolts, Retaining Lock And Retaining Lock Adapter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > ATTACH/DISASSEMBLE RETAINING LOCK FOR ENGINE -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 529 · Applies to: 450, 451, 452, 454
AR03.30-P-1600-06MCE > 1. Insert retaining lock (1) in toothing of the flywheel and screw in mounting screws (2) for the starter. 2. Remove in the reverse order. Fig 3: Inserting Sleeve Between Retaining Lock And Cylinder Crankcase Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove poly-V¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 531 · Applies to: 450, 451, 452, 454
2 Remove poly-V belt for supercharger On vehicles with code (I01) Air conditioning Plus AR13.21- P- 1202MCU 3 Remove starter
AR15.30- P- 7100MCU 4 Attach retaining lock for engine
AR03.30- P-1600- 06MCE Figure 5 Remove bolt (2) and take off together with disc (3) *BA03.30- P-1001- 01P 6 Detach crankshaft belt pulley (1) to crankshaft and take off Installation: The guide pin on the crankshaft must engage in the bore in the crankshaft belt pulley (1).Check contact surface of the crankshaft radial sealing ring on the crankshaft belt pulley (1); replace crankshaft radial sealing ring if necessary. Refer to: ↓
Replace front crankshaft radial sealing ring AR03.20- P- 3000MCU 7 Install in the reverse order
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR Number Designation Engine 132.9 BA03.30-P-1001- 01P Belt pulley / vibration damper to crankshaft Stage 1 Nm 150 Stage 2 loosen Nm ≥ 150 Stage 3 Nm 50 Stage 4 ∠° 60
P-1002-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 533 · Applies to: 450, 451, 452, 454 · AR: BA03.00-Z-9999CZ
01P 3 Detach retaining lock for engine
AR03.30- P-1600- 06MCC Figure 4 Remove flywheel (1) from crankshaft Observe installation position of flywheel (1). Installation: Check flywheel (1) for wear; replace if necessary.
5 Install in the reverse order
FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR Number Designation Engine 132.9 BA03.30-P-1002-01P Bolt, flywheel to crankshaft Stage 1 Nm 20 Stage 2 ∠° 90 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: CRANK ASSEMBLY - BA03.00-Z-9999CZ > MODEL all Balance shaft ENGINE 639.939 in MODEL 454.0 BA03.20-P-1000-02F Balancing shaft ENGINE 134.910 /911 in MODEL 454.0 BA03.20-P-1000-02E Connecting rod ENGINE 122.9, 134.910 /911, 135.930 /950 in MODEL 454.0 BA03.10-P-1000-01N Connecting rods ENGINE 639.939 in MODEL 454.0 BA03.10-P-1000-01O Connecting rods ENGINE 132.9, 160.910 /920 /921 /922 /923 BA03.10-P-1000-01K Crankshaft ENGINE 639.939 in MODEL 454.0 BA03.20-P-1000-01I Fig 2: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Crankshaft¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 534 · Applies to: 450, 451, 452, 454
ENGINE 132.9 in MODEL 451 ENGINE 122.9, 134.910 /911, 135.930 /950 in MODEL 454.0 BA03.20-P-1000-01G Flywheel, driven plate, vibration damper, starter ring gear ENGINE 132.9 BA03.30-P-1000-01P Flywheel, driven plate, vibration damper, starter ring gear ENGINE 122.950, 134.910 /911, 135.930/950 BA03.30-P-1000-01L Flywheel, driven plate, vibration damper, starter ring gear ENGINE 639.939, 660.940 /950 /951 BA03.30-P-1000-01K Flywheel, driven plate, vibration damper, starter ring gear ENGINE 160.910 /920 /921 /922 /923 BA03.30-P-1000-01J TORQUE SPECIFICATIONS > CONNECTING RODS - BA03.10-P-1000-01K > Engine 132, 160 CONNECTING RODS Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 BA03.10-P- 1001-01K Bolt, connecting rod cap to connecting rod Stage 1 Nm 15 15 15 15 Stage 2 ∠° 90 90 90 90 CONNECTING ROD Number Designation Engine 160.922 Engine 160.923 BA03.10-P-1001- 01K Bolt, connecting rod cap to connecting rod Stage 1 Nm 15 15 Stage 2 ∠° 90 90 TORQUE SPECIFICATIONS > CRANKSHAFT - BA03.20-P-1000-01G > Engine 122, 132, 134, 135 CRANKSHAFT BEARING CAP Number Designation Engine 122.9 Engines 134.910/911, 135.930/950 BA03.20-P- 1001-01G Bolt for crankshaft bearing cap Stage 1 Nm 34 35
Stage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 535 · Applies to: 450, 451, 452, 454
2 ∠° 30 62 BA03.20-P- 1002-01G Bolt, incremental wheel to crankshaft
Nm¶
- CRANKSHAFT BEARING CAP Number Designation Engine 132.9 BA03.20-P-1001- 01G Bolt for crankshaft bearing cap Stage 1 Nm 30 Stage 2 ∠° 60 BA03.20-P-1002- 01G Bolt, incremental wheel to crankshaft
Nm 10 TORQUE SPECIFICATIONS > FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR - BA03.30-P-1000-01P > Engine 132.9 FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR Number Designation Engine 132.9 BA03.30-P-1001- 01P Belt pulley / vibration damper to crankshaft Stage 1 Nm 150 2nd stage loosen Nm ≥150 Stage 3 Nm 50 Stage 4 ∠° 60 BA03.30-P-1002- 01P Bolt, flywheel to crankshaft Stage 1 Nm 20 Stage 2 ∠° 90 TEST & ADJUSTMENT VALUES > TEST SPECIFICATIONS FOR CYLINDER BORE - BE01.40-P-1000-01P > Engine 132 TEST SPECIFICATIONS FOR CYLINDER BORE Number Designation Engine 132.910/930 BE01.40-P- 1001-01P Ø of cylinder bore Standard size mm 72.010 to 72.025 Out-of-roundness (in a new condition) mm 0.01 Wear limit in longitudinal and transverse direction mm 0.15
TEST & ADJUSTMENT VALUES > TEST SPECIFICATIONS FOR CRANKSHAFT BEARING¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 536 · Applies to: 450, 451, 452, 454
CAP BOLTS - BE03.20-P-1000-01G > Engine 132 Number Designation Engine 132.910/930 BE03.20-P-1001- 01G Bolt for crankshaft bearing cap Max. length (L) mm 75,05 See figure
SPECIAL TOOLS > 450 589 00 14 00 TENSIONING STRAP - WS03.00-P-0091C > Group 03/Set C ENGINE 160 in MODEL 450, 452 ENGINE 122, 134, 135, 639 in MODEL 454 ENGINE 132 in MODEL 451 Use: Tensioning strap to press the piston rings together NOTE: Equivalent part to MB tool W000 589 04 14 00. smart no.: 0020933 V001 0000 00. SPECIAL TOOLS > 450 589 14 37 00 PLIERS - WS03.00-P-0092C > FG 03/Set C ENGINE 160 in MODEL 450, 452 Fig 1: Identifying Tensioning Strap (450 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINE 122, 134.910 /911, 135.930 /950, 639.939 in MODEL 454¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 537 · Applies to: 450, 451, 452, 454
ENGINE 132 in MODEL 451 Use: Pliers for spreading apart piston rings. NOTE: smart no.: 0020924 V001 0000 00. SPECIAL TOOLS > 451 589 01 40 00 RETAINING LOCK - WS03.00-P-0103B > FG 03/Set B MODEL 451 with ENGINE 132 Use: Retaining lock for locking the flywheel when dismantling the belt pulley or flywheel. Fig 1: Identifying Pliers (450 589 14 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 00 40 00 COUNTERHOLDER - WS03.00-P-0104B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 538 · Applies to: 450, 451, 452, 454
FG 03/Set B Use: Counterholder for firmly holding the belt pulley on the water pump. SPECIAL TOOLS > 451 589 03 63 00 GUIDE - WS03.00-P-0106B > FG 03/Set B MODEL 451 Use: For guiding the front radial shaft sealing ring when mounting the timing case cover. NOTE: Fig 1: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Counterholder (451 589 00 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Only use in connection with W711 589 13 15 00 for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 539 · Applies to: 450, 451, 452, 454
mounting the radial shaft sealing ring. SPECIAL TOOLS > 711 589 13 15 00 DRIFT - WS03.00-P-0107B > FG 03/Set B MODEL 451 Use: Drift for assembling the shaft seal (on the drive side), for assembling bearing shells for output shafts and for assembling the front radial shaft sealing ring. SPECIAL TOOLS > 132 589 00 35 00 ASSEMBLY TOOL - WS03.00-P-0121C > FG 03/Set C Fig 1: Identifying Guide (451 589 03 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Drift (711 589 13 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 540 · Applies to: 450, 451, 452, 454 · AR: WS03.00-Z-9999CZ
For assembling pistons, piston pins and connecting rods. SPECIAL TOOLS > SPECIAL TOOLS: SMART: CRANK ASSEMBLY - WS03.00-Z-9999CZ > MODEL all 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 122 589 00 15 00 Drift FG 03/Set B WS03.00-P-0099B 122 589 00 43 00 Assembly tool FG 03/Set C WS03.00-P-0098C 122 589 00 59 00 Piston repair kit FG 03/Set C WS03.00-P-0097C 132 589 00 35 00 Assembly tool FG 03/Set C WS03.00-P-0121C 450 589 00 14 00 Tensioning strap Group 03/Set C WS03.00-P-0091C 450 589 00 40 00 Catch FG 03/Set B WS03.00-P-0080B 450 589 02 33 00 Installation aid FG 03/Set B WS03.00-P-0081B 450 589 14 37 00 Pliers FG 03/Set C WS03.00-P-0092C 451 589 00 40 00 Counterholder FG 03/Set B WS03.00-P-0104B 451 589 01 40 00 Retaining lock FG 03/Set B WS03.00-P-0103B 451 589 01 62 00 Support braces FG 01/03/Set C WS01.00-P-0145C 451 589 01 63 00 Adapter FG 01/03/05/Set B WS01.00-P-0143B Fig 1: Identifying Assembly Tool (132 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
451 589 02 40 00 Retaining¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 541 · Applies to: 450, 451, 452, 454
lock FG 03/Set B WS03.00-P-0108B 451 589 03 63 00 Guide FG 03/Set B WS03.00-P-0106B 454 589 00 40 00 Retaining lock FG 03/Set B WS03.00-P-0084B 454 589 01 40 00 Counterholder FG 03/Set B WS03.00-P-0088B 454 589 02 14 00 Sleeve FG 03/Set B WS03.00-P-0100B 454 589 03 40 00 Counterholder FG 03/Set B WS03.00-P-0085B 454 589 04 15 00 Insertion drift FG 03/Set B WS03.00-P-0093B 454 589 11 09 00 Socket wrench bit FG 03/Set B WS03.00-P-0087B 602 589 00 98 00 Case FG 03/05/18/Set C WS05.00-P-0158C 711 589 13 15 00 Drift FG 03/Set B WS03.00-P-0107B
EMISSION APPLICATIONS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 542 · Applies to: 450, 451, 452, 454
FORTWO Engine & Fuel System Emission Control Systems & Devices 2011
1.0L (61") 3-Cyl. SFI PCV, EVAP, TWC, FR, SPK, HO2S, CEC, MIL ABBREVIATIONS > CEC Computerized Engine Controls EVAP Fuel Evaporative System EVAP-VC EVAP Vapor Canister FR Fill Pipe Restrictor HO2S Heated Oxygen Sensor MIL Malfunction Indicator Light PCV Positive Crankcase Ventilation SFI Sequential Multiport Fuel Injection TWC Three-Way Catalytic Converter
GENERAL INFORMATION > NOTES ON COOLANT - AH20.00-N-2080-01A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 543 · Applies to: 450, 451, 452, 454
All engines Coolant composition Passenger car and commercial vehicle engines (normally): 50% water by volume and 50% anticorrosion/antifreeze agent by volume. Different coolant composition for CV engines, refer to MB Specifications for Operating Fluids. Tasks of anticorrosion/antifreeze agent Corrosion and cavitation protection for all components in cooling system Antifreeze protection (frost protection) Increase the boiling point so that coolant does not evaporate so rapidly. Avoiding ejection of coolant at high coolant temperatures. Antifreeze protection 50% anticorrosion/antifreeze agent by volume provides antifreeze protection down to approx. -37°C. A higher concentration is only necessary if the ambient temperatures are even lower. 55% anticorrosion/antifreeze agent by volume provides antifreeze protection down to approx. -45°C. A concentration of more than 55% anticorrosion/antifreeze agent by volume should not be used as the maximum antifreeze protection is already reached at this concentration. An even higher concentration once reduces antifreeze protection and impairs heat dissipation. Reduced heat dissipation can result in damage to components of the cooling system and to the engine. Water Use water which is clean and not too hard. Drinking water often satisfies requirements, but not always The amount of dissolved substances in the water may be of significance for the occurrence of corrosion. If in doubt, analyze the water. For fresh water specifications refer to MB Specifications for Operating Fluids. Period of use The maximum permissible period of use of the coolant is given in the maintenance booklet, the applicable "Service/Maintenance Sheet" or the MB-Specifications for Operating Fluids. For the period of use for a varying coolant composition for CV engines, refer to MB Specifications for Operating Fluids. Before pouring in fresh coolant, flush the used coolant out of the cooling system. In the case of severe fouling by dirt or oil, clean the cooling system otherwise components of the cooling system can be damaged. Disposing of coolants
Remove maintenance flap¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 545 · Applies to: 450, 451, 452, 454
1 Remove maintenance flap (3)
2 Turn cooling system cap (1) on the engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1)
Check
3 Check corrosion/antifreeze in coolant and enter in the maintenance sheet *450589012100 Coolant specifications Sheet 310.1 BB00.40-P-0310-01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325-00A If necessary:↓Correct the coolant composition - subject to separate repair order.
Replace coolant AP20.00-P- 2080MCU Notes on coolant
AH20.00-N-2080- 01A 4 Check coolant level in the expansion reservoir (2) and correct if necessary The engine coolant level at the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40-P-0310-01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325-00A In the event of a fluid loss not caused by consumption or if the coolant circuit has been opened, the cooling system must be checked for leaks - subject to separate repair order.
Inspecting cooling system for leaks AR20.00-P- 1010MCU Notes on coolant
AH20.00-N-2080- 01A Install
5 Seal expansion reservoir (2) with cap (1)
6 Install maintenance flap (3)
swallowing coolant.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 547 · Applies to: 450, 451, 452, 454
protective gloves, protective clothing and safety glasses. Notes on coolant
AH20.00-N-2080- 01A 1 Remove maintenance flap
2 Turn cooling system cap (1) on the engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1)
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 3 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver http://gotis.aftersales.mercedes- benz.com 4 Loosen hose clamp (4) for coolant hose (3), detach coolant hose (3) at radiator (5) and coolant Catch coolant in a suitable vessel.
5 Disconnect electrical connector on knock sensor and on crankshaft position sensor, lay electrical wiring harness to one side and cover crankshaft position sensor This prevents coolant finding its way into the crankshaft position sensor.
6 Remove coolant drain screw (8) at engine and drain off coolant Catch coolant in a suitable vessel.
Filling
7 Position coolant hose (3) on radiator (5) and fasten hose clamp (4) of coolant hose (3) Replace hose clamp (4).
8 Tighten coolant drain plug (8) on engine Replace seal ring of coolant drain plug (8).
9 Remove cover on crankshaft position sensor, lay electrical wiring harness and contact electrical connector on knock sensor and on crankshaft position sensor
Lower vehicle with lifting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 548 · Applies to: 450, 451, 452, 454
10 Lower vehicle with lifting platform
11 Remove engine compartment cover
Remove/install interior compartment flap above engine AR88.40-P-1100- 03MCC 12 Fill cooling system via the expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40-P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325- 00A 13 Loosen clamp (7) and pull coolant hose (6) off connection fitting on cylinder head, wait until the coolant escapes from the coolant hose (6) and from the connection fitting on the cylinder head
14 Position coolant hose (6) on the cylinder head and fasten clamp (7) Replace hose clamp (7).
15 Correct coolant level in expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40-P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325- 00A 16 Seal expansion reservoir (2) with cap (1)
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z-0005- 01A
scalding from contact with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 550 · Applies to: 450, 451, 452, 454
hot coolant spray. Risk of poisoning caused by swallowing coolant. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. Notes on coolant
AH20.00-N-2080- 01A 1 Remove maintenance flap (3)
2 Turn cooling system cap (1) on the engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1)
3 Check coolant level in expansion reservoir (2), correct if necessary. The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40-P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325- 00A 4 Attach pressure pump on expansion reservoir (2) *450589072100 5 Apply a pressure of a max. of 1.6 bar to the cooling system Observe pressure gauge for pressure pump.
*450589072100 6 Remove interior flap above engine If a pressure drop was established in the cooling system. AR88.40-P-1100- 03MCC Risk of death caused by vehicle slipping or toppling off 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 7 Raise vehicle using the vehicle lift and remove underfloor paneling If a pressure drop was established in the cooling system.Rechargeable drill / screwdriver http://gotis.aftersales.mercedes- benz.com 8 Check all components of cooling system for leaks; establish coolant loss and remove it If a pressure drop was established in the cooling system.
9 Lower vehicle with lifting platform
ENGINES 132.910 in MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 552 · Applies to: 450, 451, 452, 454
Drain
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00-Z-0001- 01A Notes on coolant
AH20.00-N-2080- 01A 1 Remove maintenance flap
2 Turn cooling system cap (1) on engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1)
Risk of death caused by vehicle slipping or toppling off the lifting platform. Align vehicle between columns of vehicle lift and po ition four upport plate AS00.00-Z-0010- 01A Fig 1: Identifying Cap, Expansion Reservoir, Coolant Hose, Hose Clamp, Radiator And Coolant Drain Plug Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
at vehicle lift support points¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 553 · Applies to: 450, 451, 452, 454
specified by vehicle manufacturer. 3 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver gotis://G_58.0_01.1 4 Loosen hose clamp (4) for coolant hose (3), detach coolant hose (3) at radiator (5) and coolant Catch coolant in a suitable vessel.
5 Unscrew coolant drain plug (8) out of the cylinder crankcase and drain coolant Catch coolant in a suitable vessel.
Filling
6 Position coolant hose (3) on radiator (5) and fasten with hose clamp (4) Replace hose clamp (4).
7 Screw coolant drain plug (8) into cylinder crankcase Replace seal ring of coolant drain plug (8).
8 Lower vehicle with vehicle lift
9 Remove interior flap above engine
AR88.40-P-1100- 03MCC 10 Fill cooling system via the expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40-P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325- 00A 11 Loosen clamp (7) and detach coolant hose (6) at coolant line, wait until coolant comes out at the coolant hose (6) and coolant line
12 Position coolant hose (6) on coolant line and fasten with clamp (7) Replace hose clamp (7).
13 Correct coolant level in expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 559 · Applies to: 450, 451, 452, 454
1 Drain coolant
AR20.00- P- 1142MCU 2 Release rear drive module
AR01.00- P- 3050MCU 3 Remove fender liner in right rear fender
AR88.10- P- 1400MCU 4 Remove poly-V belt
AR13.22- P- 1202MCU 5 Remove intake manifold (2)
AR09.20- P- 1310MCU 6 Unscrew nut (3) on alternator (G2) and remove charge current line (4) BA15.40- P-1002- 01G 7 Remove bolt (5) on alternator (G2) on timing case cover BA15.40- P-1008- 01G 8 Loosen bolt (6) and swivel alternator (G2) upwards BA15.40- P-1008- 01G 9 Remove bolts (7) and lay coolant line (8) with attached coolant hoses to one side BA20.10- P-1011- 01J *BA20.10- P-1012- 01J 10 Remove bolt (9) on holder (10) on the oil pan
11 Remove bolts (11) and pass coolant thermostat (1) under the coolant line (8) Catch coolant in a suitable vessel.
*BA20.10- P-1008- 01J 12 Loosen clamps (12) and detach coolant hoses (13) from coolant thermostat (1) Note installation locations for coolant hoses (13). Installation: Replace clamps (12).
13 Remove holder (10) on coolant thermostat (1) When replacing coolant thermostat (1).
14 Install in the reverse order
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 564 · Applies to: 450, 451, 452, 454
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00- Z-0001- 01A Notes on coolant
AH20.00- N-2080- 01A 1 Remove front module
AR62.30- P- 1575MCU 2 Turn cooling system cap (2) on engine radiator (1) a half turn counterclockwise, relieve pressure and then unscrew the cooling system cap (2)
3 Suction off coolant in expansion reservoir (1)
4 Clamp off coolant hoses (5, 6) using suitable hose clamps
5 Loosen click clamps (3) on coolant hoses (4, 5, 6 and 8) On engine 780.009 only the click clamps (3) of coolant hoses (5, 6 and 8) should be loosened Installation: Replace snap clamps (3).
Fig 2: Identifying Expansion Reservoir Components (With Engine 780) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Wear protective gloves, protective clothing and eye protection. Do not pour coolant into beverage bottles.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 567 · Applies to: 450, 451, 452, 454 · AR: AS20.00-Z-9999ZZ, BA20.00-Z-9999CZ
First aid measures Rinse affected skin with large quantities of cold water and cover with sterile bandages. Allow the person affected to drink plenty of water with the addition of medicinal charcoal. If the person has suffered severe burns or has swallowed coolant, contact a doctor. SAFETY PRECAUTIONS > SAFETY INFORMATION: ENGINE COOLING SYSTEM - AS20.00-Z-9999ZZ > MODEL all Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. ENGINE all AS20.00-Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: ENGINE COOLING SYSTEM - BA20.00-Z-9999CZ > MODEL all Coolant pump, coolant thermostat ENGINE 122.9 BA20.10-P-1000-01T Coolant pump, coolant thermostat ENGINE 639.939 BA20.10-P-1000-01R Coolant pump, coolant thermostat ENGINE 134.910 /911, 135.930 /950, 780.009 BA20.10-P-1000-01N Coolant pump, coolant thermostat ENGINE 660.940 /950 /951 BA20.10-P-1000-01K Coolant pump, coolant thermostat ENGINE 132.9, 160.910 /920 /921 /922 /923 BA20.10-P-1000-01J Radiator, coolant hoses ENGINE 160.910 /920 /921 /922 /923 BA20.20-P-1000-01J TORQUE SPECIFICATIONS > COOLANT PUMP, COOLANT THERMOSTAT - BA20.10-P- 1000-01J > Engine 132, 160 MODIFICATION NOTES 3.11.04 Tightening torque for banjo bolt for cooling water connection to major assembly carrier altered from 14 to 19 Nm Value for engine 160.910/920/921/922 altered Tightening torque for thermostat housing bolt to cylinder head altered from 14 Nm to 12 Nm Value modified for engine 160.920/921/922 COOLANT PUMP, COOLANT THERMOSTAT
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 568 · Applies to: 450, 451, 452, 454
Designation Engine 132.9 Engine 160.910 Engine 160.920 BA20.10-P- 1001-01J Belt pulley to coolant pump Nm 10 10 10 BA20.10-P- 1002-01J Bolt, coolant pump to major assembly carrier Nm - 9,5 9,5 BA20.10-P- 1003-01J Bolt, major assembly carrier to crankcase Nm - 20 20 BA20.10-P- 1004-01J Banjo bolt, coolant connection to major assembly carrier Nm - 19 19 BA20.10-P- 1005-01J Bolt, thermostat housing to cylinder head Initial torque Nm - 12 12 Continued torque Nm - 9.5 9.5 BA20.10-P- 1006-01J Bolt, water supply connection fitting to major assembly carrier Initial torque Nm - 14 14 Continued torque Nm - 9.5 9.5 BA20.10-P- 1007-01J Bolt, coolant pump to timing case cover M6 Nm 10 - - M8 Nm 23 - - BA20.10-P- 1008-01J Bolt, thermostat housing to crankcase Nm 10 - - BA20.10-P- 1009-01J Bolt, coolant pipe to crankcase Nm 10 - - BA20.10-P- 1010-01J Bolt, coolant pipe to oil pan Nm 10 - - BA20.10-P- 1011-01J Bolt connecting coolant line to cylinder head Nm 24 - - BA20.10-P- 1012-01J Bolt, coolant line to crankcase Nm 24 - - COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 160.921 Engine 160.922 Engine 160.923 BA20.10-P- 1001-01J Belt pulley to coolant pump Nm 10 10 10 BA20.10-P- 1002-01J Bolt, coolant pump to major assembly carrier Nm 9.5 9.5 9.5 BA20.10-P- 1003-01J Bolt, major assembly carrier to crankcase Nm 20 20 20 BA20.10-P- 1004-01J Banjo bolt, coolant connection to major assembly carrier Nm 19 19 19 BA20.10-P- Bolt, thermostat Initial torque Nm 12 12 12
1004-01A¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 570 · Applies to: 450, 451, 452, 454
relief valve opens 1 overpressure Coolant temp. - ≥130/134 - Stage 2 bar overpressure - 2.0 (1) - Coolant temp. - ≥137/143 - BE20.30-P- 1005-01A Test pressure for pressure-testing cooling system bar overpressure 1.4 1.4 - CAP FOR RADIATOR OR EXPANSION RESERVOIR Number Designation 2-stage cap for engine 113.968 in model 209 2-stage closing cover on model 211 Engines 160.921 / 923 in model 452.3/4 BE20.30-P- 1001-01A Cap code number 140/200 - 160 BE20.30-P- 1002-01A Pressure relief valve opens New bar overpressure - 1.5 (-0.2) 1.6 Used bar overpressure - 1.5 (-0.2) - BE20.30-P- 1003-01A Vacuum valve opens (reference value) bar vacuum 0.1 0.1 0.1 BE20.30-P- 1004-01A Pressure relief valve opens Stage 1 bar overpressure 1.4 (1) 1.5 (-0.2) - Coolant temp. ≥130/134 135 (+5) - Stage 2 bar overpressure 2.0 (1) 1.5 (-0.2) - Coolant temp. ≥137/143 145 (+5) - BE20.30-P- 1005-01A Test pressure for pressure-testing cooling system bar overpressure 1.4 1.4 1.6 CAP FOR RADIATOR OR EXPANSION RESERVOIR Number Designation Engine 160.922 in model 452.3/4 Engine 160.910 in model 450.3/4 Engine 160.920 in model 450.3/4 BE20.30-P- 1001-01A Cap code number 160 160 160 BE20.30-P- 1002-01A Pressure relief valve opens New bar overpressure 1.6 1.6 1.6
ENGINE 132.9 in MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 572 · Applies to: 450, 451, 452, 454
General Components of the engine suffer high thermal loading from the combustion taking place in the engine. Apart from actually leading away excess heat a cooling system must also fulfill the following tasks: Rapid reaching of the engine operating temperature Holding the engine operating temperature as constant as possible under all driving conditions Protecting engine lubricants from overheating Protecting fresh air from excessive warming in order to allow high efficiency of the engine Lowering the temperature in the combustion chamber in order to avoid uncontrolled self ignition Function The engine cooling is subdivided into a small and a large coolant circuit. For a cold engine the coolant flows via the small coolant circuit from the coolant pump through the engine to the thermostat and back to the coolant pump. If the engine has reached its operating temperature, the thermostat opens the large coolant circuit. This subdivides immediately after the thermostat into the cooling circuit and the heating circuit. In the cooling circuit, the coolant flows via the coolant feed pipe for the cooling circuit to the radiator and from there via the coolant return line back to the coolant pump. In the heating circuit the coolant flows via the coolant feed pipe for the heating circuit to the heater heat Fig 1: Engine Cooling Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 575 · Applies to: 450, 451, 452, 454
The coolant fan motor is located at the rear of the radiator. Task The coolant fan motor actuated by the SAM control unit (N10/10) generates a suctioned air flow behind the cooler. In this way the temperature of the coolant passing through the radiator is lowered. SPECIAL TOOLS > 450 589 06 37 00 PLIERS - WS20.00-P-0040B > FG 20/Set B MODEL 450, 451, 452, 451 Use: Pliers for assembling click clamps. NOTE: Pliers for click clampsSmart No. 0005082 Fig 1: Locating Coolant Fan Motor Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Pliers (450 589 06 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 07 37 00 PLIERS - WS20.00-P-0041B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 576 · Applies to: 450, 451, 452, 454
FG 20/Set B MODEL 450, 451, 452, 451 Use: Pliers for assembly of click clamps at points which are not easily accessible. NOTE: Pliers for click clamps (slanted)Smart No. 0005083 SPECIAL TOOLS > 450 589 01 21 00 ANTIFREEZE SPINDLE - WS20.00-P-0042A > FG 20/Set A MODEL 450, 451, 452, 454 Use: Antifreeze spindle for determining the antifreeze content in the coolant. NOTE: Antifreeze spindle, smart no.: 000 5095 V001 0000 00 Fig 1: Identifying Pliers (450 589 07 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 11 37 00 PLIERS - WS20.00-P-0043B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 577 · Applies to: 450, 451, 452, 454
FG 20/Set B MODEL 450, 452 MODEL 451 with ENGINE 132 Use: Cutting pliers for plastic lines at tank. NOTE: Cutting pliersSmart No.: 0014667 SPECIAL TOOLS > 451 589 01 31 00 MOUNTING FIXTURE - WS20.00-P-0060C > FG 20/Set C Fig 1: Identifying Antifreeze Spindle (450 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Pliers (450 589 11 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 578 · Applies to: 450, 451, 452, 454
Use: Mounting for fixing radiator for a removed front mask. NOTE: Two pieces are required. SPECIAL TOOLS > 451 589 02 31 00 ADAPTER - WS20.00-P-0061B > FG 20/Set B MODEL 451 Use: Adaptation for assembly of clamps on heat exchanger and cooler. NOTE: Only in combination with W003 589 03 37 00 hose clamp pliers. Fig 1: Identifying Mounting Fixture (451 589 01 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: ENGINE COOLING SYSTEM - WS20.00-Z-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 579 · Applies to: 450, 451, 452, 454
9999CZ > MODEL all 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 450 589 01 21 00 Antifreeze spindle FG 20/Set A WS20.00-P- 0042A 450 589 03 11 00 Screwdriver FG 20/Set B WS20.00-P-0038B 450 589 06 37 00 Pliers FG 20/Set B WS20.00-P- 0040B 450 589 07 21 00 Pressure pump FG 01/09/20/Set B WS01.00-P-0074B 450 589 07 21 07 Adapter FG 01/20/54/Set B WS01.00-P-0074- 07B 450 589 07 37 00 Pliers FG 20/Set B WS20.00-P- 0041B 450 589 11 37 00 Pliers FG 20/Set B WS20.00-P- 0043B 450 589 13 37 00 Pliers for click clamps FG 20/Set B WS20.00-P-0054B 450 589 20 63 00 Filling device FG 20/Set A WS20.00-P-0037A 451 589 01 31 00 Mounting fixture FG 20/Set C WS20.00-P- 0060C 451 589 02 31 00 Adapter FG 20/Set B WS20.00-P- Fig 1: Identifying Adapter (451 589 02 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
0061B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 580 · Applies to: 450, 451, 452, 454
454 589 00 37 00 Hose clamp pliers FG 20/Set B WS20.00-P-0052B 454 589 00 91 00 Adapter FG 20/Set B WS20.00-P-0050B
GENERAL INFORMATION > NOTES ON COOLANT - AH20.00-N-2080-01A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 581 · Applies to: 450, 451, 452, 454
All engines Coolant composition Passenger car and commercial vehicle engines (normally): 50% water by volume and 50% anticorrosion/antifreeze agent by volume. Different coolant composition for CV engines, refer to MB Specifications for Operating Fluids . Tasks of anticorrosion/antifreeze agent Corrosion and cavitation protection for all components in cooling system Antifreeze protection (frost protection) Increase the boiling point so that coolant does not evaporate so rapidly. Avoiding ejection of coolant at high coolant temperatures. Antifreeze protection 50% anticorrosion/antifreeze agent by volume provides antifreeze protection down to approx. -37°C. A higher concentration is only necessary if the ambient temperatures are even lower. 55% anticorrosion/antifreeze agent by volume provides antifreeze protection down to approx. -45°C . A concentration of more than 55% anticorrosion/antifreeze agent by volume should not be used as the maximum antifreeze protection is already reached at this concentration. An even higher concentration once reduces antifreeze protection and impairs heat dissipation. Reduced heat dissipation can result in damage to components of the cooling system and to the engine. Water Use water which is clean and not too hard. Drinking water often satisfies requirements, but not always The amount of dissolved substances in the water may be of significance for the occurrence of corrosion. If in doubt, analyze the water. For fresh water specifications refer to MB Specifications for Operating Fluids. Period of use The maximum permissible period of use of the coolant is given in the maintenance booklet, the applicable "Service/Maintenance Sheet" or the MB-Specifications for Operating Fluids. For the period of use for a varying coolant composition for CV engines, refer to MB Specifications for Operating Fluids. Before pouring in fresh coolant, flush the used coolant out of the cooling system. In the case of severe fouling by dirt or oil, clean the cooling system otherwise components of the cooling system can be damaged. Disposing of coolants Observe the legal provisions and local waste water regulations. The following brochures are available about
on the engine radiator (2) a¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 583 · Applies to: 450, 451, 452, 454
2 on the engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1)
Check
3 Check corrosion/antifreeze in coolant and enter in the maintenance sheet Fig 2 Coolant specifications Sheet 310.1 BB00.40- P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40- P-0325- 00A If necessary:↓Correct the coolant composition - subject to separate repair order.
Replace coolant AP20.00- P- 2080MCU Notes on coolant
AH20.00- N-2080- 01A 4 Check coolant level in the expansion reservoir (2) and correct if necessary The engine coolant level at the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40- P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40- P-0325- 00A In the event of a fluid loss not caused by consumption or if the coolant circuit has been opened, the cooling system must be checked for leaks - subject to separate repair order.
Inspecting cooling system for leaks AR20.00- P- 1010MCU Notes on coolant
AH20.00- N-2080- 01A Install
caused by scalding from contact¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 585 · Applies to: 450, 451, 452, 454
with hot coolant spray. Risk of poisoning caused by swallowing coolant. coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00- Z 0001 01A Notes on coolant
AH20.00- N-2080- 01A 1 Remove maintenance flap
2 Turn cooling system cap (1) on the engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1)
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 3 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver 4 Loosen hose clamp (4) for coolant hose (3), detach coolant hose (3) at radiator (5) and coolant Catch coolant in a suitable vessel.
5 Disconnect electrical connector on knock sensor and on crankshaft position sensor, lay electrical wiring harness to one side and cover crankshaft position sensor This prevents coolant finding its way into the crankshaft position sensor.
6 Remove coolant drain screw (8) at engine and drain off coolant Catch coolant in a suitable vessel.
Filling
7 Position coolant hose (3) on radiator (5) and fasten hose clamp (4) of coolant hose (3) Replace hose clamp (4).
8 Tighten coolant drain plug (8) on engine Replace seal ring of coolant drain plug (8).
9 Remove cover on crankshaft position sensor, lay electrical wiring harness and contact electrical connector on knock sensor and on crankshaft position sensor
10 Lower vehicle with lifting platform
11 Remove engine compartment cover
Remove/install interior¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 586 · Applies to: 450, 451, 452, 454
compartment flap above engine
AR88.40- P-1100- 03MCC 12 Fill cooling system via the expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40- P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40- P-0325- 00A 13 Loosen clamp (7) and pull coolant hose (6) off connection fitting on cylinder head, wait until the coolant escapes from the coolant hose (6) and from the connection fitting on the cylinder head
14 Position coolant hose (6) on the cylinder head and fasten clamp (7) Replace hose clamp (7).
15 Correct coolant level in expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40- P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40- P-0325- 00A 16 Seal expansion reservoir (2) with cap (1)
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 17 Run engine until warm Until the coolant fan motor cuts in. 18 Check coolant level in the expansion reservoir (2) and correct if necessary
AP20.00- P- 2010MCU 19 Inspecting cooling system for leaks
Inspecting cooling system for leaks AR20.00- P- 1010MCU
Raise vehicle with vehicle lift¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 587 · Applies to: 450, 451, 452, 454
20 Raise vehicle with vehicle lift
21 Install underfloor paneling
22 Lower vehicle with lifting platform
23 Install engine compartment cover
Remove/install interior compartment flap above engine AR88.40- P-1100- 03MCC 24 Install maintenance flap
TESTING & REPAIR INDEX > INSPECT COOLING SYSTEM FOR LEAKS - AR20.00-P- 1010MCU > ENGINE 132.910 in MODEL 451.3 /4 Checking
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00- Z-0001- 01A Notes on coolant
AH20.00- N-2080- 01A 1 Remove maintenance flap (3)
Turn cooling system cap (1) on the engine radiator (2) a half turn counterclockwise, Fig 1: Identifying Cap, Expansion Reservoir And Maintenance Flap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
relieve the pressure and then¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 588 · Applies to: 450, 451, 452, 454
2 relieve the pressure and then unscrew the cooling system cap (1)
3 Check coolant level in expansion reservoir (2), correct if necessary. The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40- P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40- P-0325- 00A 4 Attach pressure pump on expansion reservoir (2) Fig 2 5 Apply a pressure of a max. of 1.6 bar to the cooling system Observe pressure gauge for pressure pump.
Fig 2 6 Remove interior flap above engine If a pressure drop was established in the cooling system. AR88.40- P-1100- 03MCC Risk of death caused by vehicle slipping or toppling off 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 7 Raise vehicle using the vehicle lift and remove underfloor paneling If a pressure drop was established in the cooling system.Rechargeable drill / screwdriver 8 Check all components of cooling system for leaks; establish coolant loss and remove it If a pressure drop was established in the cooling system.
9 Lower vehicle with lifting platform
10 Disconnect pressure pump on expansion reservoir (2) and check coolant level in expansion reservoir (2); correct if necessary After removing the leakage in the cooling system. The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Fig 2 Coolant specifications Sheet 310.1 BB00.40- P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40- P-0325- 00A
Drain¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 590 · Applies to: 450, 451, 452, 454
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00- Z-0001- 01A Notes on coolant
AH20.00- N-2080- 01A 1 Remove maintenance flap
2 Turn cooling system cap (1) on engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1)
Risk of death caused by vehicle slipping or toppling off 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 Raise vehicle using the vehicle lift Fig 1: Identifying Cap, Expansion Reservoir, Coolant Hose, Hose Clamp, Radiator And Coolant Drain Plug Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
and remove underfloor paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 591 · Applies to: 450, 451, 452, 454
3 and remove underfloor paneling Rechargeable drill / crewdriver 4 Loosen hose clamp (4) for coolant hose (3), detach coolant hose (3) at radiator (5) and coolant Catch coolant in a suitable vessel.
5 Unscrew coolant drain plug (8) out of the cylinder crankcase and drain coolant Catch coolant in a suitable vessel.
Filling
6 Position coolant hose (3) on radiator (5) and fasten with hose clamp (4) Replace hose clamp (4).
7 Screw coolant drain plug (8) into cylinder crankcase Replace seal ring of coolant drain plug (8).
8 Lower vehicle with vehicle lift
9 Remove interior flap above engine
AR88.40- P-1100- 03MCC 10 Fill cooling system via the expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40- P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40- P-0325- 00A 11 Loosen clamp (7) and detach coolant hose (6) at coolant line, wait until coolant comes out at the coolant hose (6) and coolant line
12 Position coolant hose (6) on coolant line and fasten with clamp (7) Replace hose clamp (7).
13 Correct coolant level in expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.
Coolant specifications Sheet 310.1 BB00.40- P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40- P-0325- 00A 14 Seal expansion reservoir (2) with cap (1)
COOLANT PUMP, COOLANT THERMOSTAT¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 596 · Applies to: 450, 451, 452, 454
Number Designation Engine 132.9 BA20.10-P-1001-01J Belt pulley on coolant pump Nm 10 TESTING & REPAIR INDEX > REMOVE/INSTALL COOLANT THERMOSTAT - AR20.10-P- 2460MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 2: Identifying Counterholder (451 589 00 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Coolant Thermostat Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 597 · Applies to: 450, 451, 452, 454
1 Drain coolant
AR20.00- P- 1142MCU 2 Release rear drive module
AR01.00- P- 3050MCU 3 Remove fender liner in right rear fender
AR88.10- P- 1400MCU 4 Remove poly-V belt
AR13.22- P- 1202MCU 5 Remove intake manifold (2)
AR09.20- P- 1310MCU 6 Unscrew nut (3) on alternator (G2) and remove charge current line (4) BA15.40- P-1002- 01G 7 Remove bolt (5) on alternator (G2) on timing case cover BA15.40- P-1008- 01G 8 Loosen bolt (6) and swivel alternator (G2) upwards BA15.40- P-1008- 01G 9 Remove bolts (7) and lay coolant line (8) with attached coolant hoses to one side BA20.10- P-1011- 01J *BA20.10- P-1012- 01J 10 Remove bolt (9) on holder (10) on the oil pan
11 Remove bolts (11) and pass coolant thermostat (1) under the coolant line (8) Catch coolant in a suitable vessel.
*BA20.10- P-1008- 01J 12 Loosen clamps (12) and detach coolant hoses (13) from coolant thermostat (1) Note installation locations for coolant hoses (13). Installation: Replace clamps (12).
13 Remove holder (10) on coolant thermostat (1) When replacing coolant thermostat (1).
14 Install in the reverse order
Remove coolant pipe (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 601 · Applies to: 450, 451, 452, 454
9 Remove coolant pipe (1)
10 Install in the reverse order
COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1009-01J Bolt, coolant pipe at crankcase Nm 10 BA20.10-P-1010-01J Bolt, coolant pipe to oil pan Nm 10 TESTING & REPAIR INDEX > REMOVE/INSTALL EXPANSION RESERVOIR - AR20.30-P- 4950MCU > ENGINES 132.910 in MODEL 451.3 /4 ENGINES 780.009 in MODEL 451.391 /491 Shown on vehicle with engine 132 Vehicles with engine 780 Fig 1: Identifying Expansion Reservoir Components (Shown On Vehicle With Engine 132) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 602 · Applies to: 450, 451, 452, 454
Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00- Z-0001- 01A Notes on coolant
AH20.00- N-2080- 01A 1 Remove front module
AR62.30- P- 1575MCU 2 Turn cooling system cap (2) on engine radiator (1) a half turn counterclockwise, relieve pressure and then unscrew the cooling system cap (2)
3 Suction off coolant in expansion reservoir (1)
4 Clamp off coolant hoses (5, 6) using suitable hose clamps
5 Loosen click clamps (3) on coolant hoses (4, 5, 6 and 8) On engine 780.009 only the click clamps (3) of coolant hoses (5, 6 and 8) should be loosened Installation: Replace snap clamps (3).
Fig 2: Identifying Expansion Reservoir Components (Vehicle With Engine 780) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove radiator (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 604 · Applies to: 450, 451, 452, 454
1 Remove radiator (2)
AR20.20-P- 3865MCU 2 Disconnect electrical connector (3) at coolant fan motor (M4/2)
3 Unclip retaining clip (4, 5) for electrical line (6) to fan shroud (1) and lay electrical line (6) to one side
4 Remove mounts (7) from fan shroud (1) Fig 2 5 Take off fan shroud (1)
6 Install in the reverse order
SAFETY PRECAUTIONS > RISK OF INJURY TO SKIN AND EYES SUFFERING SCALDING FROM CONTACT WITH HOT COOLANT SPRAY. RISK OF POISONING FROM SWALLOWING COOLANT. - AS20.00-Z-0001-01A > Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection. Possible hazards Risk of injury When the engine is warm, the cooling system is pressurized. If the cooling system is opened suddenly, there is a risk of scalding from hot coolant which splashes out. Danger of poisoning If coolant is swallowed, this can result in manifestations of poisoning such as headaches, dizziness, stomach pain, respiratory paralysis, unconsciousness, vomiting and cramps. Safety precautions/instructions Allow cooling system to cool down to a coolant temperature of less than 90 °C. Open cap of cooling system slowly; turn a conventional coolant cap as far as the first detent and turn a screwed coolant cap approx. 1/2 turn and release the pressure. Wear protective gloves, protective clothing and eye protection. Fig 2: Identifying Mount (451 589 01 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Do not pour coolant into beverage bottles.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 605 · Applies to: 450, 451, 452, 454 · AR: AS20.00-Z-9999ZZ, BA20.00-Z-9999CZ
First aid measures Rinse affected skin with large quantities of cold water and cover with sterile bandages. Allow the person affected to drink plenty of water with the addition of medicinal charcoal. If the person has suffered severe burns or has swallowed coolant, contact a doctor. SAFETY PRECAUTIONS > SAFETY INFORMATION: ENGINE COOLING SYSTEM - AS20.00-Z-9999ZZ > MODEL all Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant. ENGINE all AS20.00- Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: ENGINE COOLING SYSTEM - BA20.00-Z-9999CZ > MODEL all Coolant pump, coolant thermostat ENGINE 122.9 BA20.10-P-1000-01T Coolant pump, coolant thermostat ENGINE 639.939 BA20.10-P-1000-01R Coolant pump, coolant thermostat ENGINE 134.910 /911, 135.930 /950, 780.009 BA20.10-P-1000-01N Coolant pump, coolant thermostat ENGINE 660.940 /950 /951 BA20.10-P-1000-01K Coolant pump, coolant thermostat ENGINE 132.9, 160.910 /920 /921 /922 /923 BA20.10-P-1000-01J Radiator, coolant hoses ENGINE 160.910 /920 /921 /922 /923 BA20.20-P-1000-01J TORQUE SPECIFICATIONS > COOLANT PUMP, COOLANT THERMOSTAT - BA20.10-P- 1000-01J > Engine 132, 160 MODIFICATION NOTES 3.11.04 Tightening torque for banjo bolt for cooling water connection to major assembly carrier altered from 14 to 19 Nm Value for engine 160.910/920/921/922 altered Tightening torque for thermostat housing bolt to Value modified for engine 160.920/921/922
cylinder head altered from 14¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 606 · Applies to: 450, 451, 452, 454
Nm to 12 Nm COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 Engine 160.910 Engine 160.920 BA20.10-P- 1001-01J Belt pulley to coolant pump Nm 10 10 10 BA20.10-P- 1002-01J Bolt, coolant pump to major assembly carrier Nm - 9,5 9,5 BA20.10-P- 1003-01J Bolt, major assembly carrier to crankcase Nm - 20 20 BA20.10-P- 1004-01J Banjo bolt, coolant connection to major assembly carrier Nm - 19 19 BA20.10-P- 1005-01J Bolt, thermostat housing to cylinder head Initial torque Nm - 12 12 Continued torque Nm - 9.5 9.5 BA20.10-P- 1006-01J Bolt, water supply connection fitting to major assembly carrier Initial torque Nm - 14 14 Continued torque Nm - 9.5 9.5 BA20.10-P- 1007-01J Bolt, coolant pump to timing case cover M6 Nm 10 - - M8 Nm 23 - - BA20.10-P- 1008-01J Bolt, thermostat housing to crankcase Nm 10 - - BA20.10-P- 1009-01J Bolt, coolant pipe to crankcase Nm 10 - - BA20.10-P- 1010-01J Bolt, coolant pipe to oil pan Nm 10 - - BA20.10-P- 1011-01J Bolt connecting coolant line to cylinder head Nm 24 - - BA20.10-P- 1012-01J Bolt, coolant line to crankcase Nm 24 - - COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 160.921 Engine 160.922 Engine 160.923 BA20.10- P-1001- 01J Belt pulley to coolant pump Nm 10 10 10
All engines¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 608 · Applies to: 450, 451, 452, 454
CAP OF RADIATOR OR EXPANSION RESERVOIR Number Designation Cap 2-stage cap 1-stage cap on model 163 BE20.30-P- 1001-01A Cap code number 140 140/200 - BE20.30-P- 1002-01A Pressure relief valve opens New bar overpressure 1.4 (+0.1) - 1.4 (+0.1) Used bar overpressure 1.4 (-0.1) - 1.4 (+0.1) BE20.30-P- 1003-01A Vacuum valve opens (reference value) bar vacuum 0.1 0.1 0.5 BE20.30-P- 1004-01A Pressure relief valve opens Stage 1 bar overpressure - 1.4 (1) - Coolant temp. - ≥130/134 - Stage 2 bar overpressure - 2.0 (1) - Coolant temp. - ≥137/143 - BE20.30-P- 1005-01A Test pressure for pressure- testing cooling system bar overpressure 1.4 1.4 - CAP FOR RADIATOR OR EXPANSION RESERVOIR Number Designation 2-stage cap for engine 113.968 in model 209 2-stage closing cover on model 211 Engines 160.921 / 923 in model 452.3/4 BE20.30- P-1001- 01A Cap code number 140/200 - 160 BE20.30- P-1002- 01A Pressure relief valve opens New bar overpressure - 1.5 (-0.2) 1.6 Used bar overpressure - 1.5 (-0.2) - BE20.30- P-1003- 01A Vacuum valve opens (reference value) bar vacuum 0.1 0.1 0.1 Stage 1 bar overpressure 1.4 (1) 1.5 (-0.2) -
BE20.30-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 609 · Applies to: 450, 451, 452, 454
P-1004- 01A Pressure relief valve opens Coolant temp. ≥130/134 135 (+5) - Stage 2 bar overpressure 2.0 (1) 1.5 (-0.2) - Coolant temp. ≥137/143 145 (+5) - BE20.30- P-1005- 01A Test pressure for pressure-testing cooling system bar overpressure 1.4 1.4 1.6 CAP FOR RADIATOR OR EXPANSION RESERVOIR Number Designation Engine 160.922 in model 452.3/4 Engine 160.910 in model 450.3/4 Engine 160.920 in model 450.3/4 BE20.30- P-1001- 01A Cap code number 160 160 160 BE20.30- P-1002- 01A Pressure relief valve opens New bar overpressure 1.6 1.6 1.6 Used bar overpressure - - - BE20.30- P-1003- 01A Vacuum valve opens (reference value) bar vacuum 0.1 0.1 0.1 BE20.30- P-1004- 01A Pressure relief valve opens Stage 1 bar overpressure - - - Coolant temp. - - - Stage 2 bar overpressure - - - Coolant temp. - - - BE20.30- P-1005- 01A Test pressure for pressure-testing cooling system bar overpressure 1.6 1.6 1.6 CAPACITIES & SPECIFICATIONS > MIXTURE RATIO FOR COOLANT - BF20.00-P-1000- 04A > Engine all MIXTURE RATIO FOR COOLANT Number Designation Engine all
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 612 · Applies to: 450, 451, 452, 454
The thermostat is located in the direction of travel on the right on the engine block. Task The thermostat separates the large from the small coolant circuit for a cold engine. This ensures that the engine reaches its operating temperature quicker. As the coolant temperature increases the thermostat opens and coolant also flows through the large coolant circuit. Fig 1: Identifying Thermostat (Shown On Engine 132.930) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Thermostat Operation Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 614 · Applies to: 450, 451, 452, 454
Pliers for assembling click clamps. NOTE: Pliers for click clampsSmart No. 0005082 SPECIAL TOOLS > 450 589 07 37 00 PLIERS - WS20.00-P-0041B > FG 20/Set B MODEL 450, 451, 452, 451 Use: Pliers for assembly of click clamps at points which are not easily accessible. NOTE: Pliers for click clamps (slanted)Smart No. 0005083 Fig 1: Identifying Pliers (450 589 06 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 01 21 00 ANTIFREEZE SPINDLE - WS20.00-P-0042A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 615 · Applies to: 450, 451, 452, 454
FG 20/Set A MODEL 450, 451, 452, 454 Use: Antifreeze spindle for determining the antifreeze content in the coolant. NOTE: Antifreeze spindle, smart no.: 000 5095 V001 0000 00 SPECIAL TOOLS > 450 589 11 37 00 PLIERS - WS20.00-P-0043B > FG 20/Set B MODEL 450, 452 Fig 1: Identifying Pliers (450 589 07 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Antifreeze Spindle (450 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451 with ENGINE 132¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 616 · Applies to: 450, 451, 452, 454
Use: Cutting pliers for plastic lines at tank. NOTE: Cutting pliersSmart No.: 0014667 SPECIAL TOOLS > 451 589 01 31 00 MOUNTING FIXTURE - WS20.00-P-0060C > FG 20/Set C MODEL 451 Use: Mounting for fixing radiator for a removed front mask. NOTE: Two pieces are required. Fig 1: Identifying Pliers (450 589 11 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 02 31 00 ADAPTER - WS20.00-P-0061B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 617 · Applies to: 450, 451, 452, 454
FG 20/Set B MODEL 451 Use: Adaptation for assembly of clamps on heat exchanger and cooler. NOTE: Only in combination with W003 589 03 37 00 hose clamp pliers. SPECIAL TOOLS > SPECIAL TOOLS: SMART: ENGINE COOLING SYSTEM - WS20.00-Z- 9999CZ > MODEL all Fig 1: Identifying Mounting Fixture (451 589 01 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Adapter (451 589 02 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
000 589 45 33 00 Puller¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 618 · Applies to: 450, 451, 452, 454
FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 450 589 01 21 00 Antifreeze spindle FG 20/Set A WS20.00-P-0042A 450 589 03 11 00 Screwdriver FG 20/Set B WS20.00-P-0038B 450 589 06 37 00 Pliers FG 20/Set B WS20.00-P-0040B 450 589 07 21 00 Pressure pump FG 01/09/20/Set B WS01.00-P-0074B 450 589 07 21 07 Adapter FG 01/20/54/Set B WS01.00-P-0074-07B 450 589 07 37 00 Pliers FG 20/Set B WS20.00-P-0041B 450 589 11 37 00 Pliers FG 20/Set B WS20.00-P-0043B 450 589 13 37 00 Pliers for click clamps FG 20/Set B WS20.00-P-0054B 450 589 20 63 00 Filling device FG 20/Set A WS20.00-P-0037A 451 589 01 31 00 Mounting fixture FG 20/Set C WS20.00-P-0060C 451 589 02 31 00 Adapter FG 20/Set B WS20.00-P-0061B 454 589 00 37 00 Hose clamp pliers FG 20/Set B WS20.00-P-0052B 454 589 00 91 00 Adapter FG 20/Set B WS20.00-P-0050B
and remove eal ring on the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 620 · Applies to: 450, 451, 452, 454
oil drain screw (2) uitable container 5 Remove filter screen on the oil drain screw (2) and clean
6 Unscrew oil filter (1) *454589060900 Install
7 Tighten oil filter (1) Replace oil filter (1).Wet sealing ring of oil filter (1) with engine oil.
*BA18.20-P-1002-01N
*454589060900 8 Position new seal ring on the oil drain screw (2)
9 Insert filter screen on the oil drain screw (2) and tighten oil drain screw (2) *BA01.45-P-1003-01J 10 Lower vehicle with vehicle lift
11 Pour in engine oil *BF18.00-P-1001-01N 12 Tighten oil filler neck cap (3)
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z-0005-01A 13 Conduct engine test run and check engine for leaks while it is running
14 Check engine oil level by means of oil dipstick The fill level must be between "Min." and "Max." otherwise the engine may be damaged. Let engine run for approx. 1 minute, then switch off and wait appro 5 minute Recheck fill level and correct if necessary.
15 Install engine compartment cover
Remove/install interior compartment flap above engine
AR88.40-P-1100- 03MCC
1250MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 622 · Applies to: 450, 451, 452, 454 · AR: BA18.00-Z-9999CZ
Measure oil consumption ENGINE 122, 132, 134, 135, 160, 639, 660... AR18.00-P- 0025MCC Remove/install oil pressure switch ENGINE 132.9 in MODEL 451.3/4 AR18.40-P- 4132MCC Remove/install oil pressure switch ENGINE 132.910 in MODEL 451.3/4 AR18.40-P- 4132MCU TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - BA18.00-Z-9999CZ > MODEL all Oil filter ENGINE 122.950, 132.9, 134.910 /911,135.930 /950 BA18.20-P-1000-01N Oil filter ENGINE 660.940 BA18.20-P-1000-01K Oil filter ENGINE 160.910 /920 /921 /922 /923 BA18.20-P-1000-01J Oil filter ENGINE 639.939 BA18.20-P-1000-01S Oil level/oil pressure sensor ENGINE 660.940 /950 /951 BA18.40-P-1000-01H Oil level/oil pressure sensor ENGINE 132.9, 160.910 /920 /921 /922 /923 BA18.40-P-1000-01G Oil level/oil pressure sensor ENGINE 122.950, 134.910 /911, 135.930/950, 639.939 BA18.40-P-1000-01K Oil pump ENGINE 132.9, 160.910 /920 /921 /922 /923 BA18.10-P-1000-01G Oil pump ENGINE 639.939, 122.9 in MODEL 454.0 BA18.10-P-1000-01L Oil pump ENGINE 660.940 /950 /951 BA18.10-P-1000-01H Oil/water heat exchanger ENGINE 639.939, 660.950 /951 BA18.30-P-1000-02B Oil/water heat exchanger ENGINE 122.9 BA18.30-P-1000-02C TORQUE SPECIFICATIONS > OIL PUMP - BA18.10-P-1000-01G > Engines 132, 160 OIL PUMP Number Designation Engines 160.910/920/ 921/922/923 Engine 132.9 BA18.10-P- 1001-01G Bolt of drive gear to oil pump Nm 20 - BA18.10-P- 1002-01G Bolt of oil suction pipe to crankcase Initial torque Nm 14 - Continued Nm 9.5 -
torque¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 623 · Applies to: 450, 451, 452, 454
BA18.10-P- 1003-01G Bolt, oil pump to crankcase Initial torque Nm 12 - Continued torque Nm 9.5 - BA18.10-P- 1004-01G Bolt, oil baffle at crankcase Nm - 24 TORQUE SPECIFICATIONS > OIL FILTER - BA18.20-P-1000-01N > Engine 122, 132, 134, 135 OIL FILTER Number Designation Engine 122.950 Engine 132.9 Engine 134.910 Engine 134.911 BA18.20-P- 1001-01N Oil filter to crankcase Nm 14 - 14 14 BA18.20-P- 1002-01N Oil filter to timing case cover Nm - 14 - - OIL FILTER Number Designation Engine 135.930 Engine 135.950 BA18.20-P-1001- 01N Oil filter to crankcase Nm 14 14 BA18.20-P-1002- 01N Oil filter to timing case cover Nm - - TORQUE SPECIFICATIONS > OIL LEVEL/OIL PRESSURE SENSOR - BA18.40-P-1000-01G
Engine 132, 160 OIL LEVEL/OIL PRESSURE SENSOR Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 Engine 160.922 BA18.40-P- 1001-01G Oil pressure sensor to oil filter housing Nm - 18 18 18 18 BA18.40-P- 1002-01G Oil pressure sensor to timing case cover Nm 10 - - - - OIL LEVEL/OIL PRESSURE SENSOR Number Designation Engine 160.923 BA18.40-P-1001- Oil pressure sensor to oil filter housing Nm 18
BA18.40-P-1002-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 624 · Applies to: 450, 451, 452, 454
01G BA18.40-P-1002- 01G Oil pressure sensor to timing case cover Nm - TEST & ADJUSTMENT VALUES > OIL PRESSURE - BE18.00-P-1000-01E > Engines 122, 132, 134, 135, 160 CHECK VALUES FOR OIL PRESSURE Number Designation Engine 122 Engine 132 Engine 134 BE18.00-P-1001- 01E Oil pressure engine cold and idling bar - - - BE18.00-P-1002- 01E Oil pressure engine at operating temperature and idling bar 0,29 0.6 to 1.6 1,65 BE18.00-P-1003- 01E Oil pressure at engine operating temperature and 3500 RPM bar 2.94 to 6.86 2.5 to 4.3 - CHECK VALUES FOR OIL PRESSURE Number Designation Engine 135 Engine 160 BE18.00-P-1001- 01E Oil pressure engine cold and idling bar - 4.0 to 4.5 BE18.00-P-1002- 01E Oil pressure engine at operating temperature and idling bar ≥1,5 2.0 to 2.5 BE18.00-P-1003- 01E Oil pressure at engine operating temperature and 3500 RPM bar - - TEST & ADJUSTMENT VALUES > ENGINE OIL CHANGE - BE18.00-P-1000-06P > Model 451 MODIFICATION NOTES Starting distance of 15,000 km for a service when using oils according to MBBV Engine 132 turbo in model 451 ENGINE OIL CHANGE Number Designation Engine 132 in model 451 Engine 132 turbo in model 451 BE18.00-P-1001- 06P Starting distance of 15,000 km for a service when using oils according to MBBV - - - 229.3 - 229.31 - 229.5 - 229.51
SYSTEM - BF18.00-P-1000-01N >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 626 · Applies to: 450, 451, 452, 454
ENGINES 132, 160, 660 FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 132.9 Engine 160.910 BF18.00-P- 1001-01N Engine oil Filling capacity (oil and filter change) Liters 3.7 2.5 Specifications for Operating Fluids Sheet - - Sheet - - Sheet - - Sheet - - Sheet - - Sheet BB00.40-left- 05A BB00.40-P-0229- 05A Sheet - - FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 160.920 Engine 160.921 Engine 160.922 BF18.00- P-1001- 01N Engine oil Filling capacity (oil and filter change) Liters 3.00 3.00 3.00 Specifications for Operating Fluids Sheet - - - Sheet - - - Sheet - - - Sheet - - - Sheet - - - Sheet BB00.40-P- 0229-05A BB00.40-P- 0229-05A BB00.40-P- 0229-05A Sheet - - - FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 160.923 Engine 660.940 Engine 660.950 without code 474 BF18.00- P-1001- 01N Engine oil Filling capacity (oil and filter change) Liters 3.00 2.7 2.7 Specifications for Operating Fluids Sheet - BB00.40-P- 0228-01A -
4000MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 629 · Applies to: 450, 451, 452, 454
ENGINE 132.9 in MODEL 451.3/4 Location The oil pump is located on the side of the engine and is integrated in the timing case cover. Task The oil pump generates the required engine oil pressure for lubrication of the engine. Function The internal rotor (3) driven by the crankshaft drives the outer rotor (4) via the outer toothing. The volume between the gearwheels increases initially and thus generates a vacuum. The engine oil is suctioned out of the oil pan (6). The volume between the gearwheels and the engine oil reduces at the upper end of the delivery path and the engine oil is pushed back into the oil circuit. As the RPM increases the pressure inside the pump also increases. This is regulated via the pressure limiting valve (5). Excess engine oil is led back into the oil pan. Fig 1: Identifying Oil Pump And Timing Case Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 631 · Applies to: 450, 451, 452, 454
The oil pressure switch sits at bottom right on the oil filter flange. Task The oil pressure switch detects the engine oil pressure and leads this to the ME-SFI [ME] control unit (N3/10). Function As soon as there is sufficient oil pressure applied at the switch it opens and thus interrupts the electric circuit. This serves the ME-SFI [ME] control unit as information about sufficient oil pressure in the oil circuit. The oil pressure warning lamp (A1e30) in the instrument cluster (A1) goes out. SPECIAL TOOLS > 450 589 13 21 00 OIL PRESSURE TESTER - WS18.00-P-0030B > FG 18/Set B ENGINE 122, 132, 134, 135, 160, 639, 660 Use: Oil pressure testing device for measurement of oil pressure for a running drive. NOTE: Oil pressure testing device, Smart no.: 000 5692 V001 0000 00. SPECIAL TOOLS > 454 589 06 09 00 SOCKET WRENCH BIT - WS18.00-P-0035A > FG 18/Set A MODEL 454 with ENGINE 134, 135 MODEL 451 with ENGINE 132 Use: Fig 1: Identifying Oil Pressure Tester (450 589 13 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Socket wrench bit 14-edged, SW 66, for loosening and tightening up the oil filter.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 632 · Applies to: 450, 451, 452, 454 · AR: WS18.00-Z-9999CZ
NOTE: For petrol engines. SPECIAL TOOLS > SPECIAL TOOLS: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - WS18.00-Z-9999CZ > MODEL all 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 450 589 00 59 00 Assembly tool FG 18/Set C WS18.00-P- 0050C 450 589 13 21 00 Oil pressure tester FG 18/Set B WS18.00-P- 0030B 450 589 28 63 00 Oil suction sensor FG 18/Set A WS18.00-P-0041A 452 589 02 09 00 Socket wrench bit FG 18/Set B WS18.00-P-0036B 454 589 03 91 00 Adapter Group 18/Set A WS18.00-P-0047A 454 589 06 09 00 Socket wrench bit FG 18/Set A WS18.00-P- 0035A 454 589 10 09 00 Socket wrench bit FG 18/Set A WS18.00-P-0038A 602 589 00 39 00 Riveting FG 05/18/Set C WS05.00-P- Fig 1: Identifying Socket Wrench Bit (454 589 06 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
tool¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 633 · Applies to: 450, 451, 452, 454
0162C 602 589 00 98 00 Case FG 03/05/18/Set C WS05.00-P- 0158C 602 589 02 33 00 Chain separating tool FG 05/18/Set C WS05.00-P- 0159C 602 589 02 40 00 Assembly links FG 05/18/Set C WS05.00-P- 0171C 602 589 05 63 00 Pressure screw FG 05/18/Set C WS05.00-P- 0161C 602 589 05 63 01 Pressure pins FG 05/18/Set C WS05.00-P-0161- 01C 642 589 00 33 00 Riveting tool FG05/18/Set C WS05.00-P- 0260C
Unscrew oil filter (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 635 · Applies to: 450, 451, 452, 454
6 Unscrew oil filter (1) Fig 2 Install
7 Tighten oil filter (1) Replace oil filter (1).Wet sealing ring of oil filter (1) with engine oil.
*BA18.20- P-1002- 01N
Fig 2 8 Position new seal ring on the oil drain screw (2)
9 Insert filter screen on the oil drain screw (2) and tighten oil drain screw (2) *BA01.45- P-1003- 01J 10 Lower vehicle with vehicle lift
11 Pour in engine oil *BF18.00- P-1001- 01N 12 Tighten oil filler neck cap (3)
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 13 Conduct engine test run and check engine for leaks while it is running
14 Check engine oil level by means of oil dipstick The fill level must be between "Min." and "Max." otherwise the engine may be damaged. Let engine run for approx. 1 minute, then switch off and wait approx. 5 minutes. Recheck fill level and correct if necessary.
15 Install engine compartment cover
Remove/install interior compartment flap above engine
AR88.40- P-1100- 03MCC OIL PAN Number Designation Engine 132.9 BA01.45-P-1003-01J Oil drain screw to oil pan Nm 65 OIL FILTER
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 638 · Applies to: 450, 451, 452, 454
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 1 Remove oil pressure switch (S41/1)
AR18.40- P- 4132MCU Checking
2 Screw adapter into threaded hole for oil pressure switch (S41/1) Fig 2 3 Attach oil pressure testing device to adapter Fig 2 4 Lower vehicle with vehicle lift
5 Remove interior flap above engine
AR88.40- P-1100- 03MCC 6 Check engine oil level, correct if necessary
Multigrade engine oils (Sheet 229.5) Sheet 229.5 BB00.40- P-0229- 05A 7 Let the engine to run until it reaches an operating temperature of about 144°C, then read off the oil pressure at idle speed on the pressure gauge of the oil pressure tester
*BE18.00- P-1002- 01E
Fig 2 8 Increase the engine speed to 3500 rpm and read off the pressure on the gauge of the oil pressure tester with the engine warm.
*BE18.00- P-1003- 01E
Fig 2 Fig 1: Identifying Oil Pressure Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove oil pressure switch (S41/1) from¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 641 · Applies to: 450, 451, 452, 454 · AR: BA18.00-Z-9999CZ
4 Remove oil pressure switch (S41/1) from timing case cover pressure switch (S41/1) with sealant into timing case cover.
*BA18.40- P-1002- 01G
Sealant *BR00.45- Z-1053- 01A 5 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 6 Conduct engine test run and check engine around the oil pressure switch (S41/1) for leaks
OIL LEVEL/OIL PRESSURE SENSOR Number Designation Engine 132.9 BA18.40-P-1002-01G Oil pressure sensor to timing case cover Nm 10 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1053-01A Sealant Q0000282V000000000 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - BA18.00-Z-9999CZ > MODEL all Oil filter ENGINE 122.950, 132.9, 134.910 /911,135.930 /950 BA18.20-P-1000-01N Oil filter ENGINE 660.940 BA18.20-P-1000-01K Oil filter ENGINE 160.910 /920 /921 /922 /923 BA18.20-P-1000-01J Oil filter ENGINE 639.939 BA18.20-P-1000-01S Oil level/oil pressure sensor ENGINE 660.940 /950 /951 BA18.40-P-1000-01H Oil level/oil pressure sensor ENGINE 132.9, 160.910 /920 /921 /922 /923 BA18.40-P-1000-01G Oil level/oil pressure sensor ENGINE 122.950, 134.910 /911, 135.930/950, 639.939 BA18.40-P-1000-01K
Oil pump¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 642 · Applies to: 450, 451, 452, 454
ENGINE 132.9, 160.910 /920 /921 /922 /923 BA18.10-P-1000-01G Oil pump ENGINE 639.939, 122.9 in MODEL 454.0 BA18.10-P-1000-01L Oil pump ENGINE 660.940 /950 /951 BA18.10-P-1000-01H Oil/water heat exchanger ENGINE 639.939, 660.950 /951 BA18.30-P-1000-02B Oil/water heat exchanger ENGINE 122.9 BA18.30-P-1000-02C TORQUE SPECIFICATIONS > OIL PUMP - BA18.10-P-1000-01G > Engines 132, 160 OIL PUMP Number Designation Engines 160.910/920/ 921/922/923 Engine 132.9 BA18.10-P- 1001-01G Bolt of drive gear to oil pump Nm 20 - BA18.10-P- 1002-01G Bolt of oil suction pipe to crankcase Initial torque Nm 14 - Continued torque Nm 9.5 - BA18.10-P- 1003-01G Bolt, oil pump to crankcase Initial torque Nm 12 - Continued torque Nm 9.5 - BA18.10-P- 1004-01G Bolt, oil baffle at crankcase Nm - 24 TORQUE SPECIFICATIONS > OIL FILTER - BA18.20-P-1000-01N > Engine 122, 132, 134, 135 OIL FILTER Number Designation Engine 122.950 Engine 132.9 Engine 134.910 Engine 134.911 BA18.20-P- 1001-01N Oil filter to crankcase Nm 14 - 14 14 BA18.20-P- 1002-01N Oil filter to timing case cover Nm - 14 - - OIL FILTER Number Designation Engine 135.930 Engine 135.950 BA18.20-P-1001-01N Oil filter to crankcase Nm 14 14
BA18.20-P-1002-01N¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 643 · Applies to: 450, 451, 452, 454
Oil filter to timing case cover Nm - - TORQUE SPECIFICATIONS > OIL LEVEL/OIL PRESSURE SENSOR - BA18.40-P-1000-01G
Engine 132, 160 OIL LEVEL/OIL PRESSURE SENSOR Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 Engine 160.922 BA18.40-P- 1001-01G Oil pressure sensor to oil filter housing Nm - 18 18 18 18 BA18.40-P- 1002-01G Oil pressure sensor to timing case cover Nm 10 - - - - OIL LEVEL/OIL PRESSURE SENSOR Number Designation Engine 160.923 BA18.40-P-1001-01G Oil pressure sensor to oil filter housing Nm 18 BA18.40-P-1002-01G Oil pressure sensor to timing case cover Nm - TEST & ADJUSTMENT VALUES > OIL PRESSURE - BE18.00-P-1000-01E > Engines 122, 132, 134, 135, 160 CHECK VALUES FOR OIL PRESSURE Number Designation Engine 122 Engine 132 Engine 134 BE18.00-P- 1001-01E Oil pressure engine cold and idling bar - - - BE18.00-P- 1002-01E Oil pressure engine at operating temperature and idling bar 0,29 0.6 to 1.6 1,65 BE18.00-P- 1003-01E Oil pressure at engine operating temperature and 3500 rpm bar 2.94 to 6.86 2.5 to 4.3 - CHECK VALUES FOR OIL PRESSURE Number Designation Engine 135 Engine 160 BE18.00-P-1001- 01E Oil pressure engine cold and idling bar - 4.0 to 4.5 BE18.00-P-1002- 01E Oil pressure engine at operating temperature and idling bar ≥1,5 2.0 to 2.5 BE18.00-P-1003- Oil pressure at engine operating temperature and bar - -
3500 rpm¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 644 · Applies to: 450, 451, 452, 454
01E 3500 rpm TEST & ADJUSTMENT VALUES > ENGINE OIL CHANGE - BE18.00-P-1000-06P > Model 451 MODIFICATION NOTES Starting distance of 15,000 km for a service when using oils according to MBBV Engine 132 turbo in model 451 ENGINE OIL CHANGE Number Designation Engine 132 in model 451 Engine 132 turbo in model 451 BE18.00-P- 1001-06P Starting distance of 15,000 km for a service when using oils according to MBBV - - - 229.3 - 229.31 - 229.5 - 229.51 Sheet - BB00.40-P- 0223-02A BE18.00-P- 1002-06P Starting distance of 20,000 km for a service when using oils according to MBBV - - 229.3 - 229.31 - 229.5 - 229.51 - Sheet BB00.40-P- 0223-02A - ENGINE OIL CHANGE Number Designation Engine 660 in model 451 Engine 660 DPF in model 451 BE18.00-P- 1001-06P Starting distance of 15,000 km for a service when using oils according to MBBV - - 229.3 - 229.31 229.31 229.5 - 229.51 229.51 Sheet BB00.40-P- 0223-02A BB00.40-P- 0223-02A - -
BF18.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 646 · Applies to: 450, 451, 452, 454
1001-01N Engine oil Filling capacity (oil and filter change) Liters 3.00 3.00 3.00 Specifications for Operating Fluids Sheet - - - Sheet - - - Sheet - - - Sheet - - - Sheet - - - Sheet BB00.40- P-0229- 05A BB00.40- P-0229- 05A BB00.40- P-0229- 05A Sheet - - - FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 160.923 Engine 660.940 Engine 660.950 without code 474 BF18.00-P- 1001-01N Engine oil Filling capacity (oil and filter change) Liters 3.00 2.7 2.7 Specifications for Operating Fluids Sheet - BB00.40- P-0228- 01A - Sheet - BB00.40- P-0228- 03A - Sheet - BB00.40- P-0228- 05A - Sheet - BB00.40- P-0229- 01A - Sheet - BB00.40- P-0229- 03A - Sheet BB00.40- P-0229- 05A BB00.40- P-0229- 05A BB00.40-P- 0229-05A Sheet - BB00.40- P-0229- 31A BB00.40-P- 0229-31A FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 660.950 with code 474 Engine 660.951
4000MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 649 · Applies to: 450, 451, 452, 454
ENGINE 132.9 in MODEL 451.3 /4 Location The oil pump is located on the side of the engine and is integrated in the timing case cover. Task The oil pump generates the required engine oil pressure for lubrication of the engine. Function The internal rotor (3) driven by the crankshaft drives the outer rotor (4) via the outer toothing. The volume between the gearwheels increases initially and thus generates a vacuum. The engine oil is suctioned out of the oil pan (6). The volume between the gearwheels and the engine oil reduces at the upper end of the delivery path and the engine oil is pushed back into the oil circuit. As the rpm increases the pressure inside the pump also increases. This is regulated via the pressure limiting valve (5). Excess engine oil is led back into the oil pan. Fig 1: Identifying Oil Pump And Timing Case Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 651 · Applies to: 450, 451, 452, 454
The oil pressure switch sits at bottom right on the oil filter flange. Task The oil pressure switch detects the engine oil pressure and leads this to the ME-SFI [ME] control unit (N3/10). Function As soon as there is sufficient oil pressure applied at the switch it opens and thus interrupts the electric circuit. This serves the ME-SFI [ME] control unit as information about sufficient oil pressure in the oil circuit. The oil pressure warning lamp (A1e30) in the instrument cluster (A1) goes out. SPECIAL TOOLS > 450 589 13 21 00 OIL PRESSURE TESTER - WS18.00-P-0030B > FG 18/Set B ENGINE 122, 132, 134, 135, 160, 639, 660 Use: Oil pressure testing device for measurement of oil pressure for a running drive. NOTE: Oil pressure testing device, Smart no.: 000 5692 V001 0000 00. SPECIAL TOOLS > 454 589 06 09 00 SOCKET WRENCH BIT - WS18.00-P-0035A > FG 18/Set A MODEL 454 with ENGINE 134, 135 MODEL 451 with ENGINE 132 Use: Fig 1: Identifying Oil Pressure Tester (450 589 13 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Socket wrench bit 14-edged, SW 66, for loosening and tightening up the oil filter.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 652 · Applies to: 450, 451, 452, 454 · AR: WS18.00-Z-9999CZ
NOTE: For petrol engines. SPECIAL TOOLS > SPECIAL TOOLS: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - WS18.00-Z-9999CZ > MODEL all 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 450 589 00 59 00 Assembly tool FG 18/Set C WS18.00-P-0050C 450 589 13 21 00 Oil pressure tester FG 18/Set B WS18.00-P-0030B 450 589 28 63 00 Oil suction sensor FG 18/Set A WS18.00-P-0041A 452 589 02 09 00 Socket wrench bit FG 18/Set B WS18.00-P-0036B 454 589 03 91 00 Adapter Group 18/Set A WS18.00-P-0047A 454 589 06 09 00 Socket wrench bit FG 18/Set A WS18.00-P-0035A 454 589 10 09 00 Socket wrench bit FG 18/Set A WS18.00-P-0038A Fig 1: Identifying Socket Wrench Bit (454 589 06 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
602 589 00 39 00 Riveting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 653 · Applies to: 450, 451, 452, 454
tool FG 05/18/Set C WS05.00-P-0162C 602 589 00 98 00 Case FG 03/05/18/Set C WS05.00-P-0158C 602 589 02 33 00 Chain separating tool FG 05/18/Set C WS05.00-P-0159C 602 589 02 40 00 Assembly links FG 05/18/Set C WS05.00-P-0171C 602 589 05 63 00 Pressure screw FG 05/18/Set C WS05.00-P-0161C 602 589 05 63 01 Pressure pins FG 05/18/Set C WS05.00-P-0161-01C 642 589 00 33 00 Riveting tool FG05/18/Set C WS05.00-P-0260C
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 655 · Applies to: 450, 451, 452, 454
Risk of death caused by vehicle slipping or toppling off 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
2 Support engine at oil pan using transmission jack Use a suitable protective underlay in order to avoid damage to the oil pan. Transmission jackhttp://gotis.aftersales.mercedes- benz.com
3 Remove bolts (2) for front engine mount carrier (1) on cylinder crankcase BA22.10- P-1013- 01M 4 Remove bolt (3) for torque support on front engine mount carrier (1) BA22.10- P-1011- 01M 5 Remove bolts (4) for front engine mount carrier (1) on transmission and remove front engine mount carrier (1) *BA22.10- P-1012- 01M 6 Install in the reverse order
ENGINE MOUNTS, ENGINE SUPPORTS Fig 1: Identifying Carrier For Front Engine Mount And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Support engine on oil pan with hydraulic¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 657 · Applies to: 450, 451, 452, 454
5 Support engine on oil pan with hydraulic floor jack in order to avoid damage to the oil pan. Hydraulic floor jackgotis://H_00.12_01.0
6 Remove bolts (5) BA22.10- P-1006- 01M 7 Undo bolts (6) and remove bracket (3) BA22.10- P-1007- 01M 8 Remove engine mount (1) upwards
9 Install in the reverse order
ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 BA22.10-P-1006- 01M Bolt, right engine mount to frame-type integral support Nm 56 BA22.10-P-1007- 01M Bolt, right engine mount to timing case cover Nm 80 TESTING & REPAIR > REMOVE/INSTALL FRAME-TYPE INTEGRAL SUPPORT - AR22.10- P-1300MCU > ENGINES 132.910, 780.009 in MODEL 451.3/4
Remove/install
Risk of death when touching components on vehicles with high-voltage Do not touch components and open lines of high-voltage system. Persons with electronic implants (e.g. cardiac pacemakers) must AS54.00- Z-0001- Fig 1: Identifying Frame-Type Integral Support Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
system¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 658 · Applies to: 450, 451, 452, 454
never work on high-voltage systems. 02MEV 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 1 Remove axle tube
AR35.10- P- 0070MCC 2.1 Remove engine with transmission Engine 132.910 AR01.10- P- 2401MCU 2.2 Remove electric motor drive with transmission Engine 780.009 AR08.10- P- 0010MEV 3 Remove pull rod (2) from frame-type integral support (1) Installation: The toothing on the pull rod (2) must be point in the direction of travel to the left. The function of the hand brake is not assured if the pull rod (2) is positioned incorrectly.
4 Unscrew bolts (3, 4) of frame-type integral support (1) on the body, remove frame-type integral support (1) and place on suitable stands Aid of helper required.
*BA35.10- P-1001- 01F 5 Remove engine mount on the right (5) and transmission mounting bearing (6) on frame-type integral support (1) When replacing the frame-type integral support (1).
Engine 132.9 BA22.10- P-1006- 01M Engine 780.009 BA22.10- P-1006- 01M Transmission 717.4 BA26.00- P-1009- 01D Engine 780.009 BA26.00- P-1003- 01E 6 Detach shock absorber (7) from frame-type integral support (1) When replacing the frame-type integral support (1).
*BA32.25- P-1002-
Remove rests (8) for the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 659 · Applies to: 450, 451, 452, 454
03N 7 Remove rests (8) for the rear spring and remove rubber support (9) for exhaust system from frame- type integral support (1) When replacing the frame-type integral support (1). Rubber supports (9) not for engine 780.009. Installation: Attach new crash protection cover (10) to frame-type integral support (1).Pliersgotis://K_68- 80_06.0
8 Remove CMS rear end (11) from frame-type integral support (1) When replacing the frame-type integral support (1). The CMS rear end (11) is attached using six bolts on frame-type integral support (1).
*BA64.20- P-1001- 01B 9 Remove secondary air injection pump (M33) together with holder from frame-type integral support (1) When replacing the frame-type integral support (1) for engine 132.910. The holder for the secondary air injection pump (M33) is attached using three bolts on frame-type integral support (1).
10 Install in the reverse order
11 Check function of the hand brake
ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 Engine 780.009 BA22.10-P-1006- 01M Bolt, right engine mount to frame-type integral support Nm 56 56 COMPLETE MANUAL TRANSMISSION Number Designation Trans-mission 717.48 BA26.00-P-1009- 01D Bolt, transmission mount to frame-type integral support Nm 56 COMPLETE MANUAL TRANSMISSION Number Designation Engine 780.009 BA26.00-P-1003- 01E Bolt, left transmission mount on frame-type integral support Nm 56 REAR AXLE SHOCK ABSORBER Number Designation Model 451.3/4 BA32.25-P-1002- 03N Nut, shock absorber to frame-type integral support Nm 20
Raise vehicle with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 661 · Applies to: 450, 451, 452, 454 · AR: BA22.00-Z-9999CZ
1 Raise vehicle with vehicle lift
2 Support transmission using a transmission jack and removal fixture The transmission must not be raised under any circumstances. The torque supports (1) will be stretched by this during installation and thus pre-damaged.
Transmission jack gotis://H_00.10_01.0 450589026200 3 Unscrew bolt (2) BA22.10-P- 1011-01M 4 Counterhold nuts (4) and remove bolt (3) *BA22.10-P- 1010-01M 5 Remove torque support (1)
6 Install in the reverse order
ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 Engine 780.009 BA22.10-P-1010- 01M Bolt, torque support to frame-type integral support Nm 115 115 BA22.10-P-1011- 01M Bolt, torque support to front engine mount carrier Nm 115 115 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: ENGINE SUSPENSION - BA22.00-Z-9999CZ > MODEL all Engine mount, engine support ENGINE 122.9, 134.9, 135.9, 639.9 BA22.10-P-1000-01Q Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Engine mounts, engine¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 662 · Applies to: 450, 451, 452, 454
supports ENGINE 660.940 in MODEL 450.3 /4 ENGINE 660.951 /950 in MODEL 451.3/4 BA22.10-P-1000-01N Engine mounts, engine supports ENGINE 132, 160, 780... BA22.10-P-1000-01M TORQUE SPECIFICATIONS > ENGINE MOUNTS, ENGINE SUPPORTS - BA22.10-P-1000- 01M > Engine 132, 160, 780.009 ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 Engine 160.922 Engine 160.923 BA22.10-P- 1001-01M Bolt, engine support to cylinder head Initial torque Nm - 28 28 Retightening torque Nm - 23 23 BA22.10-P- 1002-01M Bolt, rear engine support to transmission Initial torque Nm - 28 28 Retightening torque Nm - 23 23 BA22.10-P- 1003-01M Bolt, front engine support to crankcase Initial torque Nm - 28 28 Retightening torque Nm - 23 23 BA22.10-P- 1004-01M Bolt, front engine support to frame-type integral support Nm - 58 58 BA22.10-P- 1005-01M Bolt, rear engine support to frame-type integral support Nm - 58 58 BA22.10-P- 1006-01M Bolt, right engine mount to frame-type integral support Nm 56 - - BA22.10-P- 1007-01M Bolt, right engine mount to timing case cover Nm 80 - - BA22.10-P- 1008-01M Bolt, left engine mount to major assembly carrier Nm 56 - - BA22.10-P- 1009-01M Bolt, left engine mount to transmission Nm 80 - - BA22.10-P- 1010-01M Bolt, torque support to frame-type integral support Nm 115 - - BA22.10-P- 1011-01M Bolt, torque support to front engine mount carrier Nm 115 - - BA22.10-P- 1012-01M Bolt, carrier for front engine mount to transmission Nm 23 - - BA22.10-P- 1013-01M Bolt, carrier for front engine mount to crankcase Nm 56 - -
BA22.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 663 · Applies to: 450, 451, 452, 454
1014-01M Bolt, right engine support to engine Nm - - - ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 160.910 Engine 160.920 Engine 160.921 BA22.10-P- 1001-01M Bolt, engine support to cylinder head Initial torque Nm 28 28 28 Retightening torque Nm 23 - 23 BA22.10-P- 1002-01M Bolt, rear engine support to transmission Initial torque Nm 28 28 28 Retightening torque Nm 23 - 23 BA22.10-P- 1003-01M Bolt, front engine support to crankcase Initial torque Nm 28 28 28 Retightening torque Nm 23 - 23 BA22.10-P- 1004-01M Bolt, front engine support to frame-type integral support Nm 58 58 58 BA22.10-P- 1005-01M Bolt, rear engine support to frame-type integral support Nm 58 58 58 BA22.10-P- 1006-01M Bolt, right engine mount to frame-type integral support Nm - - - BA22.10-P- 1007-01M Bolt, right engine mount to timing case cover Nm - - - BA22.10-P- 1008-01M Bolt, left engine mount to major assembly carrier Nm - - - BA22.10-P- 1009-01M Bolt, left engine mount to transmission Nm - - - BA22.10-P- 1010-01M Bolt, torque support to frame-type integral support Nm - - - BA22.10-P- 1011-01M Bolt, torque support to front engine mount carrier Nm - - - BA22.10-P- 1012-01M Bolt, carrier for front engine mount to transmission Nm - - - BA22.10-P- 1013-01M Bolt, carrier for front engine mount to crankcase Nm - - - BA22.10-P- 1014-01M Bolt, right engine support to engine Nm - - - ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 780.009
BA22.10-P-1001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 664 · Applies to: 450, 451, 452, 454
01M Bolt, engine support to cylinder head Initial torque Nm - Retightening torque Nm - BA22.10-P-1002- 01M Bolt, rear engine support to transmission Initial torque Nm - Retightening torque Nm - BA22.10-P-1003- 01M Bolt, front engine support to crankcase Initial torque Nm - Retightening torque Nm - BA22.10-P-1004- 01M Bolt, front engine support to frame-type integral support Nm - BA22.10-P-1005- 01M Bolt, rear engine support to frame-type integral support Nm - BA22.10-P-1006- 01M Bolt, right engine mount to frame-type integral support Nm 56 BA22.10-P-1007- 01M Bolt, right engine mount to timing case cover Nm - BA22.10-P-1008- 01M Bolt, left engine mount to major assembly carrier Nm - BA22.10-P-1009- 01M Bolt, left engine mount to transmission Nm - BA22.10-P-1010- 01M Bolt, torque support to frame-type integral support Nm 115 BA22.10-P-1011- 01M Bolt, torque support to front engine mount carrier Nm 115 BA22.10-P-1012- 01M Bolt, carrier for front engine mount to transmission Nm 23 BA22.10-P-1013- 01M Bolt, carrier for front engine mount to crankcase Nm - BA22.10-P-1014- 01M Bolt, right engine support to engine Nm 56 SPECIAL TOOLS > 001 589 01 16 03 BOX WRENCH - WS22.00-P-0008-03B > FG22/09/28/Set B MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251, 451 Use: Box wrench SW16 from set of engine mount wrenches 001 589 01 16 00.
SPECIAL TOOLS > 001 589 01 16 09 BOX WRENCH BIT - WS22.00-P-0008-09B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 665 · Applies to: 450, 451, 452, 454
FG22/09/28/Set B MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251, 451 Use: Box wrench bit SW17 from set of engine mount wrenches 001 589 01 16 00
SPECIAL TOOLS > 001 589 01 16 00 ENGINE MOUNT WRENCH SET - WS22.00-P-0008B > FG 22/07/09/28/61/ Set B MODEL all
Further use 001 589 01 16 00 Engine mount wrench set WS09.00-P-0010B
Further use 001 589 01 16 00 Engine mount WS28.00-P-0088B Fig 1: Identifying Box Wrench (001 589 01 16 03) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Box Wrench Bit (001 589 01 16 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
wrench set¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 666 · Applies to: 450, 451, 452, 454 · AR: WS22.00-Z-9999CZ
Separate part FG22/Set B 001 589 01 16 01 Plug-in adapter WS22.00-P-0008-01B Separate part FG22/Set B 001 589 01 16 02 Box wrench bit WS22.00-P-0008-02B Separate part FG22/Set B 001 589 01 16 03 Box wrench WS22.00-P-0008-03B Separate part FG22/Set B 001 589 01 16 04 Wrench socket WS22.00-P-0008-04B Separate part FG22/Set B 001 589 01 16 05 Wrench socket WS22.00-P-0008-05B Separate part FG22/Set B 001 589 01 16 06 Wrench socket WS22.00-P-0008-06B Separate part FG22/Set B 001 589 01 16 07 Angled piece WS22.00-P-0008-07B Separate part FG22/Set B 001 589 01 16 09 Box wrench bit WS22.00-P-0008-09B Separate part FG22/Set B 001 589 01 16 08 Plug-in joint adapter WS22.00-P-0008-10B Use: Set of engine mount wrenches for removing/installing the engine mount and diagonal struts.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: ENGINE SUSPENSION - WS22.00-Z-9999CZ
MODEL all 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P-0006Z 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B 001 589 01 16 03 box wrench FG22/09/28/Set B WS22.00-P-0008- 03B 001 589 01 16 09 Box wrench bit FG22/09/28/Set B WS22.00-P-0008- Fig 1: Identifying Engine Mount Wrench Set (001 589 01 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
454 589 04 09 00 Set of socket¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 667 · Applies to: 450, 451, 452, 454
09B 454 589 04 09 00 Set of socket wrench bits FG 22/26/01 Set B WS22.00-P-0007B
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 669 · Applies to: 450, 451, 452, 454
Risk of death caused by vehicle slipping or toppling off 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
2 Support engine at oil pan using transmission jack Use a suitable protective underlay in order to avoid damage to the oil pan. Transmission jack
3 Remove bolts (2) for front engine mount carrier (1) on cylinder crankcase BA22.10- P-1013- 01M 4 Remove bolt (3) for torque support on front engine mount carrier (1) BA22.10- P-1011- 01M 5 Remove bolts (4) for front engine mount carrier (1) on transmission and remove front engine mount carrier (1) *BA22.10- P-1012- 01M 6 Install in the reverse order
ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 Fig 1: Identifying Carrier For Front Engine Mount And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA22 10 P 1011 01M¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 670 · Applies to: 450, 451, 452, 454
Bolt, torque upport to front engine mount carrier Nm 115 BA22.10-P-1012-01M Bolt, carrier for front engine mount to transmission Nm 23 BA22.10-P-1013-01M Bolt, carrier for front engine mount to crankcase Nm 56 TESTING & REPAIR INDEX > REMOVE/INSTALL RIGHT ENGINE MOUNT - AR22.10-P- 1102MCU > ENGINES 132.910 in MODEL 451.3 /4 Remove/install
1 Remove interior flap above engine
AR88.40- P-1100- 03MCC 2 Disconnect electrical connector (2) at tank vent valve (Y58/1)
3 Remove tank vent valve (Y58/1) from holder (3) on engine mount (1) and turn until so the lock on the vent line (4) is accessible
4 Disconnect vent line (4) on tank vent valve (Y58/1) and lay tank vent valve (Y58/1) to the side
5 Support engine on oil pan with hydraulic floor jack Use a suitable protective underlay in order to avoid damage to the oil pan. Hydraulic floor jack
*BA22.10- Fig 1: Identifying Right Engine Mount Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(9) for exhaust system¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 673 · Applies to: 450, 451, 452, 454
from frame-type integral support (1) supports (9) not for engine 780.009. Installation: Attach new cra h protection cover (10) to frame- type integral support (1).Pliers 8 Remove CMS rear end (11) from frame-type integral support (1) When replacing the frame-type integral support (1). The CMS rear end (11) is attached using six bolts on frame-type integral support (1).
*BA64.20-P-1001- 01B 9 Remove secondary air injection pump (M33) together with holder from frame-type integral support (1) When replacing the frame-type integral support (1) for engine 132.910. The holder for the secondary air injection pump (M33) is attached using three bolts on frame-type integral support (1).
10 Install in the reverse order
11 Check function of the hand brake
ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 Engine 780.009 BA22.10-P-1006- 01M Bolt, right engine mount to frame-type integral support Nm 56 56 COMPLETE MANUAL TRANSMISSION Number Designation Trans-mission 717.48 BA26.00-P-1009- 01D Bolt, transmission mount to frame-type integral support Nm 56 COMPLETE MANUAL TRANSMISSION Number Designation Engine 780.009 BA26.00-P-1003- Bolt, left transmission mount on frame-type integral
support¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 674 · Applies to: 450, 451, 452, 454
01E support Nm 56 REAR AXLE SHOCK ABSORBER Number Designation Model 451.3/4 BA32.25-P-1002-03N Nut, shock absorber to frame-type integral support Nm 20 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1001-01F Bolt, frame-type integral support to body Nm 125 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 FRONT ENGINE MOUNT - AR22.10-P- 4330MCC > ENGINE 132.9 in MODEL 451.3 /4 ENGINE 780.009 in MODEL 451.391 /491 Shown on vehicle with engine 132.9
Remove/install
Risk of death when touching components on vehicles with a high- voltage system Do not touch components and open lines of the high-voltage system. Persons with electronic implants (e.g. cardiac pacemakers) must never work on high-voltage systems. AS54.00- Z-0001- 02MEV Note on high-voltage Model 451.391/491 AH54.10- P-0006- Fig 1: Identifying Front Engine Mount Components (Shown On Vehicle With Engine 132.9) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
battery¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 675 · Applies to: 450, 451, 452, 454
01MEV Note on high-voltage system Model 451.391/491 AH54.00- P-0011- 01MEV Risk of death caused by vehicle slipping or toppling off 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
2 Support transmission using a transmission jack and removal fixture The transmission must not be raised under any circumstances. The torque supports (1) will be stretched by this during installation and thus pre- damaged.
Transmission jack Fig 2 3 Unscrew bolt (2) BA22.10- P-1011- 01M 4 Counterhold nuts (4) and remove bolt (3) BA22.10- P-1010- 01M 5 Remove torque support (1)
6 Install in the reverse order
ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 Engine 780.009 BA22.10-P-1010- 01M Bolt, torque support to frame-type integral support Nm 115 115 BA22.10-P-1011- 01M Bolt, torque support to front engine mount carrier Nm 115 115
TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: ENGINE SUSPENSION -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 676 · Applies to: 450, 451, 452, 454 · AR: BA22.00-Z-9999CZ
BA22.00-Z-9999CZ > MODEL all Engine mount, engine support ENGINE 122.9, 134.9, 135.9, 639.9 BA22.10-P-1000-01Q Engine mounts, engine supports ENGINE 660.940 in MODEL 450.3 /4 ENGINE 660.951 /950 in MODEL 451.3 /4 BA22.10-P-1000-01N Engine mounts, engine supports ENGINE 132, 160, 780... BA22.10-P-1000-01M TORQUE SPECIFICATIONS > ENGINE MOUNTS, ENGINE SUPPORTS - BA22.10-P-1000- 01M > Engine 132, 160, 780.009 ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 Engine 160.922 Engine 160.923 BA22.10-P- 1001-01M Bolt, engine support to cylinder head Initial torque Nm - 28 28 Retightening torque Nm - 23 23 BA22.10-P- 1002-01M Bolt, rear engine support to transmission Initial torque Nm - 28 28 Retightening torque Nm - 23 23 BA22.10-P- 1003-01M Bolt, front engine support to crankcase Initial torque Nm - 28 28 Retightening torque Nm - 23 23 BA22.10-P- Bolt, front engine support to frame-type Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1004 01M¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 677 · Applies to: 450, 451, 452, 454
integral upport Nm 58 58 BA22.10-P- 1005-01M Bolt, rear engine support to frame-type integral support Nm - 58 58 BA22.10-P- 1006-01M Bolt, right engine mount to frame-type integral support Nm 56 - - BA22.10-P- 1007-01M Bolt, right engine mount to timing case cover Nm 80 - - BA22.10-P- 1008-01M Bolt, left engine mount to major assembly carrier Nm 56 - - BA22.10-P- 1009-01M Bolt, left engine mount to transmission Nm 80 - - BA22.10-P- 1010-01M Bolt, torque support to frame-type integral support Nm 115 - - BA22.10-P- 1011-01M Bolt, torque support to front engine mount carrier Nm 115 - - BA22.10-P- 1012-01M Bolt, carrier for front engine mount to transmission Nm 23 - - BA22.10-P- 1013-01M Bolt, carrier for front engine mount to crankcase Nm 56 - - BA22.10-P- 1014-01M Bolt, right engine support to engine Nm - - - ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 160.910 Engine 160.920 Engine 160.921 BA22.10-P- 1001-01M Bolt, engine support to cylinder head Initial torque Nm 28 28 28 Retightening torque Nm 23 - 23 BA22.10-P- 1002-01M Bolt, rear engine support to transmission Initial torque Nm 28 28 28 Retightening torque Nm 23 - 23 BA22.10-P- 1003-01M Bolt, front engine support to crankcase Initial torque Nm 28 28 28 Retightening torque Nm 23 - 23 BA22.10-P- 1004-01M Bolt, front engine support to frame-type integral support Nm 58 58 58 BA22.10-P- 1005-01M Bolt, rear engine support to frame-type integral support Nm 58 58 58 BA22.10-P- 1006-01M Bolt, right engine mount to frame-type integral support Nm - - -
BA22.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 678 · Applies to: 450, 451, 452, 454
1007-01M Bolt, right engine mount to timing ca e cover Nm - - - BA22.10-P- 1008-01M Bolt, left engine mount to major assembly carrier Nm - - - BA22.10-P- 1009-01M Bolt, left engine mount to transmission Nm - - - BA22.10-P- 1010-01M Bolt, torque support to frame-type integral support Nm - - - BA22.10-P- 1011-01M Bolt, torque support to front engine mount carrier Nm - - - BA22.10-P- 1012-01M Bolt, carrier for front engine mount to transmission Nm - - - BA22.10-P- 1013-01M Bolt, carrier for front engine mount to crankcase Nm - - - BA22.10-P- 1014-01M Bolt, right engine support to engine Nm - - - ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 780.009 BA22.10-P-1001- 01M Bolt, engine support to cylinder head Initial torque Nm - Retightening torque Nm - BA22.10-P-1002- 01M Bolt, rear engine support to transmission Initial torque Nm - Retightening torque Nm - BA22.10-P-1003- 01M Bolt, front engine support to crankcase Initial torque Nm - Retightening torque Nm - BA22.10-P-1004- 01M Bolt, front engine support to frame-type integral support Nm - BA22.10-P-1005- 01M Bolt, rear engine support to frame-type integral support Nm - BA22.10-P-1006- 01M Bolt, right engine mount to frame-type integral support Nm 56 BA22.10-P-1007- 01M Bolt, right engine mount to timing case cover Nm - BA22.10-P-1008- 01M Bolt, left engine mount to major assembly carrier Nm - BA22.10-P-1009- 01M Bolt, left engine mount to transmission Nm -
BA22.10-P-1010-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 679 · Applies to: 450, 451, 452, 454
01M Bolt, torque support to frame-type integral support Nm 115 BA22.10-P-1011- 01M Bolt, torque support to front engine mount carrier Nm 115 BA22.10-P-1012- 01M Bolt, carrier for front engine mount to transmission Nm 23 BA22.10-P-1013- 01M Bolt, carrier for front engine mount to crankcase Nm - BA22.10-P-1014- 01M Bolt, right engine support to engine Nm 56 SPECIAL TOOLS > 001 589 01 16 03 BOX WRENCH - WS22.00-P-0008-03B > FG22/09/28/Set B MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251, 451 Use: Box wrench SW16 from set of engine mount wrenches 001 589 01 16 00.
SPECIAL TOOLS > 001 589 01 16 09 BOX WRENCH BIT - WS22.00-P-0008-09B > FG22/09/28/Set B MODEL 163, 164, 171, 203, 210, 211, 215, 219, 220, 221, 230, 251, 451 Use: Box wrench bit SW17 from set of engine mount wrenches 001 589 01 16 00
Fig 1: Identifying Box Wrench (001 589 01 16 03) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 001 589 01 16 00 ENGINE MOUNT WRENCH SET - WS22.00-P-0008B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 680 · Applies to: 450, 451, 452, 454
FG 22/07/09/28/61/ Set B MODEL all
Further use 001 589 01 16 00 Engine mount wrench set WS09.00-P-0010B
Further use 001 589 01 16 00 Engine mount wrench set WS28.00-P-0088B Separate part FG22/Set B 001 589 01 16 01 Plug-in adapter WS22.00-P-0008-01B Separate part FG22/Set B 001 589 01 16 02 Box wrench bit WS22.00-P-0008-02B Separate part FG22/Set B 001 589 01 16 03 Box wrench WS22.00-P-0008- 03B Separate part FG22/Set B 001 589 01 16 04 Wrench socket WS22.00-P-0008-04B Separate part FG22/Set B 001 589 01 16 05 Wrench socket WS22.00-P-0008-05B Separate part FG22/Set B 001 589 01 16 06 Wrench socket WS22.00-P-0008-06B Separate part FG22/Set B 001 589 01 16 07 Angled piece WS22.00-P-0008-07B Separate part FG22/Set B 001 589 01 16 09 Box wrench bit WS22.00-P-0008- 09B Separate part FG22/Set B 001 589 01 16 08 Plug-in joint adapter WS22.00-P-0008-10B Use: Fig 1: Identifying Box Wrench Bit (001 589 01 16 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Set of engine mount wrenches for removing/installing the engine mount and diagonal struts.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 681 · Applies to: 450, 451, 452, 454 · AR: WS22.00-Z-9999CZ
SPECIAL TOOLS > SPECIAL TOOLS: SMART: ENGINE SUSPENSION - WS22.00-Z-9999CZ
MODEL all 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P-0006Z 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B 001 589 01 16 03 box wrench FG22/09/28/Set B WS22.00-P-0008-03B 001 589 01 16 09 Box wrench bit FG22/09/28/Set B WS22.00-P-0008-09B 454 589 04 09 00 Set of socket wrench bits FG 22/26/01 Set B WS22.00-P-0007B Fig 1: Identifying Engine Mount Wrench Set (001 589 01 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 687 · Applies to: 450, 451, 452, 454
1 Check basic position of camshafts
AR05.20-P- 6010MCU 2 Remove timing case cover
AR01.40-P- 8000MCU 3 Turn back ratchet (9) on chain tensioner (8) using a suitable screwdriver and lock chain tensioner (8) via the bore (arrow A) In order to lock the chain tensioner (8), place a pin with a diameter of 1.5 mm into the bore (arrow A) in the chain tensioner (8). Installation: Attach adapter to crankshaft, remove retaining lock on starter ring gear and turn engine in direction of engine rotation through about two revolutions until the markings on the crankshaft sprocket and on the cylinder crankcase stand opposite each other. Then check whether the marking (arrow B) on the camshaft sprocket (2) and the marking (arrow C) on the camshaft adjuster (3) stand opposite each other; remove timing chain (1) if necessary and mount again anew.
Attach/disassemble retaining lock for engine AR03.30-P- 1600-06MCE
*451589014000
*451589016300 Unscrew bolts Installation: Check slide rail (6) for wear; replace if Fig 1: Identifying Timing Chain Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(5) and remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 688 · Applies to: 450, 451, 452, 454
4 (5) and remove slide rail (6) nece ary
*BA05.10-P- 1002-01P
*BA05.10-P- 1003-01P 5 Unscrew bolt (4) and remove tensioning rail (7) Installation: Check tensioning rail (7) for wear; replace if necessary.
*BA05.10-P- 1001-01P 6 Take off timing chain (1) Installation: Before mounting the timing chain (1), check whether the marking (arrow B) on the camshaft sprocket (2) and the marking (arrow C) on the camshaft adjuster (3) are standing opposite each other. The intake camshaft and exhaust camshaft must be turned appropriately otherwise.
7 Install in the reverse order
TIMING CHAIN DRIVE Number Designation Engine 132.9 BA05.10-P-1001- 01P Bolt, timing chain tensioning rail to cylinder head Nm 23 BA05.10-P-1002- 01P Bolt, timing chain slide rail to cylinder head Nm 10 BA05.10-P-1003- 01P Bolt, timing chain slide rail to crankcase Nm 10 Fig 2: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TIMING CHAIN DRIVE¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 691 · Applies to: 450, 451, 452, 454
Number Designation Engine 132.9 BA05.10-P-1001- 01P Bolt, timing chain tensioning rail to cylinder head Nm 23 TESTING & REPAIR > REMOVE/INSTALL SLIDE RAIL OF TIMING CHAIN - AR05.10-P- 8128MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install
1 Remove timing case cover
AR01.40- P- 8000MCU 2 Mark position of timing chain (2) relative to intake and exhaust camshaft and crankshaft. Mark position of intake and exhaust camshaft relative to cylinder head Installation: Check markings and correct settings if necessary.
3 Push back ratchet (9) using a suitable screwdriver, press together chain tensioner (3) and secure using a pin with a diameter of 1.5 mm via the bore (arrow)
4 Loosen bolt (4), remove bolt (5) and turn chain tensioner (3) to the side Installation: Lead chain tensioner (3) into tensioning rail (6) guide.
Fig 1: Identifying Slide Rail Of Timing Chain Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 693 · Applies to: 450, 451, 452, 454
1 Remove cylinder head cover
AR01.20- P- 5014MCU 2 Detach right rear wheel
AR40.10- P- 1100MCU Remove expansion Fig 2: Identifying Crankshaft Belt Pulley, Center Bolt And Timing Case Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Timing Case Cover, Camshaft Adjuster And Camshaft Sprocket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown with the engine removed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 696 · Applies to: 450, 451, 452, 454
Removing
Fig 2: Identifying Camshaft Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Adjusting Camshaft Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ca e cover (5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 701 · Applies to: 450, 451, 452, 454
6 ca e cover (5) 1008 01M 7 Lower vehicle with lifting platform
8 Mark position of timing chain (6) relative to camshaft sprocket (1)
9 Mark position of camshaft sprocket (1) and camshaft adjuster (7) relative to each other and to the upper edge of the timing case cover (5)
10 Press timing chain (6) downwards using a suitable tool in the area between the camshaft sprocket (1) and the camshaft adjuster (7), push back ratchet (8) on chain tensioner (9) using a suitable screwdriver and lock chain tensioner (9) An aid for pressing down the timing chain (6) is required.In order to lock the chain tensioner (9) place a pin with a diameter of 1.5 mm into the bore (arrow B) in the chain tensioner (9).
11 Remove bolt (3) and detach camshaft sprocket (1) from exhaust camshaft (2) and remove from timing chain (6) Installation: Ensure correct installation position of camshaft sprocket (1) on the exhaust camshaft (2). Align camshaft sprocket (1) according to markings and insert in the timing chain (6).
12 Install in the reverse order
CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 BA01.40-P-1008- 01M Screw plug on timing case cover Nm 50 CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1005- 01M Bolt connecting camshaft sprocket to exhaust camshaft Nm 90
TESTING & REPAIR > REMOVE/INSTALL CAMSHAFT BEARING CAPS - AR05.20-P-6992-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 702 · Applies to: 450, 451, 452, 454
04MCU > CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1001- 01M Bolt, camshaft bearing bridge to cylinder head Nm 20 BA05.20-P-1002- 01M Bolt connecting camshaft bearing cap to cylinder head Nm 11 When removing the exhaust camshaft 1. Loosen bolts (1 to 3) for bearing bridge (4) in a number of stages according to the represented sequence until the back pressure is dissipated. Installation: Screw in bolts (1 to 3) in the reverse order in a number of stages all the way and tighten using the prescribed torque. 2. Remove bolts (1 to 3) and take off bearing bridge (4). Installation: Clean running surface of bearing bridge (4) and wet with engine oil. Fig 2: Identifying Plug-In Adapter (001 589 01 16 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Box Wrench Bit (001 589 01 16 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Loosen bolts (5 to 10) for bearing cap (11) in a number of stages according to the represented¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 703 · Applies to: 450, 451, 452, 454
sequence until the back pressure is dissipated. Installation: Screw in bolts (5 to 10) in the reverse order in a number of stages all the way and tighten using the prescribed torque. 4. Remove bolts (5 to 10) and take off bearing cap (11). Installation: Clean contact surfaces of bearing cap (11) and wet with engine oil. Pay attention to installation position. The arrows on the bearing caps (11) must be aligned straight to the control side. The bearing caps (11) are numbered in ascending order starting from the control side. 5. Install in the reverse order. When removing the intake camshaft 6. Loosen bolts (1 to 3) for bearing bridge (4) in a number of stages according to the represented sequence until the back pressure is dissipated. Installation: Screw in bolts (1 to 3) in the reverse order in a number of stages all the way and tighten using the prescribed torque. 7. Remove bolts (1 to 3) and take off bearing bridge (4). Installation: Clean running surface of bearing bridge (4) and wet with engine oil. Fig 1: Removing Exhaust Camshaft Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 705 · Applies to: 450, 451, 452, 454
The intake camshaft (1) and exhaust camshaft (2) can be removed separately
1 Check basic position of intake camshaft (1) and exhaust camshaft (2) and mark position of camshaft adjuster (3) relative to timing chain (4)
AR05.20- P- 6010MCU 2 Remove camshaft sprocket (5) on exhaust camshaft (2) Only the exhaust camshaft (2) is removed and adjusting of the basic setting is not required; fix camshaft sprocket (5) with cable tie to timing chain (4). AR05.20- P- 6040MCU 3 Remove bearing bridge (6) Observe loosening and tightening sequence otherwise the bearing bridge (6) can be damaged. AR05.20- P-6992- 04MCU
*BA05.20- P-1001- Fig 1: Identifying Camshaft Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Exhaust¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 706 · Applies to: 450, 451, 452, 454
01M
Exhaust camshaft (2)
4 Remove camshaft bearing cap (7) for exhaust camshaft (2) Observe loosening and tightening sequence otherwise the exhaust camshaft (2) can be damaged. Installation: Insert camshaft sprocket (5) into timing chain (4), position on exhaust camshaft (2) and check whether the marking (arrow C) on camshaft sprocket (5) and marking (arrow D) on camshaft adjuster (3) are standing opposite to each other at the height of the upper edge of the timing case cover (9). Ensure that the crankshaft is not turned. AR05.20- P-6992- 04MCU
*BA05.20- P-1002- 01M 5 Detach and remove exhaust camshaft (2) from the bearing seat by turning at hexagon (arrow A)
Intake camshaft (1)
6 Remove camshaft bearing cap (8) for intake camshaft (1) Observe loosening and tightening sequence otherwise the intake camshaft (1) can be damaged. AR05.20- P-6992- 04MCU
*BA05.20- P-1002- 01M 7 Detach and remove intake camshaft (1) from the bearing seat by turning at hexagon (arrow A)
8 Lift timing chain (4) and remove intake camshaft (1) Installation: Insert intake camshaft (1) in the timing chain (4) using the camshaft adjuster (3) in such a way that the marking (arrow D) on the camshaft adjuster (3) is at the upper edge of the timing case cover (9). Ensure that the crankshaft is not turned.
9 Remove camshaft adjuster (3) on inlet camshaft (1) When replacing the intake camshaft (1). AR05.20- P- 7201MCU Checking
Check cam on intake camshaft (1) or exhaust
Thread extension for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 711 · Applies to: 450, 451, 452, 454
retaining fork 451589011600 5 Attach lever handle and depressor (4) to the thrust fork (3) and hook into the counter stay (2) Valve assembly tool case 111589256100
Depressor 272589006100 6 Position depressor (4) in the middle on the upper valve spring retainer (6) and press valve spring (7) together through pressing together the lever handle Valve assembly tool case 111589256100
Depressor 272589006100 7 Remove valve collets (5) using suitable magnets and also remove thrust fork (3) using a depressor (4) and lever handle Valve assembly tool case 111589256100
Depressor *272589006100 8 Remove valve spring retainer (6) and valve spring (7) Observe installation position of valve spring (7).The valve spring retainer (8) can remain in the cylinder head.
9 Detach valve stem seal (9), using pliers out of the valves repair tool, from the valve guide Valve assembly tool case *111589256100 Install
10 Lubricate new valve shaft seal (11) with engine oil
11 Insert new valve stem seal (11) on the valve stem (10) and press on using drift (12). The new valve stem seal (11) must not removed again from the valve stem (10). The valve stem seal (11) is damaged during removal and is therefore unusable.
Drift *132589004300 12 Insert valve spring (7) and valve spring retainer (6) Observe installation position of valve spring (7).
13 Hook thrust fork (3) with depressor (4) and lever handle into the counter stay (2) Valve assembly tool case *111589256100
Repair tools for valves¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 718 · Applies to: 450, 451, 452, 454
452589019900 13 Position depressor (6) in the middle on the upper valve spring retainer (8) and press valve spring (9) together through pressing together the lever handle Depressor 272589006100
Repair tools for valves 452589019900 14 Remove valve collets (7) using suitable magnets and also remove thrust fork (5) using a depressor (6) and lever handle Depressor 272589006100
Repair tools for valves *452589019900 15 Remove valve spring retainer (8) and valve spring (9) Observe installation position of valve spring (9).The valve spring retainer (10) can remain in the cylinder head.
16 Detach valve stem seal (11), using pliers out of the valves repair tool, from the valve guide Repair tools for valves *452589019900 Installation
17 Lubricate new valve shaft seal (13) with engine oil
18 Insert new valve stem seal (13) on the valve stem (12) and press on using drift (14). The new valve stem seal (13) must not removed again from the valve stem (12). The valve stem seal (13) is damaged during removal and is therefore unusable.
Drift *132589004300 19 Insert valve spring (9) and valve spring retainer (8) Observe installation position of valve spring (9).
20 Hook thrust fork (5) with depressor (6) and lever handle into the counter stay (4) Depressor *272589006100
Repair tools for valves *452589019900 21 Position depressor (6) in the middle on the valve spring retainer (8) and press together valve spring (9) Check for correct seating of the valve conical pieces (7); repeat the operation step if necessary.
Fig 6: Identifying Adaptation (450 589 01 91 00)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 721 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 7: Identifying Thread Extension For Retaining Fork (451 589 01 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SAFETY PRECAUTIONS > SAFETY INFORMATION: ENGINE TIMING - AS05.00-Z-9999ZZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 722 · Applies to: 450, 451, 452, 454 · AR: AS05.00-Z-9999ZZ, BA05.00-Z-9999CZ
MODEL all OS05.30-P-0001- 01A Disposal of sodium-filled valves ENGINE 111, 112, 113, 137, 155, 156, 159, 166, 266, 646, 647, 648... AS05.30-Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: ENGINE TIMING - BA05.00-Z-9999CZ > MODEL all Camshaft ENGINE 122.9 in MODEL 454.0 BA05.20-P-1000-01L Camshaft ENGINE 134.910 /911, 135.930 /950 BA05.20-P-1000-01I Camshaft ENGINE 639.939 in MODEL 454 ENGINE 660.940 in MODEL 450 ENGINE 660.950 /951 in MODEL 451 BA05.20-P-1000-01H Camshaft ENGINE 160.910 /920 /921 /922 /923 BA05.20-P-1000-01G Camshaft ENGINE 132.9 in MODEL 451.3/4 BA05.20-P-1000-01M Timing chain drive, toothed belt drive ENGINE 134.910 /911, 135.930 /950 in MODEL 454.0 BA05.10-P-1000-01I Timing chain drive, toothed belt drive ENGINE 160.910 /920 /921 /922 /923, 660.940 /950 /951 BA05.10-P-1000-01G Timing chain drive, toothed belt drive ENGINE 132.9 in MODEL 451.3/4 BA05.10-P-1000-01P Timing chain drive, toothed belt drive ENGINE 122.950 BA05.10-P-1000-01O Timing chain drive, toothed belt drive ENGINE 639.939 BA05.10-P-1000-01M TORQUE SPECIFICATIONS > TIMING CHAIN DRIVE, TOOTHED BELT DRIVE - BA05.10-P- Fig 9: Identifying Repair Tools For Valves (452 589 01 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 725 · Applies to: 450, 451, 452, 454
The adjustable camshaft timing solenoid is located at the upper right on the cylinder head. Task The adjustable camshaft timing solenoid controls the oil pressure for the camshaft adjuster. Function Actuation of the adjustable camshaft timing solenoid takes place map-controlled via the ME-SFI [ME] control unit (N3/10). The adjustable camshaft timing solenoid integrated in the oil circuit guides the engine oil, according to actuation, through the ME-SFI [ME] control unit (N3/10), via the oil pressure line "advanced" or the oil pressure line "retarded" to the camshaft adjuster. Fig 1: Locating Adjustable Camshaft Timing Solenoid Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Adjustable Camshaft Timing Solenoid Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Excess engine oil in the engine oil circuit is led back via the return on the adjustable camshaft timing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 726 · Applies to: 450, 451, 452, 454
solenoid. SPECIAL TOOLS > 602 589 00 98 00 CASE - WS05.00-P-0158C > FG 03/05/18/Set C ENGINE all Use: Case for storing individual assembly tool parts for timing chains
SPECIAL TOOLS > 602 589 02 33 00 CHAIN SEPARATING TOOL - WS05.00-P-0159C > FG 05/18/Set C ENGINES all Use: Timing chain separating tool (basic unit) in combination with thrust spindle 602 589 04 63 00 or 602 589 05 63 00 for separating installed endless timing chain.
Fig 1: Identifying Case (602 589 00 98 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 602 589 00 39 00 RIVETING TOOL - WS05.00-P-0162C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 727 · Applies to: 450, 451, 452, 454
FG 05/18/Set C ENGINES all MODIFICATION NOTES 9.6.95 Replaces: 000 589 58 43 00
20.11.07 Replaced by 642 589 00 33 00 WS05.00-P-0260C Use: Rivet press tool for timing chains (basic unit).
SPECIAL TOOLS > 602 589 02 40 00 ASSEMBLY LINKS - WS05.00-P-0171C > FG 05/18/Set C Fig 1: Identifying Chain Separating Tool (602 589 02 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Riveting Tool (602 589 00 39 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINE all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 728 · Applies to: 450, 451, 452, 454
Use: Assembly links (3 in total) for simplex roller chain, duplex roller chain and duplex bushed roller chain for connecting repair chain to installed chain Assembly links must not be left in the engine.
SPECIAL TOOLS > 272 589 00 61 00 DEPRESSOR - WS05.00-P-0233B > FG 05/Set B ENGINE 132, 272, 273 MODIFICATION NOTES 14.2.06 Replaced by 273 589 00 61 00 WS05.00-P-0256B Use: Depressor for valve spring retainer in combination with valve assembly tool" 111 589 25 61 00. The associated guide sleeve is used to mount valve key in depressor.
Fig 1: Identifying Assembly Links (602 589 02 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 00 61 00 DEPRESSOR - WS05.00-P-0235B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 729 · Applies to: 450, 451, 452, 454
FG 05/Set B ENGINE 122, 132, 134, 135, 160, 639, 660 Use: Depressor for disassembly of valve lock with detent depressor 111 589 25 61 05. NOTE: Smart no.: Q 002 1182 V001 0000 00 SPECIAL TOOLS > 642 589 00 33 00 RIVETING TOOL - WS05.00-P-0260C > FG05/18/Set C ENGINE all MODIFICATION NOTES Fig 1: Identifying Depressor (272 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Depressor (450 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Replacement for 602 589 00 39 00¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 730 · Applies to: 450, 451, 452, 454
20.11.07 Replacement for 602 589 00 39 00 WS05.00-P-0162C 20.11.07 Replacement for 272 589 00 39 00 WS05.00-P-0223B Use: Rivet press tool (basic unit) to rivet timing chains. Assembly inserts 651 589 04 63 00 should be used for engine 651.
SPECIAL TOOLS > 451 589 01 16 00 THREAD EXTENSION FOR RETAINING FORK - WS05.00-P-0265B > FG 05/Set B ENGINE 132 in MODEL 451 Use: Thread extension for retaining fork M6 x 20mm to remove the valve springs. NOTE: Only in combination with tool valve assembly caseW111 589 25 61 00. Fig 1: Identifying Riveting Tool (642 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 132 589 00 43 00 DRIFT - WS05.00-P-0270C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 731 · Applies to: 450, 451, 452, 454
FG 05/Set C ENGINES 132 Use: Drift for pressing on valve stem seal with valve installed. SPECIAL TOOLS > 111 589 25 61 03 LEVER HANDLE - WS05.00-P-3137-03C > FG05/Set C ENGINE 122, 132, 134, 135, 160, 639, 660 ENGINE 651 Use: Lever handle for operating the thrust fork and assembly cartridge. Fig 1: Identifying Thread Extension For Retaining Fork (451 589 01 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Drift (132 589 00 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
NOTE:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 732 · Applies to: 450, 451, 452, 454
Smart No.: 001 7009 V000 0000 00. SPECIAL TOOLS > 111 589 25 61 05 DETENT DEPRESSOR - WS05.00-P-3137-05C > FG05/Set C ENGINE 122, 132, 134, 135, 160, 639, 660 ENGINE 651 Use: Detent depressor for disassembly of valve key in combination with depressor W 450 589 00 61 00. SPECIAL TOOLS > 111 589 25 61 06 THRUST FORK - WS05.00-P-3137-06C > Fig 1: Identifying Lever Handle (111 589 25 61 03) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Detent Depressor (111 589 25 61 05) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG05/Set C¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 733 · Applies to: 450, 451, 452, 454
ENGINE 122, 132, 134, 135, 160, 639, 660 ENGINE 651 Use: Thrust fork for mounting the assembly cartridge. NOTE: Smart No.: 001 7006 V000 0000 00. SPECIAL TOOLS > 111 589 25 61 12 FIXING BRACKET - WS05.00-P-3137-12C > FG05/Set C ENGINE 122, 132, 134, 135, 160, 639, 660 ENGINE 651 Use: Retaining fork M6 15 for screwing in the cylinder head. Mount for grid 111 589 25 61 19. NOTE: Smart no.: 001 7007 V000 0000 00. Fig 1: Identifying Thrust Fork (111 589 25 61 06) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 111 589 25 61 19 GRID - WS05.00-P-3137-19C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 734 · Applies to: 450, 451, 452, 454
FG05/Set C ENGINE 122, 132, 134, 135, 160, 639, 660 ENGINE 651 Use: Grid for mounting thrust fork 111 589 25 61 06. NOTE: Smart No.: 001 7008 V000 0000 00. SPECIAL TOOLS > 001 589 01 16 01 PLUG-IN ADAPTER - WS05.00-P-3149-01B > FG05/Set B Fig 1: Identifying Fixing Bracket (111 589 25 61 12) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Grid (111 589 25 61 19) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINES 132.9 in MODEL 451¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 735 · Applies to: 450, 451, 452, 454
Use: Insert adapter 9x12 on 3/8 from set of engine mount wrenches 001 589 01 16 00 SPECIAL TOOLS > 001 589 01 16 09 BOX WRENCH BIT - WS05.00-P-3149-09B > FG05/Set B ENGINES 132.9 in MODEL 451 Use: Box wrench bit SW17 from set of engine mount wrenches 001 589 01 16 00 Fig 1: Identifying Plug-In Adapter (001 589 01 16 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Box Wrench Bit (001 589 01 16 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 001 589 01 16 00 ENGINE MOUNT WRENCH SET - WS05.00-P-3149B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 736 · Applies to: 450, 451, 452, 454 · AR: WS05.00-Z-9999CZ, WS05.00-P-3137BA
FG 05/Set B ENGINES 132.9 in MODEL 451 Separate part FG 05/Set B 001 589 01 16 01 Plug-in adapter WS05.00-P-3149-01B Separate part FG 05/Set B 001 589 01 16 09 Box wrench bit WS05.00-P-3149-09B Use: Engine mount wrench set to loosen and tighten camshaft sprocket bolt of the exhaust camshaft. SPECIAL TOOLS > SPECIAL TOOLS: SMART: ENGINE TIMING - WS05.00-Z-9999CZ > MODEL all 001 589 01 16 00 Engine mount wrench set FG 05/Set B WS05.00-P-3149B 001 589 01 16 01 Plug-in adapter FG05/Set B WS05.00-P-3149- 01B 001 589 01 16 09 Box wrench bit FG05/Set B WS05.00-P-3149- 09B 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K 111 589 25 61 00 Valve assembly tools kit FG 05/Set B WS05.00-P-3137BA 111 589 25 61 03 Lever handle FG05/Set C WS05.00-P-3137- 03C Fig 1: Identifying Engine Mount Wrench Set (001 589 01 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
111 589 25 61 05 Detent¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 737 · Applies to: 450, 451, 452, 454
depressor FG05/Set C WS05.00-P-3137- 05C 111 589 25 61 06 Thrust fork FG05/Set C WS05.00-P-3137- 06C 111 589 25 61 12 Fixing bracket FG05/Set C WS05.00-P-3137- 12C 111 589 25 61 19 Grid FG05/Set C WS05.00-P-3137- 19C 122 589 00 63 00 Locking tool FG 05/Set B WS05.00-P-0254B 122 589 01 15 00 Drift FG 05/Set C WS05.00-P-0247C 122 589 01 61 00 Insertion tool FG 05/Set C WS05.00-P-0246C 122 589 02 61 00 Assembly tool FG 05/Set C WS05.00-P-0248C 132 589 00 43 00 Drift FG 05/Set C WS05.00-P-0270C 272 589 00 61 00 Depressor FG 05/Set B WS05.00-P-0233B 450 589 00 01 00 Open end wrench FG 05/Set B WS05.00-P-0210B 450 589 00 61 00 Depressor FG 05/Set B WS05.00-P-0235B 450 589 03 33 00 Puller FG 05/Set B WS05.00-P-0212B 450 589 05 99 00 Chain repair kit FG 05/Set B WS05.00-P-0211B 451 589 01 16 00 Thread extension for retaining fork FG 05/Set B WS05.00-P-0265B 451 589 01 63 00 Adapter FG 01/03/05/Set B WS01.00-P-0143B 452 589 01 99 04 Assembly cartridge FG01/05/Set C WS01.00-P-0108- 04C 452 589 01 99 09 Drift FG01/05/Set C WS01.00-P-0108- 09C 452 589 01 99 10 Drift FG01/05/Set C WS01.00-P-0108- 10C 452 589 01 99 15 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 15C 452 589 01 99 16 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 16C 452 589 01 99 17 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 17C 452 589 01 99 18 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 18C 452 589 01 99 19 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108- 19C
452 589 01 99 20 Valve seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 738 · Applies to: 450, 451, 452, 454
milling cutter FG01/05/Set C WS01.00-P-0108- 20C 452 589 01 99 21 T-handle FG01/05/Set C WS01.00-P-0108- 21C 452 589 01 99 22 Guide FG01/05/Set C WS01.00-P-0108- 22C 452 589 01 99 23 Guide FG01/05/Set C WS01.00-P-0108- 23C 452 589 01 99 24 Straightedge FG01/05/Set C WS01.00-P-0108- 24C 452 589 01 99 26 Roll pin FG01/05/Set C WS01.00-P-0108- 26C 452 589 01 99 28 Adapter FG01/05/Set C WS01.00-P-0108- 28C 454 589 00 14 00 Spacer FG 05/Set B WS05.00-P-0241B 454 589 00 21 00 Torque wrench FG 05/Set B WS05.00-P-0245B 454 589 00 23 00 Feeler gauge FG 05/Set B WS05.00-P-0221B 454 589 01 23 00 Template FG 05/Set B WS05.00-P-0237B 454 589 02 40 00 Tie-down set FG 05/Set B WS05.00-P-0231B 454 589 09 09 00 Socket wrench bit FG 05/Set C WS05.00-P-0219C 454 589 12 09 00 Socket wrench FG 05/Set C WS05.00-P-0244C 454 589 13 09 00 Socket wrench bit FG 05/Set B WS05.00-P-0240B 454 589 14 09 00 Plug adapter FG 05/Set B WS05.00-P-0243B 454 589 16 15 00 Centering pin FG 05/Set C WS05.00-P-0242C 602 589 00 39 00 Riveting tool FG 05/18/Set C WS05.00-P-0162C 602 589 00 98 00 Case FG 03/05/18/Set C WS05.00-P-0158C 602 589 02 33 00 Chain separating tool FG 05/18/Set C WS05.00-P-0159C 602 589 02 40 00 Assembly links FG 05/18/Set C WS05.00-P-0171C 602 589 03 63 00 Thrust piece FG 05/Set C WS05.00-P-0164C 602 589 05 63 00 Pressure screw FG 05/18/Set C WS05.00-P-0161C 602 589 05 63 01 Pressure pins FG 05/18/Set C WS05.00-P-0161- 01C 611 589 00 63 00 Connector FG 01/05/Set B WS01.00-P-0057B
640 589 01 40 00 Hold-down¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 739 · Applies to: 450, 451, 452, 454
device Group 05/Set B WS05.00-P-0225B 640 589 01 63 00 Guide Group 05/Set B WS05.00-P-0218B 642 589 00 33 00 Riveting tool FG05/18/Set C WS05.00-P-0260C
if necessary continue turning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 741 · Applies to: 450, 451, 452, 454
5 if necessary continue turning engine one revolution in direction of engine rotation at the central bolt of the crankshaft pulley
6 Check valve clearance of the intake valves of the 1st and 2nd cylinder as well as the exhaust valves of the 1st and 3rd cylinder It must be possible to insert the feeler gauge making smooth contact all round between the cam of the intake camshaft (1) or exhaust camshaft (2) and the valve tappet, if necessary determine and note the deviation.
Inlet valve *BE05.30- P-1001- 06C
Outlet valve *BE05.30- P-1002- 06C 7 Continue turning engine at the center bolt of the crankshaft belt pulley by 180° in the direction of engine rotation
8 Check valve clearance of exhaust valve of 2nd cylinder as well as the intake valve of the 3rd cylinder It must be possible to insert the feeler gauge making smooth contact all round between the cam of the intake camshaft (1) or exhaust camshaft (2) and the valve tappet, if necessary determine and note the deviation.
Inlet valve *BE05.30- P-1001- 06C
Outlet valve *BE05.30- P-1002- 06C
Adjust
9 Remove valve tappet of the corresponding inlet or exhaust valve
Remove/install valve tappets
AR05.00- P- 2310MCU 10 Select valve tappet of appropriate thickness and install The sum of the thickness of the valve tappet removed and the tolerance deviation of the valve clearance gives the thickness of the valve tappet to be installed. The dimension for the thickne of the valve tappet i located on its underside.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 745 · Applies to: 450, 451, 452, 454
1 Check basic position of camshafts
AR05.20- P- 6010MCU 2 Remove timing case cover
AR01.40- P- 8000MCU 3 Turn back ratchet (9) on chain tensioner (8) using a suitable screwdriver and lock chain tensioner (8) via the bore (arrow A) In order to lock the chain tensioner (8), place a pin with a diameter of 1.5 mm into the bore (arrow A) in the chain tensioner (8). Installation: Attach adapter to crankshaft, remove retaining lock on starter ring gear and turn engine in direction of engine rotation through about two revolutions until the markings on the crankshaft sprocket and on the cylinder crankcase stand opposite each other. Then check whether the marking (arrow B) on the camshaft sprocket (2) and the marking (arrow C) on the camshaft adjuster (3) stand opposite each other; remove timing chain (1) if necessary and mount again anew.
Attach/disassemble retaining lock for engine AR03.30- P-1600- 06MCE
Fig 2
Fig 3 Fig 1: Identifying Timing Chain Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Un crew bolt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 746 · Applies to: 450, 451, 452, 454
4 Un crew bolt (5) and remove slide rail (6) Installation: Check lide rail (6) for wear; replace if necessary.
*BA05.10- P-1002- 01P
*BA05.10- P-1003- 01P 5 Unscrew bolt (4) and remove tensioning rail (7) Installation: Check tensioning rail (7) for wear; replace if necessary.
*BA05.10- P-1001- 01P 6 Take off timing chain (1) Installation: Before mounting the timing chain (1), check whether the marking (arrow B) on the camshaft sprocket (2) and the marking (arrow C) on the camshaft adjuster (3) are standing opposite each other. The intake camshaft and exhaust camshaft must be turned appropriately otherwise.
7 Install in the reverse order
TIMING CHAIN DRIVE Number Designation Engine 132.9 BA05.10-P-1001-01P Bolt, timing chain tensioning rail to cylinder head Nm 23 BA05.10-P-1002-01P Bolt, timing chain slide rail to cylinder head Nm 10 BA05.10-P-1003-01P Bolt, timing chain slide rail to crankcase Nm 10 Fig 2: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > REMOVE/INSTALL CHAIN TENSIONER - AR05.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 747 · Applies to: 450, 451, 452, 454
7800MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install
1 Remove timing case cover (2)
AR01.40- P- 8000MCU 2 Push back ratchet (3) using a suitable screwdriver, press together chain tensioner (1) and secure using a pin with a diameter of 1.5 mm via the bore (arrow)
3 Remove bolts (4) and chain tensioner (1) *BA05.10- P-1004- 01P 4 Install in the reverse order
TIMING CHAIN DRIVE Number Designation Engine 132.9 Fig 3: Identifying Adapter (451 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Chain Tensioner Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA05.10-P-1004-01P¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 748 · Applies to: 450, 451, 452, 454
Bolt, cam chain tensioner to crankcase Nm 9 TESTING & REPAIR INDEX > REMOVE, INSTALL TENSIONING RAIL - AR05.10-P- 8127MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install
1 Remove timing case cover
AR01.40- P- 8000MCU 2 Mark position of timing chain (2) relative to intake and exhaust camshaft and crankshaft. Mark position of intake and exhaust camshaft relative to cylinder head Installation: Check markings and correct settings if necessary.
3 Push back ratchet (5) using a suitable screwdriver, press together chain tensioner (3) and secure using a pin with a diameter of 1.5 mm via the bore (arrow)
4 Unscrew bolt (4) *BA05.10- P-1001- 01P 5 Pull out tensioning rail (1) between timing chain (2) and chain tensioner (3)
6 Install in the reverse order
Fig 1: Identifying Tensioning Rail Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TIMING CHAIN DRIVE¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 749 · Applies to: 450, 451, 452, 454
Number Designation Engine 132.9 BA05.10-P-1001-01P Bolt, timing chain tensioning rail to cylinder head Nm 23 TESTING & REPAIR INDEX > REMOVE/INSTALL SLIDE RAIL OF TIMING CHAIN - AR05.10- P-8128MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install
1 Remove timing case cover
AR01.40- P- 8000MCU 2 Mark position of timing chain (2) relative to intake and exhaust camshaft and crankshaft. Mark position of intake and exhaust camshaft relative to cylinder head Installation: Check markings and correct settings if necessary.
3 Push back ratchet (9) using a suitable screwdriver, press together chain tensioner (3) and secure using a pin with a diameter of 1.5 mm via the bore (arrow)
4 Loosen bolt (4), remove bolt (5) and turn chain tensioner (3) to the side Installation: Lead chain tensioner (3) into tensioning rail (6) guide.
*BA05.10- Fig 1: Identifying Slide Rail Of Timing Chain Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
P 1004¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 750 · Applies to: 450, 451, 452, 454
01P 5 Remove bolts (7) *BA05.10- P-1002- 01P
*BA05.10- P-1003- 01P 6 Relieve timing chain (2) through careful turning at the camshaft and remove slide rail (1) from bearing pin (8)
7 Install in the reverse order
TIMING CHAIN DRIVE Number Designation Engine 132.9 BA05.10-P-1002-01P Bolt, timing chain slide rail to cylinder head Nm 10 BA05.10-P-1003-01P Bolt, timing chain slide rail to crankcase Nm 10 BA05.10-P-1004-01P Bolt, cam chain tensioner to crankcase Nm 9 TESTING & REPAIR INDEX > CHECK BASIC POSITION OF CAMSHAFTS - AR05.20-P- 6010MCU > 1 tips Question: Timing marks - smart passion and coupe ENGINES 132.910 in MODEL 451.3/4 Fig 1: Identifying Expansion Clip And Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 751 · Applies to: 450, 451, 452, 454
1 Remove cylinder head cover
AR01.20- P- 5014MCU 2 Detach right rear wheel
AR40.10- P- 1100MCU Remove expansion Fig 2: Identifying Crankshaft Belt Pulley, Center Bolt And Timing Case Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Timing Case Cover, Camshaft Adjuster And Camshaft Sprocket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
clips (1) and remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 752 · Applies to: 450, 451, 452, 454
3 clips (1) and remove cover (2)
Checking
4 Turn crankshaft on center bolt (4) of crankshaft belt pulley (3) in direction of engine rotation until marking (arrow A) is visible The crankshaft must not be turned back, otherwise timing chain can skip and this can result in engine damage.
5 Transfer marking (arrow A) on crankshaft belt pulley (3) onto the front side of the crankshaft belt pulley (3) (arrow B) using a suitable colored pencil
6 Rotate crankshaft in direction of engine rotation until marking (arrow B) corresponds with marking "10" (arrow C) on timing case cover (5) The marking "10" (arrow C) represents 10° BTDC.
7 Lower vehicle with vehicle lift
8 Check adjustment of camshaft Check whether marking (arrow E) on camshaft adjuster (6) and marking (arrow D) on camshaft sprocket (7) stand opposite each other at the height of the upper edge of the timing case cover (5)If the marking (arrow E) on the camshaft adjuster (6) and marking (arrow D) on the camshaft sprocket (7) are not visible, turn crankshaft one more turn.If marking (arrow D) and marking (arrow E) are not flush: ↓
Set basic position of camshafts AR05.20- P- 6020MCU 9 Install in the reverse order
TESTING & REPAIR INDEX > SET BASIC POSITION OF CAMSHAFTS - AR05.20-P- 6020MCU > ENGINES 132.910 in MODEL 451.3/4
Shown with the engine removed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 754 · Applies to: 450, 451, 452, 454
Fig 2: Identifying Exhaust Camshaft, Timing Chain, Chain Tensioner, Camshaft Adjuster And Intake Camshaft Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Camshaft Sprocket, Exhaust Camshaft, Timing Case Cover, Timing Chain And Camshaft Adjuster Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 755 · Applies to: 450, 451, 452, 454
1 Bring intake camshaft (10) and exhaust camshaft (2) into their basic position The marking (arrow A or arrow B) on the crankshaft (11) belt pulley must be correspond during the whole correction process with marking "10" (arrow C) on the timing case cover (5).The marking "10" (arrow C) represents 10° BTDC.
-
not for USA AR05.20- P- 6010MCC
-
for USA only AR05.20- P- 6010MCU 2 Counterhold exhaust camshaft (2) at hexagon (arrow D) and loosen bolt (3) on camshaft sprocket (1) Fig 4
Fig 5 3 Remove screw plug (4) on timing case cover (5)
4 Press timing chain (6) downwards using a suitable tool in the area between the camshaft sprocket (1) and the camshaft adjuster (7), push back ratchet (8) on chain tensioner (9) using a suitable screwdriver and lock chain tensioner (9) An aid for pressing down the timing chain (6) is required.In order to lock the chain tensioner (9), place a pin with a diameter of 1.5 mm into the bore (arrow E) in the chain tensioner (9).
5 Remove bolt (3); detach camshaft sprocket (1) from exhaust camshaft (2) and remove from timing chain (6)
Adjust
6 Lift timing chain (6) and turn intake camshaft (10) on hexagon in the direction of the arrow until marking (arrow F) on the camshaft adjuster (7) is standing at the height of the timing case cover contact surface (5) Do not turn intake camshaft (10) against the direction of the arrow; this can cause folding up of the timing chain (6) which will cause damage.
7 Lay timing chain (6) on camshaft adjuster (7) ring gear
8 Turn exhaust camshaft (2) at hexagon (arrow D) until the drive plate (12) is vertical to the timing case cover (5) contact surface
9 Align camshaft sprocket (1) according to markings (arrow G) and insert in the The marking (arrow G) must stand at the height of the timing case cover (5) contact surface and opposite the
timing chain (6).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 756 · Applies to: 450, 451, 452, 454
marking (arrow F) on the camshaft adjuster (7). 10 Screw bolt (3) into exhaust camshaft (2) for centering Just put bolt (3) into place; do not tighten.
11 Press camshaft sprocket (1) with the cutout (arrow H) onto the exhaust camshaft (2) drive plate (12) Turn exhaust camshaft (2) at hexagon if necessary.
Install
12 Counterhold exhaust camshaft (2) at hexagon (arrow D) and tighten bolt (3) on camshaft sprocket (1) Fig 4
Fig 5
*BA05.20- P-1005- 01M 13 Push timing chain (6) downwards using a suitable tool in the area between the camshaft sprocket (1) and the camshaft adjuster (7); pull out the pin from the bore (arrow E) on chain tensioner (9) An aid for pressing down the timing chain (6) is required.
14 Remove screw plug (4) on timing case cover (5) Use new sealing ring.
*BA01.40- P-1008- 01M 15 Turn engine in direction of engine rotation through two revolutions
16 Again check basic position of intake camshaft (10) and exhaust camshaft (2) Repeat steps 2 to 16 times if necessary.
-
not for USA AR05.20- P- 6010MCC
-
for USA only AR05.20- P- 6010MCU 17 Install cover for the belt pulley (11)
18 Attach right rear wheel * not for USA AR40.10- P- 1100MCC
- for USA only AR40.10- P- 1100MCU
Install cylinder head cover¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 757 · Applies to: 450, 451, 452, 454
19 Install cylinder head cover * not for USA AR01.20- P- 5014MCC
- for USA only AR01.20- P- 5014MCU CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 BA01.40-P-1008-01M Screw plug at timing case cover Nm 50 CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1005- 01M Bolt connecting camshaft sprocket to exhaust camshaft Nm 90 TESTING & REPAIR INDEX > REMOVE/INSTALL CAMSHAFT SPROCKET - AR05.20-P- 6040MCU > Fig 4: Identifying Plug-In Adapter (001 589 01 16 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Box Wrench Bit (001 589 01 16 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINE 132.910 in MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 758 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove spark plugs
Replace spark plugs
AP15.10- P- 1580MCU 2 Remove cylinder head cover
AR01.20- P- 5014MCU 3 Counterhold exhaust camshaft (2) at hexagon (arrow A) and loosen bolt (3) on camshaft sprocket (1) Figure
Figure
*BA05.20- P-1005- 01M 4 Detach right rear wheel
AR40.10- P- 1100MCU 5 Check basic position of intake camshaft and exhaust camshaft (2) Installation: Turn engine in direction of engine rotation through two revolutions and check basic position of intake camshaft and exhaust camshaft (2). AR05.20- P- 6010MCU Fig 1: Identifying Camshaft Sprocket Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove crew plug (4) on timing ca e¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 759 · Applies to: 450, 451, 452, 454
6 Remove crew plug (4) on timing ca e cover (5) *BA01 40 P-1008- 01M 7 Lower vehicle with lifting platform
8 Mark position of timing chain (6) relative to camshaft sprocket (1)
9 Mark position of camshaft sprocket (1) and camshaft adjuster (7) relative to each other and to the upper edge of the timing case cover (5)
10 Press timing chain (6) downwards using a suitable tool in the area between the camshaft sprocket (1) and the camshaft adjuster (7), push back ratchet (8) on chain tensioner (9) using a suitable screwdriver and lock chain tensioner (9) An aid for pressing down the timing chain (6) is required.In order to lock the chain tensioner (9) place a pin with a diameter of 1.5 mm into the bore (arrow B) in the chain tensioner (9).
11 Remove bolt (3) and detach camshaft sprocket (1) from exhaust camshaft (2) and remove from timing chain (6) Installation: Ensure correct installation position of camshaft sprocket (1) on the exhaust camshaft (2). Align camshaft sprocket (1) according to markings and insert in the timing chain (6).
12 Install in the reverse order
CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 BA01.40-P-1008-01M Screw plug on timing case cover Nm 50 CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1005- 01M Bolt connecting camshaft sprocket to exhaust camshaft Nm 90
TESTING & REPAIR INDEX > REMOVE/INSTALL CAMSHAFT BEARING CAPS - AR05.20-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 760 · Applies to: 450, 451, 452, 454
P-6992-04MCU > CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1001- 01M Bolt, camshaft bearing bridge to cylinder head Nm 20 BA05.20-P-1002- 01M Bolt connecting camshaft bearing cap to cylinder head Nm 11 When removing the exhaust camshaft 1. Loosen bolts (1 to 3) for bearing bridge (4) in a number of stages according to the represented sequence until the back pressure is dissipated. Installation: Screw in bolts (1 to 3) in the reverse order in a number of stages all the way and tighten using the prescribed torque. 2. Remove bolts (1 to 3) and take off bearing bridge (4). Installation: Clean running surface of bearing bridge (4) and wet with engine oil. Fig 2: Identifying Plug-In Adapter (001 589 01 16 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Box Wrench Bit (001 589 01 16 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Loosen bolts (5 to 10) for bearing cap (11) in a number of stages according to the represented¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 761 · Applies to: 450, 451, 452, 454
sequence until the back pressure is dissipated. Installation: Screw in bolts (5 to 10) in the reverse order in a number of stages all the way and tighten using the prescribed torque. 4. Remove bolts (5 to 10) and take off bearing cap (11). Installation: Clean contact surfaces of bearing cap (11) and wet with engine oil. Pay attention to installation position. The arrows on the bearing caps (11) must be aligned straight to the control side. The bearing caps (11) are numbered in ascending order starting from the control side. 5. Install in the reverse order. When removing the intake camshaft 6. Loosen bolts (1 to 3) for bearing bridge (4) in a number of stages according to the represented sequence until the back pressure is dissipated. Installation: Screw in bolts (1 to 3) in the reverse order in a number of stages all the way and tighten using the prescribed torque. 7. Remove bolts (1 to 3) and take off bearing bridge (4). Installation: Clean running surface of bearing bridge (4) and wet with engine oil. Fig 1: Position For Exhaust Camshaft Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 763 · Applies to: 450, 451, 452, 454
The intake camshaft (1) and exhaust camshaft (2) can be removed separately
1 Check basic position of intake camshaft (1) and exhaust camshaft (2) and mark position of camshaft adjuster (3) relative to timing chain (4)
AR05.20- P- 6010MCU 2 Remove camshaft sprocket (5) on exhaust camshaft (2) Only the exhaust camshaft (2) is removed and adjusting of the basic setting is not required; fix camshaft sprocket (5) with cable tie to timing chain (4). AR05.20- P- 6040MCU 3 Remove bearing bridge (6) Observe loosening and tightening sequence otherwise the bearing bridge (6) can be damaged. AR05.20- P-6992- 04MCU
*BA05.20- P-1001- Fig 1: Identifying Camshaft Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Exhaust¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 764 · Applies to: 450, 451, 452, 454
01M
Exhaust camshaft (2)
4 Remove camshaft bearing cap (7) for exhaust camshaft (2) Observe loosening and tightening sequence otherwise the exhaust camshaft (2) can be damaged. Installation: Insert camshaft sprocket (5) into timing chain (4), position on exhaust camshaft (2) and check whether the marking (arrow C) on camshaft sprocket (5) and marking (arrow D) on camshaft adjuster (3) are standing opposite to each other at the height of the upper edge of the timing case cover (9). Ensure that the crankshaft is not turned. AR05.20- P-6992- 04MCU
*BA05.20- P-1002- 01M 5 Detach and remove exhaust camshaft (2) from the bearing seat by turning at hexagon (arrow A)
Intake camshaft (1)
6 Remove camshaft bearing cap (8) for intake camshaft (1) Observe loosening and tightening sequence otherwise the intake camshaft (1) can be damaged. AR05.20- P-6992- 04MCU
*BA05.20- P-1002- 01M 7 Detach and remove intake camshaft (1) from the bearing seat by turning at hexagon (arrow A)
8 Lift timing chain (4) and remove intake camshaft (1) Installation: Insert intake camshaft (1) in the timing chain (4) using the camshaft adjuster (3) in such a way that the marking (arrow D) on the camshaft adjuster (3) is at the upper edge of the timing case cover (9). Ensure that the crankshaft is not turned.
9 Remove camshaft adjuster (3) on inlet camshaft (1) When replacing the intake camshaft (1). AR05.20- P- 7201MCU Checking
Check cam on intake camshaft (1) or exhaust
Install in the reverse¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 766 · Applies to: 450, 451, 452, 454
01M 4 Install in the reverse order
CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1004-01M Bolt connecting camshaft adjuster to intake camshaft Nm 90 TESTING & REPAIR INDEX > REMOVE/INSTALL SOLENOID CHAMSHAFT - AR05.20-P- 7295MCU > ENGINE 132.910 in MODEL 451.3/4
Remove/install
1 Remove interior flap above engine
AR88.40- P-1100- 03MCC 2 Disconnect electrical connector (1) on adjustable camshaft timing solenoid (Y49)
3 Unscrew bolt (2) *BA05.20- P-1006- 01M 4 Pull adjustable camshaft timing solenoid (Y49) out of cylinder head Ensure that no dirt can find its way into oil holes on the adjustable camshaft timing solenoid (Y49) or in the bore in the cylinder head otherwise damage can occur on the engine. Installation: Check sealing ring on the adjustable
Fig 1: Identifying Adjustable Camshaft Timing Solenoid, Electrical Connector And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 768 · Applies to: 450, 451, 452, 454
1 Remove cylinder head * Not for USA AR01.30- P- 5800MCC
- For USA only AR01.30- P- 5800MCU 2 Cut fuel hose with an inside diameter of 6 mm to a length of about 5 cm
3 Lay cylinder head on the wooden plate and lay the cut to length fuel hose in the combustion chamber under the valves
4 Screw in thread extension (1) and counter stay (2) in the area of the respective valves into a threaded hole on the cylinder head Valve assembly tool case Fig 3
Thread extension for retaining fork Fig 6 5 Attach lever handle and depressor (4) to the thrust fork (3) and hook into the counter stay (2) Valve assembly tool case Fig 3
Depressor Fig 5 6 Position depressor (4) in the middle on the upper valve spring retainer (6) and press valve spring (7) together through pressing together the lever handle Valve assembly tool case Fig 3
Depressor Fig 5 7 Remove valve collets (5) using suitable magnets and also remove thrust fork (3) using a depressor (4) and lever handle Valve assembly tool case Fig 3 Fig 2: Identifying Valve Stem Seals (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Depre¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 769 · Applies to: 450, 451, 452, 454
or Fig 5 8 Remove valve spring retainer (6) and valve spring (7) Observe installation position of valve spring (7).The valve spring retainer (8) can remain in the cylinder head.
9 Detach valve stem seal (9), using pliers out of the valves repair tool, from the valve guide Valve assembly tool case Fig 3 Install
10 Lubricate new valve shaft seal (11) with engine oil
11 Insert new valve stem seal (11) on the valve stem (10) and press on using drift (12). The new valve stem seal (11) must not removed again from the valve stem (10). The valve stem seal (11) is damaged during removal and is therefore unusable.
Drift Fig 4 12 Insert valve spring (7) and valve spring retainer (6) Observe installation position of valve spring (7).
13 Hook thrust fork (3) with depressor (4) and lever handle into the counter stay (2) Valve assembly tool case Fig 3
Depressor Fig 5 14 Position depressor (4) in the middle on the valve spring retainer (6) and press together valve spring (7) through pressing down the lever handle, insert the valve conical pieces (5) on the valve stem (10) in the cutout and then relieve the valve spring retainer (6) Check for correct seating of the valve conical pieces (5); repeat the operation step if necessary.
Valve assembly tool case Fig 3
Depressor Fig 5 15 Remove thrust fork (3) with depressor (4) and lever handle Valve assembly tool case Fig 3
Depressor Fig 5 16 Remove thread extension (1) and counter stays (2) on the cylinder head Valve assembly tool case Fig 3
Thread extension for retaining fork Fig 6 17 Repeat operation steps 3 to 16 until all valve stem seals (9) have been replaced by new valve stem seals (11)
18 Install cylinder head * Not for USA AR01.30- P-
5800MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 770 · Applies to: 450, 451, 452, 454
- For USA only AR01.30- P- 5800MCU Fig 3: Identifying Case For Valve Installation Tools (111 589 25 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Drift (132 589 00 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Depressor (272 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(1) and remove intake¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 772 · Applies to: 450, 451, 452, 454 · AR: AS05.00-Z-9999ZZ, BA05.00-Z-9999CZ
3 (1) and remove intake valves (2) and exhaust valves (3) with the valve grinding tool (6) out of the cylinder head (1) roughness and ridging, replace intake valves (2), exhaust valves (3) or cylinder head (1) if necessary.Mark installation position if the removed intake valves (2) and exhaust valves (3) are reinstalled.
Repair tools for valves Fig 2 Install
4 Insert intake valves (2) and exhaust valve (3) into cylinder head (1) If removed intake valves (2) and exhaust valves (3) are used again then these should be reinserted in the same position.
5 Turn over the cylinder head (1) and insert valve spring retainer (4) in the cylinder head
6 Replace valve stem seals (5).
AR05.30- P- 3510MCC SAFETY PRECAUTIONS > SAFETY INFORMATION: ENGINE TIMING - AS05.00-Z-9999ZZ > MODEL all Disposal of sodium-filled valves ENGINE 111, 112, 113, 137, 155, 156, 159, 166, 266, 646, 647, 648... TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: ENGINE TIMING - BA05.00-Z-9999CZ > MODEL all Camshaft ENGINE 122.9 in MODEL 454.0 BA05.20-P-1000-01L Camshaft ENGINE 134.910 /911, 135.930 /950 BA05.20-P-1000-01I Fig 2: Identifying Repair Tools For Valves (452 589 01 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Camshaft¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 773 · Applies to: 450, 451, 452, 454
ENGINE 639.939 in MODEL 454 ENGINE 660.940 in MODEL 450 ENGINE 660.950 /951 in MODEL 451 BA05.20-P-1000-01H Camshaft ENGINE 160.910 /920 /921 /922 /923 BA05.20-P-1000-01G Camshaft ENGINE 132.9 in MODEL 451.3 /4 BA05.20-P-1000-01M Timing chain drive, toothed belt drive ENGINE 134.910 /911, 135.930 /950 in MODEL 454.0 BA05.10-P-1000-01I Timing chain drive, toothed belt drive ENGINE 160.910 /920 /921 /922 /923, 660.940 /950 /951 BA05.10-P-1000-01G Timing chain drive, toothed belt drive ENGINE 132.9 in MODEL 451.3 /4 BA05.10-P-1000-01P Timing chain drive, toothed belt drive ENGINE 122.950 BA05.10-P-1000-01O Timing chain drive, toothed belt drive ENGINE 639.939 BA05.10-P-1000-01M TORQUE SPECIFICATIONS > TIMING CHAIN DRIVE, TOOTHED BELT DRIVE - BA05.10-P- 1000-01P > Model 451.3/4 with engine 132.9 TIMING CHAIN DRIVER Number Designation Engine 132.9 BA05.10-P-1001-01P Bolt, timing chain tensioning rail to cylinder head Nm 23 BA05.10-P-1002-01P Bolt, timing chain slide rail to cylinder head Nm 10 BA05.10-P-1003-01P Bolt, timing chain slide rail to crankcase Nm 10 BA05.10-P-1004-01P Bolt, cam chain tensioner to crankcase Nm 9 TORQUE SPECIFICATIONS > CAMSHAFT - BA05.20-P-1000-01M > Model 451.3/4 with engine 132.9 CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1001- 01M Bolt, camshaft bearing bridge to cylinder head Nm 20 BA05.20-P-1002- 01M Bolt connecting camshaft bearing cap to cylinder head Nm 11 BA05.20-P-1004- Bolt connecting camshaft adjuster to intake camshaft Nm 90
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 776 · Applies to: 450, 451, 452, 454
Actuation of the adjustable camshaft timing solenoid takes place map-controlled via the ME-SFI [ME] control unit (N3/10). The adjustable camshaft timing solenoid integrated in the oil circuit guides the engine oil, according to actuation, through the ME-SFI [ME] control unit (N3/10), via the oil pressure line "advanced" or the oil pressure line "retarded" to the camshaft adjuster. Excess engine oil in the engine oil circuit is led back via the return on the adjustable camshaft timing solenoid. SPECIAL TOOLS > 602 589 00 98 00 CASE - WS05.00-P-0158C > FG 03/05/18/Set C Fig 1: Identifying Adjustable Camshaft Timing Solenoid Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Adjustable Camshaft Timing Solenoid Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINE all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 777 · Applies to: 450, 451, 452, 454
Use: Case for storing individual assembly tool parts for timing chains
SPECIAL TOOLS > 602 589 02 33 00 CHAIN SEPARATING TOOL - WS05.00-P-0159C > FG 05/18/Set C ENGINES all Use: Timing chain separating tool (basic unit) in combination with thrust spindle 602 589 04 63 00 or 602 589 05 63 00 for separating installed endless timing chain.
SPECIAL TOOLS > 602 589 00 39 00 RIVETING TOOL - WS05.00-P-0162C > Fig 1: Identifying Case (602 589 00 98 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Chain Separating Tool (602 589 02 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 05/18/Set C¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 778 · Applies to: 450, 451, 452, 454
ENGINES all MODIFICATION NOTES 9.6.95 Replaces: 000 589 58 43 00
20.11.07 Replaced by 642 589 00 33 00 WS05.00-P-0260C Use: Rivet press tool for timing chains (basic unit).
SPECIAL TOOLS > 602 589 02 40 00 ASSEMBLY LINKS - WS05.00-P-0171C > FG 05/18/Set C ENGINE all Use: Assembly links (3 in total) for simplex roller chain, duplex roller chain and duplex bushed roller chain for connecting repair chain to installed chain Assembly links must not be left in the engine.
Fig 1: Identifying Riveting Tool (602 589 00 39 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: PART NUMBERS 272 - WS00.01-Z-9272CZ¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 779 · Applies to: 450, 451, 452, 454 · AR: WS00.01-Z-9272CZ
MODEL all 272 589 00 61 00 Depressor FG 05/Set B SPECIAL TOOLS > 450 589 00 61 00 DEPRESSOR - WS05.00-P-0235B > FG 05/Set B ENGINE 122, 132, 134, 135, 160, 639, 660 Use: Depressor for disassembly of valve lock with detent depressor 111 589 25 61 05. NOTE: Smart no.: Q 002 1182 V001 0000 00 Fig 1: Identifying Assembly Links (602 589 02 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 642 589 00 33 00 RIVETING TOOL - WS05.00-P-0260C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 780 · Applies to: 450, 451, 452, 454
FG05/18/Set C ENGINE all MODIFICATION NOTES 20.11.07 Replacement for 602 589 00 39 00 WS05.00-P-0162C 20.11.07 Replacement for 272 589 00 39 00 WS05.00-P-0223B Use: Rivet press tool (basic unit) to rivet timing chains. Assembly inserts 651 589 04 63 00 should be used for engine 651.
Fig 1: Identifying Depressor (450 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Riveting Tool (642 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 01 16 00 THREAD EXTENSION FOR RETAINING FORK -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 781 · Applies to: 450, 451, 452, 454
WS05.00-P-0265B > FG 05/Set B ENGINE 132 in MODEL 451 Use: Thread extension for retaining fork M6 x 20mm to remove the valve springs. NOTE: Only in combination with tool valve assembly caseW111 589 25 61 00. SPECIAL TOOLS > 132 589 00 43 00 DRIFT - WS05.00-P-0270C > FG 05/Set C ENGINES 132 Use: Drift for pressing on valve stem seal with valve installed. Fig 1: Identifying Thread Extension For Retaining Fork (451 589 01 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 111 589 25 61 03 LEVER HANDLE - WS05.00-P-3137-03C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 782 · Applies to: 450, 451, 452, 454
FG05/Set C ENGINE 122, 132, 134, 135, 160, 639, 660 ENGINE 651 Use: Lever handle for operating the thrust fork and assembly cartridge. NOTE: Smart No.: 001 7009 V000 0000 00. SPECIAL TOOLS > 111 589 25 61 05 DETENT DEPRESSOR - WS05.00-P-3137-05C > FG05/Set C Fig 1: Identifying Drift (132 589 00 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Lever Handle (111 589 25 61 03) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINE 122, 132, 134, 135, 160, 639, 660¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 783 · Applies to: 450, 451, 452, 454
ENGINE 651 Use: Detent depressor for disassembly of valve key in combination with depressor W 450 589 00 61 00. SPECIAL TOOLS > 111 589 25 61 06 THRUST FORK - WS05.00-P-3137-06C > FG05/Set C ENGINE 122, 132, 134, 135, 160, 639, 660 ENGINE 651 Use: Thrust fork for mounting the assembly cartridge. NOTE: Smart No.: 001 7006 V000 0000 00. Fig 1: Identifying Detent Depressor (111 589 25 61 05) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 111 589 25 61 12 FIXING BRACKET - WS05.00-P-3137-12C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 784 · Applies to: 450, 451, 452, 454
FG05/Set C ENGINE 122, 132, 134, 135, 160, 639, 660 ENGINE 651 Use: Retaining fork M6 15 for screwing in the cylinder head. Mount for grid 111 589 25 61 19. NOTE: Smart no.: 001 7007 V000 0000 00. SPECIAL TOOLS > 111 589 25 61 19 GRID - WS05.00-P-3137-19C > Fig 1: Identifying Thrust Fork (111 589 25 61 06) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Fixing Bracket (111 589 25 61 12) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG05/Set C¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 785 · Applies to: 450, 451, 452, 454 · AR: WS05.00-P-3137BA
ENGINE 122, 132, 134, 135, 160, 639, 660 ENGINE 651 Use: Grid for mounting thrust fork 111 589 25 61 06. NOTE: Smart No.: 001 7008 V000 0000 00. SPECIAL TOOLS > 111 589 25 61 00 VALVE ASSEMBLY TOOLS KIT - WS05.00-P-3137BA
FG 05/Set B ENGINE 104, 111, 112, 113, 119, 120, 122, 132, 134, 135, 155, 156, 159, 160, 166, 266, 271, 272, 273, 601, 602, 603, 604, 605, 606, 611 /980, 612 /965 /966, 613, 628, 629, 639, 640, 642, 646, 647, 648, 651, 660, 668 ENGINE 648.960 in MODEL 220 Separate part 111 589 25 61 06 Thrust fork FG05/Set C WS05.00-P-3137-06C Separate part 111 589 25 61 12 Fixing bracket FG05/Set C WS05.00-P-3137-12C Separate part 111 589 25 61 19 Step spacing FG05/Set C WS05.00-P-3137-19C Separate part 111 589 25 61 03 Lever handle FG05/Set C WS05.00-P-3137-03C Separate part 111 589 25 61 05 Detent depressor FG05/Set C WS05.00-P-3137-05C Use: Assembly tool for valve springs in a plastic case. Fig 1: Identifying Grid (111 589 25 61 19) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
NOTE:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 786 · Applies to: 450, 451, 452, 454
For engines with tappet holes in cylinder head assembly of the valve keys is performed automatically by the assembly cartridges.
Consisting of: Part 1 Empty case Part 2 Impact pin Part 3 Lever handle Part 4 Extension Part 5 Detent depresser for thrust piece Part 6 Thrust fork for assembly cartridges Part 7 Thrust piece for detent depresser Part 8 Assembly cartridge length 83 mm (gasoline engine) Part 9 Assembly cartridge length 102 mm (diesel engine) Part 10 Pilot bushing length 28.6 mm (gasoline engine) Part 11 Pilot bushing length 53 mm (diesel engine) Part 12 Retaining fork M 6 X 15 mm Part 13 Retaining fork M 7 X 25 mm Fig 1: Identifying Valve Assembly Tools Kit (111 589 25 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Part 14 Retaining fork M 7 X 30 (bolt length 60 mm)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 787 · Applies to: 450, 451, 452, 454
Part 15 Retaining fork M 8 X 20 mm Part 16 Threaded hook M6 X 23 mm Part 17 Threaded hook M7 X 23 mm Part 18 Threaded hook M8 X 20 mm Part 19 Grid with a joint bearing SPECIAL TOOLS > 001 589 01 16 01 PLUG-IN ADAPTER - WS05.00-P-3149-01B > FG05/Set B ENGINES 132.9 in MODEL 451 Use: Insert adapter 9x12 on 3/8 from set of engine mount wrenches 001 589 01 16 00 SPECIAL TOOLS > 001 589 01 16 09 BOX WRENCH BIT - WS05.00-P-3149-09B > FG05/Set B ENGINES 132.9 in MODEL 451 Use: Box wrench bit SW17 from set of engine mount wrenches 001 589 01 16 00 Fig 1: Identifying Plug-In Adapter (001 589 01 16 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 001 589 01 16 00 ENGINE MOUNT WRENCH SET - WS05.00-P-3149B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 788 · Applies to: 450, 451, 452, 454 · AR: WS05.00-Z-9999CZ
FG 05/Set B ENGINES 132.9 in MODEL 451 Separate part FG 05/Set B 001 589 01 16 01 Plug-in adapter WS05.00-P-3149-01B Separate part FG 05/Set B 001 589 01 16 09 Box wrench bit WS05.00-P-3149-09B Use: Engine mount wrench set to loosen and tighten camshaft sprocket bolt of the exhaust camshaft. SPECIAL TOOLS > SPECIAL TOOLS: SMART: ENGINE TIMING - WS05.00-Z-9999CZ > MODEL all 001 589 01 16 00 Engine FG 05/Set B WS05.00-P-3149B Fig 1: Identifying Box Wrench Bit (001 589 01 16 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Engine Mount Wrench Set (001 589 01 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
mount wrench set¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 789 · Applies to: 450, 451, 452, 454 · AR: WS05.00-P-3137BA
001 589 01 16 01 Plug-in adapter FG05/Set B WS05.00-P-3149-01B 001 589 01 16 09 Box wrench bit FG05/Set B WS05.00-P-3149-09B 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K 111 589 25 61 00 Valve assembly tools kit FG 05/Set B WS05.00-P-3137BA 111 589 25 61 03 Lever handle FG05/Set C WS05.00-P-3137-03C 111 589 25 61 05 Detent depressor FG05/Set C WS05.00-P-3137-05C 111 589 25 61 06 Thrust fork FG05/Set C WS05.00-P-3137-06C 111 589 25 61 12 Fixing bracket FG05/Set C WS05.00-P-3137-12C 111 589 25 61 19 Grid FG05/Set C WS05.00-P-3137-19C 122 589 00 63 00 Locking tool FG 05/Set B WS05.00-P-0254B 122 589 01 15 00 Drift FG 05/Set C WS05.00-P-0247C 122 589 01 61 00 Insertion tool FG 05/Set C WS05.00-P-0246C 122 589 02 61 00 Assembly tool FG 05/Set C WS05.00-P-0248C 132 589 00 43 00 Drift FG 05/Set C WS05.00-P-0270C 272 589 00 61 00 Depressor FG 05/Set B WS05.00-P-0233B 450 589 00 01 00 Open end wrench FG 05/Set B WS05.00-P-0210B 450 589 00 61 00 Depressor FG 05/Set B WS05.00-P-0235B 450 589 03 33 00 Puller FG 05/Set B WS05.00-P-0212B 450 589 05 99 00 Chain repair kit FG 05/Set B WS05.00-P-0211B 451 589 01 16 00 Thread extension for retaining fork FG 05/Set B WS05.00-P-0265B 451 589 01 63 00 Adapter FG 01/03/05/Set B WS01.00-P-0143B 452 589 01 99 04 Assembly cartridge FG01/05/Set C WS01.00-P-0108-04C
452 589 01 99 09 Drift¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 790 · Applies to: 450, 451, 452, 454
FG01/05/Set C WS01.00-P-0108-09C 452 589 01 99 10 Drift FG01/05/Set C WS01.00-P-0108-10C 452 589 01 99 15 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108-15C 452 589 01 99 16 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108-16C 452 589 01 99 17 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108-17C 452 589 01 99 18 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108-18C 452 589 01 99 19 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108-19C 452 589 01 99 20 Valve seat milling cutter FG01/05/Set C WS01.00-P-0108-20C 452 589 01 99 21 T-handle FG01/05/Set C WS01.00-P-0108-21C 452 589 01 99 22 Guide FG01/05/Set C WS01.00-P-0108-22C 452 589 01 99 23 Guide FG01/05/Set C WS01.00-P-0108-23C 452 589 01 99 24 Straightedge FG01/05/Set C WS01.00-P-0108-24C 452 589 01 99 26 Roll pin FG01/05/Set C WS01.00-P-0108-26C 452 589 01 99 28 Adapter FG01/05/Set C WS01.00-P-0108-28C 454 589 00 14 00 Spacer FG 05/Set B WS05.00-P-0241B 454 589 00 21 00 Torque wrench FG 05/Set B WS05.00-P-0245B 454 589 00 23 00 Feeler gauge FG 05/Set B WS05.00-P-0221B 454 589 01 23 00 Template FG 05/Set B WS05.00-P-0237B 454 589 02 40 00 Tie-down set FG 05/Set B WS05.00-P-0231B 454 589 09 09 00 Socket wrench bit FG 05/Set C WS05.00-P-0219C 454 589 12 09 00 Socket wrench FG 05/Set C WS05.00-P-0244C 454 589 13 09 00 Socket wrench bit FG 05/Set B WS05.00-P-0240B 454 589 14 09 00 Plug adapter FG 05/Set B WS05.00-P-0243B 454 589 16 15 00 Centering pin FG 05/Set C WS05.00-P-0242C
602 589 00 39 00 Riveting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 791 · Applies to: 450, 451, 452, 454
tool FG 05/18/Set C WS05.00-P-0162C 602 589 00 98 00 Case FG 03/05/18/Set C WS05.00-P-0158C 602 589 02 33 00 Chain separating tool FG 05/18/Set C WS05.00-P-0159C 602 589 02 40 00 Assembly links FG 05/18/Set C WS05.00-P-0171C 602 589 03 63 00 Thrust piece FG 05/Set C WS05.00-P-0164C 602 589 05 63 00 Pressure screw FG 05/18/Set C WS05.00-P-0161C 602 589 05 63 01 Pressure pins FG 05/18/Set C WS05.00-P-0161-01C 611 589 00 63 00 Connector FG 01/05/Set B WS01.00-P-0057B 640 589 01 40 00 Hold-down device Group 05/Set B WS05.00-P-0225B 640 589 01 63 00 Guide Group 05/Set B WS05.00-P-0218B 642 589 00 33 00 Riveting tool FG05/18/Set C WS05.00-P-0260C
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 793 · Applies to: 450, 451, 452, 454
1 Remove resonance tank
AR09.20- P- 0010MCU 2 Remove bolts (2) for pipework (1) on cylinder head Installation: Replace seal for pipework (1) on cylinder head.
*BA14.30- P-1002- 03C 3 Remove bolts (3) for pipework (1) on valve for secondary air injection (4) Installation: Replace seal for pipework (1) on valve for secondary air injection (4).
*BA14.30- P-1003- 03C 4 Remove pipework (1) upwards out of the engine compartment
5 Install in the reverse order
COMBINATION VALVE Number Designation Engine 132.910 BA14.30-P-1002- Bolt, pipe for secondary air injection to cylinder head Nm 8 Fig 1: Identifying Pipeline, Valve For Secondary Air Injection And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA14.30-P-1003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 794 · Applies to: 450, 451, 452, 454
03C BA14.30-P-1003- 03C Bolt, pipe for secondary air injection to valve for secondary air injection Nm 8 TESTING & REPAIR > REMOVE/INSTALL SECONDARY AIR INJECTION PUMP - AR14.30- P-8000MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 1: Identifying Secondary Air Injection Pump Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Secondary Air Injection Pump Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 795 · Applies to: 450, 451, 452, 454
1 Release rear drive module
AR01.00-P- 3050MCU 2 Detach molded hose (1) to secondary air injection pump (M33)
3 Remove bolts (2) for holder (3) on frame-type integral support (4)
4 Disconnect electrical connector (5) from secondary air injection pump (M33)
5 Remove secondary air injection pump (M33) complete with holder (3) from frame-type integral support (4)
6 Loosen nuts (6) and remove secondary air injection pump (M33) with holder (7) from holder (3) Ensure that the rubber mount on the holder (7) does turn when loosening and tightening the nuts (6) and is thereby damaged. The holder (7) is attached with three nuts (6) to the holder (3).
7 Remove bolts (8)
8 Loosen adhesive pad (9), remove expansion clip (10) and remove rubber disks between the holder (7) and the noise damper (11)
9 Remove secondary air injection pump (M33) with noise damper (11) from holder (7)
10 Detach molded hose (12) on secondary air injection pump (M33) and remove together with the noise damper (11)
11 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL SECONDARY AIR INJECTION PUMP
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 797 · Applies to: 450, 451, 452, 454
1 Remove interior flap above engine
AR88.40- P-1100- 03MCC 2 Detach vacuum hose (2) at secondary air injection pump switchover valve (1)
3 Detach supply line (3) at secondary air injection pump switchover valve (1)
4 Disconnect connector O2 for sensor upstream of TWC (G3/2x1) and unclip from holder to the cylinder head cover
5 Raise vehicle with vehicle lift
6 Support the rear axle crossmember (4) using a transmission jack, unscrew bolts (5) and lower the rear axle crossmember (4) Transmission jack http://gotis.aftersales.mercedes- benz.com *BA35.10- P-1003- 01F 7 Remove bolts (6) for pipework (7) on valve for secondary air injection (1) Installation: Replace seal for pipework (7) on valve for secondary air injection (1).
*BA14.30- P-1003- Fig 1: Identifying Secondary Air System Valve Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove bolts (8) on secondary air¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 798 · Applies to: 450, 451, 452, 454 · AR: AS14.00-Z-9999ZZ
03C 8 Remove bolts (8) on secondary air injection valve (1) on cylinder head and remove secondary air injection valve (1) downwards *BA14.30- P-1001- 03C 9 Install in the reverse order
COMBINATION VALVE Number Designation Engine 132.910 BA14.30-P-1001- 03C Bolt, valve for secondary air injection to cylinder head Nm 20 BA14.30-P-1003- 03C Bolt, pipe for secondary air injection to valve for secondary air injection Nm 8 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1003- 01F Bolt, crossmember to frame-type integral support Nm 65 SAFETY PRECAUTIONS > SAFETY INFORMATION: EXHAUST MANIFOLD, ENGINE BRAKE, EMISSION CONTROL SYSTEM - AS14.00-Z-9999ZZ > MODEL all Risk of burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue ENGINE all AS14.40-Z-0001- 01A TORQUE SPECIFICATIONS > O2 SENSOR - BA14.00-P-1000-01B > Engine 132, 160, 660 O2 SENSOR Number Designation Engine 132.9 Engine 160.910 Engine 160.920 BA14.00-P-1001- 01B O sensor on exhaust pipe/ exhaust manifold Nm - 50 50 BA14.00-P-1002- 01B O2 sensor upstream of TWC to catalytic converter Nm 50 - - BA14.00-P-1003- 01B O2 sensor downstream of TWC to catalytic converter Nm 40 - - O2 SENSOR 2
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 799 · Applies to: 450, 451, 452, 454 · AR: BA14.00-Z-9999CZ
Designation Engine 160.921 Engine 160.922 Engine 160.923 BA14.00-P-1001- 01B O sensor on exhaust pipe/ exhaust manifold Nm 50 50 50 BA14.00-P-1002- 01B O2 sensor upstream of TWC to catalytic converter Nm - - - BA14.00-P-1003- 01B O2 sensor downstream of TWC to catalytic converter Nm - - - O2 SENSOR Number Designation Engine 660.950/951 BA14.00-P-1001- 01B O sensor on exhaust pipe/ exhaust manifold Nm - BA14.00-P-1002- 01B O2 sensor upstream of TWC to catalytic converter Nm 50 BA14.00-P-1003- 01B O2 sensor downstream of TWC to catalytic converter Nm - TORQUE SPECIFICATIONS > O2 SENSOR - BA14.00-P-1000-01G > Engine 132.9 O2 SENSOR Number Designation Engine 132.9 BA14.00-P-1001- 01G O2 sensor upstream of TWC on catalytic converter Nm 50 BA14.00-P-1002- 01G O2 sensor downstream TWC on catalytic converter Nm 50 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: EXHAUST MANIFOLD, ENGINE BRAKE, EMISSION CONTROL SYSTEM - BA14.00-Z-9999CZ > MODEL all Air pump ENGINE 160.920 /921 /922 /923 BA14.30-P-1000-01C Combination valve ENGINE 160.910 /920 in MODEL 450.3 /4ENGINE 160.921 /922 /923 in MODEL 452.3 /4 BA14.30-P-1000-03A Combination valve ENGINE 132.910 in MODEL 451.3/4 BA14.30-P-1000- 03C Diesel particulate filter ENGINE 660.940 BA14.40-P-1000-01C Exhaust gas recirculation ENGINE 639.939 BA14.20-P-1000-01H 2 2
E hau t ga¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 800 · Applies to: 450, 451, 452, 454
recirculation ENGINE 660 940 /950 /951 BA14 20 P 1000 01E Exhaust manifold ENGINE 134.910 /911, 135.930 /950 BA14.10-P-1000-01H Exhaust manifold ENGINE 660.940 BA14.10-P-1000-01G Exhaust manifold ENGINE 160.910 /920 /921 /922 /923 BA14.10-P-1000-01F Exhaust manifold ENGINE 132.9 in MODEL 451.3/4 BA14.10-P-1000- 01O Exhaust manifold ENGINE 122.950 BA14.10-P-1000-01M Exhaust manifold ENGINE 639.939 BA14.10-P-1000-01K O2 sensor ENGINE 132.9, 160.910 /920 /921 /922 /923, 660.950 /951 BA14.00-P-1000- 01B O2 sensor ENGINE 132.9 BA14.00-P-1000- 01G O2 Sensor ENGINE 122.950, 134.910 /911, 135.930/950, 639.939 BA14.00-P-1000-01D TORQUE SPECIFICATIONS > EXHAUST MANIFOLD - BA14.10-P-1000-01O > Engine 132.9 EXHAUST MANIFOLD Number Designation Engine 132.9 BA14.10-P-1001- 01O Nut, exhaust manifold to cylinder head Nm 34 BA14.10-P-1002- 01O Bolt, exhaust manifold to exhaust pipe Nm 50 BA14.10-P-1003- 01O Bolt, exhaust manifold support brace to crankcase Nm 23 BA14.10-P-1004- 01O Bolt, exhaust manifold support brace to exhaust manifold Nm 23 BA14.10-P-1005- 01O Bolt connecting shield to exhaust manifold Nm 11 TORQUE SPECIFICATIONS > COMBINATION VALVE - BA14.30-P-1000-03C > Engine 132 COMBINATION VALVE Number Designation Engine 132.910 BA14.30-P-1001- 03C Bolt, valve for secondary air injection to cylinder head Nm 20 BA14.30-P-1002- Bolt, pipe for secondary air injection to cylinder Nm 8
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 802 · Applies to: 450, 451, 452, 454
The secondary air injection pump switchover valve is located on the left next to the cylinder head cover in the direction of travel. Task The secondary air injection pump switchover valve actuates the secondary air valve with a vacuum from the intake manifold for air injection. Design Fig 1: Locating Secondary Air Injection Pump Switchover Valve Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Secondary Air Injection Pump Switchover Valve Design Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 804 · Applies to: 450, 451, 452, 454 · AR: WS14.00-Z-9999CZ
Socket wrench bit for removal/installation of oxygen sensor. NOTE: Removal/Installation of oxygen sensor can be performed without disassembly of the CBS Rear.smart no.: 000 7097 V001 0000 00. SPECIAL TOOLS > SPECIAL TOOLS: SMART: EXHAUST MANIFOLD, ENGINE BRAKE, EMISSION CONTROL SYSTEM - WS14.00-Z-9999CZ > MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P-0007B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P-0006Z 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P-0111B 126 589 00 10 00 Screwdriver bit FG 46/91/14/32/ Set B WS46.00-P-0033B 220 589 01 99 10 Crimp pliers FG 00/14/54/83/Set B WS00.19-P-0001- 09B 220 589 01 99 30 Unlocking device with RK 2.5 ejector FG00/14/54/Set B WS00.19-P-0001- 20B 220 589 01 99 50 Blade holder with clamping pliers FG00/14/54/83/Set B WS00.19-P-0001- 25B 450 589 04 09 00 Socket wrench bit FG 14/Set B WS14.00-P-0005B Fig 1: Identifying Socket Wrench Bit (450 589 04 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
450 589 07 09 00 Socket wrench bit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 805 · Applies to: 450, 451, 452, 454
FG 14/Set B WS14 00 P 0006B 930 589 00 99 00 Supplemental truck wiring harness repair kit FG 00/14/54/67 / Set B WS00.19-N-0004B
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 807 · Applies to: 450, 451, 452, 454
1 Remove resonance tank
AR09.20- P- 0010MCU 2 Remove bolts (2) for pipework (1) on cylinder head Installation: Replace seal for pipework (1) on cylinder head.
*BA14.30- P-1002- 03C 3 Remove bolts (3) for pipework (1) on valve for secondary air injection (4) Installation: Replace seal for pipework (1) on valve for secondary air injection (4).
*BA14.30- P-1003- 03C 4 Remove pipework (1) upwards out of the engine compartment
5 Install in the reverse order
COMBINATION VALVE Number Designation Engine 132.910 Fig 1: Identifying Valve For Secondary Air Injection, Pipeline & Mounting Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA14 30 P 1002¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 808 · Applies to: 450, 451, 452, 454
03C Bolt, pipe for econdary air injection to cylinder head Nm 8 BA14.30-P-1003- 03C Bolt, pipe for secondary air injection to valve for secondary air injection Nm 8 TESTING & REPAIR > REMOVE/INSTALL SECONDARY AIR INJECTION PUMP - AR14.30- P-8000MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 1: Identifying Secondary Air Injection Pump 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. 809 · Applies to: 450, 451, 452, 454
1 Release rear drive module
AR01.00- P- 3050MCU 2 Detach molded hose (1) to secondary air injection pump (M33)
3 Remove bolts (2) for holder (3) on frame-type integral support (4)
4 Disconnect electrical connector (5) from secondary air injection pump (M33)
5 Remove secondary air injection pump (M33) complete with holder (3) from frame-type integral support (4)
6 Loosen nuts (6) and remove secondary air injection pump (M33) with holder (7) from holder (3) Ensure that the rubber mount on the holder (7) does turn when loosening and tightening the nuts (6) and is thereby damaged. The holder (7) is attached with three nuts (6) to the holder (3).
7 Remove bolts (8)
Loosen adhesive pad (9), Fig 2: Identifying Secondary Air Injection Pump Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Raise vehicle with vehicle lift¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 812 · Applies to: 450, 451, 452, 454 · AR: AS14.00-Z-9999ZZ
5 Raise vehicle with vehicle lift
6 Support the rear axle crossmember (4) using a transmission jack, unscrew bolts (5) and lower the rear axle crossmember (4) Transmission jack *BA35.10- P-1003- 01F 7 Remove bolts (6) for pipework (7) on valve for secondary air injection (1) Installation: Replace seal for pipework (7) on valve for secondary air injection (1).
BA14.30- P-1003- 03C 8 Remove bolts (8) on secondary air injection valve (1) on cylinder head and remove secondary air injection valve (1) downwards BA14.30- P-1001- 03C 9 Install in the reverse order
COMBINATION VALVE Number Designation Engine 132.910 BA14.30-P-1001-03C Bolt, valve for secondary air injection to cylinder head Nm 20 BA14.30-P-1003-03C Bolt, pipe for secondary air injection to valve for secondary air injection Nm 8 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1003-01F Bolt, crossmember to frame-type integral support Nm 65 SAFETY PRECAUTIONS > SAFETY INFORMATION: EXHAUST MANIFOLD, ENGINE BRAKE, EMISSION CONTROL SYSTEM - AS14.00-Z-9999ZZ > MODEL all Risk of burn injuries and scalding when working at AdBlue lines and the components attached to them. Risk of injury to skin and eyes when handling AdBlue. Risk of poisoning caused by swallowing AdBlue ENGINE all AS14.40- Z-0001- 01A TORQUE SPECIFICATIONS > O2 SENSOR - BA14.00-P-1000-01B > Engine 132, 160, 660 O2 SENSOR Number Designation Engine 132.9 Engine 160.910 Engine 160.920 BA14.00-P- 1001-01B O sensor on exhaust pipe/ exhaust manifold Nm - 50 50 2
BA14.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 813 · Applies to: 450, 451, 452, 454 · AR: BA14.00-Z-9999CZ
1002-01B O2 sensor upstream of TWC to catalytic converter Nm 50 - - BA14.00-P- 1003-01B O2 sensor downstream of TWC to catalytic converter Nm 40 - - O2 SENSOR Number Designation Engine 160.921 Engine 160.922 Engine 160.923 BA14.00-P- 1001-01B O sensor on exhaust pipe/ exhaust manifold Nm 50 50 50 BA14.00-P- 1002-01B O2 sensor upstream of TWC to catalytic converter Nm - - - BA14.00-P- 1003-01B O2 sensor downstream of TWC to catalytic converter Nm - - - O2 SENSOR Number Designation Engine 660.950/951 BA14.00-P-1001- 01B O sensor on exhaust pipe/ exhaust manifold Nm - BA14.00-P-1002- 01B O2 sensor upstream of TWC to catalytic converter Nm 50 BA14.00-P-1003- 01B O2 sensor downstream of TWC to catalytic converter Nm - TORQUE SPECIFICATIONS > O2 SENSOR - BA14.00-P-1000-01G > Engine 132.9 O2 SENSOR Number Designation Engine 132.9 BA14.00-P-1001-01G O2 sensor upstream of TWC on catalytic converter Nm 50 BA14.00-P-1002-01G O2 sensor downstream TWC on catalytic converter Nm 50 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: EXHAUST MANIFOLD, ENGINE BRAKE, EMISSION CONTROL SYSTEM - BA14.00-Z-9999CZ > MODEL all Air pump ENGINE 160.920 /921 /922 /923 BA14.30-P-1000-01C Combination valve ENGINE 160.910 /920 in MODEL 450.3 /4ENGINE 160.921 /922 /923 in MODEL 452.3 /4 BA14.30-P-1000-03A Combination valve ENGINE 132.910 in MODEL 451.3 /4 BA14.30-P-1000-03C 2 2
Diesel particulate filter¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 814 · Applies to: 450, 451, 452, 454
ENGINE 660.940 BA14.40-P-1000-01C Exhaust gas recirculation ENGINE 639.939 BA14.20-P-1000-01H Exhaust gas recirculation ENGINE 660.940 /950 /951 BA14.20-P-1000-01E Exhaust manifold ENGINE 134.910 /911, 135.930 /950 BA14.10-P-1000-01H Exhaust manifold ENGINE 660.940 BA14.10-P-1000-01G Exhaust manifold ENGINE 160.910 /920 /921 /922 /923 BA14.10-P-1000-01F Exhaust manifold ENGINE 132.9 in MODEL 451.3 /4 BA14.10-P-1000-01O Exhaust manifold ENGINE 122.950 BA14.10-P-1000-01M Exhaust manifold ENGINE 639.939 BA14.10-P-1000-01K O2 sensor ENGINE 132.9, 160.910 /920 /921 /922 /923, 660.950 /951 BA14.00-P-1000-01B O2 sensor ENGINE 132.9 BA14.00-P-1000-01G O2 Sensor ENGINE 122.950, 134.910 /911, 135.930/950, 639.939 BA14.00-P-1000-01D TORQUE SPECIFICATIONS > EXHAUST MANIFOLD - BA14.10-P-1000-01O > Engine 132.9 EXHAUST MANIFOLD Number Designation Engine 132.9 BA14.10-P-1001- 01O Nut, exhaust manifold to cylinder head Nm 34 BA14.10-P-1002- 01O Bolt, exhaust manifold to exhaust pipe Nm 50 BA14.10-P-1003- 01O Bolt, exhaust manifold support brace to crankcase Nm 23 BA14.10-P-1004- 01O Bolt, exhaust manifold support brace to exhaust manifold Nm 23 BA14.10-P-1005- 01O Bolt connecting shield to exhaust manifold Nm 11 TORQUE SPECIFICATIONS > COMBINATION VALVE - BA14.30-P-1000-03C > Engine 132 COMBINATION VALVE Number Designation Engine 132.910
ENGINES 132.9 in MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 816 · Applies to: 450, 451, 452, 454
Location The secondary air injection pump switchover valve is located on the left next to the cylinder head cover in the direction of travel. Task The secondary air injection pump switchover valve actuates the secondary air valve with a vacuum from the intake manifold for air injection. Design Fig 1: Identifying Secondary Air Injection Pump Switchover Valve Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 818 · Applies to: 450, 451, 452, 454
The secondary air injection pump relay is located in the driver footwell above the accelerator pedals. Task The ME-SFI [ME] control unit (N3/10) actuates the secondary air injection pump (M33) via the secondary air injection pump relay. SPECIAL TOOLS > 50 589 04 09 00 SOCKET WRENCH BIT - WS14.00-P-0005B4 > FG 14/Set B MODEL 450, 452, 454 MODEL 451 with ENGINE 132 Use: Socket wrench bit for removal/installation of oxygen sensor. NOTE: Removal/Installation of oxygen sensor can be performed without disassembly of the CBS Rear.smart no.: 000 7097 V001 0000 00. Fig 1: Identifying Secondary Air Injection Pump Relay Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: EXHAUST MANIFOLD, ENGINE BRAKE,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 819 · Applies to: 450, 451, 452, 454 · AR: WS14.00-Z-9999CZ
EMISSION CONTROL SYSTEM - WS14.00-Z-9999CZ > MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P-0007B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P-0006Z 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P-0111B 126 589 00 10 00 Screwdriver bit FG 46/91/14/32/ Set B WS46.00-P-0033B 220 589 01 99 10 Crimp pliers FG 00/14/54/83/Set B WS00.19-P-0001- 09B 220 589 01 99 30 Unlocking device with RK 2.5 ejector FG00/14/54/Set B WS00.19-P-0001- 20B 220 589 01 99 50 Blade holder with clamping pliers FG00/14/54/83/Set B WS00.19-P-0001- 25B 450 589 04 09 00 Socket wrench bit FG 14/Set B WS14.00-P-0005B 450 589 07 09 00 Socket wrench bit FG 14/Set B WS14.00-P-0006B 930 589 00 99 00 Supplemental truck wiring harness repair kit FG 00/14/54/67 / Set B WS00.19-N-0004B Fig 1: Identifying Socket Wrench Bit (450 589 04 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT BRABUS MUFFLER - AN49.10-P-1003MCF¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 820 · Applies to: 450, 451, 452, 454 · AR: AN49.10-P-1003MCF
ENGINES 132.9 in MODEL 451.3/4 as of 31.8.10 Remove
1 Remove rear apron (2.1)
AR88.30-P- 0502MCC 2 Remove rear muffler (1.1)
AR49.10-P- 4823MCF Install
3 Clean sealing surface on catalytic converter seal
4 Install Brabus shock absorber (1.2)
AR49.10-P- 4823MCF Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z-0005- 01A Fig 1: Locating Brabus Muffler Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
near the engine a it i running¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 821 · Applies to: 450, 451, 452, 454 · AR: AN49.10-P-1003MCU
5 Perform engine test run and inspect exhaust system around BRABUS muffler (1.2) for leaks
6 Retrofit BRABUS (2.2) rear apron
AN88.20-P- 0001MCC 7 Add special equipment to the vehicle data card and to the online vehicle data card Retrofit Code (F04) sport exhaust system, Brabus (DFO).
8 Print out certificate and lay in the vehicle The certificate should be printed out in DIN A4 landscape format.
Installation or attachment of exhaust mufflers certificate * Applies to Europe only OF49.10-P-1000- 01HA RETROFITTING & CONVERSION > RETROFIT BRABUS MUFFLER - AN49.10-P-1003MCU
ENGINES 132.910 in MODEL 451.3/4 Remove
1 Remove rear muffler
Remove/install rear
AR49.10-P- Fig 1: Identifying Brabus Muffler Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
muffler¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 822 · Applies to: 450, 451, 452, 454
4823MCU Install
2 Clean sealing surfaces on exhaust pipe
3 Fit new seal ring on exhaust pipe
4 Position BRABUS muffler (1) at the catalytic converter and support with transmission jack and removal fixture Transmission jack http://gotis.aftersales.mercedes- benz.com 450589026200 5 Fasten BRABUS muffler (1) with bolts (5) BA49.10-P-1001- 01AD 6 Carefully lower BRABUS muffler (1) with transmission jack and removal fixture
7 Insert heat shield (4) in the two retaining clips at the front of the catalytic converter
8 Fasten bolts (3) on the heat shield (4)
9 Lift BRABUS muffler (1) and insert in rubber mountings (6)
10 Retrofit BRABUS (2) rear apron The BRABUS muffler (1) can only be installed in combination with BRABUS rear apron (2). AN88.20-P- 0001MCU Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z-0005- 01A 11 Do an engine test run and check the exhaust system around the BRABUS muffler (1) for leaks
12 Add special equipment to the vehicle data card Retrofit Code (F04) sport exhaust system, Brabus (DFO).
Detach heat shield (4) from the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 825 · Applies to: 450, 451, 452, 454
7 Detach heat shield (4) from the two retaining clips The two retaining clips are located in the front area on the catalytic converter.
8 Remove bolts (5) on rear muffler (1) and remove rear muffler (1) with seal Installation: Install new gasket
*BA49.10-P- 1001-01AD 9 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z- 0005-01A 10 Conduct engine test run and check exhaust system around the rear muffler (1) for leaks
EXHAUST SYSTEM Number Designation Engine 132.9 BA49.10-P-1001- 01AD Bolt, rear muffler to catalytic converter Nm 25 TESTING & REPAIR > REMOVE/INSTALL CATALYTIC CONVERTER - AR49.10-P- 5500MCU > ENGINES 132.910 in MODEL 451.3/4 with CODE (494) USA version ENGINES 132.910 in MODEL 451.3/4 as of 31.8.10 except CODE (494) USA version Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 826 · Applies to: 450, 451, 452, 454
Risk of injury to skin and eyes caused by handling hot or glowing objects. Wear safety gloves, protective clothing and safety glasses, if necessary. AS00.00- Z-0002- 01A 1 Remove rear muffler * for USA onlyEngine 132.910 AR49.10- P- 4823MCU * not for USAEngine 132.910 as of 31.8.10 AR49.10- P- 4823MCF 2 Unclip bracket (7) from connector on O2 sensor upstream of CAT [KAT] (G3/2x1)
3 Disconnect connector for O2 sensor upstream of CAT [KAT] (G3/2x1) and connector for O2 sensor downstream of CAT [KAT] (G3/1x1)
4 Support rear axle crossmember (1) using a transmission jack, unscrew bolts (arrows) and lower the rear axle crossmember (1) Use a suitable base.
Transmission jack gotis://H_00/10_01.0 *BA35.10- P-1003- 01F Fig 1: Identifying Catalytic Converter Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unscrew bolts (8) and remove heat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 827 · Applies to: 450, 451, 452, 454
5 Unscrew bolts (8) and remove heat shield (5)
6 Unscrew bolts (3) from bracket (4)
7 Unscrew bolt (9) from bracket (10) *BA49.10- P-1003- 01AD 8 Unscrew nuts (6) and remove three- way catalytic converter (2) Replace self-locking nuts (6). Installation: Clean sealing surfaces on cylinder head, on catalytic converter (2). Replace exhaust manifold gasket.
*BA49.10- P-1002- 01AD 9 Remove heat shield (5) When replacing catalytic converter (2). AR49.10- P- 6905MCU 10 Remove O2 sensor upstream of CAT [KAT] and O2 sensor downstream of CAT [KAT] from catalytic converter (2) When replacing catalytic converter (2). Use a suitable 22 mm socket wrench. Installation: Coat thread on O2 sensor downstream of CAT [KAT] and O2 sensor upstream of CAT [KAT] with paste.
BA14.00- P-1002- 01B BA14.00- P-1003- 01B Paste *BR00.45- Z-1005- 06A 11 Unscrew nuts (11) and remove bracket (10) When replacing catalytic converter (2). The holder (10) is attached using two nuts (11).
*BA49.10- P-1004- 01AD 12 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A
Risk of injury to skin and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 830 · Applies to: 450, 451, 452, 454
eyes caused by handling hot or glowing objects. Wear safety gloves, protective clothing and safety glasses, if necessary. AS00.00- Z-0002- 01A 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
2 Remove bolts (2)
3 Remove heat shield (1)
4 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL EXHAUST SYSTEM COMPLETE - AR49.10-P- 7000MCU > ENGINES 132.910 in MODEL 451.3/4 with CODE (494) USA version ENGINES 132.910 in MODEL 451.3/4 as of 31.8.10 except CODE (494) USA version
Remove/install
Align vehicle between Fig 1: Identifying Exhaust System Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of death caused by vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 831 · Applies to: 450, 451, 452, 454
slipping or toppling off of the lifting platform. 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
2 Remove rear apron
AR88.30-P- 0502MCC 3 Support rear axle crossmember (4) using a transmission jack, unscrew bolts (3) and lower the rear axle crossmember (4) Use a suitable base.
Transmission jack gotis://H_00/10_01.0 *BA35.10-P- 1003-01F 4 Remove heat shield for exhaust system
AR49.10-P- 6945MCU 5 Unclip bracket (5O2) from connector on sensor upstream of CAT [KAT] (G3/2x1)
6 Disconnect connector for O2 sensor upstream of CAT [KAT] (G3/2x1) and connector for O2 sensor downstream of CAT [KAT] (G3/1x1)
7 Unscrew bolts (9) from bracket (10)
8 Support rear muffler (1) with a transmission jack and a removal fixture Removal fixtureTransmission jack gotis://H_00/10_01. *450589026200 9 Unhook rear muffler (1) from the rubber retainers (2)
10 Unscrew bolt (8) *BA49.10-P- 1003-01AD 11 Unscrew nuts (6) Replace self-locking nuts (6). When unscrewing last nut (6), use helper to support rear muffler (1) with catalytic converter (7).
*BA49.10-P- 1002-01AD 12 Lower rear muffler (1) with catalytic converter (7) and take hold of it under the vehicle Aid of helper required. Installation: Clean sealing surfaces on cylinder head, on catalytic converter (7). Replace exhaust manifold gasket.
13 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is Secure vehicle to prevent it from moving by itself.Wear
running. Risk of injury caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 832 · Applies to: 450, 451, 452, 454
contusions and burns during starting procedure or when working near the engine as it is running closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z- 0005-01A 14 Perform engine test run and inspect exhaust system around catalytic convertor (7) for leaks
REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1003- 01F Bolt, crossmember to frame-type integral support Nm 65 EXHAUST SYSTEM Number Designation Engine 132.9 BA49.10-P-1002- 01AD Nut, catalytic converter to cylinder head Nm 25 BA49.10-P-1003- 01AD Bolt, bracket to cylinder head Nm 20 SAFETY PRECAUTIONS > SAFETY INFORMATION: EXHAUST SYSTEM - AS49.00-Z- 9999ZZ > MODEL all Risk of injury to skin and eyes from airborne particles and fibers when blowing out the SCR catalytic converter as well as from metal parts if it bursts. Hearing impairment from the loud sound of the air explosion. Risk of suffocation from breathing in soot particles and fibers. Risk of explosion of the pressurized SCR catalytic converter. ENGINE all AS49.10-Z-0001- 01A Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Function (Schematic presentation)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 834 · Applies to: 450, 451, 452, 454
Function Exhaust gases flow through the catalytic converters and hence come into contact with the rare metals, platinum and rhodium. Oxidation causes carbon monoxide to be converted to carbon dioxide and hydrocarbons into water and carbon dioxide. The nitrogen oxide is converted through reduction into nitrogen and carbon dioxide. The remaining oxygen content in the exhaust is a crucial factor in the conversion of pollutants. This is determined by the lambda control and maintained at=1 under normal operating conditions. Fig 2: Three-Way Catalytic Converter Function Schematic Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT BRABUS MUFFLER - AN49.10-P-1003MCF¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 835 · Applies to: 450, 451, 452, 454 · AR: AN49.10-P-1003MCF
ENGINES 132.9 in MODEL 451.3 /4 as of 31.8.10 Remove
1 Remove rear apron (2.1)
AR88.30- P- 0502MCC 2 Remove rear muffler (1.1)
AR49.10- P- 4823MCF Install
3 Clean sealing surface on catalytic converter seal
4 Install Brabus shock absorber (1.2)
AR49.10- P- 4823MCF Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting AS00.00- Z-0005- Fig 1: Identifying BRABUS Muffler Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
during tarting procedure or when working¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 836 · Applies to: 450, 451, 452, 454 · AR: AN49.10-P-1003MCU
near the engine as it is running work clothe Do not touch hot or rotating parts. 01A 5 Perform engine test run and inspect exhaust system around BRABUS muffler (1.2) for leaks
6 Retrofit BRABUS (2.2) rear apron
AN88.20- P- 0001MCC 7 Add special equipment to the vehicle data card and to the online vehicle data card Retrofit Code (F04) sport exhaust system, Brabus (DFO).
8 Print out certificate and lay in the vehicle The certificate should be printed out in DIN A4 landscape format.
Installation or attachment of exhaust mufflers certificate * Applies to Europe only OF49.10- P-1000- 01HA RETROFITTING & CONVERSION > RETROFIT BRABUS MUFFLER - AN49.10-P-1003MCU
ENGINES 132.910 in MODEL 451.3 /4 Remove
Fig 1: Identifying BRABUS Muffler Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove rear muffler¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 837 · Applies to: 450, 451, 452, 454
1 Remove rear muffler
Remove/install rear muffler
AR49.10- P- 4823MCU Install
2 Clean sealing surfaces on exhaust pipe
3 Fit new seal ring on exhaust pipe
4 Position BRABUS muffler (1) at the catalytic converter and support with transmission jack and removal fixture Transmission jack Fig 2 5 Fasten BRABUS muffler (1) with bolts (5) EXHAUST SYSTEM 6 Carefully lower BRABUS muffler (1) with transmission jack and removal fixture
7 Insert heat shield (4) in the two retaining clips at the front of the catalytic converter
8 Fasten bolts (3) on the heat shield (4)
9 Lift BRABUS muffler (1) and insert in rubber mountings (6)
10 Retrofit BRABUS (2) rear apron The BRABUS muffler (1) can only be installed in combination with BRABUS rear apron (2). AN88.20- P- 0001MCU Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 11 Do an engine test run and check the exhaust system around the BRABUS muffler (1) for leaks
12 Add special equipment to the vehicle data card and to the online vehicle data card Retrofit Code (F04) sport exhaust system, Brabus (DFO).
EXHAUST SYSTEM Number Designation Engine 132.9 BA49.10-P-1001-01AD Bolt, rear muffler to catalytic converter Nm 25
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 839 · Applies to: 450, 451, 452, 454
Risk of death caused by vehicle slipping or toppling off 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
2 Remove rear apron
AR88.30- P- 0502MCC 3 Support rear muffler (1) with a transmission jack and a removal fixture Transmission jack Figure 4 Unhook rear muffler (1) from the rubber retainers (2)
5 Lower rear muffler (1) using a transmission jack and removal fixture until the heat shield (4) bolts (3) are accessible
6 Remove heat shield (4) bolts (3)
7 Detach heat shield (4) from the two retaining clips The two retaining clips are located in the front area on the catalytic converter.
Fig 1: Identifying Rear Muffler Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove bolts (5) on rear muffler (1) and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 840 · Applies to: 450, 451, 452, 454
8 Remove bolts (5) on rear muffler (1) and remove rear muffler (1) with seal Installation: In tall new gasket
*BA49.10- P-1001- 01AD 9 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 10 Conduct engine test run and check exhaust system around the rear muffler (1) for leaks
EXHAUST SYSTEM Number Designation Engine 132.9 BA49.10-P-1001-01AD Bolt, rear muffler to catalytic converter Nm 25 TESTING & REPAIR INDEX > REMOVE/INSTALL CATALYTIC CONVERTER - AR49.10-P- 5500MCU > ENGINES 132.910 in MODEL 451.3 /4 with CODE (494) USA version ENGINES 132.910 in MODEL 451.3 /4 as of 31.8.10 except CODE (494) USA version Fig 2: Identifying Rear Muffler Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 841 · Applies to: 450, 451, 452, 454
Risk of injury to skin and eyes caused by handling hot or glowing objects. Wear safety gloves, protective clothing and safety glasses, if necessary. AS00.00- Z-0002- 01A 1 Remove rear muffler * for USA onlyEngine 132.910 AR49.10- P- 4823MCU * not for USAEngine 132.910 as of 31.8.10 AR49.10- P- 4823MCF 2 Unclip bracket (7) from connector on O2 sensor upstream of CAT [KAT] (G3/2x1)
3 Disconnect connector for O2 sensor upstream of CAT [KAT] (G3/2x1) and connector for O2 sensor downstream of CAT [KAT] (G3/1x1)
4 Support rear axle crossmember (1) using a transmission jack, unscrew bolts (arrows) and lower the rear axle crossmember (1) Use a suitable base.
Transmission jack *BA35.10- P-1003- 01F Fig 1: Identifying Catalytic Converter Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unscrew bolts (8) and remove heat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 842 · Applies to: 450, 451, 452, 454
5 Unscrew bolts (8) and remove heat shield (5)
6 Unscrew bolts (3) from bracket (4)
7 Unscrew bolt (9) from bracket (10) *BA49.10- P-1003- 01AD 8 Unscrew nuts (6) and remove three- way catalytic converter (2) Replace self-locking nuts (6). Installation: Clean sealing surfaces on cylinder head, on catalytic converter (2). Replace exhaust manifold gasket.
*BA49.10- P-1002- 01AD 9 Remove heat shield (5) When replacing catalytic converter (2). AR49.10- P- 6905MCU 10 Remove O2 sensor upstream of CAT [KAT] and O2 sensor downstream of CAT [KAT] from catalytic converter (2) When replacing catalytic converter (2). Use a suitable 22 mm socket wrench. Installation: Coat thread on O2 sensor downstream of CAT [KAT] and O2 sensor upstream of CAT [KAT] with paste.
BA14.00- P-1002- 01B BA14.00- P-1003- 01B Paste *BR00.45- Z-1005- 06A 11 Unscrew nuts (11) and remove bracket (10) When replacing catalytic converter (2). The holder (10) is attached using two nuts (11).
*BA49.10- P-1004- 01AD 12 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running Risk of injury cau ed by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A
Risk of death caused by vehicle slipping¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 846 · Applies to: 450, 451, 452, 454
or toppling off of the lifting platform. 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
2 Remove rear apron
AR88.30- P- 0502MCC 3 Support rear axle crossmember (4) using a transmission jack, unscrew bolts (3) and lower the rear axle crossmember (4) Use a suitable base.
Transmission jack *BA35.10- P-1003- 01F 4 Remove heat shield for exhaust system
AR49.10- P- 6945MCU 5 Unclip bracket (5O2) from connector on sensor upstream of CAT [KAT] (G3/2x1)
6 Disconnect connector for O2 sensor upstream of CAT [KAT] (G3/2x1) and connector for O2 sensor downstream of CAT [KAT] (G3/1x1)
7 Unscrew bolts (9) from bracket (10)
8 Support rear muffler (1) with a transmission jack and a removal fixture Removal fixtureTransmission jack . Figure 9 Unhook rear muffler (1) from the rubber retainers (2)
10 Unscrew bolt (8) *BA49.10- P-1003- 01AD 11 Unscrew nuts (6) Replace self-locking nuts (6). When unscrewing last nut (6), use helper to support rear muffler (1) with catalytic converter (7).
*BA49.10- P-1002- 01AD 12 Lower rear muffler (1) with catalytic converter (7) and take hold of it under the vehicle Aid of helper required. Installation: Clean sealing surfaces on cylinder head, on catalytic converter (7). Replace exhaust manifold gasket.
13 Install in the reverse order
Risk of accident caused by vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 847 · Applies to: 450, 451, 452, 454 · AR: BA49.00-Z-9999CZ
starting off by itself when engine is running. Risk of injury caused by contu ion and burn during tarting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothe Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 14 Perform engine test run and inspect exhaust system around catalytic convertor (7) for leaks
REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1003-01F Bolt, crossmember to frame-type integral support Nm 65 EXHAUST SYSTEM Number Designation Engine 132.9 BA49.10-P-1002-01AD Nut, catalytic converter to cylinder head Nm 25 BA49.10-P-1003-01AD Bolt, bracket to cylinder head Nm 20 SAFETY PRECAUTIONS > SAFETY INFORMATION: EXHAUST SYSTEM - AS49.00-Z- 9999ZZ > MODEL all Risk of injury to skin and eyes from airborne particles and fibers when blowing out the SCR catalytic converter as well as from metal parts if it bursts. Hearing impairment from the loud sound of the air explosion. Risk of suffocation from breathing in soot particles and fibers. Risk of explosion of the pressurized SCR catalytic converter. ENGINE all AS49.10- Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: EXHAUST SYSTEM - BA49.00-Z-9999CZ > MODEL all Fig 2: Identifying Exhaust System Complete Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Exhaust system¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 848 · Applies to: 450, 451, 452, 454
ENGINE 132.9 BA49.10-P-1000-01AD Exhaust system ENGINE 639.9 BA49.10-P-1000-01P Exhaust system ENGINE 122.950, 134.910 /911, 135.930 /950 BA49.10-P-1000-01M Exhaust system ENGINE 132.9, 160.910 /920 /921 /922 /923, 660.940 /950 /951 BA49.10-P-1000-01J TORQUE SPECIFICATIONS > EXHAUST SYSTEM - BA49.10-P-1000-01AD > Engine 132.9 EXHAUST SYSTEM Number Designation Engine 132.9 BA49.10-P-1001-01AD Bolt, rear muffler to catalytic converter Nm 25 BA49.10-P-1002-01AD Nut, catalytic converter to cylinder head Nm 25 BA49.10-P-1003-01AD Bolt, bracket to cylinder head Nm 20 BA49.10-P-1004-01AD Nut connecting bracket to catalytic converter Nm 25 BA49.10-P-1005-01AD Bolt, bracket to transmission Nm 20 TORQUE SPECIFICATIONS > EXHAUST SYSTEM - BA49.10-P-1000-01J > ENGINE 132, 160, 660 EXHAUST SYSTEM Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 BA49.10-P- 1001-01J Bolt connecting exhaust system to transmission Nm - 23 23 23 BA49.10-P- 1002-01J Nut, exhaust system to manifold Nm - 30 30 30 BA49.10-P- 1003-01J Bolt for exhaust system bracket above Nm - - 25 25 BA49.10-P- 1004-01J Bolt connecting retaining clamp to exhaust system Nm - 8 8 8 BA49.10-P- 1005-01J Bolt connecting vibration damper bracket to exhaust system Nm 50 - - - BA49.10-P- 1006-01J Bolt, catalytic converter to exhaust pipe Nm 50 - - - BA49.10-P- 1007-01J Bolt, heat shield to cylinder head cover Nm 12 - - -
BA49.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 849 · Applies to: 450, 451, 452, 454
1008-01J Bolt, heat shield to bracket on exhaust manifold Nm 21 - - - BA49.10-P- 1009-01J Bolt, heat shield to turbocharger Nm 21 - - - BA49.10-P- 1010-01J Bolt, rear muffler to turbocharger Nm - - - - BA49.10-P- 1011-01J Nut, rear muffler to turbocharger Nm - - - - BA49.10-P- 1012-01J Union nut, regeneration line to rear muffler Nm - - - - EXHAUST SYSTEM Number Designation Engine 160.922 Engine 160.923 Engine 660.940 Engine 660.950 without code 474 Engine 660.950/ 951 with code 474 BA49.10- P-1001- 01J Bolt connecting exhaust system to transmission Nm 23 23 23 - - BA49.10- P-1002- 01J Nut, exhaust system to manifold Nm 30 30 30 - - BA49.10- P-1003- 01J Bolt for exhaust system bracket above Nm 25 25 - - - BA49.10- P-1004- 01J Bolt connecting retaining clamp to exhaust system Nm 8 8 8 - - BA49.10- P-1005- 01J Bolt connecting vibration damper bracket to exhaust system Nm 12 12 12 - - BA49.10- P-1006- 01J Bolt, catalytic converter to exhaust pipe Nm - - - - - BA49.10- P-1007- 01J Bolt, heat shield to cylinder head cover Nm - - - - - BA49.10- P-1008- 01J Bolt, heat shield to bracket on exhaust manifold Nm - - - - - BA49.10- P-1009- 01J Bolt, heat shield to turbocharger Nm - - - - - BA49.10- Bolt, rear muffler to
alloy teel wire and fitted in a double walled tainle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 851 · Applies to: 450, 451, 452, 454
teel hou ing Ceramic monoliths require a substrate made out of aluminum oxide which increases the effective surface of the catalytic converter. The active catalytic layer coated on the substrate is available in three-way catalysts primarily out of platinum and Rhodium. Platinum accelerates oxidation of the hydrocarbon and carbon monoxide. Rhodium accelerates reduction of nitrogen oxides. Function (Schematic presentation) Function Exhaust gases flow through the catalytic converters and hence come into contact with the rare metals, platinum and Rhodium. Oxidation causes carbon monoxide to be converted to carbon dioxide and hydrocarbons into water and carbon dioxide. The nitrogen oxide is converted through reduction into nitrogen and carbon dioxide. The remaining oxygen content in the exhaust is a crucial factor in the conversion of pollutants. This is determined by the lambda control and maintained at=1 under normal operating conditions. Fig 2: Three-Way Catalytic Converter Function Schematic Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Open fuel filler flap and unscrew¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 854 · Applies to: 450, 451, 452, 454
7 Open fuel filler flap and unscrew cap for fuel tank so that there is no vacuum in the fuel tank when pumping out the fuel.
8 Actuate fuel pump with fuel level sensor using STAR DIAGNOSIS and pump out fuel into a suitable safety container (6) The fuel pump with fuel level sensor must not run dry otherwise it must be replaced. Menu points: Systems ME-SFI [ME] control unit Actuations Actuation of fuel pump
Connect STAR DIAGNOSIS and read out fault memory
AD00.00-P-2000- 04MCC 9 Loosen hose clamp (4) and pull drain hose (5) out of the adapter Allow fuel to flow back from drain hose (5) into the safety container (6).
*454589049100 10 Pull drain hose (5) out of the safety container (6)
11 Loosen clamp (1) and pull adaptation out of fuel line (2) 3 *454589049100 12 Place fuel line (2) on the fuel distributor (3) and fixed in place with a clamp (1) Replace hose clamp (1).Remove rags.
*450589073700
Fill
13 Fill fuel tank via filler neck
14 Screw on fuel tank cap and close fuel filler flap
15 Switch on ignition then wait for power-down of the fuel pump with fuel level sensor. Switch off ignition again and check leaktightness of the fuel line (2) on the fuel distributor (3)
16 Install interior flap above engine
AR88.40-P-1100- 03MCC
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 856 · Applies to: 450, 451, 452, 454
28.3.08 Replacement of bolts on fuel tank, added Step 10
Remove/install
Risk of explosion caused by fuel igniting, risk of poisoning No fire, sparks, open flames or smoking. Pour Fig 2: Identifying Fuel Tank Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Fuel Tank Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
caused by inhaling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 857 · Applies to: 450, 451, 452, 454
and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel fuels only into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00-Z- 0001-01A 1 Drain fuel tank (7)
AR47.10-P- 4001MCU 2 Remove fender liner in right rear fender
AR88.10-P- 1400MCU 3 Remove cable tie (3) on filler neck (1)
4 Unlock and detach purge line (2) at filler neck (1) Close off opening of the purge line (2) and the filler neck (1) using suitable plugs.
5 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
6 Remove diagonal struts (16) On model 451.4 AR61.10-P- 5138MCU 7 Remove rear bulkhead (14) On model 451.4 AR61.25-P- 6600MCU 8 Detach screw clamp (8) and disconnect hose (9) on fuel tank (7) Seal openings of hose (9) and the fuel tank (7) using a suitable plug.
9 Support fuel tank (7) with a transmission jack and a removal fixture *450589026200
Transmission jackhttp://gotis.aftersales.mercedes- benz.com
10 Remove bolts (15) and bolt (arrow A) for fuel tank (7) Installation: Replace self-locking bolts (15) and self-locking bolt (arrow A).
*BA47.10-P- 1001-01F 11 Carefully lower fuel tank (7) until the electrical connector (17) on activated charcoal canister
(4) is accessible¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 858 · Applies to: 450, 451, 452, 454
12 Disconnect electrical connector (17) on activated charcoal canister (4)
13 Release clamp (6) and detach purge line (5) from activated charcoal canister (4)
14 Lower the fuel tank (7) further until electrical connector (12) becomes accessible at the fuel pump with fuel level sensor (M3/3)
15 Disconnect electrical plug (12) on fuel pump with fuel level sensor (M3/3)
16 Disconnect electrical connector (13) on tank pressure sensor (B4/3)
17 Lay out rags in the area of the fuel pump with fuel level sensor (M3/3)
18 Unlock fuel lines (10, 11) at fuel pump with fuel level sensor (M3/3) and detach Close off openings for fuel line (10, 11) and the fuel tank (7) using a suitable stop plug.
19 Release purge line (5) from bracket (arrow B) and from the brackets at fuel tank (7)
20 Lower fuel tank (7) further and remove from removal fixture Aid of helper required.If the fuel tank (7) is replaced the removed fuel tank (7) must be professionally disposed of.Refer to: ↓
Disposing fuel tanks OS47.10-P- 0001-01A M3/3 Remove
existing fuel pump¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 859 · Applies to: 450, 451, 452, 454
21 existing fuel pump with fuel level sensor When replacing the fuel tank (7). AR47.20-P- 7000MCU 22 Release clamp (18) and detach purge line (19) from activated charcoal canister (4) When replacing the fuel tank (7).
23 Unlock catch hook (arrow C) and remove activated charcoal canister (4) forwards from holder on fuel tank (7) When replacing the fuel tank (7).
24 Remove fuel tank pressure sensor (B4/3) When replacing the fuel tank (7). AR47.50-P- 0050MCU 25 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z- 0005-01A 26 Perform test run engine and check fuel tank (7) and connections for leaks
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13
TESTING & REPAIR > REMOVE/INSTALL FILLER NECK OF FUEL TANK - AR47.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 860 · Applies to: 450, 451, 452, 454
7541MCU > MODEL 451.3/4 with ENGINE 132.910
Remove/install
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when AS47.00- Z-0001- 01A Fig 4: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Fuel Tank Filler Neck Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 862 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00-Z- 0001-01A 1 Remove fuel tank
AR47.10-P- 4100MCU 2 Lay out rags in the area of the fuel pump with fuel level sensor (M3/3)
3 Counterhold fuel tank (1), loosen locking ring (2) and remove Installation: Tighten the locking ring (2) until the arrow tips (arrow A) on locking ring (2) for arrow tips (arrow B) on fuel tank (1) are opposite one another.
*450589000700 4 Lift fuel pump carefully with fuel level sensor (M3/3) and unlock and detach fuel line (5) to fuel pump with fuel level sensor (M3/3) Installation: The guide (3) for the fuel pump with fuel level sensor (M3/3) must be positioned in the cutout (arrow C).
Fig 1: Identifying Fuel Pump & Fuel Level Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 864 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00-Z- 0001-01A 1 Remove interior flap above engine
AR88.40-P- 1100-03MCC 2 Lay out rags in the area of the fuel line (2) on the fuel distributor (4)
3 Loosen clamp (1), detach fuel line (2) from fuel distributor (4) and unclip from mounts (3). Then close off fuel Installation: Switch on ignition then wait for power-down of the fuel pump with fuel level sensor (M3/3). Switch off ignition again and check fuel system in the area of the fuel line (2) for leaksThen lift vehicle with vehicle lift and
Fig 1: Identifying Fuel Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
di tributor (4) u ing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 865 · Applies to: 450, 451, 452, 454
suitable stop plugs in tall underfloor paneling 4 Remove fender liner in right rear fender
AR88.10-P- 1400MCU 5 Remove cable ties (5) on the filler neck
6 Raise vehicle using the vehicle lift and remove underfloor paneling Installation: The underfloor paneling will be installed at a later point in time.Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
7 Remove the diagonal struts (8) On model 451.4 AR61.10-P- 5138MCU 8 Remove bulkhead at the rear (6) On model 451.4 AR61.25-P- 6600MCU 9 Support fuel tank (9) with a transmission jack and a removal fixture *450589026200
Transmission jackhttp://gotis.aftersales.mercedes- benz.com
10 Remove bolts (7) and bolt (arrow) for fuel tank (9) *BA47.10-P- 1001-01F 11 Lower fuel tank (9) carefully until the fuel line (2) is accessible
12 Lay out rags in the area of the fuel pump with fuel level sensor (M3/3)
13 Unlock fuel line (2) to fuel pump with fuel level sensor (M3/3), detach and close off fuel pump with fuel level sensor (M3/3) using a suitable stop plug
14 Expose and take off fuel line (2) Ensure that fuel line (2) is not kinked or damaged Observe routing of fuel line (2).
15 Install in the reverse
order¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 866 · Applies to: 450, 451, 452, 454
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 TESTING & REPAIR > REMOVE, INSTALL FUEL TANK BLEED VALVE - AR47.30-P- 1000MCU > MODEL 451.3/4 with ENGINE 132.910 Remove/install
Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Fuel Tank Bleed Valve Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove interior flap above engine¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 867 · Applies to: 450, 451, 452, 454
1 Remove interior flap above engine
AR88.40- P 1100 03MCC 2 Unclip and interrupt separation point (arrow) for the line coming out of the mount on the intake manifold (1) from the tank vent valve (Y58/1)
3 Disconnect electrical connector (2) at tank vent valve (Y58/1)
4 Unhook tank vent valve (Y58/1) on holder (3)
5 Disconnect vent line (4) on tank vent valve (Y58/1) and remove tank vent valve (Y58/1)
6 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL ACTIVATED CHARCOAL CANISTER - AR47.30- P-8212MCU > MODEL 451.3/4 with ENGINE 132.910 Illustrated on model 451.4
Remove/install
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00-Z- 0001-01A Fig 1: Identifying Activated Charcoal Canister Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
eyes and skin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 868 · Applies to: 450, 451, 452, 454
caused by contact with fuel 1 Drain fuel tank.
AR47.10-P- 4001MCU Risk of death caused by vehicle slipping or toppling off 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 2 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
3 Remove diagonal struts (4) On model 451.4 AR61.10-P- 5138MCU 4 Remove bulkhead at the rear (2) On model 451.4 AR61.25-P- 6600MCU 5 Support fuel tank (3) with transmission jack (7) and removal fixture (6) *450589026200
Transmission jackhttp://gotis.aftersales.mercedes- benz.com
6 Remove bolts (5) and bolt (arrow) for fuel tank (3) *BA47.10-P- 1001-01F 7 Lower fuel tank (3) carefully until the activated charcoal canister (1) is accessible
8 Loosen clamps (9) and remove purge line (8) and vent line (10) on activated charcoal canister (1)
9 Disconnect electrical connector (11) on outside air shutoff valve for activated charcoal canister (1)
10 Unlock catch hook (12) and remove activated charcoal canister (1) forwards
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 870 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking.Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A Risk of death caused by vehicle slipping or toppling off 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 rear underfloor paneling Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
2 Remove bulkhead at the rear On model 451.4 AR61.25- P- 6600MCU 3 Release clamp (4) and detach purge line (2) on activated charcoal canister (5)
Unclip purge line (2) from The brackets (arrows A) and the bracket Fig 1: Identifying Purge Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
caused by fuel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 872 · Applies to: 450, 451, 452, 454
igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Always pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00-Z- 0001-01A 1 Empty fuel tank (9)
AR47.10-P- 4001MCU 2 Remove fender liner in right rear fender
AR88.10-P- 1400MCU 3 Undo bolts (2) and remove bracket (1) *BA63.50-P- 1001-01B 4 Remove cable tie (4) on the filler neck (3) There are three cable ties (4) on the filler neck (3).
5 Unlock and detach purge line (5) on filler neck (3)
6 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
7 Remove diagonal struts (8) On model 451.4 AR61.10-P- 5138MCU 8 Remove rear bulkhead (6) On model 451.4 AR61.25-P- 6600MCU 9 Support fuel tank (9) with a transmission jack and a removal fixture *450589026200
Transmission jackhttp://gotis.aftersales.mercedes- benz.com
10 Remove bolts (7) and bolt (arrow) for fuel tank (9) *BA47.10-P- 1001-01F 11 Lower fuel tank (9) carefully until the purge line (5) is accessible
12 Lay out rags in the area of the fuel pump with fuel level sensor (M3/3)
Unlock purge line (5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 873 · Applies to: 450, 451, 452, 454
13 Unlock purge line (5) on fuel pump with fuel level sensor (M3/3) and detach Close off opening on fuel pump with fuel level sensor (M3/3) using a suitable stop plug.
14 Expose and take off purge line (5)
15 Install in the reverse order
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 REINFORCEMENT IN RIGHT REAR FENDER Number Designation Model 451.3/4 BA63.50-P-1001- 01B Bolt, reinforcement in right rear fender Nm 15 TESTING & REPAIR > REMOVE/INSTALL FUEL TANK PRESSURE SENSOR - AR47.50-P- 0050MCU > ENGINE 132.910 in MODEL 451.3/4 Shown on model 451.4 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 874 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Always pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00-Z- 0001-01A 1 Drain fuel tank (1)
AR47.10-P- 4001MCU Risk of death caused by vehicle slipping or toppling off 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 2 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriverhttp://gotis.aftersales.mercedes- benz.com
3 Remove diagonal struts (4) On model 451.4 AR61.10-P- 5138MCU 4 Remove rear bulkhead (3) On model 451.4 AR61.25-P- 6600MCU Fig 1: Identifying Fuel Tank Pressure Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Support fuel tank (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 875 · Applies to: 450, 451, 452, 454
5 Support fuel tank (1) with a transmission jack and a removal fixture *450589026200
Transmission jackhttp://gotis.aftersales.mercedes- benz.com
6 Remove bolts (2) and bolt (arrow) for fuel tank (1) *BA47.10-P- 1001-01F 7 Lower fuel tank (1) carefully until the tank pressure sensor (B4/3) is accessible
8 Disconnect electrical connector (5) on tank pressure sensor (B4/3)
9 Unlock detent hooks (6) and pull tank pressure sensor (B4/3) out of the fuel tank (1) Do not damage seal (7) on tank pressure sensor (B4/3) otherwise the tank pressure sensor (B4/3) must be replaced.
10 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z- 0005-01A 11 Perform engine test run and check fuel tank (1) for leaks in the area of the tank pressure sensor (B4/3)
FUEL TANK Number Designation Model 451.3/4
BA47 10 P 1001 01F¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 876 · Applies to: 450, 451, 452, 454
Bolt, fuel tank to body Nm 13 SAFETY PRECAUTIONS > RISK OF EXPLOSION CAUSED BY FUEL IGNITING, RISK OF POISONING CAUSED BY INHALING AND SWALLOWING FUEL AS WELL AS RISK OF INJURY TO EYES AND SKIN CAUSED BY CONTACT WITH FUEL. - AS47.00-Z-0001-01A > No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. Potential risks Risk of explosion, poisoning and injury Fuels are highly inflammable and toxic if inhaled. Fuel may cause damage to skin. For example, skin is degreased when it comes into contact with gasoline fuel. Fuel vapors are explosive, invisible and spread out at floor level. This vapor is poisonous when inhaled and has an anesthetizing effect in high concentrations. Safety precautions/instructions Observe the national safety precautions and regulations. No fire, sparks, open flames or smoking. Ensure the work place is adequately ventilated. Never drain or pour in fuels over assembly pits. Store drained fuel in a suitable and sealed vessel. Immediately eliminate any fuel which has flowed out. Conducting work on a vehicle with open flames (e.g. welding etc.) Before carrying out this work, remove relevant parts of fuel system and seal open fuel lines with plugs. First aid measures Clean affected skin areas with water and soap. Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Change affected clothing as quickly as possible.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 877 · Applies to: 450, 451, 452, 454 · AR: AS47.00-Z-9999ZZ
If fuel gets into the eyes, rinse eyes with water immediately and call a doctor if necessary. SAFETY PRECAUTIONS > SAFETY INFORMATION: FUEL SYSTEM - AS47.00-Z-9999ZZ > MODEL all Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. ENGINE all except CODE (MS8) Natural gas engine M 906 LAG 205 kW (279 PS) 2500 RPM AS47.00-Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: FUEL SYSTEM - BA47.00- Z-9999CZ > MODEL all Fuel pump ENGINE 134.910 /911, 135.930 /950 BA47.20-P-1000-01D Fuel tank MODEL 454.0 with ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BA47.10-P-1000-01H Fuel tank MODEL 450.3 /4, 451.3 /4, 452.334 /432/434 BA47.10-P-1000-01F Ventilation system ENGINE 122.9 in MODEL 454.0 BA47.31-P-1000-01B CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: FUEL SYSTEM - BF47.00-Z- 9999CZ > MODEL all Fuel tank capacity MODEL 450 BF47.10-P-1000-01B BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE FUEL PUMP - GF47.20-P- 2000MCC > ENGINE 132.9 in MODEL 451.3/4 Location The fuel pump is located in the fuel tank.
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 881 · Applies to: 450, 451, 452, 454
The outside air shutoff valve is activated by the ME-SFI [ME] control unit (N3/10) at the ground end to perform the leak test. In case of any faults (outside air shutoff valve does not open any more), a mechanical safety valve takes over the ventilation of the activated charcoal canister. MISCELLANEOUS NOTES > DISPOSING OF FUEL TANKS - OS47.10-P-0001-01A > Before opening the fuel tank, empty completely, clean thoroughly and rinse out with a non-combustible fluid, e.g. with water, steam or an inert gas, e.g. nitrogen, carbon dioxide. Sheet metal fuel tanks Open sheet metal fuel tanks with a chisel or metal saw by approx. 30 x 30 cm. Dispose of sheet metal ventilated fuel tanks as metal scrap. Plastic fuel tanks Open the plastic fuel tank using a suitable saw by approx. 30 x 30 cm. In Germany the opened plastic fuel tank can be returned through the Mercedes Recycling System (MeRSy) as "other plastic parts" for recycling. Operations not connected to MeRSy can dispose of similarly pretreated plastic fuel tanks along with the fraction of industrial refuse similar to household waste. Transport Cut-open and ventilated end of life fuel tanks are not subject to the requirements of the Hazardous Goods Road Transport Regulations. Fig 1: Locating Outside Air Shutoff Valve Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 00 07 00 TANK MODULE TOOL - WS47.00-P-0021B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 882 · Applies to: 450, 451, 452, 454
FG 47/83/Set B MODEL 450, 451, 452, 454, 636, 639, 906 MODIFICATION NOTES 3.6.08 Replacement for the 639 589 00 07 00 hook wrench WS47.00-N-3005B Use: Assembly and disassembly of the union nut on the tank module. NOTE: Tank module toolSmart no.: 0014621Identical with MB tool W639 589 00 07 00.
Fig 1: View Of Cut-Open Fuel Tank Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 454 589 04 91 00 ADAPTER - WS47.00-P-0033B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 883 · Applies to: 450, 451, 452, 454 · AR: WS47.00-Z-9999CZ
FG 47/Set B MODEL 454.0 MODEL 451 with ENGINE 132.9, 660.9 Use: Adaptation for suctioning out fluid residues from the fuel tank. SPECIAL TOOLS > SPECIAL TOOLS: SMART: FUEL SYSTEM - WS47.00-Z-9999CZ > MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P- 0007B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ WS00.00-P- Fig 1: Identifying Tank Module Tool (450 589 00 07 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Adapter (454 589 04 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
18/20/22/28/33/46/47/82/83/Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 884 · Applies to: 450, 451, 452, 454
0006Z 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P- 0050B 220 589 04 99 00 New passenger car wiring harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P- 0006B 450 589 00 05 00 Hook wrench FG 47/Set B WS47.00-P- 0020B 450 589 00 07 00 Tank module tool FG 47/83/Set B WS47.00-P- 0021B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P- 0090B 454 589 04 91 00 Adapter FG 47/Set B WS47.00-P- 0033B 454 589 05 91 00 Adapter FG 47/Set B WS47.00-P- 0032B
Actuate fuel pump with fuel level¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 887 · Applies to: 450, 451, 452, 454
8 Actuate fuel pump with fuel level sensor using STAR DIAGNOSIS and pump out fuel into a suitable safety container (6) The fuel pump with fuel level sensor must not run dry otherwise it must be replaced. Menu points: Systems ME-SFI [ME] control unit Actuations Actuation of fuel pump
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC 9 Loosen hose clamp (4) and pull drain hose (5) out of the adapter Allow fuel to flow back from drain hose (5) into the safety container (6).
Fig 3 10 Pull drain hose (5) out of the safety container (6)
11 Loosen clamp (1) and pull adaptation out of fuel line (2) 3 Fig 3 12 Place fuel line (2) on the fuel distributor (3) and fixed in place with a clamp (1) Replace hose clamp (1).Remove rags.
Fig 2
Fill
13 Fill fuel tank via filler neck
14 Screw on fuel tank cap and close fuel filler flap
15 Switch on ignition then wait for power- down of the fuel pump with fuel level sensor. Switch off ignition again and check leak tightness of the fuel line (2) on the fuel distributor (3)
16 Install interior flap above engine
AR88.40- P-1100- 03MCC
TESTING & REPAIR INDEX > LOWER FUEL TANK AND POSITION - AR47.10-P-4100-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 888 · Applies to: 450, 451, 452, 454
03MCU > FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 Fig 2: Identifying Pliers (450 589 07 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Adaptation (454 589 04 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Illustrated on model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 890 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Fuel Tank Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Fuel Tank Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 891 · Applies to: 450, 451, 452, 454
28.3.08 Replacement of bolts on fuel tank, added Step 10
Remove/install
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A 1 Drain fuel tank (7)
AR47.10- P- 4001MCU 2 Remove fender liner in right rear fender
AR88.10- P- 1400MCU 3 Remove cable tie (3) on filler neck (1)
4 Unlock and detach purge line (2) at filler neck (1) Close off opening of the purge line (2) and the filler neck (1) using suitable plugs.
5 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
6 Remove diagonal struts (16) On model 451.4 AR61.10- P- 5138MCU AR61.25- Fig 3: Identifying Fuel Tank Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove rear bulkhead (14)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 892 · Applies to: 450, 451, 452, 454
7 Remove rear bulkhead (14) On model 451 4 P 6600MCU 8 Detach screw clamp (8) and disconnect hose (9) on fuel tank (7) Seal openings of hose (9) and the fuel tank (7) using a suitable plug.
9 Support fuel tank (7) with a transmission jack and a removal fixture Figure
Transmission jack
10 Remove bolts (15) and bolt (arrow A) for fuel tank (7) Installation: Replace self- locking bolts (15) and self- locking bolt (arrow A).
*BA47.10- P-1001- 01F 11 Carefully lower fuel tank (7) until the electrical connector (17) on activated charcoal canister (4) is accessible
12 Disconnect electrical connector (17) on activated charcoal canister (4)
13 Release clamp (6) and detach purge line (5) from activated charcoal canister (4)
14 Lower the fuel tank (7) further until electrical connector (12) becomes accessible at the fuel pump with fuel level sensor (M3/3)
15 Disconnect electrical plug (12) on fuel pump with fuel level sensor (M3/3)
16 Disconnect electrical connector (13) on tank pressure sensor (B4/3)
17 Lay out rags in the area of the fuel pump with fuel level sensor (M3/3)
18 Unlock fuel lines (10, 11) at fuel pump with fuel level sensor (M3/3) and detach Close off openings for fuel line (10, 11) and the fuel tank (7) using a suitable stop plug.
19 Release purge line (5) from bracket (arrow B) and from the brackets at fuel tank (7)
20 Lower fuel tank (7) further and remove from removal fixture Aid of helper required.If the fuel tank (7) is replaced the removed fuel tank (7) must be professionally disposed of.Refer to: ↓
Disposing fuel tanks OS47.10- P-0001- 01A
M3/3 Remove existing fuel pump with fuel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 893 · Applies to: 450, 451, 452, 454
21 M3/3 Remove existing fuel pump with fuel level sensor When replacing the fuel tank (7). AR47.20- P- 7000MCU 22 Release clamp (18) and detach purge line (19) from activated charcoal canister (4) When replacing the fuel tank (7).
23 Unlock catch hook (arrow C) and remove activated charcoal canister (4) forwards from holder on fuel tank (7) When replacing the fuel tank (7).
24 Remove fuel tank pressure sensor (B4/3) When replacing the fuel tank (7). AR47.50- P- 0050MCU 25 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 26 Perform test run engine and check fuel tank (7) and connections for leaks
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 TESTING & REPAIR INDEX > REMOVE/INSTALL FILLER NECK OF FUEL TANK - AR47.10- P-7541MCU > MODEL 451.3 /4 with ENGINE 132.910 Fig 4: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 894 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A 1 Drain fuel tank (1)
AR47.10- P- 4001MCU 2 Remove tank recess
AR88.60- P- 2000MCC 3 Remove bolt (4) on filler neck (3)
4 Remove fender liner in right rear fender
AR88.10- P- 1400MCU 5 Undo bolts (2) and remove bracket (1) *BA63.50- P-1001- 01B 6 Remove cable ties (5) on the filler neck (3)
7 Unlock and detach lines (6) on filler neck
Fig 1: Identifying Filler Neck Of Fuel Tank Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 897 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A 1 Remove interior flap above engine
AR88.40- P-1100- 03MCC 2 Lay out rags in the area of the fuel line (2) on the fuel distributor (4)
3 Loosen clamp (1), detach fuel line (2) from fuel distributor (4) and unclip from mounts (3). Then close off fuel distributor (4) using suitable stop plugs Installation: Switch on ignition then wait for power-down of the fuel pump with fuel level sensor (M3/3). Switch off ignition again and check fuel system in the area of the fuel line (2) for leaksThen lift vehicle with vehicle lift and install underfloor paneling
4 Remove fender liner in right rear fender
AR88.10- P- 1400MCU Fig 1: Identifying Fuel Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove cable ties (5) on the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 898 · Applies to: 450, 451, 452, 454
5 Remove cable ties (5) on the filler neck
6 Raise vehicle using the vehicle lift and remove underfloor paneling Installation: The underfloor paneling will be installed at a later point in time.Rechargeable drill / screwdriver
7 Remove the diagonal struts (8) On model 451.4 AR61.10- P- 5138MCU 8 Remove bulkhead at the rear (6) On model 451.4 AR61.25- P- 6600MCU 9 Support fuel tank (9) with a transmission jack and a removal fixture Figure
Transmission jack
10 Remove bolts (7) and bolt (arrow) for fuel tank (9) *BA47.10- P-1001- 01F 11 Lower fuel tank (9) carefully until the fuel line (2) is accessible
12 Lay out rags in the area of the fuel pump with fuel level sensor (M3/3)
13 Unlock fuel line (2) to fuel pump with fuel level sensor (M3/3), detach and close off fuel pump with fuel level sensor (M3/3) using a suitable stop plug
14 Expose and take off fuel line (2) Ensure that fuel line (2) is not kinked or damaged Observe routing of fuel line (2).
15 Install in the reverse order
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13
TESTING & REPAIR INDEX > REMOVE, INSTALL FUEL TANK BLEED VALVE - AR47.30-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 899 · Applies to: 450, 451, 452, 454
1000MCU > MODEL 451.3/4 with ENGINE 132.910 Remove/install
1 Remove interior flap above engine
AR88.40- P-1100- 03MCC 2 Unclip and interrupt separation point (arrow) for the line coming out of the mount on the intake manifold (1) from the tank vent valve (Y58/1)
Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Fuel Tank Bleed Valve Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
support points specified by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 901 · Applies to: 450, 451, 452, 454
vehicle manufacturer. 2 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
3 Remove diagonal struts (4) On model 451.4 AR61.10- P- 5138MCU 4 Remove bulkhead at the rear (2) On model 451.4 AR61.25- P- 6600MCU 5 Support fuel tank (3) with transmission jack (7) and removal fixture (6) Figure
Transmission jack
6 Remove bolts (5) and bolt (arrow) for fuel tank (3) *BA47.10- P-1001- 01F 7 Lower fuel tank (3) carefully until the activated charcoal canister (1) is accessible
8 Loosen clamps (9) and remove purge line (8) and vent line (10) on activated charcoal canister (1)
9 Disconnect electrical connector (11) on outside air shutoff valve for activated charcoal canister (1)
10 Unlock catch hook (12) and remove activated charcoal canister (1) forwards from holder on fuel tank (3)
11 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 12 Conduct engine test run and check fuel system in the area of the activated charcoal canister (1)
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 904 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Always pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A 1 Empty fuel tank (9)
AR47.10- P- 4001MCU 2 Remove fender liner in right rear fender
AR88.10- P- 1400MCU 3 Undo bolts (2) and remove bracket (1) *BA63.50- P-1001- 01B 4 Remove cable tie (4) on the filler neck (3) There are three cable ties (4) on the filler neck (3).
5 Unlock and detach purge line (5) on filler neck (3)
6 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
Fig 1: Identifying Purge Line Components (Filler Neck) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove diagonal struts (8)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 905 · Applies to: 450, 451, 452, 454
7 Remove diagonal struts (8) On model 451.4 AR61 10 P- 5138MCU 8 Remove rear bulkhead (6) On model 451.4 AR61.25- P- 6600MCU 9 Support fuel tank (9) with a transmission jack and a removal fixture Figure
Transmission jack
10 Remove bolts (7) and bolt (arrow) for fuel tank (9) *BA47.10- P-1001- 01F 11 Lower fuel tank (9) carefully until the purge line (5) is accessible
12 Lay out rags in the area of the fuel pump with fuel level sensor (M3/3)
13 Unlock purge line (5) on fuel pump with fuel level sensor (M3/3) and detach Close off opening on fuel pump with fuel level sensor (M3/3) using a suitable stop plug.
14 Expose and take off purge line (5)
15 Install in the reverse order
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 REINFORCEMENT IN RIGHT REAR FENDER Number Designation Model 451.3/4 BA63.50-P-1001-01B Bolt, reinforcement in right rear fender Nm 15 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove rear bulkhead (3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 907 · Applies to: 450, 451, 452, 454
4 Remove rear bulkhead (3) On model 451.4 AR61.25- P- 6600MCU 5 Support fuel tank (1) with a transmission jack and a removal fixture Figure
Transmission jack
6 Remove bolts (2) and bolt (arrow) for fuel tank (1) *BA47.10- P-1001- 01F 7 Lower fuel tank (1) carefully until the tank pressure sensor (B4/3) is accessible
8 Disconnect electrical connector (5) on tank pressure sensor (B4/3)
9 Unlock detent hooks (6) and pull tank pressure sensor (B4/3) out of the fuel tank (1) Do not damage seal (7) on tank pressure sensor (B4/3) otherwise the tank pressure sensor (B4/3) must be replaced.
10 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 11 Perform engine test run and check fuel tank (1) for leaks in the area of the tank pressure sensor (B4/3)
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SAFETY PRECAUTIONS > RISK OF EXPLOSION CAUSED BY FUEL IGNITING, RISK OF¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 908 · Applies to: 450, 451, 452, 454 · AR: AS47.00-Z-9999ZZ
POISONING CAUSED BY INHALING AND SWALLOWING FUEL AS WELL AS RISK OF INJURY TO EYES AND SKIN CAUSED BY CONTACT WITH FUEL. - AS47.00-Z-0001-01A > No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. Potential risks Risk of explosion, poisoning and injury Fuels are highly inflammable and toxic if inhaled. Fuel may cause damage to skin. For example, skin is degreased when it comes into contact with gasoline fuel. Fuel vapors are explosive, invisible and spread out at floor level. This vapor is poisonous when inhaled and has an anesthetizing effect in high concentrations. Safety precautions/instructions Observe the national safety precautions and regulations. No fire, sparks, open flames or smoking. Ensure the work place is adequately ventilated. Never drain or pour in fuels over assembly pits. Store drained fuel in a suitable and sealed vessel. Immediately eliminate any fuel which has flowed out. Conducting work on a vehicle with open flames (e.g. welding etc.) Before carrying out this work, remove relevant parts of fuel system and seal open fuel lines with plugs. First aid measures Clean affected skin areas with water and soap. Change affected clothing as quickly as possible. If fuel gets into the eyes, rinse eyes with water immediately and call a doctor if necessary. SAFETY PRECAUTIONS > SAFETY INFORMATION: FUEL SYSTEM - AS47.00-Z-9999ZZ > MODEL all Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contact with fuel. ENGINE all except CODE (MS8) Natural gas engine M 906 LAG 205 kW (279 PS) 2500 rpm AS47.00- Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: FUEL SYSTEM - BA47.00-
Z-9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 909 · Applies to: 450, 451, 452, 454
MODEL all Fuel pump ENGINE 134.910 /911, 135.930 /950 BA47.20-P-1000-01D Fuel tank MODEL 454.0 with ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BA47.10-P-1000-01H Fuel tank MODEL 450.3 /4, 451.3 /4, 452.334 /432/434 BA47.10-P-1000-01F Ventilation system ENGINE 122.9 in MODEL 454.0 BA47.31-P-1000-01B TORQUE SPECIFICATIONS > FUEL TANK - BA47.10-P-1000-01F > Model 450, 451, 452 Number Designation Model450.3/4 Model451.3/4 Model452.3/4 BA47.10-P- 1001-01F Bolt, fuel tank to body Nm 10 13 10 CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: FUEL SYSTEM - BF47.00-Z- 9999CZ > MODEL all Fuel tank capacity MODEL 450 BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE FUEL PUMP - GF47.20-P- 2000MCC > ENGINE 132.9 in MODEL 451.3/4 Location The fuel pump is located in the fuel tank.
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 913 · Applies to: 450, 451, 452, 454
The outside air shutoff valve is activated by the ME-SFI [ME] control unit (N3/10) at the ground end to perform the leak test. In case of any faults (outside air shutoff valve does not open any more), a mechanical safety valve takes over the ventilation of the activated charcoal canister. MISCELLANEOUS NOTES > DISPOSING OF FUEL TANKS - OS47.10-P-0001-01A > Before opening the fuel tank, empty completely, clean thoroughly and rinse out with a non-combustible fluid, e.g. with water, steam or an inert gas, e.g. nitrogen, carbon dioxide. Sheet metal fuel tanks Open sheet metal fuel tanks with a chisel or metal saw by approx. 30 x 30 cm. Dispose of sheet metal ventilated fuel tanks as metal scrap. Plastic fuel tanks Open the plastic fuel tank using a suitable saw by approx. 30 x 30 cm. In Germany the opened plastic fuel tank can be returned through the Mercedes Recycling System (MeRSy) as "other plastic parts" for recycling. Operations not connected to MeRSy can dispose of similarly pretreated plastic fuel tanks along with the fraction of industrial refuse similar to household waste. Transport Cut-open and ventilated end of life fuel tanks are not subject to the requirements of the Hazardous Goods Road Transport Regulations. Fig 1: Identifying Outside Air Shutoff Valve Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 00 07 00 TANK MODULE TOOL - WS47.00-P-0021B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 914 · Applies to: 450, 451, 452, 454
FG 47/83/Set B MODEL 450, 451, 452, 454, 636, 639, 906 MODIFICATION NOTES 3.6.08 Replacement for the 639 589 00 07 00 hook wrench WS47.00-N-3005B Use: Assembly and disassembly of the union nut on the tank module. NOTE: Tank module toolSmart no.: 0014621Identical with MB tool W639 589 00 07 00.
Fig 1: Identifying Fuel Tank Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 454 589 04 91 00 ADAPTER - WS47.00-P-0033B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 915 · Applies to: 450, 451, 452, 454 · AR: WS47.00-Z-9999CZ
FG 47/Set B MODEL 454.0 MODEL 451 with ENGINE 132.9, 660.9 Use: Adaptation for suctioning out fluid residues from the fuel tank. SPECIAL TOOLS > SPECIAL TOOLS: SMART: FUEL SYSTEM - WS47.00-Z-9999CZ > MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P-0007B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ WS00.00-P-0006Z Fig 1: Identifying Tank Module Tool (450 589 00 07 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Adapter (454 589 04 91 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
18/20/22/28/33/46/47/82/83/Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 916 · Applies to: 450, 451, 452, 454
220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 220 589 04 99 00 New passenger car wiring harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P-0006B 450 589 00 05 00 Hook wrench FG 47/Set B WS47.00-P-0020B 450 589 00 07 00 Tank module tool FG 47/83/Set B WS47.00-P-0021B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 454 589 04 91 00 Adapter FG 47/Set B WS47.00-P-0033B 454 589 05 91 00 Adapter FG 47/Set B WS47.00-P-0032B
Shown on model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 919 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove rear-end door paneling
AR72.20- P- 1000MCC 2 Disconnect electrical connector (3) from rear-end door CL motor (M14/7) Installation: Ensure that electrical connector (3) arrests correctly.
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
Fig 1: Identifying Rear-End Door CL Motor Components - Shown On Model 451.3 Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear-End Door CL Motor Components - Shown On Model 451.4 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Start teach-in procedure by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 923 · Applies to: 450, 451, 452, 454
10 Start teach-in procedure by pressing "Button F2"
11 Switch ignition on and off according to the request on the display. After completion of the teach-in procedure the message "Key taught in successfully" appears on the display.
12 Start teach-in procedure for another transmitter key by pressing "Button F3" Insert transmitter key to be taught in into ignition/starter switch within 20 s and switch on ignition (c. 15).If the ignition (c. 15) is not switched back on within 20 s, the teach-in procedure is interrupted.After a successful teach-in procedure, the number of the transmitter key taught in appears on the display.Repeat step until all transmitter keys are taught in.
13 Complete teach-in procedure by pressing "Button F4" The number of the transmitter keys taught in appears on the display.
14 Press "Button F2" and the complete STAR DIAGNOSIS
BASIC KNOWLEDGE > CENTRAL LOCKING (CL), LOCATION OF COMPONENTS - GF80.20-P-0005-01MCU >
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 925 · Applies to: 450, 451, 452, 454
The vehicle doors, rear-end door and fuel filler flap, as well as separate opening of the rear-end door upper section, are locked and unlocked by the central locking (on model 451.3). The SAM control unit is the master control unit for these functions. Manual functions The central locking is operated by: Locking/Unlocking via transmitter key Locking via inner lock CL switch Unlocking via inner lock CL switch Locking via inside door opener Emergency operation Fig 1: Central Locking CAN Communication Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remote trunk lid opening (on model 451.3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 926 · Applies to: 450, 451, 452, 454
Automatic functions Speed-dependent locking Relocking Emergency opening after crash recognition Locking via transmitter key Function requirement Vehicle doors and rear-end door closed Function When the lock button on the transmitter key is actuated, it transmits a radio signal to the SAM control unit. It checks the access authorization of the transmitter key. If the access authorization is valid, the opening request of the rear-end door handle switch is inhibited and the following motors are actuated directly by the SAM control unit: Right door CL [ZV] motor Left door CL [ZV] motor Fuel filler flap CL [ZV] motor On vehicles with code (V54) Rain/light sensor, Rain/light sensor, the parking lights and the low beams are switched on for approx. 12 s by the SAM control unit depending on the ambient brightness. Unlocking via transmitter key When the unlock button on the transmitter key is actuated, it transmits a radio signal to the SAM control unit. The SAM control unit checks the access authorization of the transmitter key. If the access authorization is valid, the vehicle is unlocked selectively. For this purpose, the following motors are actuated directly by the SAM control unit: Left door CL [ZV] motor Fuel filler flap CL [ZV] motor When the unlock button on the transmitter key is reactuated, the vehicle is unlocked globally. For this purpose, the following motor is actuated directly by the SAM control unit: Right door CL [ZV] motor Moreover, the opening request from the rear-end door handle switch is enabled. The status of the rear-end door handle switch is read in directly by the SAM control unit, which actuates the trunk lid CL motor. If the vehicle is unlocked selectively, the SAM control unit fades on the interior illumination. On vehicles with code (V54) Rain/light sensor, the parking lights and the low beams are switched on for approx. 12 s by the SAM control unit depending on the ambient brightness. Visual feedback After locking or unlocking, the turn signal lights, as well as additional turn signal lamps, are actuated directly
by the SAM control unit.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 927 · Applies to: 450, 451, 452, 454
Locking: Flashing three times Unlocking: Flashing once When the vehicle is locked, the LED in the inner lock CL switch flashes. Locking via inner lock CL switch Function requirement Vehicle doors and rear-end door closed The locking request is read in directly by the SAM control unit via the inner lock CL switch in the cockpit switch group. This inhibits the opening request of the rear-end door handle switch and actuates the following central locking motors: Right door CL [ZV] motor Left door CL [ZV] motor Fuel filler flap CL [ZV] motor Visual feedback When the vehicle is locked and circuit 15 ON, the LED comes on in the inner lock switch. When the vehicle is locked and circuit 15 OFF, the LED flashes in the inner lock switch. Unlocking via inner lock CL switch The unlocking request is read in directly by the SAM control unit via the inner lock CL switch in the cockpit switch group. This enables the opening request from the rear-end door handle switch and actuates the following central locking motors: Right door CL [ZV] motor Left door CL [ZV] motor Fuel filler flap CL [ZV] motor Unlocking via inside door opener When the vehicle is opened manually with the inside door opener, the door status is relayed to SAM control unit via the door rotary tumbler microswitch and the door CL microswitch. It then actuates the fuel filler flap CL motor. The other door remains locked, the opening request from the rear-end door handle switch remains inhibited. Emergency operation Lock When the driver door is open, circuit 15 ON and the inner lock CL switch actuated, the vehicle is locked after circuit 15 OFF and when the driver door is closed. If the vehicle is locked with the emergency operation, an acoustic feedback is transmitted to the warning sound generator integrated into the instrument cluster after circuit 15 OFF and removal of the transmitter key.
BASIC KNOWLEDGE > ANTI-THEFT ALARM SYSTEM (ATA), LOCATION OF¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 930 · Applies to: 450, 451, 452, 454
COMPONENTS - GF80.50-P-0001-02MCU > Fig 1: Anti-Theft Alarm System (EDW) Block Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > ANTI-THEFT ALARM SYSTEM (ATA [EDW]), FUNCTION - GF80.50-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 931 · Applies to: 450, 451, 452, 454
P-0001MCU > MODEL 451.3/4 with CODE (V01) Antitheft alarm system (FFO) General information The anti-theft alarm system (ATA) monitors all relevant inputs for their non-actuated state If it detects a change of state in one of the monitored inputs, it triggers a country-specific acoustic and visual alarm. The acoustic signals are output by the alarm siren with inclination sensor (H3/2), the visual signals via the exterior lights. The SAM control module (N10/10) is the master control module for the ATA. The ATA is activated when the central locking (CL) is locked. The ATA, when armed, monitors: Doors and rear-end door Position change of vehicle Motions in the interior compartment Voltage supply and data line for alarm siren Status of panic button on transmitter key A status change of the panic button, can also be recognized in the deactivated state. The visual feedback for the ATA status is output by a flashing LED integrated into the tow-away protection/interior protection switch (S6/1s10). Fig 1: Locating Anti-Theft Alarm System Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > ANTI-THEFT ALARM SYSTEM TRIGGER, FUNCTION - GF80.50-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 934 · Applies to: 450, 451, 452, 454
2004MCU > MODEL 451.3/4 with CODE (V01) Anti-theft alarm system (FFO) Function requirements: Anti-theft alarm system (ATA) activated Function The ATA evaluates the following alarm inputs: Left rotary tumbler microswitch Right rotary tumbler microswitch Trunk lid rotary tumbler microswitch Remote trunk opening switch Alarm siren with inclination sensor ATA [EDW] microwave sensor If it detects a change of state in one of the monitored inputs, it triggers a country-specific acoustic and visual alarm. Fig 1: Anti-Theft Alarm System Trigger Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Alarm actuation via switch¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 935 · Applies to: 450, 451, 452, 454
The following components are read in directly by the SAM control unit: Left rotary tumbler microswitch Right rotary tumbler microswitch Trunk lid rotary tumbler microswitch Remote trunk opening switch If the switch exits its non-actuated state, a visual alarm is triggered by the SAM control unit by actuating the turn signal lights as well as the additional turn signal lamps. Moreover, the SAM control unit requests an acoustic alarm from the alarm siren via LIN C. If the rear-end door upper section is opened via the trunk lid remote opening feature, the remote trunk opening switch is deactivated as an alarm input. If the vehicle is unlocked by mechanically unlocking the driver lock, a visual and acoustic alarm is triggered when the driver door is opened. Alarm actuation by alarm siren The alarm siren is actuated cyclically by the SAM control unit. If no answer is received from the alarm siren within approx. 1 s, an alarm is triggered. The alarm is only output visually, as the alarm siren cannot be addressed If the alarm siren detects loss of the supply power or the communication to the SAM control unit, it outputs an acoustic alarm automatically. Alarm triggering by tow-away protection The SAM control unit checks cyclically the input of the inclination sensor integrated into the alarm siren. If the inclination sensor detects a position change of the vehicle, it relays a signal to the SAM control unit, which requests the acoustic alarm output from the alarm siren via LIN C. Moreover, a visual alarm is output by the SAM control unit by directly actuating the turn signal lights and additional turn signal lamps. Alarm triggered by interior motion sensor The alarm decision is accomplished by considering the duration and the speed of the motion in the interior compartment. If the ATA microwave sensor recognizes forced entry into the vehicle, it relays a signal to the SAM control unit. This outputs a visual alarm via the turn signal lights and additional turn signal lights and requests an acoustic alarm from the alarm siren via LIN C. If the rear-end door upper section is opened with the trunk lid remote opening function, the interior protection function is deactivated as long as it is open. Visual alarm The alarm is output via the SAM control unit, which directly actuates the turn signal lights and additional turn signal lamps. The type of alarm and the alarm duration are stored in the SAM control unit. Acoustic alarm The acoustic alarm is output via the alarm siren. The alarm duration is approx. 25 s.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 937 · Applies to: 450, 451, 452, 454
The microwave sensor is located in the center console below the cover of the electronic selector lever module control unit (N15/5). Task The microwave sensor monitors the interior compartment for motion. The status of the microwave sensor is transmitted by the local interconnect network interior 2 to the SAM control unit (N10/10). BASIC KNOWLEDGE > ALARM SIGNAL HORN, COMPONENT DESCRIPTION - GF80.50-P- 6020MCC > MODEL 451.3/4 with CODE (V01) Anti-theft alarm system (FFO) Fig 1: Locating Microwave Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 938 · Applies to: 450, 451, 452, 454
The alarm siren is located on the right side of the vehicle at the bottom of the vehicle. Task Acoustic alarm output for anti-theft alarm (ATA) Self-alarm output upon loss of supply voltage or communication to SAM control unit (N10/10) Monitoring vehicle inclination for realizing tow-away protection function The status of the alarm siren is polled via the local interconnect network interior compartment 2 by the SAM control unit. Design The alarm siren includes: Rechargeable battery for ensuring power supply Inclination sensor for analyzing vehicle inclination Speaker for acoustic alarm output Inclination sensor, function When the tow-away protection function is activated, the ATA inclination sensor determines the reference position with which the relative vehicle inclination is compared during the activated time period. If the maximum vehicle inclination in relation to the reference position is exceeded, an alarm is triggered, at the earliest, 25 s after the ATA is activated. If the vehicle inclination changes very slowly (e.g. leaky tire), the reference position adapts to the current vehicle position to prevent inadvertent activation of the inclination sensor. Fig 1: Locating Alarm Siren With Inclination Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Panic alarm button¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 942 · Applies to: 450, 451, 452, 454
Central locking Pressing lock button once: Driver door, front passenger door and fuel filler flap are locked. Pressing release button once: Driver door, front passenger door and fuel filler flap are unlocked. Press rear-end door open button and hold down for 2 s: Rear-end door upper section is unlocked. Press folding top open button and hold down for 2 s: Folding top opens to rear end position. Panic alarm Actuating panic alarm button. The panic alarm is triggered when actuated for t = 2 s. The panic alarm is terminated when reactuated for t = 0.5 s. Drive authorization system After inserting the transmitter key into the ignition/starter switch (S2/1) data is exchanged for checking the drive authorization when circuit 15 is on. Battery check If the battery is weak, the hazard warning system is actuated 9 times in rapid sequence when the lock button is pressed. It is then possible to actuate the transmitter key approx. another 100 times. BASIC KNOWLEDGE > TRANSPONDER COIL, COMPONENT DESCRIPTION - GF80.57-P- 6030MCC > MODEL 451.3/4 Fig 1: Locating Transponder Coil Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
M14/10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 944 · Applies to: 450, 451, 452, 454
Fuel filler flap CL [ZV] motor 2L M14/5 Right door CL [ZV] motor 12L M14/5s1 Right door CL [ZV] microswitch
M14/6 Left door CL [ZV] motor 5L M14/6s1 Left door CL [ZV] microswitch
N10/10 SAM control unit 20A N10/10 SAM control unit 26A N10/10 SAM control unit 12A N10/10 SAM control unit 5A N10/10f31 Fuse 31 3A S15 Remote trunk opening switch 25L S17/8 Trunk lid rotary tumbler microswitch 27L S6/1 Cockpit switch group 19L S6/1s11 Inside unlock CL [ZV] switch
S6/1s12 Inside lock CL [ZV] switch
S87/6 Right door rotary tumbler microswitch 14L S87/7 Left door rotary tumbler microswitch 7L S88/9 Rear-end door handle switch 23L U1012 Valid up to 30/08/2010 2E U1013 Valid as of 31/08/2010 3E U23 Valid for convertibles 27F U606 Valid for all except convertibles 24F W11/7 Ground (tank neck) 30G W43 Ground (outside left fire wall) 11C W43 Ground (outside left fire wall) 9C W6 Ground (left wheelhouse in luggage compartment) 23G W6 Ground (left wheelhouse in luggage compartment) 27G W6 Ground (left wheelhouse in luggage compartment) 25G W7 Ground (right wheelhouse in luggage compartment) 30E X35/1 Left door separation point 9E X35/1 Left door separation point 5G
X35/2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 945 · Applies to: 450, 451, 452, 454
Right door separation point 11E X35/2 Right door separation point 12G Z19/1 CL [ZV] "open" connector sleeve 4F Z19/2 CL [ZV] "closed" connector sleeve 1E Z19/2 CL [ZV] "closed" connector sleeve 14E Z19/2 CL [ZV] "closed" connector sleeve 6E Z21/6 CL [ZV] status "open" connector sleeve 12E Z21/6 CL [ZV] status "open" connector sleeve 8E Z6/35 Left door ground connector sleeve 9H Z6/36 Right door ground connector sleeve 11H Fig 1: Central Locking (CL) - Wiring Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 952 · Applies to: 450, 451, 452, 454
1 Remove center console
AR68.20- P- 2000MCU 2 Lift microwave sensor (B32), disconnect electrical connector (3) and remove microwave sensor (B32)
3 Unclip microwave sensor (B32) from bracket (2) and remove When replacing microwave sensor (B32).
4 Install in the reverse order
TESTING & REPAIR INDEX > REMOVE/INSTALL ATA ALARM SIREN - AR80.50-P- 9840MCC > MODEL 451.3 /4 with CODE (V01) Antitheft alarm system (FFO)
Remove/install
Fig 1: Identifying Microwave Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying ATA Alarm Siren Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
with "Button F3"¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 954 · Applies to: 450, 451, 452, 454
4 Select in menu "Systems" "N10/10 (SAM control unit)" and confirm with "Button F3"
5 Select in menu "N10/10 (SAM control unit)" "Control unit adaptations" and confirm with "Button F3"
6 Select in menu "Control unit adaptations" the submenu "Teach in transponder code for key" and confirm with "Button F3"
7 Select in submenu "Teach in transponder code for key" the submenu "Teach in transponder code for key" and confirm with "Button F3"
8 Press "Start button F3"
9 Enter code number for transmitter key in input field in Diagnosis Assistance system and confirm with "Button F2" The number of the transmitter keys taught in and the status of the transmitter key in the ignition/starter switch appears on the display.
10 Start teach-in procedure by pressing "Button F2"
11 Switch ignition on and off according to the request on the display. After completion of the teach-in procedure the message "Key taught in successfully" appears on the display.
Start teach-in procedure for Insert transmitter key to be taught in into ignition/starter switch within 20 s and switch on ignition (c. 15).If the ignition (c. 15) is not switched back on within 20 s, the teach-in procedure is
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 956 · Applies to: 450, 451, 452, 454
The vehicle doors, rear-end door and fuel filler flap, as well as separate opening of the rear-end door upper section, are locked and unlocked by the central locking (on model 451.3). The SAM control unit is the master control unit for these functions. Manual functions The central locking is operated by: Locking/Unlocking via transmitter key Locking via inner lock CL switch Unlocking via inner lock CL switch Locking via inside door opener Emergency operation Fig 1: Identifying Central Locking (CL) Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remote trunk lid opening (on model 451.3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 957 · Applies to: 450, 451, 452, 454
Automatic functions Speed-dependent locking Relocking Emergency opening after crash recognition Locking via transmitter key Function requirement Vehicle doors and rear-end door closed Function When the lock button on the transmitter key is actuated, it transmits a radio signal to the SAM control unit. It checks the access authorization of the transmitter key. If the access authorization is valid, the opening request of the rear-end door handle switch is inhibited and the following motors are actuated directly by the SAM control unit: Right door CL [ZV] motor Left door CL [ZV] motor Fuel filler flap CL [ZV] motor On vehicles with code (V54) Rain/light sensor, Rain/light sensor, the parking lights and the low beams are switched on for approx. 12 s by the SAM control unit depending on the ambient brightness. Unlocking via transmitter key When the unlock button on the transmitter key is actuated, it transmits a radio signal to the SAM control unit. The SAM control unit checks the access authorization of the transmitter key. If the access authorization is valid, the vehicle is unlocked selectively. For this purpose, the following motors are actuated directly by the SAM control unit: Left door CL [ZV] motor Fuel filler flap CL [ZV] motor When the unlock button on the transmitter key is reactuated, the vehicle is unlocked globally. For this purpose, the following motor is actuated directly by the SAM control unit: Right door CL [ZV] motor Moreover, the opening request from the rear-end door handle switch is enabled. The status of the rear-end door handle switch is read in directly by the SAM control unit, which actuates the trunk lid CL motor. If the vehicle is unlocked selectively, the SAM control unit fades on the interior illumination. On vehicles with code (V54) Rain/light sensor, the parking lights and the low beams are switched on for approx. 12 s by the SAM control unit depending on the ambient brightness. Visual feedback After locking or unlocking, the turn signal lights, as well as additional turn signal lamps, are actuated directly
by the SAM control unit.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 958 · Applies to: 450, 451, 452, 454
Locking: Flashing three times Unlocking: Flashing once When the vehicle is locked, the LED in the inner lock CL switch flashes. Locking via inner lock CL switch Function requirement Vehicle doors and rear-end door closed The locking request is read in directly by the SAM control unit via the inner lock CL switch in the cockpit switch group. This inhibits the opening request of the rear-end door handle switch and actuates the following central locking motors: Right door CL [ZV] motor Left door CL [ZV] motor Fuel filler flap CL [ZV] motor Visual feedback When the vehicle is locked and circuit 15 ON, the LED comes on in the inner lock switch. When the vehicle is locked and circuit 15 OFF, the LED flashes in the inner lock switch. Unlocking via inner lock CL switch The unlocking request is read in directly by the SAM control unit via the inner lock CL switch in the cockpit switch group. This enables the opening request from the rear-end door handle switch and actuates the following central locking motors: Right door CL [ZV] motor Left door CL [ZV] motor Fuel filler flap CL [ZV] motor Unlocking via inside door opener When the vehicle is opened manually with the inside door opener, the door status is relayed to SAM control unit via the door rotary tumbler microswitch and the door CL microswitch. It then actuates the fuel filler flap CL motor. The other door remains locked, the opening request from the rear-end door handle switch remains inhibited. Emergency operation Lock When the driver door is open, circuit 15 ON and the inner lock CL switch actuated, the vehicle is locked after circuit 15 OFF and when the driver door is closed. If the vehicle is locked with the emergency operation, an acoustic feedback is transmitted to the warning sound generator integrated into the instrument cluster after circuit 15 OFF and removal of the transmitter key.
BASIC KNOWLEDGE > ANTI-THEFT ALARM SYSTEM (ATA), LOCATION OF¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 961 · Applies to: 450, 451, 452, 454
COMPONENTS - GF80.50-P-0001-02MCU > Fig 1: Identifying Anti-Theft Alarm System (ATA (EDW)) Block Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > ANTI-THEFT ALARM SYSTEM (ATA [EDW]), FUNCTION - GF80.50-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 962 · Applies to: 450, 451, 452, 454
P-0001MCU > MODEL 451.3 /4 with CODE (V01) Antitheft alarm system (FFO) General information The anti-theft alarm system (ATA) monitors all relevant inputs for their non-actuated state If it detects a change of state in one of the monitored inputs, it triggers a country-specific acoustic and visual alarm. The acoustic signals are output by the alarm siren with inclination sensor (H3/2), the visual signals via the exterior lights. The SAM control module (N10/10) is the master control module for the ATA. The ATA is activated when the central locking (CL) is locked. The ATA, when armed, monitors: Doors and rear-end door Position change of vehicle Motions in the interior compartment Voltage supply and data line for alarm siren Status of panic button on transmitter key A status change of the panic button, can also be recognized in the deactivated state. The visual feedback for the ATA status is output by a flashing LED integrated into the tow-away protection/interior protection switch (S6/1s10). Fig 1: Identifying Anti-Theft Alarm System (ATA) Components Location Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Moreover, the ATA can be activated via the automatic CL relocking function:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 964 · Applies to: 450, 451, 452, 454
If the vehicle is unlocked via the transmitter key and if one of the doors or the trunk lid is not opened within 60 s, the vehicle is relocked and the ATA is completely activated 25 s after the vehicle is locked. During the arming phase, the LED integrated into the tow-away protection/interior protection switch (S6/1s10) flashes at a higher frequency. Visual feedback from the completely activated ATA is output by flashing at a low frequency. If the vehicle is locked with the CL emergency locking function, the ATA is not activated. When the ATA is activated, the following functions are performed: Monitoring doors and rear-end door Interior motion sensor tow-away protection Partial activation Function requirements ATA not activated Transmitter key removed Function If the tow-away protection/interior protection switch is actuated within 60 s after the transmitter key is removed, the tow-away protection and interior protection functions are deactivated. In this case, the LED integrated into the tow-away protection/interior protection switch comes on. After locking, the visual feedback is analog to complete activation. Deactivation of the tow-away protection and interior protection is only valid for the following activation. Deactivation is reset with circuit 15 On or each time the ATA is deactivated. An exception here is automatic activation of the trunk lid remote opening (on model 451.3). The previous status is restored during this procedure. Deactivating The ATA can be deactivated by: Unlocking CL with transmitter key or Circuit 15 On Unlocking CL with transmitter key: The request of the transmitter key is received by the SAM control unit. This checks the validity of the transmitter key. If the transmitter key is valid, the ATA is deactivated. Circuit 15 On: After inserting the transmitter key into the ignition/starter switch (S2/1) the ID code of the transmitter key is received inductively by the transponder coil (L11) when circuit 15 is On. It directly relays the ID code to the SAM control unit for checking. If the ID code is valid, the ATA is deactivated.
Right rotary tumbler microswitch¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 966 · Applies to: 450, 451, 452, 454
Trunk lid rotary tumbler microswitch Remote trunk opening switch Alarm siren with inclination sensor ATA [EDW] microwave sensor If it detects a change of state in one of the monitored inputs, it triggers a country-specific acoustic and visual alarm. Alarm actuation via switch The following components are read in directly by the SAM control unit: Left rotary tumbler microswitch Right rotary tumbler microswitch Trunk lid rotary tumbler microswitch Remote trunk opening switch If the switch exits its non-actuated state, a visual alarm is triggered by the SAM control unit by actuating the turn signal lights as well as the additional turn signal lamps. Moreover, the SAM control unit requests an acoustic alarm from the alarm siren via LIN C. If the rear-end door upper section is opened via the trunk lid remote opening feature, the remote trunk opening switch is deactivated as an alarm input. If the vehicle is unlocked by mechanically unlocking the driver lock, a visual and acoustic alarm is triggered when the driver door is opened. Alarm actuation by alarm siren The alarm siren is actuated cyclically by the SAM control unit. If no answer is received from the alarm siren within approx. 1 s, an alarm is triggered. The alarm is only output visually, as the alarm siren cannot be addressed If the alarm siren detects loss of the supply power or the communication to the SAM control unit, it outputs an acoustic alarm automatically. Alarm triggering by tow-away protection The SAM control unit checks cyclically the input of the inclination sensor integrated into the alarm siren. If the inclination sensor detects a position change of the vehicle, it relays a signal to the SAM control unit, which requests the acoustic alarm output from the alarm siren via LIN C. Moreover, a visual alarm is output by the SAM control unit by directly actuating the turn signal lights and additional turn signal lamps. Alarm triggered by interior motion sensor The alarm decision is accomplished by considering the duration and the speed of the motion in the interior compartment. If the ATA microwave sensor recognizes forced entry into the vehicle, it relays a signal to the SAM control unit. This outputs a visual alarm via the turn signal lights and additional turn signal lights and requests an
MODEL 451.3 /4 with CODE (V01) Anti-theft alarm system (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 968 · Applies to: 450, 451, 452, 454
Location The microwave sensor is located in the center console below the cover of the electronic selector lever module control unit (N15/5). Task The microwave sensor monitors the interior compartment for motion. The status of the microwave sensor is transmitted by the local interconnect network interior 2 to the SAM control unit (N10/10). BASIC KNOWLEDGE > ALARM SIGNAL HORN, COMPONENT DESCRIPTION - GF80.50-P- 6020MCC > MODEL 451.3 /4 with CODE (V01) Anti-theft alarm system (FFO) Fig 1: Identifying Microwave Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 969 · Applies to: 450, 451, 452, 454
The alarm siren is located on the right side of the vehicle at the bottom of the vehicle. Task Acoustic alarm output for anti-theft alarm (ATA) Self-alarm output upon loss of supply voltage or communication to SAM control unit (N10/10) Monitoring vehicle inclination for realizing tow-away protection function The status of the alarm siren is polled via the local interconnect network interior compartment 2 by the SAM control unit. Design The alarm siren includes: Rechargeable battery for ensuring power supply Inclination sensor for analyzing vehicle inclination Speaker for acoustic alarm output Inclination sensor, function When the tow-away protection function is activated, the ATA inclination sensor determines the reference position with which the relative vehicle inclination is compared during the activated time period. If the maximum vehicle inclination in relation to the reference position is exceeded, an alarm is triggered, at the earliest, 25 s after the ATA is activated. If the vehicle inclination changes very slowly (e.g. leaky tire), the reference position adapts to the current vehicle position to prevent inadvertent activation of the inclination sensor. Fig 1: Identifying Alarm Signal Horn Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Release button¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 973 · Applies to: 450, 451, 452, 454
Rear-end door upper section open button or folding top open button Panic alarm button Central locking Pressing lock button once: Driver door, front passenger door and fuel filler flap are locked. Pressing release button once: Driver door, front passenger door and fuel filler flap are unlocked. Press rear-end door open button and hold down for 2 s: Rear-end door upper section is unlocked. Press folding top open button and hold down for 2 s: Folding top opens to rear end position. Panic alarm Actuating panic alarm button. The panic alarm is triggered when actuated for t = 2 s. The panic alarm is terminated when reactuated for t = 0.5 s. Drive authorization system After inserting the transmitter key into the ignition/starter switch (S2/1) data is exchanged for checking the drive authorization when circuit 15 is on. Battery check If the battery is weak, the hazard warning system is actuated 9 times in rapid sequence when the lock button is pressed. It is then possible to actuate the transmitter key approx. another 100 times. BASIC KNOWLEDGE > TRANSPONDER COIL, COMPONENT DESCRIPTION - GF80.57-P- 6030MCC > MODEL 451.3/ 4
U1012¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 976 · Applies to: 450, 451, 452, 454
Valid up to 30/08/2010 2E U1013 Valid as of 31/08/2010 3E U23 Valid for convertibles 27F U606 Valid for all except convertibles 24F W11/7 Ground (tank neck) 30G W43 Ground (outside left fire wall) 11C W43 Ground (outside left fire wall) 9C W6 Ground (left wheelhouse in luggage compartment) 23G W6 Ground (left wheelhouse in luggage compartment) 27G W6 Ground (left wheelhouse in luggage compartment) 25G W7 Ground (right wheelhouse in luggage compartment) 30E X35/1 Left door separation point 9E X35/1 Left door separation point 5G X35/2 Right door separation point 11E X35/2 Right door separation point 12G Z19/1 CL [ZV] "open" connector sleeve 4F Z19/2 CL [ZV] "closed" connector sleeve 1E Z19/2 CL [ZV] "closed" connector sleeve 14E Z19/2 CL [ZV] "closed" connector sleeve 6E Z21/6 CL [ZV] status "open" connector sleeve 12E Z21/6 CL [ZV] status "open" connector sleeve 8E Z6/35 Left door ground connector sleeve 9H Z6/36 Right door ground connector sleeve 11H
Fig 1: Central Locking (CL) - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 977 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
S6/1s10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 980 · Applies to: 450, 451, 452, 454
Tow-away protection/interior protection switch 7D S6/1s11 Inside unlock CL [ZV] switch 8E S6/1s12 Inside lock CL [ZV] switch 8E S15 Remote trunk opening switch 12E S17/8 Trunk lid rotary tumbler microswitch 9H S87/6 Right door rotary tumbler microswitch 9H S87/7 Left door rotary tumbler microswitch 9H WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR ANTI-THEFT ALARM SYSTEM (ATA [EDW]) - PE80.50-P-2050-99MCU > Code: Designation: Position: A1 Instrument cluster 3 C A1e1 Left tern signal indicator lamp 1 B A1e2 Right turn signal indicator lamp 1 B B32 Microwave sensor 7 L E1e5 Left turn signal lamp 10 C E22/1 Left auxiliary turn signal lamp 10 E E22/2 Right auxiliary turn signal lamp 10 E E2e5 Right turn signal lamp 10 D E3e11 Left brake/turn signal light 10 D E4e11 Right brake/turn signal light 10 D H3/2 Alarm siren with inclination sensor 13 L L11 Transponder coil 9 G M14/5s1 Right door CL [ZV] microswitch 12 D M14/6s1 Left door CL [ZV] microswitch 12 E N10/10 SAM control unit 8 G N3/10 ME-SFI [ME] control module 3 K S15 Remote trunk release switch 12 E S17/8 Trunk lid rotary tumbler microswitch 9 H S2/1 Ignition/starter switch 9 H S6/1s1 Hazard flasher switch 7 D S6/1s10 Tow-away protection/interior protection switch 7 D S6/1s11 Inside unlock CL [ZV] switch 8 E S6/1s12 Inside lock CL [ZV] switch 8 E
GENERAL INFORMATION > NOTES ON AUDIO SETTINGS - AH82.60-P-0002-01MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 983 · Applies to: 450, 451, 452, 454
Model 451 with code (527) High-Line radio Before delivery of the new car to the customer, after installation of the smart Premium radio and after every interruption of the power supply, settings must be made on the smart Premium radio in order to obtain the best sound results: In combination with the following sound system variants, the "Dynamic Noise Covering (DNC)" must be calibrated: Code (C08) Radio preinstallation incl. rod antenna (FFO) Code (C54) Sound system 2 Code (C17) smart surround sound system In addition, with code (C17) smart surround sound system, the audio settings must be changed. The equalizer must be switched off so that this function can be performed by the control unit of the surround sound system. Optimum settings for the smart Premium radio only in combination with the surround sound system: "Balance" 0 "Bass" 0 "Treble" 0 "X bass level" 0 "X bass frequency" 63 "Hz sound profile" OFF "Equalizer" 0 (off) "Dynamic Noise Covering (DNC)" Calibrated "Volume boost" 5 The procedures for calibrating and making the settings are described in the operating instructions of the radio. RETROFITTING & CONVERSION > RETROFIT BRABUS ADDITIONAL HEADLAMP WIRING HARNESS - AN82.10-P-0007-01MCC >
Connection diagram on vehicles without retrofitted ambiance illumination¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 984 · Applies to: 450, 451, 452, 454
The dashed brown/gray line (br/gr) shows the original installation of lines in the vehicle and the continuous lines are the retrofit. Connection diagram on vehicles with retrofitted ambiance illumination Fig 1: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Brabus Additional Headlamp - Connection Diagram On Vehicles Without Retrofitted Ambiance Illumination Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The dashed brown/gray line (br/gr) and gray/blue line (gr/bl) show the original installation of lines in the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 985 · Applies to: 450, 451, 452, 454
vehicle; the continuous lines show the retrofit. Routing diagram shown on vehicles without retrofitted ambiance illumination Fig 3: Brabus Additional Headlamp - Connection Diagram On Vehicles With Retrofitted Ambiance Illumination Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Ensure that the wiring harnesses are not damaged by chafing or being trapped otherwise the appropriate¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 986 · Applies to: 450, 451, 452, 454
wiring harness must be replaced. 1. Route engine compartment branch-off line (3.1) of additional headlamp wiring harness along vehicle wiring harness, as shown, from installation location of additional headlamp to grommet (16) and to left front ground (with lamp unit) and fix in place using cable ties. Pay attention to routing of line in area of wiper system since wiper linkage must have freedom of movement in every position. Failure to observe this can result in short circuit or the wiper system locking up. Fig 4: Brabus Additional Headlamp - Routing Diagram (Shown On Vehicles Without Retrofitted Ambiance Illumination) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Screw on brown line (br) of engine compartment branch-off line of additional headlamp wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 987 · Applies to: 450, 451, 452, 454
harness to left front ground (with lamp unit) (W9) and fix brown line (br) in place using cable ties. 3. Carefully cut a rubber plug (arrow) at grommet (16). 4. Route engine compartment branch-off line (3.1) of additional headlamp wiring harness through Fig 5: Identifying Branch-Off Line Of Additional Headlamp Wiring Harness And Grommet Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Brown Line Of Additional Headlamp Wiring Harness And Left Front Ground (With Lamp Unit) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
opening in grommet (16) into interior and fix in place using cable ties.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 988 · Applies to: 450, 451, 452, 454
- Seal grommet (16) using suitable sealant.
- Remove screws/bolts (17) at SAM control unit (N10/10).
- Unclip SAM control unit (N10/10) in rear area (arrow A) and guide downwards until connectors at rear of SAM control unit (N10/10) are accessible. Fig 7: Locating Rubber Plug Of Grommet Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Remove relay (14) from relay socket (13).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 989 · Applies to: 450, 451, 452, 454
- Plug engine compartment branch-off line (3.1) of additional headlamp wiring harness into free center slot at relay socket (13). Fig 8: Locating SAM Control Unit Rear Area Courtesy of MERCEDES BENZ OF NORTH AMERICA
10. Plug blue/gray line (bl/gr) into slot 1 of black 2-pin coupling (10).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 990 · Applies to: 450, 451, 452, 454
The black 2-pin connector (15) that is located on the second blue/gray line (bl/gr) is only required on vehicles with ambiance illumination. Operation steps 11 to 16 only on vehicles without retrofitted ambiance illumination. Fig 9: Identifying Relay, Relay Socket And Engine Compartment Branch-Off Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 10: Identifying Black 2-Pin Coupling, 2-Pin Connector And Second Blue/Gray Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Release coupling "N11-5" and disconnect at SAM control unit (N10/10).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 991 · Applies to: 450, 451, 452, 454
Coupling "N11-5" is located in the marked slot (arrow). 12. Unplug pin (5.8) of brown/gray line (br/gr) from slot 8 of coupling "N11-5" (5). 13. Plug pin of brown/gray line (br/gr) of adapter line into slot 8 of coupling "N11-5" (5). Fig 11: Locating Coupling "N11-5" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. Plug brown/gray line (br/gr) unplugged from slot 8 of coupling "N11-5" (5) into slot 1 of black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 992 · Applies to: 450, 451, 452, 454
coupling (7). 15. Connect black 2-pin coupling (7) to black 2-pin connector (8) of adapter line. 16. Connect coupling "N11-5" (5) at SAM control unit (N10/10). Fig 12: Identifying Pin Of Brown/Gray Line And Coupling "N11-5" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
17. Disconnect black 2-pin coupling (20) of ambiance illumination wiring harness (21) from black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 993 · Applies to: 450, 451, 452, 454
connector (9) of adapter line. Only on vehicles with retrofitted ambiance illumination. On these, the adapter line is already installed and the ambiance illumination wiring harness (21) connected to this. 18. Connect black 2-pin connector (9) to black 2-pin coupling (10) of gray/blue line (gr/bl) of interior branch-off line. 19. Connect black 2-pin coupling (20) of gray/blue line (gr/bl) of ambiance illumination wiring harness (21) to black 2-pin connector (15) of gray/blue line (gr/bl) 20. Fix wiring harnesses of SAM control unit (N10/10) in place with cable tie. Fig 13: Identifying Black 2-Pin Coupling, Connector, Coupling N11-5 & SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
21. Remove cable tie at bracket (18) and unhook bracket (18) from longitudinal strut (19).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 994 · Applies to: 450, 451, 452, 454
- Insert relay (14) into relay socket (13) and clip relay socket (13) into bracket (18)
- Hook bracket (18) into longitudinal strut (19) and fasten with cable tie
- Insert fuse carrier with fuse (6) at SAM control unit (N10/10). Fig 14: Identifying Ambiance Illumination Wiring Harness Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 15: Identifying Bracket Of Longitudinal Strut And Relay Of Relay Socket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The slot and the fuse carrier with fuse (6) are coded. The fuse has a fuse rating of 10 A.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 995 · Applies to: 450, 451, 452, 454
- Screw on brown line (br) at left interior floor ground (W14).
- Clip SAM control unit (N10/10) into rear area (arrow A) and screw down using screws/bolts (17). RETROFITTING & CONVERSION > RETROFIT BRABUS ADDITIONAL HEADLAMP LAMP UNIT - AN82.10-P-0007-02MCC > The following operation steps are shown on the right side of the vehicle. Retrofitting on the left side of the vehicle is performed in the same manner.
- Drill hole with diameter of 4 mm in center at pin (20). Hand drill gotis://G_58.0_00.1 Wet/dry vacuum cleaner gotis://P_00.12_06.0
- Connect black 2-pin connector (12) and daytime running lights electrical connector (21) at right additional headlamp (2). Fig 16: Identifying SAM Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Screw down right additional headlamp (2) at attachment points of front fog lamp.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 996 · Applies to: 450, 451, 452, 454 · AR: AN82.10-P-0007MCC
- Tighten right additional headlamp (2) with screws/bolts included in delivery contents at pin (20). RETROFITTING & CONVERSION > RETROFIT BRABUS ADDITIONAL HEADLAMPS - AN82.10-P-0007MCC > MODEL 451.3/4 (except 451.391 /491) with CODE (V07) Front fog lamps (FFO) except CODE (460) Canada version Fig 1: Identifying 2-Pin Connector And Daytime Running Lights Electrical Connector Of Right Additional Headlamp Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Right And Left Additional Headlamps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Vehicle is locked:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1000 · Applies to: 450, 451, 452, 454
Lamp units (3) are switched off in a dimmed state. Door opened: Lamp units (3) light up. Lamp units (3) are switched off when ignition is switched on (circuit 15). RETROFITTING & CONVERSION > RETROFIT DAYTIME RUNNING LIGHTS HEADLAMP WIRING HARNESS - AN82.10-P-0100-01MCC > Fig 2: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connection diagram¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1001 · Applies to: 450, 451, 452, 454
Fig 2: Identifying Expanding Pliers (450 589 12 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Puller Aid (450 589 25 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The dashed brown/gray line (br/gr) shows the original installation of lines in the vehicle and the continuous¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1002 · Applies to: 450, 451, 452, 454
lines are the retrofit. Routing diagram for front wiring harness (3.1) Fig 4: Daytime Running Lights Headlamp Wiring Harness - Connection Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Daytime Running Lights Headlamp Wiring Harness - Routing Diagram For Front Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Routing diagram for interior wiring harness (3.2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1003 · Applies to: 450, 451, 452, 454
- Route front wiring harness (3.1), as shown, to vehicle-side wiring harness and temporarily fasten with cable ties. Do not damage front wiring harness (3.1) while routing by means of crushing or pinching as this may lead to a short circuit. Use puller aid in the area of the wiper system.
- Lay interior wiring harness (3.2) in area of windshield washer reservoir until it is routed further. Fig 6: Daytime Running Lights Headlamp Wiring Harness - Routing Diagram For Interior Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Route front wiring harness (3.1), as shown, at vehicle wiring harness and guide coupling (16)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1004 · Applies to: 450, 451, 452, 454
through opening in front module. Do not damage front wiring harness (3.1) while routing by means of crushing or pinching as this may lead to a short circuit. 4. Temporarily fasten front wiring harness (3.1) in illustrated area at vehicle-side wiring harness using cable ties. Fig 7: Identifying Front And Interior Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Front Wiring Harness Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Cut open cable duct (arrow A) of firewall rubber grommet (15).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1005 · Applies to: 450, 451, 452, 454
- Enlarge cable duct (arrow A) using expanding pliers and guide interior wiring harness (3.2) through opening into interior. Do not damage interior wiring harness (3.2) while routing by means of crushing or pinching as this may lead to a short circuit.
- Route interior wiring harness (3.2) and front wiring harness (3.1), as shown, at vehicle-side wiring harness and temporarily fasten using cable ties.
- Connect brown line (br) at outer left firewall ground (W43).
- Route brown line (br) and front wiring harness (3.1) to vehicle-side wiring harness and temporarily fasten with cable ties. Fig 9: Interior And Front Wiring Harness Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
10. Route front wiring harness (3.1), as shown, at vehicle-side wiring harness and guide coupling (17)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1006 · Applies to: 450, 451, 452, 454
through opening in front module. Do not damage front wiring harness (3.1) while routing by means of crushing or pinching as this may lead to a short circuit. 11. Temporarily fasten front wiring harness (3.1) in illustrated area at vehicle-side wiring harness using cable ties. 12. Check routing of front wiring harness (3.1) and tighten all cable ties used, then shorten excess length of cable ties. Operation steps 13 to 18 only on vehicles without retrofitted ambiance illumination. Fig 10: Identifying Brown Line Of Outer Left Firewall Ground And Front Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 11: Front Wiring Harness Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
13. Release and disconnect coupling "N11-5" at SAM control unit (N10/10).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1007 · Applies to: 450, 451, 452, 454
Coupling "N11-5" is located in the marked slot (arrow). 14. Detach pin (5.8) of brown/gray line (br/gr) from slot 8 of coupling "N11-5" (5) with wiring harness repair kit, basic. 15. Plug pin (4) of brown/gray line (br/gr) of adapter line (12) into slot 8 of coupling "N11-5" (5). Fig 12: Locating Marked Slot Of Coupling "N11-5" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
16. Unlatch secondary lock (10) of coupling (9) and carefully pull out of coupling (9) up to end stop.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1008 · Applies to: 450, 451, 452, 454
- Plug pin (5.8) of brown/gray line (br/gr) into slot 1 of coupling (9). Brown/gray line (br/gr) can be guided through closed cap (arrow D) and through seal (11).
- Slide secondary lock (10) into coupling (9) until it engages. Fig 13: Identifying Pin Of Brown/Gray Line, Adapter And Coupling N11-5 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
19. Plug gray/blue line (gr/bl) of interior wiring harness into slot 1 of coupling (6).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1009 · Applies to: 450, 451, 452, 454
On vehicles with retrofitted ambiance illumination, the gray/blue line (gr/bl) must be crimped with gray/blue line (gr/bl) of adapter line already installed. 20. Plug red/blue line (rt/bl) of interior wiring harness into fuse holder (14). Ensure that fuse (13) is seated correctly. 21. Insert fuse holder (14) in one of the suitably coded slots "R1" to "R4" (arrow B) at SAM control unit (N10/10). Fig 14: Identifying Pin Of Brown/Gray Line And Secondary Lock Of Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Operation steps 22 to 24 only on vehicles without retrofitted ambiance illumination.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1010 · Applies to: 450, 451, 452, 454
- Connect coupling (9) with connector of adapter line (12).
- Connect coupling (6) with connector (7) of adapter line (12).
- Insert coupling "N11-5" (5) into slot (arrow C) at SAM control unit (N10/10). Fig 15: Identifying Coupling, Fuse, Fuse Holder And Gray/Blue Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 16: Identifying Coupling With Connector Of Adapter Line And Coupling N11-5 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Operation steps 25 to 29 only on vehicles with retrofitted ambiance illumination.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1011 · Applies to: 450, 451, 452, 454
- Separate gray/blue line (gr/bl) of adapter line (12). Do not separate the gray/blue line (gr/bl) of the ambiance illumination wiring harness connected to the adapter line (12).
- Slide heat-shrinkable tube over gray/blue line (gr/bl) of adapter line (12).
- Crimp together gray/blue line (gr/bl) of adapter line (12) and gray/blue line (gr/bl) of front wiring harness (3.1).
- Fasten wiring harnesses of SAM control unit (N10/10) using cable tie (2), as shown, and then shorten excess length of cable tie (2).
- Protect crimped connection (18) with heat-shrinkable tube. Fig 17: Identifying Gray/Blue Line Of Adapter Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT DAYTIME RUNNING LIGHTS HEADLAMP¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1012 · Applies to: 450, 451, 452, 454
CONTROL UNIT - AN82.10-P-0100-02MCC > The following steps are shown on the left side of the vehicle. Installation on the right side of vehicle is performed in the same manner. 1. Before installing the daytime running lights control unit (1) check whether the ferrite core (10) is positioned, as shown, on the wiring harness. If necessary, align the ferrite core (10) again. Fig 18: Fastening Wiring Harnesses Of SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Tighten daytime running lights control unit (1) with screws/bolts (2) at bracket (6).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1013 · Applies to: 450, 451, 452, 454
- Temporarily fasten connector (4) using cable tie (5) at front side of bracket (6) at peg (arrow A).
- Drill out mounting dome (arrow B) of front module (7) at center using a drill bit (diameter 2.0 mm). Cordless drill/driver gotis://G_58.0_01.1 Fig 1: Identifying Daytime Running Lights Control Unit And Ferrite Core Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Daytime Running Lights Control Unit, Screws/Bolts & Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Connect connector (3) of daytime running lights control unit (1) to coupling (8) of front wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1014 · Applies to: 450, 451, 452, 454
harness. 6. Tighten bracket (6) with screws/bolts (9) at front module (7). 7. Align connector (4), as shown, and tighten cable tie (5). Fig 3: Locating Mounting Dome Of Front Module Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Connector Of Daytime Running Lights Control Unit And Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Shorten excess length of cable tie (5).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1015 · Applies to: 450, 451, 452, 454
RETROFITTING & CONVERSION > RETROFIT DAYTIME RUNNING LIGHTS HEADLAMP IN CBS FRONT END - AN82.10-P-0100-04MCC > Installation of the daytime running lights headlamp unit (7) is shown on the left side of the vehicle. Installation on the right side of vehicle is performed in the same manner. 1. Tighten bracket (6) with screws/bolts (5) at daytime running lights headlamp (3). 2. Position installation frame (1) at trim (2). 3. Insert daytime running lights headlamp (3) into trim (2). 4. Tighten installation frame (1) with screws/bolts (4). Fig 5: Identifying Bracket With Screws/Bolts Of Front Module, Connector And Cable Tie Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Unclip trim (8) from CBS front end (9).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1016 · Applies to: 450, 451, 452, 454 · AR: AN82.10-P-0100MCC
- Clip daytime running lights headlamp unit (7) into CBS front end (9). Ensure that catch hooks (arrows) of trim (2) are seated correctly in CBS front end (9). RETROFITTING & CONVERSION > RETROFIT DAYTIME RUNNING LIGHTS HEADLAMP - AN82.10-P-0100MCC > MODEL 451.3/4 (except 451.391 /491) except CODE (V07) Front fog lamps (FFO) except CODE (460) Canada version Fig 1: Identifying Bracket, Screws/Bolts, Daytime Running Lights Headlamp, Frame And Trim Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Locating Catch Hooks Of Trim Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT BRABUS SUBWOOFER - AN82.62-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1020 · Applies to: 450, 451, 452, 454
0004MCC > MODEL 451.3/4 (except 451.391 /491) up to 30.8.10 with CODE (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO) Shown on vehicle with Code (I01) AC Plus Fig 5: Identifying Puller Aid (450 589 25 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Subwoofer Wiring Harness, Lines, Connector And Clutches Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1021 · Applies to: 450, 451, 452, 454
Fig 2: Identifying Subwoofer Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Subwoofer Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Perform function test on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1023 · Applies to: 450, 451, 452, 454
14 Perform function test on subwoofer speaker (4)
REPAIR MATERIALS Number Designation Order number BR00.45-Z-1071-02A Adhesive tape roll, gray Tesa tape, 50 meters 0.3X50, 236 mm A 001 989 17 85 MAINTENANCE > CHECK SETTING OF HIGH BEAM - AP82.10-P-8260-02MCC > The center of the luminous beam must be the corresponding central marks (6). If this is not the case: adjust high beam. MAINTENANCE > ADJUST OR CHECK FRONT FOG LIGHTS - AP82.10-P-8260-04MCC > Shown on vehicle with code (V07) Front fog lamps (FFO) The light-dark boundary must run as horizontal as possible at the height of the corresponding division mark (4), if necessary correct with the adjustment screw (arrow). Fig 1: Identifying Central Marks Of High Beam Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MAINTENANCE > CHECK LOW BEAM - AP82.10-P-8260-05MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1024 · Applies to: 450, 451, 452, 454
The light-dark boundary must be on the horizontal division mark (4) of the device. The kink line (5) must start below the central mark (6) on the horizontal division mark (4) and rise to the right. Fig 1: Identifying Light-Dark Boundary And Division Mark Of Fog Light Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Locating Adjustment Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1026 · Applies to: 450, 451, 452, 454
14.5.08 Adjust headlamps in the vertical direction, added Steps 8, 9, 10, 13, 14 and 15 Removing
1 Drive vehicle onto level surface. The vehicle must be in the ready-to-drive condition (curb weight, fuel tank full or corresponding additional weight). Front wheels in straight-ahead position.
2 Check tire pressure, correct if necessary
AP40.15-P- 4061MCU 3 Place 75 kg or one person on driver seat and set headlamp height adjustment to "0"
4 Remove maintenance flap
Checking
5 Align headlamp aimer with the vehicle and perform height adjustment towards the center of the headlamps Follow operating instructions of the headlamp aimer.Headlamp aimer http://gotis.aftersales.mercedes- benz.com
6 Switch on left high beam (E1e1) and right high beam (E2e1)
Fig 2: Identifying Front Headlamp Unit And Expanding Rivet Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Check adjustment of the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1027 · Applies to: 450, 451, 452, 454
7 Check adjustment of the left high beam (E1e1) and right high beam (E2e1), if necessary adjust the left high beam (E1e1) or right high beam (E2e1) at the adjustment screw (horizontal) (2)
AP82.10-P-8260- 02MCC 8 Remove rivet (3) or expanding rivet (4) which is located above the adjustment screw (vertical) (1) If the left high beam (E1e1) or right high beam (E2e1) has to be adjusted in the vertical direction. The expanding rivet (4) can be removed when the left front lamp unit (E1) or right front lamp unit (E2) is installed.To drill out the rivet (3) the left front lamp unit (E1) or right front lamp unit (E2) must be removed. See: ↓
Remove/install lamp unit AR82.10-P- 4730MCU 9 Install left front lamp unit (E1) and right front lamp unit (E2) If the rivet (3) above the adjustment screw (vertical) (1) has been removed. AR82.10-P- 4730MCU 10 Adjust the left high beam (E1e1) or right high beam (E2e1) at the adjustment screw (vertical) (1) If the left high beam (E1e1) or right high beam (E2e1) has to be adjusted in the vertical direction. AP82.10-P-8260- 02MCC 11 Switch on left low beam (E1e2) and right low beam (E2e2)
12 Check adjustment of the left low beam (E1e2) and the right low beam (E2e2) if necessary adjust the left low beam (E1e2) or right low beam (E2e2) at the adjustment screw (horizontal) (2)
AP82.10-P-8260- 05MCC 13 Remove rivet (3) or expanding rivet (4) which is located above the adjustment screw (vertical) (1) If the left low beams (E1e2) or right low beam (E2e2) has to be adjusted in the vertical direction and the rivet (3) or expanding rivet (4) is still fitted. The expanding rivet (4) can be removed when the left front lamp unit (E1) or right front lamp unit (E2) is installed.To drill out the rivet (3) the left front lamp unit (E1) or right front lamp unit (E2) must be
Checking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1030 · Applies to: 450, 451, 452, 454
1 Check front windshield washer nozzle (2) for proper operation Clean clogged front windshield washer nozzle (2) from outside using a suitable needleIf necessary: ↓Replace front windshield washer nozzles (2) subject to separate repair order.
Remove/install windshield washer nozzle AR82.35-P- 6970MCC 2 Check adjustment of the front windshield washer nozzle (2), and adjust if necessary corresponding to the diagram shown
3 Check rubber lip of front wiper blades (1) for hardening and cracks. If necessary:↓Replace front wiper blades (1). subject to separate repair order.
Replace wiper blade AR82.30-P- 6251MCC 4 Check setting of wiper arms If necessary: ↓Adjust wiper arms. subject to separate repair order.
Remove and install wiper arm AR82.30-P- 6100MCC 5 Check operation of windshield wipers
6 Check rear window windshield washer nozzle (3) for proper operation In case of model 451.3 Clean clogged rear window windshield washer nozzle (3) from outside using a suitable needle.If necessary: ↓Replace rear window windshield washer nozzles (3). subject to separate repair order.
Remove/install spray-nozzle for rear window AR82.35-P- 7338MCC 7 Check the adjustment of In case of model 451.3 The
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1035 · Applies to: 450, 451, 452, 454
1 Unclip trim (1) of left front fog lamp (E5/1) or right front fog lamp (E5/2) in the marked areas (arrows) and remove
2 Remove bolts (2) from left front fog lamp (E5/1) or right front fog lamp (E5/2)
3 Remove left front fog lamp (E5/1) or right front fog lamp (E5/2) toward the front until the electrical connector (3) is accessible Carefully lead left front fog lamp (E5/1) or right front fog lamp (E5/2) out of front CBS, otherwise it may be scratched and therefore damaged.
4 Disconnect electrical connector (3) from left front fog lamp (E5/1) or from right front fog lamp (E5/2) and remove left front fog lamp (E5/1) or right front fog lamp (E5/2)
5 Install in the reverse order
6 Check adjustment of left front fog lamp (E5/1) or right front fog lamp (E5/2) and correct if necessary
Check and correct the adjustment of the headlamps AP82.10- P- 8260MCU Fig 1: Identifying Fog Lamps, Electrical Connector, Screw And Trim Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1039 · Applies to: 450, 451, 452, 454
Remove/install
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 1 Allow wiper motor to run in end position and switch off ignition
2 Remove paneling (1) from center piece in front of windshield
AR88.00-P- 2792MCC 3 Remove cap on nut (3)
4 Unscrew nut (3) on wiper arm (2) BA82.30-P- 1002-01F 5 Position puller (5) on wiper arm shaft (4) 001589383300 6 Detach wiper arm (2) using puller (5) 001589383300 7 Remove puller (5) 001589383300 8 Remove wiper arm (2)
9 Install in the reverse order
WINDSHIELD WIPER Number Designation Model 451.3 Model 451.4 Fig 1: Removing/Installing Wiper Arm Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3/4 with CODE (V54) Rain/light sensor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1043 · Applies to: 450, 451, 452, 454
Remove
1 Remove inside rearview mirror * for USA only AR68.40-P- 0001MCU except USA AR68.40-P- 0001MCC 2 Unclip cover (1) from the retaining collar (3) and detach cable routing (2) out of the cover (1) Carefully unclip cover (1) to prevent the retaining clips from breaking.
3 Disconnect electrical connector (4)
4 Unclip retaining clip (5) for rain sensor/light sensor (B38) at retaining collar (3) (arrows)
5 Remove rain sensor/light sensor (B38) from the retaining collar (3) The rain sensor/light sensor (B38) must always be replaced after removing from the windshield.
Install
6.1 Remove protective cap from retaining collar (3) When replacing the windshield. With the new windshield, the contact surface of the rain sensor/light sensor
Fig 1: Identifying Rain/Light Sensor 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. 1046 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove front module
AR62.30- P- 1575MCU 2 Suction off window washer fluid in washer fluid reservoir (1)
3 Unscrew nuts (5) from washer fluid reservoir (1) Installation: Replace self-locking nuts (5).
4 Remove washer fluid reservoir (1) until windshield washer fluid pump (M5/1) is accessible
5 Detach electrical connector (2) from windshield washer fluid pump (M5/1)
6 Unclip windshield washer fluid pump (M5/1) from washer fluid reservoir (1) and place to one side with connected hoses (3, 4) On model 451.4 only the hose (4) is installed. Installation: Ensure that seal of windshield washer fluid pump (M5/1) is 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)
Fig 1: Identifying Windshield Washer System Pump Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying Wiper Motor And Electrical Connector¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1048 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Windshield Washer Nozzle And Front Wiper Arm Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Windshield Washer Nozzle For Rear Window And Rear Wiper Blade Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on vehicle with code (494) USA version¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1054 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Antenna Cable Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
and push protective tube¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1056 · Applies to: 450, 451, 452, 454
(5) back until main wiring harness is exposed 6 Expose antenna cable (1) at main wiring harne and cut off (arrow A) Cut off antenna cable (1) directly at the pu hed back protective tube (5).
7 Expose antenna amplifier supply line (6) at main wiring harness and cut off (arrow A) With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version Cut off antenna amplifier supply line (6) approx. 5 cm before the pushed back protective tube (5).
8 Make cable hole at grommet (8) Cut off pin (7).
9 Cut off antenna cable (1) in radio recess (arrow B)
Install
10 Remove adhesive tape (9) from new antenna cable (1)
11.1 Clip antenna cable (1) into body in area of upper door hinge Without code (460) Canada version,without code (494) USA version orwithout code (498) Japan version
11.2 Clip antenna amplifier (3) into body With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version
12 Screw antenna cable (1) onto antenna base (2) by hand
13 Route antenna cable (1) along main wiring harness and guide through grommet (8) into interior Expanding pliers *450589123700 14 Route new antenna amplifier supply line (6.1) along antenna cable (1) to antenna amplifier supply line (6) at main wiring harness
15 Cut new antenna amplifier supply line (6.1) to length and connect to antenna amplifier supply line (6) With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version Use solder AR00.19-P-0100A
MODEL 451.3/4 with CODE (C17) smart surround sound system¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1058 · Applies to: 450, 451, 452, 454
Shown on left side of vehicle Remove/install
1 Remove left or right paneling (1) at side in trunk
AR68.30- P- 4800MCC 2 Place paneling (1) onto suitable base
3 Lift off spring clips (2) Installation: Replace spring clips (2).
4 Remove left rear speaker (H4/7) or right rear speaker (H4/8) Installation: Note installation position of left rear speaker (H4/7) or right rear speaker (H4/8).
5 Install in the reverse order
6 Perform function test of left rear speaker (H4/7) or right rear speaker (H4/8)
TESTING & REPAIR > REMOVE/INSTALL BASS MODULE SPEAKER - AR82.62-P- 7839MCC > MODEL 451.3/4 with CODE (C54) Sound system 2 MODEL 451.3/4 as of 31.8.10 with CODE (C17) smart surround sound system Fig 1: Identifying Loudspeakers, Cover And Spring Clip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1059 · Applies to: 450, 451, 452, 454
1 Remove left seat (1) * not for USA AR91.10-P- 1000MCC
- for USA only AR91.10-P- 1010MCU 2 Disconnect electrical connector (2) from subwoofer (H4/29)
3 Fold back floor covering in marked area (arrows) and take subwoofer (H4/29) up and out Installation: The subwoofer (H4/29) must be aligned with the attachment points of the left seat (1).
4 Install in the reverse order
5 Perform function test on subwoofer (H4/29)
TESTING & REPAIR > REMOVE/INSTALL LOUDSPEAKERS IN FRONT DOORS - AR82.62- P-7845MCC > MODEL 451.3/4 with CODE (C17) smart surround sound system with CODE (C50) smart radio 10 with CODE (C54) Sound system 2 with CODE (C57) smart radio 9 with CODE (516) RADIO WITH USB INTERFACE with CODE (527) High-Line radio Fig 1: Identifying Left Seat, Electrical Connector And Subwoofer Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1062 · Applies to: 450, 451, 452, 454
1 Remove antenna rod (3)
2 Open left door, press edge guard (5) to one side in area of fender cover (1) and remove expansion clip (4)
3 Push fender cover (1) slightly upwards and remove
4 Remove bolts (7, 8) Installation: Check whether guide sleeve of bolt (8) is properly seated. 5 Remove bolt (9) from antenna base (2)
6 Slightly press CBS front (6) to one side and carefully take antenna base (2) up and out until the antenna cable (11) is accessible Pay attention to routing of antenna cable (11). 7 Unscrew union nut (10) of antenna cable (11) and remove antenna base (2) Installation: Screw on union nut (10) finger-tight and continue turning a quarter turn using suitable pliers. 8 Install in the reverse order
Fig 1: Identifying Antenna Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Injury hazard from pinching and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1064 · Applies to: 450, 451, 452, 454
crushing, in extreme cases extremities can even be cut off when caught in windshield wiper mechanism. MODEL all AS82.30-Z-0001- 01A Risk of death caused by high voltage at xenon headlamps. Risk of explosion/risk of fire caused by highly flammable materials in the vicinity of damaged xenon bulbs. Risk of injury caused by UV light, hot components at xenon headlamps and glass splinters produced by bursting xenon bulbs. Risk of poisoning caused by inhalation of mercury vapors and by toxic salts and mercury compounds being ingested or coming into contact with skin MODEL all... AS82.10-Z-0001- 01A Risk of fire and explosion caused by ignition of window washing fluid or antifreeze and their vapors. Risk of poisoning caused by swallowing window washing fluid or antifreeze or inhaling their vapors. Risk of injury or physical irritations caused by contact of window washing fluid or antifreeze with eyes, mucous membranes or skin. MODEL all AS82.35-Z-0001- 01A Danger! The demagnetizing coil presents a lethal hazard for persons with active electronic implants (e.g. heart pacemakers). MODEL 140 with CODE (350a) Communikations- Navigations - System (CNS) with CODE (498) Japan - Ausfuhrung AS82.85-Z-0001- 01A SAFETY PRECAUTIONS > INJURY HAZARD FROM PINCHING AND CRUSHING, IN EXTREME CASES EXTREMITIES CAN EVEN BE CUT OFF WHEN CAUGHT IN WINDSHIELD WIPER MECHANISM. - AS82.30-Z-0001-01A > Always remove ignition key before working on windshield wiper mechanism. Injury hazard When working in the area of the windshield wiper mechanism with the ignition key in position "1" or "2" the wiper arm or wiper linkage can be pushed out of its end position and start running unintentionally . This can result in severe injuries by cutting, pinching or crushing body parts. Rules of behavior/protective measures Always remove ignition key before working on windshield wiper mechanism. Secure operating range of mechanism against reaching in.
Keep sufficient distance away from moving parts.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1065 · Applies to: 450, 451, 452, 454
Supervise hazard area. Wear tight fitting clothing and hair net. SAFETY PRECAUTIONS > RISK OF FIRE AND EXPLOSION CAUSED BY IGNITION OF WINDOW WASHING FLUID OR ANTIFREEZE AND THEIR VAPORS. RISK OF POISONING CAUSED BY SWALLOWING WINDOW WASHING FLUID OR ANTIFREEZE OR INHALING THEIR VAPORS. RISK OF INJURY OR PHYSICAL IRRITATIONS CAUSED BY CONTACT OF WINDOW WASHING FLUID OR ANTIFREEZE WITH EYES, MUCOUS MEMBRANES OR SKIN. - AS82.35-Z-0001-01A > Wear protective clothing and tight fitting safety glasses. No fire, open light or ignition sources. Avoid contact with eyes, mucous membranes and skin. When working with window washing fluids or antifreeze, do not eat, drink, or smoke. Do not inhale vapors and ensure sufficient ventilation in the working area. Store window washing fluid and antifreeze leakfree in safely closed original containers and out of children's' reach only. Potential risks Risk of fire and explosion Window washing fluids and antifreeze are highly flammable. Vapors in contact with air can ignite and spontaneously combust in an explosion. Risk of poisoning Window washing fluids and antifreeze are a health hazard and can cause dizziness, nausea and symptoms of poisoning when swallowed. Window washing fluid vapors and antifreeze vapors are a health hazard and can cause dizziness, nausea and symptoms of poisoning when inhaled. Risk of injury Window washing fluids and antifreeze cause physical irritations when coming in contact with eyes, mucous membranes or skin. Safety precautions and rules of conduct Observe manufacturer's operating instructions and safety notes. Wear protective clothing and tight fitting safety glasses. No fire, open light or ignition sources. Avoid contact with eyes, mucous membranes and skin. When working with window washing fluids or antifreeze, do not eat, drink, or smoke. Do not inhale vapors of window washing fluid or antifreeze, and ensure sufficient ventilation in the working area. Store window washing fluid and antifreeze leakfree in safely closed original containers and out of children's' reach only. First aid measures
center high-mounted brake¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1067 · Applies to: 450, 451, 452, 454 · AR: AZ82.10-P-0010MCC
lamp (E21). 3 Perform function test of center high-mounted brake lamp (E21)
RETROFITTING & CONVERSION > RETROFIT FRONT FOG LAMP - AZ82.10-P-0010MCC > MODEL 451.3/4 Fig 1: Identifying SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Locating Wiring Harness For Front Fog Lamps¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1068 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Front Fog Lamps Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Cockpit Switch Group Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The dashed brown/gray line (br/gr), yellow/black line (ge/sw) and yellow/white line (ge/ws) show the original¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1071 · Applies to: 450, 451, 452, 454
installation of lines in the vehicle; the continuous lines show the retrofit. The black continuous lines show the adapter lines. Routing diagram Fig 2: Ambiance Illumination Wiring Harness - Connection Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Route inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1072 · Applies to: 450, 451, 452, 454
harness (16) from SAM control unit (N10/10), as shown, along vehicle wiring harness behind instrument panel (17) to top of A-pillar. Only route the 1700 mm long branch-off line of the inside rearview mirror ambiance illumination to the top of the A-pillar. The three black 2-pin couplings and the fuse carrier with fuse of the ambiance illumination wiring harness (16) must be located in the area of the SAM control unit (N10/10). They will be connected to the SAM control unit (N10/10) at a later point. Fig 3: Ambiance Illumination Wiring Harness - Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Ambiance Illumination Wiring Harness Of SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Route inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1073 · Applies to: 450, 451, 452, 454
harness (16), as shown, along vehicle wiring harness to installation location of inside rearview mirror (4). 3. Fix inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring harness (16) in place using cable tie (18) at vehicle wiring harness. 4. Slide inside rearview mirror (4) onto bracket on windshield. 5. Connect black 2-pin connector (21) of inside rearview mirror ambiance illumination wiring harness (22) to black 2-pin coupling (20) of ambiance illumination wiring harness (16). 6. Form a loop with excess length of inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring harness (16) and fix in place using cable tie (19). 7. Route footwell branch-off line of ambiance illumination wiring harness (16), as shown, along vehicle wiring harness behind instrument panel and fix in place using cable tie. Do not tighten cable tie yet. The black 2-pin couplings at the footwell branch-off line of ambiance illumination wiring harness (16) must be positioned centrally in the driver and front passenger footwell. Fig 5: Identifying Ambiance Illumination Wiring Harness, Black 2-Pin Connector And Inside Rearview Mirror Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Release coupling "N11-5" and disconnect at SAM control unit (N10/10).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1074 · Applies to: 450, 451, 452, 454
Coupling "N11-5" is located in the marked slot (arrow). Fig 6: Footwell Branch-Off Line Of Ambiance Illumination Wiring Harness Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. Unplug pin (5.8) of brown/gray line (br/gr) from slot 8 of coupling "N11-5" (5).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1075 · Applies to: 450, 451, 452, 454
- Plug pin of brown/gray line (br/gr) of adapter line into slot 8 of coupling "N11-5" (5). Fig 7: Locating Coupling "N11-5" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Plug brown/gray line (br/gr) unplugged from slot 8 of coupling "N11-5" (5) into slot 1 of black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1076 · Applies to: 450, 451, 452, 454
coupling (6). 12. Connect black 2-pin coupling (6) to black 2-pin connector (7) of adapter line. 13. Connect coupling "N11-5" (5) at control unit (N10/10). Fig 8: Identifying Pin Of Brown/Gray Line And Coupling N11-5 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. Connect black 2-pin connector (9) of gray/blue line (gr/bl) of adapter line to black 2-pin coupling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1077 · Applies to: 450, 451, 452, 454
(10) of gray/blue line (gr/ bl) of ambiance illumination wiring harness (16). 15. Release coupling "N11-8" and disconnect at SAM control unit (N10/10). Coupling "N11-8" is located in the marked slot (arrow A). Fig 9: Identifying Black 2-Pin Coupling, Connector And Blue/Gray Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 10: Identifying Black 2-Pin Coupling Of Ambiance Illumination Wiring Harness And 2-Pin Connector Courtesy of MERCEDES BENZ OF NORTH AMERICA
16. Remove white insert (8a) from coupling "N11-8" (8).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1078 · Applies to: 450, 451, 452, 454
- Unplug pin (8.4) of yellow/white line (ge/ws) from slot 4 of white insert (8a).
- Plug pin of yellow/white adapter line (ge/ws) into slot 4 of white insert (8a). Fig 11: Locating Coupling "N11-8" Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 12: Identifying White Insert Of Coupling N11-8 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
19. Plug yellow/white line (ge/ws) unplugged from slot 4 of white insert (8a) into slot 4 of black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1079 · Applies to: 450, 451, 452, 454
coupling (12) of yellow/white line (ge/ws) of ambiance illumination wiring harness (16). 20. Connect black 2-pin coupling (12) of ambiance illumination wiring harness (16) to black 2-pin connector (11) of yellow/white adapter line (ge/ws). 21. Unplug pin (8.19) of yellow/black line (ge/sw) from slot 19 of white insert (8a). 22. Plug pin of yellow/black adapter line (ge/sw) into slot 19 of white insert (8a). Fig 13: Identifying Pin Of Yellow/White Line And White Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
23. Plug yellow/black line (ge/sw) unplugged from slot 19 of white insert (8a) into slot 19 of black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1080 · Applies to: 450, 451, 452, 454
coupling (14) of yellow/black line (ge/sw) of ambiance illumination wiring harness (16). 24. Connect black 2-pin coupling (14) of ambiance illumination wiring harness (16) to black 2-pin connector (13) of yellow/black adapter line (ge/sw). 25. Install white insert (8a) in coupling "N11-5" (8). 26. Connect coupling "N11-5" (8) at SAM control unit. 27. Insert fuse carrier with fuse (15) at SAM control unit (N10/10). The slot and the fuse carrier with fuse (15) are coded. The fuse has a fuse rating of 10 A. Fig 14: Identifying Pin Of Yellow/White Line, White Insert And 2-Pin Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 15: Identifying White Insert Of Coupling N11-8 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
28. Screw on brown line (br) of ambiance illumination wiring harness to left interior floor ground (W14).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1081 · Applies to: 450, 451, 452, 454
- Clip SAM control unit (N10/10) into rear area (arrow B) and screw on using screws/bolts (23). RETROFITTING & CONVERSION > RETROFIT AMBIANCE ILLUMINATION WIRING HARNESS - AZ82.20-P-0010-01MCD > Fig 16: Identifying Fuse Of SAM Control Unit And Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connection diagram¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1082 · Applies to: 450, 451, 452, 454
Fig 2: Identifying Hot-Air Gun (450 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Wiring Harness Repair Kit (452 589 02 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The dashed yellow/black line (ge/sw) and yellow/white line (ge/ws) show the original installation of lines in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1083 · Applies to: 450, 451, 452, 454
the vehicle; the continuous lines show the retrofit. The black continuous lines show the adapter lines. Routing diagram Fig 4: Ambiance Illumination Wiring Harness - Connection Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Route inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1084 · Applies to: 450, 451, 452, 454
harness (16) from SAM control unit (N10/10), as shown, along vehicle wiring harness behind in trument panel (17) to top of A pillar Only route the 1700 mm long branch-off line of the inside rearview mirror ambiance illumination to the top of the A-pillar. The three black 2-pin couplings and the fuse carrier with fuse of the ambiance illumination wiring harness (16) must be located in the area of the SAM control unit (N10/10). They will be connected to the SAM control unit (N10/10) at a later point. Fig 5: Ambiance Illumination Wiring Harness - Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Ambiance Illumination Wiring Harness Of SAM Control Unit And Instrument Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Route inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1085 · Applies to: 450, 451, 452, 454
harness (16), as shown, along vehicle wiring harness to installation location of inside rearview mirror (4). 3. Fix inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring harness (16) in place using cable tie (18) at vehicle wiring harness. 4. Slide inside rearview mirror (4) onto bracket on windshield. 5. Connect black 2-pin connector (21) of inside rearview mirror ambiance illumination wiring harness (22) to black 2-pin coupling (20) of ambiance illumination wiring harness (16). 6. Form a loop with excess length of inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring harness (16) and fix in place using cable tie (19). 7. Route footwell branch-off line of ambiance illumination wiring harness (16), as shown, along vehicle wiring harness behind instrument panel and fix in place using cable tie. Do not tighten cable tie yet. The black 2-pin couplings at the footwell branch-off line of ambiance illumination wiring harness (16) must be positioned centrally in the driver and front passenger footwell. Fig 7: Identifying Ambiance Illumination Wiring Harness, Black 2-Pin Connector And Inside Rearview Mirror Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Operation steps 8 and 9 on vehicles with BRABUS twin headlamps.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1086 · Applies to: 450, 451, 452, 454
- Connect individual black 2-pin coupling (24) to free gray/blue line (gr/bl) of BRABUS twin headlamp wiring harness (25).
- Connect black 2-pin coupling (24) of gray/blue line (gr/bl) of BRABUS twin headlamp wiring harness (25) to black 2-pin connector (10) of gray/blue line (gr/bl) of ambiance illumination wiring harness (16). Fig 8: Identifying Ambiance Illumination Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 9: Identifying 2-Pin Coupling, Connector And Gray/Blue Line Of Ambiance Illumination Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Operation steps 10 to 13 on vehicles with daytime running light headlamps.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1087 · Applies to: 450, 451, 452, 454
- Cut off black 2-pin connector (10) of gray/blue line (gr/bl) of ambiance illumination wiring harness (16).
- Slide heat-shrinkable tube over gray/blue line (gr/bl) of ambiance illumination wiring harness (16).
- Crimp together gray/blue line (gr/bl) of ambiance illumination wiring harness (16) and gray/blue line (gr/bl) of daytime running light headlamp wiring harness. The daytime running light headlamp wiring harness is connected to the gray/blue line (gr/bl) of the adapter line in exactly the same manner as the BRABUS twin headlamp wiring harness (25). But because the branch-off line for connection of the black 2-pin coupling (24) is missing, the gray/blue line (gr/bl) of the ambiance illumination wiring harness (16) must be connected by means of a crimped connection to the gray/blue line (gr/bl) of the daytime running light headlamp wiring harness.
- Protect crimped connection with heat-shrinkable tube.
- Release coupling "N11-8" and disconnect at SAM control unit (N10/10). Coupling "N11-8" is located in the marked slot (arrow A).
- Remove white insert (8a) from coupling "N11-8" (8). Fig 10: Locating Coupling "N11-8" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
16. Unplug pin (8.4) of yellow/white line (ge/ws) from slot 4 of white insert (8a).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1088 · Applies to: 450, 451, 452, 454
- Plug pin of yellow/white adapter line (ge/ws) into slot 4 of white insert (8a).
- Plug yellow/white line (ge/ws) unplugged from slot 4 of white insert (8a) into slot 4 of black 2-pin coupling (12) of yellow/white line (ge/ws) of ambiance illumination wiring harness (16).
- Connect black 2-pin coupling (12) of ambiance illumination wiring harness (16) to black 2-pin connector (11) of yellow/white adapter line (ge/ws).
- Unplug pin (8.19) of yellow/black line (ge/sw) from slot 19 of white insert (8a).
- Plug pin of yellow/black adapter line (ge/sw) into slot 19 of white insert (8a). Fig 11: Identifying White Insert Of Coupling N11-8 Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 12: Identifying Pin Of Yellow/White Line And White Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
22. Plug yellow/black line (ge/sw) unplugged from slot 19 of white insert (8a) into slot 19 of black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1089 · Applies to: 450, 451, 452, 454
coupling (14) of yellow/black line (ge/sw) of ambiance illumination wiring harness (16). 23. Connect black 2-pin coupling (14) of ambiance illumination wiring harness (16) to black 2-pin connector (13) of yellow/black adapter line (ge/sw). 24. Install white insert (8a) in coupling "N11-8" (8). 25. Connect coupling "N11-8" (8) at SAM control unit. 26. Insert fuse carrier with fuse (15) at SAM control unit (N10/10). The slot and the fuse carrier (15) are coded. The fuse has a fuse rating of 10 A. Fig 13: Identifying Pin Of Yellow/White Line, White Insert And 2-Pin Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 14: Identifying White Insert Of Coupling N11-8 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
27. Screw on brown line (br) of ambiance illumination wiring harness to left interior floor ground (W14).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1090 · Applies to: 450, 451, 452, 454
- Clip SAM control unit (N10/10) into rear area (arrow B) and screw on using screws/bolts (23). RETROFITTING & CONVERSION > RETROFIT AMBIANCE ILLUMINATION IN FOOTWELL - AZ82.20-P-0010-02MCC >
- Clip lamps (2, 3) into driver footwell lighting strip (4).
- Clip lamps (2, 3) into front passenger footwell lighting strip (1). Fig 15: Identifying Fuse Of SAM Control Unit And Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Remove bolt (5) from vertical strut paneling (9)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1091 · Applies to: 450, 451, 452, 454
- Carefully push down vertical strut paneling (9) and position driver footwell lighting strip (4) behind vertical strut paneling (9). Fig 1: Identifying Lamps Of Driver Footwell Lighting Strip Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Bolt Of Vertical Strut Paneling And Driver Footwell Lighting Strip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Screw driver footwell lighting strip (4) in position using bolts (7).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1092 · Applies to: 450, 451, 452, 454
- Position front passenger footwell lighting strip (1) at lower section of instrument panel and tighten using screws/bolts (7).
- Create all four electrical connections (8) between the ambiance illumination main wiring harness (6) and the lamps (2, 3). The connectors and couplings of the electrical connectors (8) are coded.
- Tighten bolt (5) of vertical strut paneling (9).
- Fasten main ambiance illumination wiring harness (6) in place at driver footwell lighting strip (4) and front passenger footwell lighting strip (1) using cable ties. RETROFITTING & CONVERSION > RETROFIT AMBIANCE ILLUMINATION IN INSIDE REARVIEW MIRROR - AZ82.20-P-0010-03MCC > Fig 1: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Drill hole in marked area (arrow) at inside rearview mirror (1) with a diameter of 4.5 mm.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1093 · Applies to: 450, 451, 452, 454
Hand drill gotis://G_58.0_00.1 2. Lead wiring harness (2) through hole and clip bracket with ambiance illumination (3) into inside rearview mirror (1). 3. Plug pin of brown wire (2.1) into slot 1 and pin of gray/blue line (2.2) into slot 2 of connector (4). The slots in the connector (4) are marked. 4. Install inside rearview mirror (1). 5. Create electrical connections (5) between wiring harness (2) and main ambiance illumination wiring harness (6). Fig 2: Identifying Inside Rearview Mirror, Wiring Harness And Ambiance Illumination Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT AMBIANCE ILLUMINATION - AZ82.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1094 · Applies to: 450, 451, 452, 454
0010MCC > MODEL 451.3/4 up to 30.8.10 Fig 3: Identifying Inside Rearview Mirror, Electrical Connections And Main Ambiance Illumination Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Inside Rearview Mirror/Footwell Ambiance And Entrance Illuminations Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT IPOD INTERFACE WIRING HARNESS -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1097 · Applies to: 450, 451, 452, 454
AZ82.60-P-0001-01MCC > Connection scheme Fig 3: Identifying Hot-Air Gun (450 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Wiring Harness Repair Kit (452 589 02 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Drill hole with diameter of 9 mm, as shown, at instrument panel (arrow).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1098 · Applies to: 450, 451, 452, 454
Cordless drill/driver gotis://G_58.0_01.1 Ensure that the components behind this are not damaged as otherwise these must be replaced. Fig 1: iPod Interface Wiring Harness - Connection Scheme Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Locating Hole On Instrument Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Lead electrical wiring harness for iPod adapter (4) through the hole (arrow) and route in the front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1099 · Applies to: 450, 451, 452, 454
passenger footwell as shown. 3. Fix electrical wiring harness for iPod adapter (4) in area of instrument panel and in area of front passenger footwell with cable ties and felt tape. 4. Wrap iPod adapter (A34/8) with felt tape included in the installation kit. Ensure that all connections to iPod adapter (A34/8) remain accessible. 5. Detach Bluetooth module (A34/7) at crossmember below instrument panel and place in front passenger footwell with connected electrical lines. 6. Connect electrical wiring harness for iPod adapter (4) to iPod adapter (A34/8) as shown. Fig 3: Leading Electrical Wiring Harness For iPod Adapter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Unplug electrical wiring harness for display (5) at Bluetooth module (A34/7) and connect to iPod¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1100 · Applies to: 450, 451, 452, 454
adapter (A34/8) as shown. Electrical wiring harness for Bluetooth microphone (1) and electrical wiring harness for Bluetooth module (6) remain at Bluetooth module (A34/7) and are not plugged in somewhere else. 8. Connect electrical lines (2, 3) to Bluetooth module (A34/7) and iPod adapter (A34/8) as shown. The slot next to the electrical wiring harness for Bluetooth microphone (1) is to be used for the electrical line (3). 9. Fasten iPod adapter (A34/8) together with previously removed Bluetooth module in front passenger footwell at crossmember below instrument panel with cable ties as shown. Ensure that the connected electrical wiring harnesses are not damaged by chafing, pinching or crushing as otherwise these must be replaced. Fig 4: Identifying iPod Adapter, Bluetooth Module And Electrical Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT RADIO - AZ82.60-P-0003MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1101 · Applies to: 450, 451, 452, 454 · AR: AZ82.60-P-0003MCC
MODEL 451.3/4 up to 30.8.10 with CODE (C08) Radio preinstallation incl. rod antenna (FFO) Fig 5: Identifying iPod Adapter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1102 · Applies to: 450, 451, 452, 454 · AR: AZ82.60-P-0003MCD
1 Remove center towage 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 gotis://G_58.0_01.1
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 > Fig 1: Identifying Smart Radio Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3/4 as of 31.8.10 with CODE (C08) Radio preinstallation incl. rod antenna (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1103 · Applies to: 450, 451, 452, 454
Parts scope for smart Entry radio (A2/3) Fig 1: Identifying Center Console And Radio Recess Cover, Smart Entry Radio Wiring Harness And Cable Tie Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Smart Entry Radio Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
DG 82 (see¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1106 · Applies to: 450, 451, 452, 454 · AR: AZ82.60-P-0014MCC
EPC) Wiring harness with external USB connector connecting point and external audio source connecting point 1 DG 68 (see EPC) Passenger-side instrument panel lower section (note equipment variants) 1
Also for retrofitting glove box
DG 68 (see EPC) Glove compartment 1 RETROFITTING & CONVERSION > RETROFIT IPOD INTERFACE - AZ82.60-P-0014MCC > MODEL 451.3/4 up to 30.8.10 with CODE (C50) smart radio 10 Telephone system/Bluetooth hands- free system with display retrofitted MODEL 451.3/4 up to 30.8.10 with CODE (C57) smart radio 9 Telephone system/Bluetooth hands- free system with display retrofitted MODEL 451.3/4 as of 31.8.10 with CODE (516) RADIO WITH USB INTERFACE Telephone system/Bluetooth hands-free system with display retrofitted Package contents of iPod kit iPod kit connection diagram Fig 1: Identifying iPod Adapter Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Checking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1107 · Applies to: 450, 451, 452, 454
1 Check whether Bluetooth handsfree system is installed
Install
2 Move front passenger seat toward rear
3 Retrofit electrical wiring harness for iPod adapter (4), iPod adapter (A34/8) and electrical lines (2, 3) Rechargeable drill / screwdriver gotis://G_58.0_01.1 AZ82.60-P-0001- 01MCC 4 Reset front passenger seat to original position
5 Perform function test of iPod
PARTS ORDERING NOTES Part no. Designation Quantity DG 98 (see EPC) Installation kit/iPod 1 RETROFITTING & CONVERSION > RETROFIT COMMUNICATION CONTROL UNIT - AZ82.60-P-0021-02MCC > Fig 2: iPod Kit Connection Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Move right seat toward rear.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1108 · Applies to: 450, 451, 452, 454
- Insert communication control unit (N4) into lower area (arrow) on the crossmember under the instrument panel (2).
- Route connector (1) from crossmember beneath dashboard (2) into radio recess.
- Plug connector (1) of communication control unit (N4) into top left slot on the smart radio 9 (A2/1) or on the smart radio 10 (A2/2). The slots are coded and cannot be interchanged.
- Attach connectors (4) and antenna plug (3) to smart radio 9 (A2/1) or smart radio 10 (A2/2) and insert smart radio 9 (A2/1) or smart radio 10 (A2/2) into radio recess. The slots for the connectors (4) are coded and cannot be interchanged.
- Move right seat back to its default position. RETROFITTING & CONVERSION > CONNECT AUDIO COMPONENTS ONTO THE COMMUNICATION CONTROL UNIT - AZ82.60-P-0021-03MCC >
- Move right seat toward rear.
- Attach connector (1) of retrofitted audio component to the communication control unit (N4).
- Connect external audio source separation point to slot (arrow A).
- Connect handsfree system to slot (arrow B).
- Connect PND (personal navigation device) holder to slot (arrow C). Fig 1: Identifying Communication Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Move right seat back to its default position.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1109 · Applies to: 450, 451, 452, 454 · AR: AZ82.62-P-0002MCC
RETROFITTING & CONVERSION > RETROFIT SOUND SYSTEM - AZ82.62-P-0002MCC > MODEL 451.3/4 except CODE (P02) car2go with CODE (C08) Radio preinstallation incl. rod antenna (FFO) Fig 1: Connecting Audio Components Onto Communication Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1110 · Applies to: 450, 451, 452, 454
1 Move seats to the rear
2 Remove door paneling from front doors
AR72.18-P- 1000MCC Fig 1: Identifying Front Speaker Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Tweeters, Dashboard Top Section And Socket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Carefully cut into inner door foil¶
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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 speaker (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¶
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1 Remove left seat (1) * not for USA AR91.10-P- 1000MCC * for USA only AR91.10-P- 1010MCU Install
2 Lift up front floor covering (3) and the route electrical connector for subwoofer (2) upwards through opening in front floor covering (3)
3 Fold back front floor covering (3) in marked area (arrows B) and position subwoofer (H4/29) at attachment points (arrows A) of left seat (1)
4 Connect electrical connector for subwoofer (2) to subwoofer (H4/29)
5 Perform function test on subwoofer (H4/29)
6 Install left seat (1) * not for USA AR91.10-P- 1000MCC *for USA only AR91.10-P- 1010MCU Fig 1: Identifying Subwoofer, Seat, Electrical Connector And Front Floor Covering Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Add special equipment to the¶
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7 Add special equipment to the vehicle data card and to the online vehicle data card Add code (C55) Active bass speaker (subwoofer).
RETROFITTING & CONVERSION > RETROFIT HANDS FREE SYSTEM WIRING HARNESS - AZ82.70-P-0005-02MCC > Connection scheme Ensure that electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) are not damaged by chafing, pinching or crushing as otherwise they must be replaced. Electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) are coded and cannot be swapped. 1. Route electrical wiring harness for display (3) from display (A15p5) along radio recess in front passenger footwell as shown. Fig 1: Hands-Free System Wiring Harness - Connection Scheme Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Route electrical wiring harness for Bluetooth module (1) from radio recess in front passenger¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1114 · Applies to: 450, 451, 452, 454
footwell as shown. 3. Fix electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) in place with cable ties at vehicle wiring harness. RETROFITTING & CONVERSION > RETROFIT HANDS-FREE SYSTEM WIRING HARNESS - AZ82.70-P-0005-02MCD > Connection scheme Fig 2: Electrical Wiring Harness For Display Of Front Passenger Footwell Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Ensure that electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth¶
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microphone (2) and electrical wiring harness for display (3) are not damaged by chafing, pinching or crushing a otherwi e they mu t be replaced Electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) are coded and cannot be swapped. 1. Route electrical wiring harness for display (3) from display (A15p5) along radio recess in front passenger footwell as shown. Fig 1: Hands-Free System Wiring Harness - Connection Scheme Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Route electrical wiring harness for Bluetooth module (1) from communications control unit (N4) to¶
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Bluetooth module (A34/7) as shown. 3. Fix electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) in place with cable ties at vehicle wiring harness. RETROFITTING & CONVERSION > RETROFIT HANDS-FREE SYSTEM CONTROL UNIT - AZ82.70-P-0005-04MCD > Ensure that electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) are not damaged by chafing, pinching or crushing as otherwise they must be replaced. 1. Stick on Bluetooth module (A34/7) with felt tape included in the installation kit. 2. Connect electrical wiring harness for Bluetooth microphone (2) to Bluetooth module (A34/7) as shown. 3. Connect electrical wiring harness for display (3) to Bluetooth module (A34/7) as shown. Fig 2: Electrical Wiring Harness For Display Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Connect electrical wiring harness for Bluetooth module (1) to Bluetooth module (A34/7) as shown.¶
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- Fix electrical wiring harness for Bluetooth microphone (2) in place with a cable tie at Bluetooth module (A34/7) to prevent loosening of the connector.
- Fasten Bluetooth module (A34/7) in front passenger footwell at crossmember below instrument panel with cable ties as shown. Fig 1: Connecting Electrical Wiring Harness For Bluetooth Microphone To Bluetooth Module Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT MICROPHONE FOR HANDS-FREE SYSTEM¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1118 · Applies to: 450, 451, 452, 454
- AZ82.70-P-0005-08MCD >
- Make a mark at the front roof frame panel (12) according to the dimensions "a" and "b". Dimensions: Fig 2: Locating Bluetooth Module Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill hole with a diameter of 9 mm according to marking made beforehand at front roof frame panel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1119 · Applies to: 450, 451, 452, 454
(12). Cordless drill/driver gotis://G_58.0_01.1 3. Route electrical wiring harness for Bluetooth microphone through drilled hole. 4. Clean bonding surface of front roof frame panel (12) in area of drilled hole with suitable cleaning agent (not corrosive toward plastic). Bonding surface must be dry and free of dust and grease to avoid adhesion problems. 5. Remove carrier foil at bracket (9) and glue bracket (9) onto front roof frame panel (12) as shown. 6. Tighten bracket (9) using screw/bolt (8). 7. Clip Bluetooth microphone into bracket (9). Fig 1: Identifying Front Roof Frame Panel Dimensions For Making Mark Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Route electrical wiring harness for Bluetooth microphone (2) as shown and fix in place with fabric¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1120 · Applies to: 450, 451, 452, 454
tape to front roof frame panel (12). 9. Position front roof frame panel (12) in vehicle and secure against falling out with two screws/bolts. Ensure that electrical wiring harness for Bluetooth microphone (2) is not damaged by chafing, pinching or crushing as otherwise it must be replaced with Bluetooth microphone. 10. Route electrical wiring harness for Bluetooth microphone (2) along right A-pillar as shown in following picture and fix in place with fabric tape. Fig 2: Installing Bracket Onto Front Roof Frame Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Route electrical wiring harness for Bluetooth microphone (2) between instrument panel and A-pillar¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1121 · Applies to: 450, 451, 452, 454
in front passenger footwell. The electrical wiring harness for Bluetooth microphone (2)will be connected to the Bluetooth control unit at a later time. RETROFITTING & CONVERSION > RETROFIT ADDITIONAL INSTRUMENT OF HANDS- FREE SYSTEM - AZ82.70-P-0005-10MCC > On vehicles without code (V31) Cockpit clock and tachometer package, the display of the hands-free system can be attached to the left or the right of the additional instruments bracket in accordance with the customer request. Installation on vehicles without code (V31) Cockpit clock and tachometer package is shown as an example on the right side. 1. Remove cover (13) from clock (A15p3). On vehicles with code (V31) Cockpit clock and tachometer package. Fig 3: Routing Electrical Wiring Harness For Bluetooth Microphone Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Remove screws/bolts (16) and remove clock from additional instruments bracket (15).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1122 · Applies to: 450, 451, 452, 454
On vehicles with code (V31) Cockpit clock and tachometer package. The clock is no longer needed. Fig 1: Identifying Clock Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Instruments Bracket And Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Saw off unnecessary right or left arm (15.1) of new additional instruments bracket (15) along broken¶
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line. On vehicles without code (V31) Cockpit clock and tachometer package. The display of the hands-free system can be attached to the left or right of the additional instruments bracket (15) in accordance with the customer request. 4. Install display (A15p5) at additional instruments bracket (15) and tighten with screws/bolts (16). 5. Make a cutout at additional instruments bracket (15) along broken line for leading through electrical wiring harness for display (3). 6. Route electrical wiring harness for display (3) in cutout made as shown. 7.1 Install cover removed from clock at display (A15p5). On vehicles with code (V31) Cockpit clock and tachometer package. 7.2 Install new cover at display (A15p5). On vehicles without code (V31) Cockpit clock and tachometer package. Fig 3: Cutting Arm Of Instruments Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8 Position additional instruments bracket (15) at instrument panel.¶
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9 Route electrical wiring harness for display (3) along broken line. 10 Tighten additional instruments bracket (15) with screws/bolts (17). Fig 4: Installing New Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Installing Additional Instruments Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11 Form cutouts (18.1 or 18.2) at cover (18) according to perforation (arrow A or arrow B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1125 · Applies to: 450, 451, 452, 454
On vehicles without code (V31) Cockpit clock and tachometer package. The cutout is only to be formed on the side on which the display of the hands-free system was installed. RETROFITTING & CONVERSION > RETROFIT ADDITIONAL INSTRUMENT OF HANDS- FREE SYSTEM - AZ82.70-P-0005-10MCD > 1. Remove cover (13) from clock (A15p3). 2. Remove screws/bolts (16) and remove clock (A15p3) from additional instruments bracket (15). The clock (A15p3) is no longer needed. Fig 6: Forming Cutout On Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Cover Of Clock Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Attach display (A15p5) on additional instruments bracket (15).¶
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- Remove stay at bracket (17) in marked area (arrows A) until coupling (3.1) of display wiring harness (3) can be guided through.
- Guide display wiring harness (3) through bracket (17).
- Tighten display (A15p5) and bracket (17) at additional instruments bracket (15) using screws/bolts (16). Fig 2: Removing Clock Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Fix display wiring harness (3) in place in the guide (arrow B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1127 · Applies to: 450, 451, 452, 454
- Install cover removed from clock at display (A15p5).
- Position additional instruments (A15) at the instrument panel.
- Route display wiring harness (3) in accordance with routing of additional instruments wiring harness (A15) in slot of smart Entry radio. Fig 3: Installing Display Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT HANDS-FREE SYSTEM OPERATING UNIT -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1128 · Applies to: 450, 451, 452, 454
AZ82.70-P-0005-11MCU > 1. Twist lower section (11.2) of push button for central operation (11) toward left and remove. 2. Insert battery (12) into lower section (11.2) of push button for central operation (11) as shown. Note polarity of battery (12). 3. Place lower section (11.2) on push button for central operation (11), twist toward right and lock. Fig 4: Routing Display Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Agree on the exact placement of the push button for central operation (11) with the customer¶
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before installation. 4. Clean bonding surface of cockpit switch group (S6/1) with suitable cleaning agent (not corrosive toward plastic). Bonding surface must be dry and free of dust and grease to avoid adhesion problems. 5. Remove carrier foil (11.1) and glue push button for central operation (11) to cockpit switch group (S6/1) as shown. Fig 1: Inserting Battery Into Lower Section Of Push Button For Central Operation Courtesy of MERCEDES BENZ OF NORTH AMERICA
6. Switch on ignition and at the same time press both control buttons at push button for central¶
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operation (11) until green LED at push button for central operation (11) lights up. The push button for central operation (11) has been taught in. RETROFITTING & CONVERSION > RETROFIT HANDSFREE CONVERSATION EQUIPMENT - AZ82.70-P-0005MCD > MODEL 451.3/4 up to 30.8.10 with CODE (C50) smart radio 10 Installation of a telephone system/Bluetooth handsfree system with display MODEL 451.3/4 up to 30.8.10 with CODE (C57) smart radio 9 Installation of a telephone system/Bluetooth hands-free system with display MODEL 451.3/4 as of 31.8.10 with CODE (516) RADIO WITH USB INTERFACE installation of a telephone system/Bluetooth hands-free system with display Package contents of handsfree system Fig 2: Installing Push Button For Central Operation Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Routing diagram for:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1131 · Applies to: 450, 451, 452, 454
Vehicles up to 30.8.10 without code (41Z) AUX jack or without code (C15) Navigation unit (DFO/FFO) or without code (C60) Portable smart navigation system or without code (C54) Sound system 2 Vehicles as of 31.8.10 Fig 1: Identifying Package Contents Of Handsfree System Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Routing diagram for:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1132 · Applies to: 450, 451, 452, 454
Vehicles up to 30.8.10 with code (41Z) AUX jack or with code (C15) Navigation unit (DFO/FFO) or with code (C60) Portable smart navigation system or with code (C54) Sound system 2 Fig 2: Routing Diagram For Handsfree System Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
* not for USA¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1136 · Applies to: 450, 451, 452, 454
AZ82.70-P-0005- 11MCC * for USA only AZ82.70-P-0005- 11MCU 17 Reset front passenger seat to original position
18 Carry out handsfree system function test
PARTS ORDERING NOTES Part no. Designation Quantity DG 98 (see EPC) Telephone system/Bluetooth handsfree system 1
In vehicles as of 31.8.10
DG 98 (see EPC) Wiring harness for telephone system/Bluetooth hands-free system 1
In vehicles up to 30.8.10 without code (V31) Cockpit clock and tachometer package
DG 98 (see EPC) Retaining plate/handsfree system 1 DG 54 (see EPC) Additional instruments trim 1
In vehicles up to 30.8.10 with code (41Z) AUX jack or with code (C15) Navigation unit (DFO/FFO) or with code (C60) Portable smart navigation system or with code (C54) Sound system 2
DG 98 (see EPC) Communication control unit 1
In vehicles as of 31.8.10 without code (V31) Cockpit clock and tachometer package
DG 54 (see EPC) Additional instruments 1 DG 54 (see EPC) Screw 1 DG 54 (see EPC) Cover 1 RETROFITTING & CONVERSION > RETROFIT TELEPHONE CONSOLE - AZ82.70-P- 0010MCU > MODEL 451.3/4 up to 30.8.10
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1137 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Template, Lower Section Of Dashboard And Center Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT IPHONE KIT WIRING HARNESS - AZ82.70-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1140 · Applies to: 450, 451, 452, 454
P-0013-01MCC > Connection scheme Fig 3: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: iPhone Kit Wiring Harness - Connection Scheme Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Route iPhone kit wiring harness (6) behind the instrument panel (3) from the iPhone kit control unit¶
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(4) into the radio recess. 2. Connect black connector (6.2) of iPhone-kit wiring harness (6) to iPhone-kit control unit (4). 3. Strap down 6-pin coupling (8) of AUX connection connector and fix in position on the vehicle wiring harness with a cable tie. Up to 30.8.10, the 6-pin coupling (8) is yellow. As of 31.8.10, the 6-pin coupling (8) is blue. The multicolored connector (6.1) is connected when installing the radio. RETROFITTING & CONVERSION > RETROFIT IPHONE-KIT CONTROL UNIT - AZ82.70-P- 0013-02MCC > Fig 2: Identifying Iphone Kit Wiring Harness, Control Unit And 6-Pin Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fix iPhone-kit control unit (4) in position, as shown, in the rear front passenger footwell behind the¶
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instrument panel (3) with two cable ties (5). RETROFITTING & CONVERSION > RETROFIT IPHONE-KIT MICROPHONE - AZ82.70-P- 0013-03MCC > 1. Carefully separate out the two front webs (arrow) on the grill of the front roof frame lining (9) on the driver-side using side cutting pliers. 2. Guide microphone wiring harness (7.1) through the opening made in the front roof frame lining (9). 3. Position microphone (7) above the opening made in the front roof frame lining (9) and route microphone wiring harness (7.1) on the front roof frame lining (9) and fix in position with fabric adhesive tape (10). Fig 1: Installing iPhone-Kit Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Microphone, Wiring Harness And Front Roof Frame Lining Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Screw down metal brackets contained in the scope of supply in the hatched area (10) on the front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1143 · Applies to: 450, 451, 452, 454
roof frame lining (9). 5. Bond microphone (7) onto the metal bracket. The contact surfaces on the microphone (7) and on the metal bracket must be free of dust and grease otherwise paint adhesion problems can occur. 6. Put down the front roof frame mounting (9) in the vehicle. 7. Route microphone wiring harness (7.1), as shown, along the A-pillar and fix in position with fabric Fig 2: Identifying Microphone And Front Roof Frame Lining Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Microphone Wiring Harness Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
adhesive tape (11).¶
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Route microphone wiring harness (7.1) so that the installation of the right A-pillar lining is not obstructed. 8. Route microphone wiring harness (7.1) along the A-pillar under the instrument panel and fix in position with cable tires. 9. Connect black 2-pin connector (6.4) of iPhone-kit wiring harness (6) with the black 2-pin connector (7.2) of the microphone wiring harness (7.1) 10. Fix the microphone wiring harness (7.1) and iPhone-kit wiring harness (6) at suitable positions with cable ties RETROFITTING & CONVERSION > RETROFIT IPHONE-KIT CRADLE - AZ82.70-P-0013- 04MCC > 1. Insert counterholder (12) from behind in the cover of the center console (2) and align with the guides (2.1). 2. Transfer bore holes (arrows) to the cover of the center console (2) and remove counterholder (12) 3. Make bores corresponding to the previously applied markings with a diameter of 4 mm in the cover of the center console (2). Rechargeable drill / screwdriver gotis://G_58.0_01.1 Fig 1: Identifying Counterholder, Center Console And Guides Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Carefully enlarge center bore at center console cover (2) (arrow A) until transparent couplings (1.2)¶
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of iPhone kit mount wiring harness (1.1) can be guided through. Only enlarge the bore enough that it can be concealed by the retaining plate (13) later. In the event of contravention the cover of the center console (2) must be replaced. 5. Guide iPhone-kit mount wiring harness (1.1) through the opening in the retaining plate (13). Observe installation position of retaining plate (13). 6. Guide iPhone-kit mount wiring harness (1.1) through the opening in the center console made previously in the cover of the center console (2). 7. Insert counterholder (12) from behind in the cover of the center console (2) and align. 8. Attach retaining plate (13) from above and fix in position with the bolts (14) and nuts contained in the scope of supply together with the counterholder (12) on the cover of the center console (2). Fig 2: Locating Center Bore Of Center Console Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Iphone-Kit Mount Wiring Harness, Retaining Plate, Counterholder And Center Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. Clip bracket of the iPhone-kit cradle (1), as shown, into the retaining plate installed previously¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1146 · Applies to: 450, 451, 452, 454
- Route iPhone-kit mount wiring harness (1.1) through the right opening (arrow B) next to the smart Radio 9 (A2/1) or the smart Radio 10 (A2/2) under the instrument panel to the iPhone-kit control unit installed previously.
- Put down cover of center console (2) with iPhone-kit cradle (1) on the center console. Put down the cover of center console (2) so that it cannot fall down.
- Connect transparent couplings (1.2) of iPhone kit mount wiring harness (1.1) to iPhone kit control unit (4)
- Fix iPhone kit cradle wiring harness (1.1) with cable ties at suitable points. Fig 4: Identifying iPhone Kit Cradle Wiring Harness, Control Unit And Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT IPHONE-KIT CRADLE - AZ82.70-P-0013-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1147 · Applies to: 450, 451, 452, 454
04MCD > 1. Insert counterholder (12) from behind in the cover of the center console (2) and align with the guides (2.1). 2. Transfer bore holes (arrows) to the cover of the center console (2) and remove counterholder (12) 3. Make bores corresponding to the previously applied markings with a diameter of 4 mm in the cover of the center console (2). Fig 5: Connecting Transparent Couplings Of iPhone Kit Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Bore Holes Of Center Console Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rechargeable drill / screwdriver gotis://G_58.0_01.1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1148 · Applies to: 450, 451, 452, 454
- Carefully enlarge center bore at center console cover (2) (arrow A) until transparent couplings (1.2) of iPhone kit mount wiring harness (1.1) can be guided through. Only enlarge the bore enough that it can be concealed by the retaining plate (13) later. In the event of contravention the cover of the center console (2) must be replaced.
- Guide iPhone-kit mount wiring harness (1.1) through the opening in the retaining plate (13). Observe installation position of retaining plate (13).
- Guide iPhone-kit mount wiring harness (1.1) through the opening in the center console made previously in the cover of the center console (2). Fig 2: Identifying Center Bore At Center Console Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Guiding iPhone Kit Mount Wiring Harness Through Retaining Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Insert counterholder (12) from behind in the cover of the center console (2) and align.¶
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- Attach retaining plate (13) from above and fasten with the screws/bolts (14) and nuts (15) contained in the delivery contents together with the counterholder (12) on the center console cover (2).
- Drill hole (arrow C) with a diameter of 2.5 mm according to the dimensions (a and b) on the right side of the center console cover (2). Dimensions: Fig 4: Locating Drill Hole On Right Side Of Center Console Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
10. Clip bracket (16) of the iPhone kit mount (1), as shown, into the retaining plate (13) installed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1150 · Applies to: 450, 451, 452, 454
previously 11. Open cover (18) of glove compartment. On vehicles with code (I63) Glove compartment. 12. Route iPhone kit mount wiring harness (1.1) through right opening (arrow B) between installation opening (17) of smart Entry radio and right instrument panel lower section (19) below instrument panel to previously installed iPhone kit control unit. The iPhone kit mount wiring harness (1.1) must be routed through the top right opening (arrow B) in the slot of the smart Entry radio, otherwise the iPhone kit mount wiring harness (1.1) may be damaged upon installation of the center console cover (2). 13. Put down cover of center console (2) with iPhone-kit cradle (1) on the center console. Put down the cover of center console (2) so that it cannot fall down. 14. Connect transparent couplings (1.2) of iPhone kit mount wiring harness (1.1) to iPhone kit control unit (4) 15. Fix wiring harness for iPhone-kit cradle (1.1) with cable ties at suitable points. Fig 5: Clipping Bracket Of iPhone Kit Mount Into Retaining Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT IPHONE KIT - AZ82.70-P-0013MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1151 · Applies to: 450, 451, 452, 454 · AR: AZ82.70-P-0013MCC
MODEL 451.3/4 (except 451.39 /49) up to 30.8.10 with CODE (C50) smart radio 10 with CODE (C57) smart radio 9 MODEL 451.3/4 (except 451.39 /49) as of 31.8.10 with CODE (516) RADIO WITH USB INTERFACE Shown on vehicle up to 30.8.10 Vehicle as of 31.8.10 Fig 6: Connecting Couplings Of iPhone Kit Mount Wiring Harness To Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying iPhone Kit Mount, Center Console Cover And Smart Radio Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
see Odus¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1154 · Applies to: 450, 451, 452, 454
iPhone kit delivery contents 1 RETROFITTING & CONVERSION > RETROFIT NAVIGATION SYSTEM - AZ82.85-P- 2000MCC > MODEL 451.3/4 as of 31.8.10 with CODE (C08) Radio preinstallation incl. rod antenna (FFO) Parts scope for smart Premium radio (A2/4) Fig 1: Identifying Center Console Cover, Smart Entry Radio Wiring Harness, Cable Tie And Radio Recess Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Disconnect Star Diagnosis¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1157 · Applies to: 450, 451, 452, 454
11 Disconnect Star Diagnosis
AD00.00-P-2000- 04MCC 12 Enter security code of smart Premium radio (A2/4), change if necessary The security code is set to "0000" by default at the factory. If the security code is to be changed, it must be documented in writing.
13 Document retrofitted equipment using vehicle documentation (VeDoc) Attach note "smart Premium radio (A2/4) retrofitted as per AZ82.85- P-2000MCC " as well as serial number of smart Premium radio (A2/4) under field organization texts to design group 82.
PARTS ORDERING NOTES Part no. Designation Quantity
smart Premium radio retrofit scope
DG 82 (see EPC) smart Premium radio 1 DG 82 (see EPC) Operator's manual for smart Premium radio 1 DG 82 (see EPC) GPS antenna 1
Also for retrofitting external USB connector connecting point and external audio source connecting point
DG 82 (see EPC) Wiring harness with external USB connector connecting point and external audio source connecting point 1 DG 68 (see EPC) Passenger-side instrument panel lower section (note equipment variants) 1
Also for retrofitting glove box
DG 68 (see EPC) Glove compartment 1 RETROFITTING & CONVERSION > RETROFIT NAVIGATION SYSTEM - AZ82.85-P- 2000MCD > MODEL 451.3/4 as of 31.8.10 with CODE (516) RADIO WITH USB INTERFACE Parts scope for smart Premium radio A2/4
documented in writing.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1159 · Applies to: 450, 451, 452, 454 · AR: AZ82.85-P-2000MCD, BA82.00-Z-9999CZ
9 Document retrofitted equipment using vehicle documentation (VeDoc) Attach note "smart Premium radio (A2/4) retrofitted as per AZ82.85-P-2000MCD " as well as serial number of smart Premium radio (A2/4) under field organization texts to design group 82.
PARTS ORDERING NOTES Part no. Designation Quantity DG 82 (see EPC) smart Premium radio 1 DG 82 (see EPC) Operator's manual for smart Premium radio 1 DG 82 (see EPC) GPS antenna 1 DG 68 (see EPC) Center console cover 1 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: ELECTRICAL SYSTEM BODY - BA82.00-Z-9999CZ > MODEL all Headlamp unit MODEL 450.3 /4 BA82.10-P-1000-06B Speaker MODEL 450.3 /4 BA82.62-P-1000-04A Windshield wiper MODEL 454.0 BA82.30-P-1000-01G Windshield wiper MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA82.30-P-1000-01F TORQUE SPECIFICATIONS > WINDSHIELD WIPER - BA82.30-P-1000-01F > Model 450, 451, 452 MODIFICATION NOTES 25.1.07 Nut for wiper arm on wiper shaft Type 451.3 Nut for wiper arm on wiper shaft Model 451.4 WINDSHIELD WIPER Number Designation Model 450.3/4 Model 451.3 Model 451.4 Model 452.3/4 BA82.30-P-1001- 01F Wiper motor to clamping plate Nm 10 10 10 10 BA82.30-P-1002- Nut for wiper arm on wiper Nm 18 20 20 18
shaft¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1160 · Applies to: 450, 451, 452, 454
01F shaft BA82.30-P-1003- 01F Nut for wiper shaft on body Nm 12 - - - BA82.30-P-1004- 01F Nut, tailgate wiper arm to wiper shaft Nm 14 12 - - BA82.30-P-1005- 01F Bolt, wiper motor to tailgate Nm 2 - - - BA82.30-P-1006- 01F Bolt, wiper drive to body Nm - - - 5 BA82.30-P-1007- 01F Bolt, wiper linkage to body Nm - 10 10 - BASIC KNOWLEDGE > EXTERIOR LIGHTS, LOCATION OF COMPONENTS - GF82.10-P- 0003-02MCU > Fig 1: Locating Exterior Lights Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > BLOCK DIAGRAM OF EXTERIOR LIGHTS - GF82.10-P-0003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1161 · Applies to: 450, 451, 452, 454
03MCU > Fig 2: Locating Exterior Lights Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Auto on/off driving lights (with code (V54) Rain/light sensor)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1163 · Applies to: 450, 451, 452, 454
Turn signal light actuation Turn signaling Hazard warning flashing Hazard warning flashing when airbag deployed Ambient illumination actuation (with code (V54) Rain/light sensor) Stop lamp actuation Front fog lamp actuation (with code (V07) Front fog lamps (FFO)) Backup lamp actuation The SAM control unit (N10/10) is a subscriber in the Controller Area Network (data bus/CAN bus) (CAN) and the master control unit for the exterior lights and all flashing functions. The following switches are read in directly by the SAM control unit: Combination switch (S4) Cockpit switch group (S6/1) Stop lamp switch (S9/1) The following sensor is read in by the SAM control unit via the Local interconnect network, interior 1 (LIN B): Rain sensor / light sensor (B38) (with code (V54) Rain/light sensor) The following information is read in and transmitted by the SAM control unit via CAN: Crash signal from the restraint systems control unit (N2/7) Feedback to the instrument cluster (A1) The SAM control unit actuates the following components: Left front lamp unit (E1) Right front lamp unit (E2) Left taillamp (E3) Right taillamp (E4) Center high-mounted stop lamp (E21) Left additional turn signal lamp (E22/1) Right additional turn signal lamp (E22/2) Left license plate lamp (E19/1) Right license plate lamp (E19/2) Left front fog lamp (E5/1) (with code (V07) (Front fog lamps (FFO))
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1166 · Applies to: 450, 451, 452, 454
Functions Low beam High beam and headlamp flasher Daytime running lights (with code (K06) Daytime running lights) Auto on/off driving lights (with code (V54) Rain/light sensor) Dipped beam Function requirement Circuit 15 On Function The low beam is switched on by rotating the combination switch to switch position 2. The SAM control unit reads in the switch position of the combination switch and actuates the left and right low beam. The status message "low beams on" is transmitted by the SAM control unit via the CAN to the instrument cluster, which then actuate the low beam indicator lamp High beam and headlamp flasher Function requirements Fig 1: Headlamp Control Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > TURN SIGNAL INDICATOR ACTUATION, FUNCTION - GF82.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1171 · Applies to: 450, 451, 452, 454
3008MCU > MODEL 451.3/4 Functions Turn signals One-touch turn signaling Hazard warning flashing Turn signaling and one-touch turn signaling Function requirements: Circ. 15 ON Turn signals Turn signaling is requested by pushing the combination switch down or up past the actuation point. The SAM control unit registers the respective position of the combination switch and actuates the following lamps: Fig 1: Turn Signal Indicator Actuation Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Left turn signal light in left front lamp unit (E1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1172 · Applies to: 450, 451, 452, 454
Left brake light/turn signal light in left taillamp (E3) Left additional turn signal lamp or Right turn signal light in right front lamp unit (E2) Right brake light/turn signal light in right taillamp (E4) Right additional turn signal lamp Stop turn signaling Turn signaling is stopped by means of countersteering (automatic return of switch), manually returning the combination switch or activating the hazard warning flasher function. One-touch turn signaling During one-touch turn signaling the combination switch is only briefly moved to the required signaling position. If the turn combination switch is not engaged into place in the signaling position, a sequence of three turn-signal cycles is triggered. The SAM control unit registers the respective position of the combination switch and actuates the following lamps: Left turn signal light in left front lamp unit Left brake light/turn signal light in left taillamp Left additional turn signal lamp or Right turn signal light in right front lamp unit Right brake light/turn signal light in right taillamp Right additional turn signal lamp One-touch turn signaling is stopped by activating the hazard warning flasher function. Turn signaling and one-touch turn signaling feedback The activated function is signaled to the instrument cluster by the SAM control unit via the CAN. The instrument cluster actuates the relevant turn signal indicator lamp as visual feedback. Acoustic feedback is also output on the speaker in the instrument cluster in the form of a turn signal sound indicator. If one of the turn signal lamps fails, the flashing frequency of the indicator lamps, the flashing frequency of the other turn signal lamps and the frequency of the turn signal sound indicator is doubled. Activating the hazard warning flasher using the hazard warning flasher switch The status of the hazard warning flasher switch is registered by the SAM control unit, which actuates the turn signal lamps in the front lamp units, the brake lights/turn signal lights in the taillamps and the additional turn signal lamps. Hazard warning flasher actuation as a result of rapid deceleration If the vehicle is braked from a speed of more than 35 mph to a standstill, the hazard warning system is
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1176 · Applies to: 450, 451, 452, 454
The interior illumination system implements the illumination of the vehicle interior. The master control unit for this is the SAM control unit. The following operations are possible Switching on and off manually Switching on automatically Automatic switch off Switching on and off manually by operating the interior lamp switch Switching on automatically when unlocking the vehicle via the transmitter key when opening the driver or front passenger door when opening the top rear-end door (with model 451.3) when opening the bottom rear-end door (with model 451.4) when an alarm is triggered (with code (V01) Anti-theft alarm system (FFO)) The interior lamp is only automatically switched on if the interior lamp switch has been pushed towards the rear. Automatically switched on when the vehicle is unlocked using the transmitter key Fig 1: Interior Illumination Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Function requirements:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1180 · Applies to: 450, 451, 452, 454
Circuit 15 Off General The panic alarm provides a facility for triggering a visual or acoustic alarm using the transmitter key (e.g. in an emergency situation). Functions Triggering the panic alarm Canceling the panic alarm Triggering the panic alarm If the panic alarm button on the transmitter key is pressed for t ≥ 1 s, a radio signal is transmitted to the SAM control unit, which checks the transmitter key authorization. If the authorization is valid, an acoustic and a visual alarm are triggered. The acoustic alarm is issued via the horn, and the visual alarm is issued via the: Left turn signal light Right turn signal light Left brake/turn signal light Right brake/turn signal light Left additional turn signal lamp Fig 1: Panic Alarm Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > WIPER SYSTEM (WSA) BLOCK DIAGRAM - GF82.30-P-0003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1182 · Applies to: 450, 451, 452, 454
04MCC > Fig 1: Locating Wiper System Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Wiper System Block Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
and the right headlamp range adjustment motor (E2m1). All other operating requests are read in by the SAM¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1187 · Applies to: 450, 451, 452, 454
control unit. Control of the individual functions: Turn signal The turn signal is switched on by pressing the combination switch upward for the right side and downward for the left side beyond the detent point. One-touch turn signaling One-touch turn signaling is activated by briefly pressing the combination switch upward for the right side and downward for the left side as far as the detent point. The turn signal flashes 3 times. Standing light The standing light is activated by rotating the combination switch to the first detent point. Low beam The low beam is activated by rotating the combination switch to the second detent point. High beam The high beam is activated by pressing the combination switch forward. The high beam is deactivated by pulling the combination switch back to the home position. Headlamp flasher The headlamp flasher is activated for as long as the combination switch is pulled to the rear. Auto on/off driving lights (with code (V54) Rain/light sensor) The auto on/off driving lights are activated by rotating the combination switch to the third detent point. Daytime running lights (with code (K06) Daytime running lights) The daytime running lights are activated and deactivated by pulling back the combination switch and simultaneously operating the lock button on the transmitter key. Headlamp range adjustment The incline angle is adapted using switch settings 0, 1 and 2 on the selector wheel of the combination switch. BASIC KNOWLEDGE > WIPER SWITCH, COMPONENT DESCRIPTION - GF82.30-P- 5002MCC > MODEL 451.3/4
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1188 · Applies to: 450, 451, 452, 454
The wiper switch is located on the steering column. Task The wiper switch is used to activate the following requests: Windshield Wipe at slow speed Wipe at fast speed Wipe with washer fluid Intermittent wipe Rear window (with model 451.3) Intermittent wipe Wipe with washer fluid The windshield washer fluid pump (M5/1) is actuated directly via the wiper switch. Operation of individual functions (windshield) Wipe Pressing the wiper switch upwards beyond the first catch point activates a wipe at a slow speed. Pressing the wiper switch upwards beyond the second catch point activates a wipe at a faster speed. Wipe with washer fluid Pulling the wiper switch backwards and holding it there directly actuates the windshield washer fluid pump. The position of the wiper switch is read in by the SAM control unit, which then actuates the wiper motor. After Fig 1: View Of Right Wiper Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
U606¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1193 · Applies to: 450, 451, 452, 454
Valid for all except convertibles 38B W10 Ground (battery) 31G W10 Ground (battery) 27G W43 Ground (outside left fire wall) 18G W43 Ground (outside left fire wall) 17G W43 Ground (outside left fire wall) 8G W6 Ground (left wheelhousing in trunk) 44B W6 Ground (left wheelhousing in trunk) 40B W6 Ground (left wheelhousing in trunk) 15G W7 Ground (right wheelhousing in trunk) 24G W9 Ground (at left headlamp unit) 2E X18/19 Trunk lid connector 40E X18/19 Trunk lid connector 38G X23/7 Soft top connector 42E Z40 Stop lamp signal connector sleeve 39E Z40 Stop lamp signal connector sleeve 42C Z40 Stop lamp signal connector sleeve 32H Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 21H Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 12H Z6/16 Soft top ground connector sleeve 43H Z6/20 Trunk lid ground connector sleeve 40H
Fig 1: Brake Lights And Turn Signal/Hazard Warning Flasher - Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1194 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Brake Lights And Turn Signal/Hazard Warning Flasher - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1195 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM INTERIOR ILLUMINATION - PE82.20-P-2000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1198 · Applies to: 450, 451, 452, 454
97MCV > Code: Designation: Position: E13/15 Driver door pocket ambiance illumination 6L E13/15 Driver door pocket ambiance illumination
E13/16 Front passenger door pocket ambiance illumination 4L E13/16x1 Front passenger door pocket ambiance illumination connector
E17/16 Left front footwell lamp 16L E17/16 Left front footwell lamp 18L E43/1 Left cockpit ambiance illumination 9L E43/1x1 Left cockpit ambiance illumination connector
E43/2 Center cockpit ambiance illumination 10L E43/2x1 Center cockpit ambiance illumination connector
Fig 1: Interior Illumination - Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
E43/3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1199 · Applies to: 450, 451, 452, 454
Right cockpit ambiance illumination 12L E43/3x1 Right cockpit ambiance illumination connector
E43/9 Overhead control panel (OCP) ambiance illumination 13L E43/9x1 Overhead control panel (OCP) ambiance illumination connector
N10/10 SAM control unit 4A N10/10 SAM control unit 12A N10/10 SAM control unit 19A W9 Ground (left front, at lamp unit) 15G X35/1 Left door separation point 6H X35/2 Right door separation point 4H Z232 Ambiance illumination supply connector sleeve 8E Z54/6 Circuit 30 footwell lamp connector sleeve 18E Z54/7 Footwell lamps connector sleeve 16E Z6/35 Left door ground connector sleeve 6G Z6/36 Right door ground connector sleeve 4G Fig 1: Interior Illumination - Wiring Diagram (1 Of 2)
Ground (battery)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1204 · Applies to: 450, 451, 452, 454
W10 Ground (battery) 33E W12 Ground (center console) 19E W14 Left floor interior compartment ground 32E W7 Ground (right wheelhouse in luggage compartment) 8G X115 USB connection connector 42L X35/1 Left door separation point 26E X35/2 Right door separation point 24E X39/45 External audio source separation point 44L Z28/18 Sound system antenna actuation connector sleeve 22F Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve 17F Z37/42 CAN bus (low) connector sleeve 4H Z81 Circuit 58d connector sleeve 15F Fig 1: Radio - Wiring Diagram (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Radio - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1205 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM RADIO - PE82.60-P-2000-97MCG >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1206 · Applies to: 450, 451, 452, 454
Code: Designation: Position: A1 Instrument cluster 13L A2/20 Radio antenna 50L A2/23 GPS antenna 48L A2/4 smart Premium radio 6A Fig 3: Radio - Wiring Diagram (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A2/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1207 · Applies to: 450, 451, 452, 454
smart Premium radio 11A A2/4 smart Premium radio 20A A2/4 smart Premium radio 29A A2/4 mart Premium radio 37A A2/4 smart Premium radio 45A A2/4 smart Premium radio 53A H4/29 Subwoofer 20L H4/29 Subwoofer 47L H4/29 Subwoofer 34L H4/33 Left tweeter 40L H4/34 Right tweeter 41L H4/64 Left door sound system woofer 43L H4/65 Right door sound system woofer 35L H4/68 Left door sound system tweeter 45L H4/69 Right door sound system tweeter 37L H4/7 Left rear speaker 38L H4/8 Right rear speaker 42L N10/10 SAM control unit 17L N10/10f15 Fuse 15 18L N10/10f20 Fuse 20 16L N15/6 Automated manual transmission control unit 3L N47-5 ESP control unit 8L S12 Parking brake indicator switch 6L U1 Valid for {{USA}} 1E U12 Valid for left-hand drive vehicles 19D U13 Valid for right-hand drive vehicles 19D U58 Valid for ECE 6E U863 Valid for external audio source 51C U97 Not valid for model 451.334/380/480 12K U97 Not valid for model 451.334/380/480 16K U98 Valid for model 451.334/380/480 12L U98 Valid for model 451.334/380/480 16K W10 Ground (battery) 20F W12 Ground (center console) 17E
Left floor interior compartment ground¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1208 · Applies to: 450, 451, 452, 454
W14 Left floor interior compartment ground 20E W7 Ground (right wheelhouse in luggage compartment) 6G X115 USB connection connector 52L X134/1 Sound connecting point 1 21G X134/2 Sound connecting point 2 27G X35/1 Left door separation point 43F X35/2 Right door separation point 35G X39/45 External audio source separation point 54L Z28/5 Left door speaker group connector sleeve (+) 43H Z28/6 Left door speaker group connector sleeve (-) 44H Z28/7 Right door speaker group connector sleeve (+) 35H Z28/8 Right door speaker group connector sleeve (-) 36H Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve 15F Z37/42 CAN bus (low) connector sleeve 2H Z81 Circuit 58d connector sleeve 13F Fig 1: Radio - Wiring Diagram (1 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Radio - Wiring Diagram (2 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1209 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Radio - Wiring Diagram (3 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1210 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM RADIO - PE82.60-P-2000-97MCF >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1211 · Applies to: 450, 451, 452, 454
Code: Designation: Position: A1 Instrument cluster 15L A2/13 Sound amplifier 28L A2/20 Radio antenna 50L Fig 4: Radio - Wiring Diagram (4 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A2/23¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1212 · Applies to: 450, 451, 452, 454
GPS antenna 48L A2/4 smart Premium radio 12A A2/4 smart Premium radio 20A A2/4 smart Premium radio 51A A2/4 smart Premium radio 5A A2/4 smart Premium radio 28A A2/4 smart Premium radio 36A A2/4 smart Premium radio 44A H4/29 Subwoofer 47L H4/33 Left tweeter 36L H4/34 Right tweeter 34L H4/64 Left door sound system woofer 45L H4/65 Right door sound system woofer 41L H4/68 Left door sound system tweeter 43L H4/69 Right door sound system tweeter 39L H4/7 Left rear speaker 38L H4/8 Right rear speaker 35L N10/10 SAM control unit 19L N10/10f15 Fuse 15 20L N10/10f20 Fuse 20 18L N15/6 Automated manual transmission control unit 4L N47-5 ESP control unit 9L S12 Parking brake indicator switch 7L U1 Valid for {{USA}} 2E U12 Valid for left-hand drive vehicles 21D U13 Valid for right-hand drive vehicles 21D U58 Valid for ECE 20G U58 Valid for ECE 6E U863 Valid for external audio source 51C U97 Not valid for model 451.334/380/480 13K U97 Not valid for model 451.334/380/480 17K U98 Valid for model 451.334/380/480 13L U98 Valid for model 451.334/380/480 17K W10 Ground (battery) 22F
Ground (center console)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1213 · Applies to: 450, 451, 452, 454
W12 Ground (center console) 18E W14 Left floor interior compartment ground 22E W7 Ground (right wheelhouse in luggage compartment) 7G X115 USB connection connector 52L X134/1 Sound connecting point 1 23G X134/2 Sound connecting point 2 28H X35/1 Left door separation point 43F X35/2 Right door separation point 39F X39/45 External audio source separation point 55L Z28/5 Left door speaker group connector sleeve (+) 44H Z28/6 Left door speaker group connector sleeve (-) 43H Z28/7 Right door speaker group connector sleeve (+) 41H Z28/8 Right door speaker group connector sleeve (-) 39H Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve 17F Z37/42 CAN bus (low) connector sleeve 3H Z81 Circuit 58d connector sleeve 15F
Fig 1: Radio - Wiring Diagram (1 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1214 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Radio - Wiring Diagram (2 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1215 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Radio - Wiring Diagram (3 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1216 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM RADIO - PE82.60-P-2000-97MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1217 · Applies to: 450, 451, 452, 454
Code: Designation: Position: A1 Instrument cluster 8L A2/1 smart radio 9 19A A2/1 smart radio 9 11A Fig 4: Radio - Wiring Diagram (4 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A2/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1218 · Applies to: 450, 451, 452, 454
smart radio 9 4A A2/1 smart radio 9 28A A2/2 smart radio 10 20A A2/2 smart radio 10 12A A2/2 smart radio 10 5A A2/2 smart radio 10 29A A2/20 Radio antenna 25L H4/10 Right front speaker 11L H4/29 Subwoofer loudspeaker 18L H4/33 Left tweeter speaker 23L H4/34 Right tweeter speaker 22L H4/9 Left front speaker 14L N10/10 SAM control unit 3L N10/10f15 Fuse 15 5L N10/10f20 Fuse 20 2L N4 Communication control unit 29L U18 Valid for communication systems 27E U90 Valid for Sound System 15A W14 Left floor interior compartment ground 19G W26 Ground (transmission tunnel) 3E X35/1 Left door separation point 13E X35/2 Right door separation point 11E Z28/18 Sound system/antenna control connector sleeve 7G Z3/44 Instrument cluster - radio circuit 15 connector sleeve (fused) 2G Z81 Circuit 58d connector sleeve 8G
Fig 1: Radio - Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1219 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Radio - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1220 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > HANDS-FREE SYSTEM CONTROL UNIT WIRING DIAGRAM -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1225 · Applies to: 450, 451, 452, 454
PE82.70-P-2103-97MCU > Fig 2: Radio Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Hands-Free System Control Unit Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1226 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Communications Interface (KOM) - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1229 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: ELECTRICAL SYSTEM BODY - WS82.00-Z-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1232 · Applies to: 450, 451, 452, 454
9999CZ > MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P- 0007B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P- 0006Z 001 589 38 33 00 Puller FG 82/Set B WS82.00-N- 3001B 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P- 0274K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P- 0027K 220 589 04 99 00 New passenger car wiring harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P- 0006B 450 589 06 99 00 Tool kit for retrofitting AC system FG 82/Set B WS82.00-P- 0030B 450 589 06 99 01 Modu 4 blade FG82/Set B WS82.00-P- 0030-01B 450 589 06 99 02 Multilock blade FG82/Set B WS82.00-P- 0030-02B 450 589 06 99 03 MDK/DFK blade FG82/Set B WS82.00-P- 0030-03B 450 589 06 99 04 AFK/AFS blade FG82/Set B WS82.00-P- 0030-04B 450 589 06 99 05 Hand pliers FG82/Set B WS82.00-P- 0030-05B Fig 1: Identifying Puller (450 589 25 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
450 589 06 99 06 Blade holder¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1233 · Applies to: 450, 451, 452, 454
FG82/Set B WS82.00-P- 0030-06B 450 589 25 63 00 Puller FG 82/Set B WS82.00-P- 0104B 450 589 26 63 00 Adapter cable SAM St.8 FG 82/Set B WS82.00-P- 0108B 450 589 27 63 00 Adapter cable SAM St.9 FG 82/Set B WS82.00-P- 0109B 452 589 00 07 00 Removal/installation tool FG 82/Set B WS82.00-P- 0033B 452 589 00 63 00 Adapter cable FG 82/set B WS82.00-P- 0102B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P- 0107K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P- 0012K
RETROFITTING & CONVERSION > RETROFIT BRABUS ADDITIONAL HEADLAMP WIRING¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1234 · Applies to: 450, 451, 452, 454
HARNESS - AN82.10-P-0007-01MCC > Connection diagram on vehicles without retrofitted ambiance illumination Fig 1: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Brabus Additional Headlamp - Connection Diagram On Vehicles Without Retrofitted Ambiance Illumination
The dashed brown/gray line (br/gr) shows the original installation of lines in the vehicle and the continuous¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1235 · Applies to: 450, 451, 452, 454
lines are the retrofit. Connection diagram on vehicles with retrofitted ambiance illumination Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The dashed brown/gray line (br/gr) and gray/blue line (gr/bl) show the original installation of lines in the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1236 · Applies to: 450, 451, 452, 454
vehicle; the continuous lines show the retrofit. Routing diagram shown on vehicles without retrofitted ambiance illumination Fig 3: Brabus Additional Headlamp - Connection Diagram On Vehicles With Retrofitted Ambiance Illumination Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Ensure that the wiring harnesses are not damaged by chafing or being trapped otherwise the appropriate¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1237 · Applies to: 450, 451, 452, 454
wiring harness must be replaced. 1. Route engine compartment branch-off line (3.1) of additional headlamp wiring harness along vehicle wiring harness, as shown, from installation location of additional headlamp to grommet (16) and to left front ground (with lamp unit) and fix in place using cable ties. Pay attention to routing of line in area of wiper system since wiper linkage must have freedom of movement in every position. Failure to observe this can result in short circuit or the wiper system locking up. Fig 4: Brabus Additional Headlamp - Routing Diagram (Shown On Vehicles Without Retrofitted Ambiance Illumination) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Screw on brown line (br) of engine compartment branch-off line of additional headlamp wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1238 · Applies to: 450, 451, 452, 454
harness to left front ground (with lamp unit) (W9) and fix brown line (br) in place using cable ties. 3. Carefully cut a rubber plug (arrow) at grommet (16). 4. Route engine compartment branch-off line (3.1) of additional headlamp wiring harness through Fig 5: Identifying Branch-Off Line Of Additional Headlamp Wiring Harness And Grommet Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Brown Line Of Additional Headlamp Wiring Harness And Left Front Ground (With Lamp Unit) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
opening in grommet (16) into interior and fix in place using cable ties.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1239 · Applies to: 450, 451, 452, 454
- Seal grommet (16) using suitable sealant.
- Remove screws/bolts (17) at SAM control unit (N10/10).
- Unclip SAM control unit (N10/10) in rear area (arrow A) and guide downwards until connectors at rear of SAM control unit (N10/10) are accessible. Fig 7: Locating Rubber Plug Of Grommet Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Remove relay (14) from relay socket (13).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1240 · Applies to: 450, 451, 452, 454
- Plug engine compartment branch-off line (3.1) of additional headlamp wiring harness into free center slot at relay socket (13). Fig 8: Locating SAM Control Unit Rear Area Courtesy of MERCEDES BENZ OF NORTH AMERICA
10. Plug blue/gray line (bl/gr) into slot 1 of black 2-pin coupling (10).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1241 · Applies to: 450, 451, 452, 454
The black 2-pin connector (15) that is located on the second blue/gray line (bl/gr) is only required on vehicles with ambiance illumination. Operation steps 11 to 16 only on vehicles without retrofitted ambiance illumination. Fig 9: Identifying Relay Of Relay Socket And Engine Compartment Branch-Off Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 10: Identifying Black 2-Pin Coupling, 2-Pin Connector And Second Blue/Gray Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Release coupling "N11-5" and disconnect at SAM control unit (N10/10).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1242 · Applies to: 450, 451, 452, 454
Coupling "N11-5" is located in the marked slot (arrow). 12. Unplug pin (5.8) of brown/gray line (br/gr) from slot 8 of coupling "N11-5" (5). 13. Plug pin of brown/gray line (br/gr) of adapter line into slot 8 of coupling "N11-5" (5). Fig 11: Locating Marked Slot Of Coupling "N11-5" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. Plug brown/gray line (br/gr) unplugged from slot 8 of coupling "N11-5" (5) into slot 1 of black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1243 · Applies to: 450, 451, 452, 454
coupling (7). 15. Connect black 2-pin coupling (7) to black 2-pin connector (8) of adapter line. 16. Connect coupling "N11-5" (5) at SAM control unit (N10/10). Fig 12: Identifying Pin Of Brown/Gray Line And Coupling "N11-5" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
17. Disconnect black 2-pin coupling (20) of ambiance illumination wiring harness (21) from black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1244 · Applies to: 450, 451, 452, 454
connector (9) of adapter line. Only on vehicles with retrofitted ambiance illumination. On these, the adapter line is already installed and the ambiance illumination wiring harness (21) connected to this. 18. Connect black 2-pin connector (9) to black 2-pin coupling (10) of gray/blue line (gr/bl) of interior branch-off line. 19. Connect black 2-pin coupling (20) of gray/blue line (gr/bl) of ambiance illumination wiring harness (21) to black 2-pin connector (15) of gray/blue line (gr/bl) 20. Fix wiring harnesses of SAM control unit (N10/10) in place with cable tie. Fig 13: Identifying Black 2-Pin Coupling, Connector And Coupling N11-5 Of SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
21. Remove cable tie at bracket (18) and unhook bracket (18) from longitudinal strut (19).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1245 · Applies to: 450, 451, 452, 454
- Insert relay (14) into relay socket (13) and clip relay socket (13) into bracket (18)
- Hook bracket (18) into longitudinal strut (19) and fasten with cable tie Fig 14: Identifying Black 2-Pin Coupling Of Ambiance Illumination Wiring Harness And 2-Pin Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 15: Identifying Bracket Of Longitudinal Strut And Relay Of Relay Socket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
24. Insert fuse carrier with fuse (6) at SAM control unit (N10/10).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1246 · Applies to: 450, 451, 452, 454
The slot and the fuse carrier with fuse (6) are coded. The fuse has a fuse rating of 10 A. 25. Screw on brown line (br) at left interior floor ground (W14). 26. Clip SAM control unit (N10/10) into rear area (arrow A) and screw down using screws/bolts (17). RETROFITTING & CONVERSION > RETROFIT BRABUS ADDITIONAL HEADLAMP LAMP UNIT - AN82.10-P-0007-02MCC > The following operation steps are shown on the right side of the vehicle. Retrofitting on the left side of the vehicle is performed in the same manner. 1. Drill hole with diameter of 4 mm in center at pin (20). Hand drill Wet/dry vacuum cleaner 2. Connect black 2-pin connector (12) and daytime running lights electrical connector (21) at right additional headlamp (2). Fig 16: Identifying SAM Control Unit Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Screw down right additional headlamp (2) at attachment points of front fog lamp.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1247 · Applies to: 450, 451, 452, 454 · AR: AN82.10-P-0007MCC
- Tighten right additional headlamp (2) with screws/bolts included in delivery contents at pin (20). RETROFITTING & CONVERSION > RETROFIT BRABUS ADDITIONAL HEADLAMPS - AN82.10-P-0007MCC > MODEL 451.3 /4 (except 451.391 /491) with CODE (V07) Front fog lamps (FFO) except CODE (460) Canada version Fig 1: Identifying 2-Pin Connector And Daytime Running Lights Electrical Connector Of Right Additional Headlamp Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Right And Left Additional Headlamps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > PREPARE LONGITUDINAL MEMBER PANEL FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1249 · Applies to: 450, 451, 452, 454
INSTALLATION OF BRABUS LONGITUDINAL MEMBER PANEL ILLUMINATION - AN82.10- P-0008-01MCB > 1. Mark drill holes at longitudinal member panel (1) in accordance with dimensions (a to e). The reference edge of the dimension (a) is always the outer edge of the longitudinal member panel (1). Dimensions: Fig 2: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill holes with a diameter of 25.5 mm in the marked areas with the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1250 · Applies to: 450, 451, 452, 454
graduated drill. Hand drill RETROFITTING & CONVERSION > PREPARE LONGITUDINAL MEMBER PANEL FOR INSTALLATION OF BRABUS LONGITUDINAL MEMBER PANEL ILLUMINATION - AN82.10- P-0008-01MCC > 1. Mark drill holes at longitudinal member panel (1) in accordance with dimensions (a to f). The reference edge of the dimensions (a to c) is always the outer edge of the longitudinal member panel (1). Dimensions: Fig 2: Identifying Dimensions For Drilling Holes On Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill holes with a diameter of 25.5 mm in the marked areas with the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1251 · Applies to: 450, 451, 452, 454
graduated drill. Hand drill gotis://G_58.0_00.1 RETROFITTING & CONVERSION > RETROFIT BRABUS LONGITUDINAL MEMBER PANEL ILLUMINATION WIRING HARNESS - AN82.10-P-0008-02MCC > Routing diagram Connection diagram Fig 2: Identifying Dimensions For Drilling Holes On Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Brabus Longitudinal Member Panel Illumination Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route wiring harness (6) such that it cannot be damaged by chafing or crushing.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1252 · Applies to: 450, 451, 452, 454
Special attention must be paid to the line routing in the vicinity of the wiper system since the wiper linkage must have clearance in every position. Failure to observe this can result in short circuit or the wiper system locking up. 1. Route branch-off line of wiring harness (6) from right longitudinal member along vehicle wiring harness up to center of firewall. The installation position of the individual branch-off lines is defined by the different length. Fig 2: Brabus Longitudinal Member Panel Illumination Connection Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Route branch-off line of wiring harness (6) along vehicle wiring harness from center of firewall to left¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1253 · Applies to: 450, 451, 452, 454
longitudinal member. The installation position of the individual branch-off lines is defined by the different length. 3. Fasten branch-off lines of wiring harness (6) using cable ties at vehicle wiring harness. Fig 3: Identifying Wiring Harness Of Right Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Wiring Harness Of Left Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Carefully cut off a rubber plug of grommet (16).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1254 · Applies to: 450, 451, 452, 454
- Route interior compartment branch-off line of wiring harness (6) through opening in grommet (16) into interior.
- Seal grommet (16) using suitable sealant.
- Route interior compartment branch-off line of wiring harness (6) along broken line to SAM control unit and to roof paneling. The installation position of the individual branch-off lines is defined by the different length.
- Fasten interior compartment branch-off line using cable ties at vehicle wiring harness. Fig 5: Identifying Wiring Harness And Grommet Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. Plug electrical lines (17) of wiring harness (6) into coupling (7) in accordance with electrical lines¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1255 · Applies to: 450, 451, 452, 454
(18) of adapter wiring harness (9). To prevent polarity reversal of electrical lines (17) and electrical lines (18), electrical lines (17, 18) have the same color coding. 10. Establish electrical connection with connector (8) and coupling (7). 11. Connect coupling (11) of adapter wiring harness (9) to front interior lamp (E15/4). 12. Connect connector (10) of adapter wiring harness (9) to coupling (16). 13. Fasten adapter wiring harness (9) with cable ties. Fig 6: Identifying Wiring Harness Of Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. Remove screws/bolts (19) at SAM control unit (N10/10).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1256 · Applies to: 450, 451, 452, 454
- Unclip SAM control unit (N10/10) in rear area (arrow).
- Plug branch-off line of wiring harness into fuse holder (4).
- Insert fuse holder (4) into free slot at SAM control unit (N10/10) and insert a fuse with a fuse rating of 5 amps. The slots are coded.
- Clip SAM control unit (N10/10) into rear area (arrow A) and screw down using screws/bolts (19). Fig 7: Identifying Electrical Lines Of Wiring Harness Into Coupling And Front Interior Lamp Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT BRABUS LONGITUDINAL MEMBER PANEL¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1257 · Applies to: 450, 451, 452, 454
LAMP UNIT - AN82.10-P-0008-03MCC > Fig 8: Locating SAM Control Unit Rear Area Courtesy of MERCEDES BENZ OF NORTH AMERICA
Ensure that the wiring harnesses are not damaged by chafing or being trapped otherwise the appropriate¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1258 · Applies to: 450, 451, 452, 454 · AR: AN82.10-P-0008MCC
wiring harness must be replaced. Following operation steps are shown on right longitudinal member panel (1). Retrofitting on the left longitudinal member panel is performed in the same manner. 1. Clip lamp units (3) into notches that were previously made on longitudinal member panel (1) Ensure that lamp units (3) are seated correctly in longitudinal member panel (1). 2. Create electrical connectors (21) with connector of lamp units (3) and wiring harness of longitudinal member panel illumination. 3. Slide electrical connectors (21) into foam brackets (20). 4. Slide coupling (15) through front foam bracket (20). 5. Glue foam bracket (20) to longitudinal member panel (1) as shown with adhesive strips included in delivery contents. Red side of adhesive strips must point in direction of longitudinal member panel (1). RETROFITTING & CONVERSION > RETROFIT BRABUS LONGITUDINAL MEMBER PANEL ILLUMINATION - AN82.10-P-0008MCC > MODEL 451.3 /4 (except 451.391 /491) Fig 1: Identifying Brabus Longitudinal Member Panel Lamp Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Prepare longitudinal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1260 · Applies to: 450, 451, 452, 454
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 450589002800 On vehicles with BRABUS longitudinal member panel AN82.10-P-0008- 01MCB Graduated drillHand drill 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. Vehicle is locked: Lamp units (3) are switched off in a dimmed state. Door opened: Lamp units (3) light up. Lamp units (3) are switched
off when¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1261 · Applies to: 450, 451, 452, 454
ignition is switched on (circuit 15). RETROFITTING & CONVERSION > RETROFIT DAYTIME RUNNING LIGHTS HEADLAMP WIRING HARNESS - AN82.10-P-0100-01MCC > Fig 2: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Expanding Pliers (450 589 12 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connection diagram¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1262 · Applies to: 450, 451, 452, 454
The dashed brown/gray line (br/gr) shows the original installation of lines in the vehicle and the continuous lines are the retrofit. Routing diagram for front wiring harness (3.1) Fig 3: Identifying Puller Aid (450 589 25 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Daytime Running Lights Headlamp Wiring Harness - Connection Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Routing diagram for interior wiring harness (3.2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1263 · Applies to: 450, 451, 452, 454
- Route front wiring harness (3.1), as shown, to vehicle-side wiring harness and temporarily fasten with cable ties. Fig 5: Daytime Running Lights Headlamp Wiring Harness - Routing Diagram For Front Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Daytime Running Lights Headlamp Wiring Harness - Routing Diagram For Interior Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Do not damage front wiring harness (3.1) while routing by means of crushing or pinching as this¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1264 · Applies to: 450, 451, 452, 454
may lead to a short circuit. Use puller aid in the area of the wiper system. 2. Lay interior wiring harness (3.2) in area of windshield washer reservoir until it is routed further. 3. Route front wiring harness (3.1), as shown, at vehicle wiring harness and guide coupling (16) through opening in front module. Do not damage front wiring harness (3.1) while routing by means of crushing or pinching as this may lead to a short circuit. 4. Temporarily fasten front wiring harness (3.1) in illustrated area at vehicle-side wiring harness using cable ties. Fig 7: Identifying Front And Interior Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Cut open cable duct (arrow A) of firewall rubber grommet (15).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1265 · Applies to: 450, 451, 452, 454
- Enlarge cable duct (arrow A) using expanding pliers and guide interior wiring harness (3.2) through opening into interior. Do not damage interior wiring harness (3.2) while routing by means of crushing or pinching as this may lead to a short circuit.
- Route interior wiring harness (3.2) and front wiring harness (3.1), as shown, at vehicle-side wiring harness and temporarily fasten using cable ties. Fig 8: Front Wiring Harness Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Connect brown line (br) at outer left firewall ground (W43).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1266 · Applies to: 450, 451, 452, 454
- Route brown line (br) and front wiring harness (3.1) to vehicle-side wiring harness and temporarily fasten with cable ties.
- Route front wiring harness (3.1), as shown, at vehicle-side wiring harness and guide coupling (17) through opening in front module. Fig 9: Interior And Front Wiring Harness Routing Diagram Courtesy of MERCEDES BENZ OF NORTH AMERICA Fig 10: Identifying Brown Line Of Outer Left Firewall Ground And Front Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Do not damage front wiring harness (3.1) while routing by means of crushing or pinching as this¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1267 · Applies to: 450, 451, 452, 454
may lead to a short circuit. 11. Temporarily fasten front wiring harness (3.1) in illustrated area at vehicle-side wiring harness using cable ties. 12. Check routing of front wiring harness (3.1) and tighten all cable ties used, then shorten excess length of cable ties. Operation steps 13 to 18 only on vehicles without retrofitted ambiance illumination. 13. Release and disconnect coupling "N11-5" at SAM control unit (N10/10). Coupling "N11-5" is located in the marked slot (arrow). Fig 11: Front Wiring Harness Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. Detach pin (5.8) of brown/gray line (br/gr) from slot 8 of coupling "N11-5" (5) with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1268 · Applies to: 450, 451, 452, 454
wiring harness repair kit, basic. 15. Plug pin (4) of brown/gray line (br/gr) of adapter line (12) into slot 8 of coupling "N11-5" (5). Fig 12: Locating Marked Slot Of Coupling "N11-5" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
16. Unlatch secondary lock (10) of coupling (9) and carefully pull out of coupling (9) up to end stop.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1269 · Applies to: 450, 451, 452, 454
- Plug pin (5.8) of brown/gray line (br/gr) into slot 1 of coupling (9). Brown/gray line (br/gr) can be guided through closed cap (arrow D) and through seal (11).
- Slide secondary lock (10) into coupling (9) until it engages. Fig 13: Identifying Pin Of Brown/Gray Line, Adapter And Coupling N11-5 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
19. Plug gray/blue line (gr/bl) of interior wiring harness into slot 1 of coupling (6).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1270 · Applies to: 450, 451, 452, 454
On vehicles with retrofitted ambiance illumination, the gray/blue line (gr/bl) must be crimped with gray/blue line (gr/bl) of adapter line already installed. 20. Plug red/blue line (rt/bl) of interior wiring harness into fuse holder (14). Ensure that fuse (13) is seated correctly. 21. Insert fuse holder (14) in one of the suitably coded slots "R1" to "R4" (arrow B) at SAM control unit (N10/10). Fig 14: Identifying Pin Of Brown/Gray Line And Secondary Lock Of Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Operation steps 22 to 24 only on vehicles without retrofitted ambiance illumination.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1271 · Applies to: 450, 451, 452, 454
- Connect coupling (9) with connector of adapter line (12).
- Connect coupling (6) with connector (7) of adapter line (12).
- Insert coupling "N11-5" (5) into slot (arrow C) at SAM control unit (N10/10). Fig 15: Identifying Coupling, Fuse, Fuse Holder And Gray/Blue Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 16: Identifying Coupling With Connector Of Adapter Line And Coupling N11-5 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Operation steps 25 to 29 only on vehicles with retrofitted ambiance illumination.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1272 · Applies to: 450, 451, 452, 454
- Separate gray/blue line (gr/bl) of adapter line (12). Do not separate the gray/blue line (gr/bl) of the ambiance illumination wiring harness connected to the adapter line (12).
- Slide heat-shrinkable tube over gray/blue line (gr/bl) of adapter line (12).
- Crimp together gray/blue line (gr/bl) of adapter line (12) and gray/blue line (gr/bl) of front wiring harness (3.1).
- Fasten wiring harnesses of SAM control unit (N10/10) using cable tie (2), as shown, and then shorten excess length of cable tie (2).
- Protect crimped connection (18) with heat-shrinkable tube. Fig 17: Identifying Gray/Blue Line Of Adapter Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT DAYTIME RUNNING LIGHTS HEADLAMP¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1273 · Applies to: 450, 451, 452, 454
CONTROL UNIT - AN82.10-P-0100-02MCC > The following steps are shown on the left side of the vehicle. Installation on the right side of vehicle is performed in the same manner. 1. Before installing the daytime running lights control unit (1) check whether the ferrite core (10) is positioned, as shown, on the wiring harness. If necessary, align the ferrite core (10) again. Fig 18: Fastening Wiring Harnesses Of SAM Control Unit Using Cable Tie Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Tighten daytime running lights control unit (1) with screws/bolts (2) at bracket (6).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1274 · Applies to: 450, 451, 452, 454
- Temporarily fasten connector (4) using cable tie (5) at front side of bracket (6) at peg (arrow A).
- Drill out mounting dome (arrow B) of front module (7) at center using a drill bit (diameter 2.0 mm). Cordless drill/driver Fig 1: Identifying Daytime Running Lights Control Unit And Ferrite Core Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Daytime Running Lights Control Unit With Screws/Bolts On Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Connect connector (3) of daytime running lights control unit (1) to coupling (8) of front wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1275 · Applies to: 450, 451, 452, 454
harness. 6. Tighten bracket (6) with screws/bolts (9) at front module (7). 7. Align connector (4), as shown, and tighten cable tie (5). Fig 3: Locating Mounting Dome Of Front Module Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Connector Of Daytime Running Lights Control Unit And Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Shorten excess length of cable tie (5).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1276 · Applies to: 450, 451, 452, 454
RETROFITTING & CONVERSION > RETROFIT DAYTIME RUNNING LIGHTS HEADLAMP IN CBS FRONT END - AN82.10-P-0100-04MCC > Installation of the daytime running lights headlamp unit (7) is shown on the left side of the vehicle. Installation on the right side of vehicle is performed in the same manner. 1. Tighten bracket (6) with screws/bolts (5) at daytime running lights headlamp (3). 2. Position installation frame (1) at trim (2). 3. Insert daytime running lights headlamp (3) into trim (2). 4. Tighten installation frame (1) with screws/bolts (4). Fig 5: Identifying Bracket With Screws/Bolts Of Front Module, Connector And Cable Tie Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Unclip trim (8) from CBS front end (9).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1277 · Applies to: 450, 451, 452, 454 · AR: AN82.10-P-0100MCC
- Clip daytime running lights headlamp unit (7) into CBS front end (9). Ensure that catch hooks (arrows) of trim (2) are seated correctly in CBS front end (9). RETROFITTING & CONVERSION > RETROFIT DAYTIME RUNNING LIGHTS HEADLAMP - AN82.10-P-0100MCC > MODEL 451.3 /4 (except 451.391 /491) except CODE (V07) Front fog lamps (FFO) except CODE (460) Canada version Fig 1: Identifying Bracket With Screws/Bolts Of Daytime Running Lights Headlamp, Frame And Trim Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Locating Catch Hook Of Trim Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1278 · Applies to: 450, 451, 452, 454
Information on preventing damage to electronic components due to electrostatic discharge
AH54.00-P- 0001-01A 1 Disconnect battery ground line
AR54.10-P- 0003MCC Fig 1: Identifying Daytime Running Lights Headlamp Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Daytime Running Lights Headlamp Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove front CBS (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1279 · Applies to: 450, 451, 452, 454
2 Remove front CBS (2)
AR88.00-P- 1010MCC 3 Remove left front lamp unit (E1) * not for USA AR82.10-P- 4730MCC * for USA only AR82.10-P- 4730MCU 4 Adjust the left front seat to the rear
5 Unclip left tweeter from instrument panel and place to one side with electrical line connected Vehicles up to 30.8.10 with code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO) orVehicles with code (C54) Sound system 2 AR82.62-P- 1000MCC 6 Unclip SAM control unit (N10/10) in the rear area (arrow A) and fold down forwards
7 Remove screws/bolts (11) and carefully lower SAM control unit (N10/10) until electrical connectors are accessible
Install
8 Retrofit electrical wiring harness (3) for daytime running lights headlamp (1)
AN82.10-P- 0100-01MCC Wiring harness repair kit, basic 000589139900 Expanding pliers 450589123700 Puller aid *450589256300 9 Tighten SAM control unit (N10/10) with screws/bolts (11)
10 Clip in SAM control unit (N10/10) in rear area (arrow A)
11 Clip left tweeter into instrument panel Vehicles up to 30.8.10 with code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO) orVehicles with code (C54) Sound system 2 AR82.62-P- 1000MCC 12 Retrofit daytime running lights control unit (8) Cordless drill/driver AN82.10-P- 0100-02MCC 13 Retrofit daytime running lights headlamp (1) in CBS front end (2) Before installation of the daytime running lights headlamps (1), the primed installation frames (5) are to be painted according to customer AN82.10-P- 0100-04MCC
request.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1280 · Applies to: 450, 451, 452, 454
14 Install left front lamp unit (E1) * not for USA AR82.10-P- 4730MCC * for USA only AR82.10-P- 4730MCU 15 Install CBS front end (2)
AR88.00-P- 1010MCC 16 Connect ground cable to battery
AR54.10-P- 0003MCC 17 Place certification in the vehicle Only for Europe.
Use for daytime running lamps, certificate * Applies to Europe only OF82.10-P- 1000-01A Fig 3: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Expanding Pliers (450 589 12 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFITTING TRUNK LAMP WIRING HARNESS -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1281 · Applies to: 450, 451, 452, 454
AN82.20-P-0001-01MCC > 1. Route trunk illumination wiring harness (2) in vehicle. 2. Attach brown line (br) with cable lug (10) at left interior floor ground (W14). 3. Insert fuse holder (12) into free slot at SAM control unit (N10/10). Fig 5: Identifying Puller Aid (450 589 25 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The slots are coded.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1282 · Applies to: 450, 451, 452, 454
Ensure that fuse (11) is seated correctly in fuse holder (12). 4. Fix red line (rt) in place with relay (13) at vehicle wiring harness. 5. Fold down SAM control unit (N10/10) until connector 8 (8) is accessible at SAM control unit (N10/10). 6. Disconnect connector 8 (8) at SAM control unit (N10/10). Fig 3: Identifying Trunk Illumination Wiring Harness, Left Interior Floor Ground, SAM Control Unit And Fuse Holder Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Unclip white plug insert (8a) with blue/black line (bl/sw) out of connector 8 (8).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1283 · Applies to: 450, 451, 452, 454
- Unplug pin 2 (8.2) out of contact cavity 2 (arrow) of white plug insert (8a) with wiring harness repair kit, basic.
- Plug pin of adapter line (5) into contact cavity 2 (arrow) of white plug insert (8a). Fig 4: Identifying Connector 8 Of SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying White Plug Insert, Pin And Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
10. Clip white plug insert (8a) with adapter line (5) into connector 8.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1284 · Applies to: 450, 451, 452, 454
- Connect plug 8 to SAM control unit.
- Route coupling (6) with adapter line (5) below electrical lines on left side of SAM control unit (N10/10).
- Route pin 2 (8.2) with blue/black line (bl/sw) below electrical lines on left side of SAM control unit (N10/10).
- Plug in pin 2 (8.2) of blue/black line (bl/sw) in free slot (arrow) of connector (7) of blue/black line (bl/sw) of relay (13).
- Fasten pin 2 (8.2) by closing the connector (7).
- Insert coupling (6) of adapter line (5) into connector (7) of relay (13). Fig 6: Locating Contact Cavity 2 Of White Plug Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
17. Carefully route trunk illumination wiring harness (2) with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1285 · Applies to: 450, 451, 452, 454
assembly wedge below floor covering. Do not damage trunk illumination wiring harness (2) when routing by means of crushing or pinching as this may lead to a short circuit. The trunk illumination wiring harness (2) should be route corresponding to the broken line that is shown. Fig 7: Identifying Coupling With Adapter Line, SAM Control Unit, Pin And Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
18. Fix trunk illumination wiring harness (2) in place at on-board wiring harness (14) using cable tie.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1286 · Applies to: 450, 451, 452, 454
Do not damage trunk illumination wiring harness (2) when routing by means of crushing or pinching as this may lead to a short circuit. 19. Route trunk illumination wiring harness (2) upwards beneath rubber seal (16) and fix in place with adhesive tape (15). Do not damage trunk illumination wiring harness (2) when routing by means of crushing or pinching as this may lead to a short circuit. Fig 8: Identifying Trunk Illumination Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
20. Insert trunk illumination (1) into rear roof frame paneling (17).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1287 · Applies to: 450, 451, 452, 454
Ensure that the trunk illumination (1) is properly seated. 21. Insert connector (3) of trunk illumination (1) into coupling (4) of trunk illumination wiring harness (2). Ensure that connector (3) is seated correctly in coupling (4). 22. Route trunk illumination wiring harness (2) on rear roof frame paneling (17), as shown, and fix in place with adhesive tape (15). Do not damage trunk illumination wiring harness (2) when routing by means of crushing or pinching as this may lead to a short circuit. Fig 9: Identifying Trunk Illumination Wiring Harness, On-Board Wiring Harness And Rubber Seal Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > PREPARE REAR ROOF FRAME PANELING FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1288 · Applies to: 450, 451, 452, 454
INSTALLATION OF TRUNK ILLUMINATION - AN82.20-P-0001-02MCC > 1. Mark drill hole on rear roof frame paneling (1) in accordance with center line (a) and distance dimension (b). The distance dimension (b) is 20 mm. 2. Drill hole with a diameter of 26 mm in marked area (arrow) using graduated drill. Cordless drill/driver Fig 10: Trunk Illumination Wiring Harness On Rear Roof Frame Paneling Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFITTING TRUNK LAMP - AN82.20-P-0002MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1289 · Applies to: 450, 451, 452, 454 · AR: AN82.20-P-0002MCC
MODEL 451.3 (except 451.391) Fig 2: Identifying Dimension Of Hole On Rear Roof Frame Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Trunk Illumination Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1290 · Applies to: 450, 451, 452, 454
Information on preventing damage to electronic components due to electrostatic discharge
AH54.00-P- 0001-01A 1 Disconnect battery ground line
AR54.10-P- 0003MCC 2 Remove rear roof frame trim
AR68.30-P- 4470MCC 3 Remove left side paneling in trunk * not for USA AR68.30-P- 4800MCC * for USA only AR68.30-P- 4800MCU 4 Fold down SAM control unit (N10/10) until connector 8 is accessible at SAM control unit (N10/10) * not for USA AR54.21-P- 1254MCC * for USA only AR54.21-P- 1254MCU Install
5 Retrofit trunk illumination wiring harness (2) Do not damage trunk illumination wiring harness (2) when routing by means of crushing or pinching as this may lead to a short circuit. AN82.20-P- 0001-01MCC Wiring harness repair kit, basic 000589139900 Mounting wedge 110589035900 Install SAM control unit * not for USA AR54.21-P- 1254MCC Fig 2: Identifying SAM Control Unit, Left Floor Interior Compartment Ground And Trunk Illumination Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(N10/10)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1291 · Applies to: 450, 451, 452, 454
6 (N10/10) * for USA only AR54.21-P- 1254MCU 7 Install left side paneling in trunk * not for USA AR68.30-P- 4800MCC * for USA only AR68.30-P- 4800MCU 8 Prepare rear roof frame paneling for installation of trunk illumination (1) Rechargeable drill / screwdriver AN82.20-P- 0001-02MCC Graduated drill *450589002800 9 Install rear roof frame trim
AR68.30-P- 4470MCC 10 Connect ground cable to battery
AR54.10-P- 0003MCC 11 Perform function test of trunk illumination (1)
Fig 3: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT BRABUS SUBWOOFER - AN82.62-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1292 · Applies to: 450, 451, 452, 454
0004MCC > MODEL 451.3 /4 (except 451.391 /491) up to 30.8.10 with CODE (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO) Shown on vehicle with Code (I01) AC Plus Fig 5: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Subwoofer Wiring Harness, Ground And Positive Lines, Connector And Clutches Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1293 · Applies to: 450, 451, 452, 454
Fig 2: Identifying Subwoofer Components - Shown On Vehicle With Code (I01) AC Plus (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Subwoofer Components - Shown On Vehicle With Code (I01) AC Plus (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Disconnect ground line (1) from the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1294 · Applies to: 450, 451, 452, 454
1 Disconnect ground line (1) from the battery (G1)
AR54.10- P- 0003MCC 2 Remove smart radio 9 (A2/1) or smart radio 10 (A2/2) * for USA only AR82.60- P- 7502MCU * not for USA AR82.60- P- 7502MCC Install
3 Route subwoofer wiring harness (2) from installation location for subwoofer speaker (4) to radio installation slot behind the instrument panel
4 Attach wiring harness for subwoofer (2) using adhesive tape (6) to air conditioner housing (7) and with cable ties (8) to the vehicle wiring harness Adhesive tape *BR00.45- Z-1071- 02A 5 Screw subwoofer ground line (3) onto battery ground (W10)
6 Connect subwoofer positive line (5) to positive terminal of battery (G1)
7 Fit connector (11) to subwoofer speaker (4)
8 Tighten subwoofer speaker (4) using nut (13) and nut (12) If a breakdown kit is stowed in the passenger side footrest, this has to be stowed in the trunk following installation of the subwoofer speaker (4).
9 Clip tow hook (14) into holder (15)
10 Join connector (18) of radio wiring harness on vehicle side with couplings (10) of subwoofer wiring harness (2)
11 Join connector (9) of subwoofer wiring harness (2) to smart radio 9 (A2/1) or smart radio 10 (A2/2)
12 Install smart radio 9 (A2/1) or smart radio 10 (A2/2) * for USA only AR82.60- P- 7502MCU * not for USA AR82.60- P- 7502MCC 13 Connect ground line (1) to battery (G1)
AR54.10- P- 0003MCC
Perform function test on subwoofer¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1295 · Applies to: 450, 451, 452, 454
14 Perform function test on subwoofer speaker (4)
REPAIR MATERIALS Number Designation Order number BR00.45-Z-1071- 02A Adhesive tape roll, gray Tesa tape, 50 meters 0.3X50, 236 mm A 001 989 17 85 MAINTENANCE > CHECK SETTING OF HIGH BEAM - AP82.10-P-8260-02MCC > The center of the luminous beam must be the corresponding central marks (6). If this is not the case: adjust high beam. MAINTENANCE > ADJUST OR CHECK FRONT FOG LIGHTS - AP82.10-P-8260-04MCC > Shown on vehicle with code (V07) Front fog lamps (FFO) The light-dark boundary must run as horizontal as possible at the height of the corresponding division mark (4), if necessary correct with the adjustment screw (arrow). Fig 1: Identifying Central Marks Of High Beam Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MAINTENANCE > CHECK LOW BEAM - AP82.10-P-8260-05MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1296 · Applies to: 450, 451, 452, 454
The light-dark boundary must be on the horizontal division mark (4) of the device. The kink line (5) must start below the central mark (6) on the horizontal division mark (4) and rise to the right. Fig 1: Identifying Light-Dark Boundary And Division Mark Of Fog Light Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Locating Adjustment Screw - Shown On Vehicle With Code (V07) Front Fog Lamps (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Checking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1302 · Applies to: 450, 451, 452, 454
1 Check front windshield washer nozzle (2) for proper operation Clean clogged front windshield washer nozzle (2) from outside using a suitable needleIf necessary: ↓Replace front windshield washer nozzles (2) subject to separate repair order.
Remove/install windshield washer nozzle AR82.35- P- 6970MCC Check adjustment of the Fig 1: Identifying Front Wiper Blades And Windshield Washer Nozzle Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Window Windshield Washer Nozzle And Wiper Blade Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
front windshield washer¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1303 · Applies to: 450, 451, 452, 454
2 front windshield washer nozzle (2), and adjust if necessary corresponding to the diagram shown
3 Check rubber lip of front wiper blades (1) for hardening and cracks. If necessary:↓Replace front wiper blades (1). subject to separate repair order.
Replace wiper blade AR82.30- P- 6251MCC 4 Check setting of wiper arms If necessary: ↓Adjust wiper arms. subject to separate repair order.
Remove and install wiper arm AR82.30- P- 6100MCC 5 Check operation of windshield wipers
6 Check rear window windshield washer nozzle (3) for proper operation In case of model 451.3 Clean clogged rear window windshield washer nozzle (3) from outside using a suitable needle.If necessary: ↓Replace rear window windshield washer nozzles (3). subject to separate repair order.
Remove/install spray-nozzle for rear window AR82.35- P- 7338MCC 7 Check the adjustment of the rear window windshield washer nozzle (3) and adjust if necessary In case of model 451.3 The rear window windshield washer nozzle (3) cannot be aligned with a point, as it moves at the same time as the wiper arm. It must spray in the center area on the rear window in front of the rear wiper blade (4).
8 Check rear wiper blade (4) In case of model 451.3 Inspect rubber lip for hardness and splitsIf necessary: ↓Replace rear wiper blade (4). subject to separate repair order.
Replace wiper blade AR82.30- P- 6251MCC TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: ELECTRICAL SYSTEM
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1308 · Applies to: 450, 451, 452, 454
1 Unclip trim (1) of left front fog lamp (E5/1) or right front fog lamp (E5/2) in the marked areas (arrows) and remove
2 Remove bolts (2) from left front fog lamp (E5/1) or right front fog lamp (E5/2)
3 Remove left front fog lamp (E5/1) or right front fog lamp (E5/2) toward the front until the electrical connector (3) is accessible Carefully lead left front fog lamp (E5/1) or right front fog lamp (E5/2) out of front CBS, otherwise it may be scratched and therefore damaged.
4 Disconnect electrical connector (3) from left front fog lamp (E5/1) or from right front fog lamp (E5/2) and remove left front fog lamp (E5/1) or right front fog lamp (E5/2)
5 Install in the reverse order
6 Check adjustment of left front fog lamp (E5/1) or right front fog lamp (E5/2) and correct if necessary
Check and correct the adjustment of the headlamps AP82.10- P- 8260MCU Fig 1: Identifying Left Front And Right Fog Lamp, Electrical Connector, Screw And Trim Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1312 · Applies to: 450, 451, 452, 454
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 1 Allow wiper motor to run in end position and switch off ignition
2 Remove paneling (1) from center piece in front of windshield
AR88.00-P- 2792MCC 3 Remove cap on nut (3)
4 Unscrew nut (3) on wiper arm (2) BA82.30-P- 1002-01F 5 Position puller (5) on wiper arm shaft (4) 001589383300 6 Detach wiper arm (2) using puller (5) 001589383300 7 Remove puller (5) 001589383300 8 Remove wiper arm (2)
9 Install in the reverse order
WINDSHIELD WIPER Number Designation Model 451.3 Model 451.4 BA82.30-P-1002- Nut for wiper arm on Nm 20 20 Fig 1: Removing/Installing Wiper Arm Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1315 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove front module
AR62.30-P- 1575MCU 2 Disconnect electrical connector (2) from wiper motor (M6/1)
3 Remove bracket (3) with rubber grommet from wiper motor (M6/1)
4 Remove bolts (1) starting from the right and take off wiper system (4) Installation: Tighten bolts (1) starting from the left.
*BA82.30-P- 1007-01F 5 Install in the reverse order
6 Perform function test of wiper system (4) with wiper motor (M6/1)
WINDSHIELD WIPER Number Designation Model 451.3 Model 451.4 BA82.30-P-1007- 01F Bolt, wiper linkage to body Nm 10 10 TESTING & REPAIR > REMOVE/INSTALL REAR WINDOW WIPER MOTOR - AR82.30-P- Fig 1: Identifying Wiper System, Motor, Bracket, Electrical Connector And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1317 · Applies to: 450, 451, 452, 454
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 1 Allow tailgate wiper motor to startup and switch off when in end position
2 Fold up cap (2)
3 Loosen nut (5)
4 Place suitable nut (4) onto wiper arm shaft and position puller (1) The puller (1) must be supported by the nut (4) when the wiper arm (3) is removed, as otherwise the wiper arm shaft will be damaged.
001589383300 5 Detach wiper arm (3) using puller (1) 001589383300 6 Remove puller (1) *001589383300 7 Remove nut (4), unscrew nut (5), and take off wiper arm (3)
8 Install in the reverse order
Fig 1: Removing/Installing Tailgate Wiper Arm Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
routing (2) out of the¶
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cover (1) 3 Disconnect electrical connector (4)
4 Unclip retaining clip (5) for rain sensor/light sensor (B38) at retaining collar (3) (arrows)
5 Remove rain sensor/light sensor (B38) from the retaining collar (3) The rain sensor/light sensor (B38) must always be replaced after removing from the windshield.
Install
6.1 Remove protective cap from retaining collar (3) When replacing the windshield. With the new windshield, the contact surface of the rain sensor/light sensor (B38) is protected from soiling by means of a protective cap. The protective cap is clipped into the retaining collar (3).
6.2 Clean contact surface of rain sensor/light sensor (B38) on windshield Only if the windshield was not protected from dirt by a protective cap. The contact surface must be clean and free of grease.
7 Carefully pull off protective foil from new rain sensor/light sensor (B38) If the silicone pad on the optics of the rain sensor/light sensor (B38) is damaged or dirty, this must be replaced.
8 Insert rain sensor/light sensor (B38) into the retaining collar (3) The contact surfaces of the rain sensor/ light sensor (B38) must not be damaged or dirty, as this will result in the rain sensor/light sensor (B38) being unusable.
9 Clip in retaining clip (5) for rain sensor/light sensor (B38) at retaining collar (3) (arrows)
10 Insert cable routing (2) into cover (1)
11 Connect electrical connector (4)
12 Clip cover (1) into retaining collar (3) Carefully clip in cover (1) to prevent the retaining clips from breaking.
13 Install inside rearview mirror * for USA only AR68.40- P- 0001MCU AR68.40-
Adjust¶
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Risk of injury caused by moving parts that can pinch, crush or , in extreme cases, even sever extremities. Keep all body parts and limbs away from moving mechanical components. AS00.00- Z-0009- 01A 1 Move front wiper arms (5) from the parked position To do this, turn on ignition (circuit 15 or circuit 15R) and turn wiper switch to position "2". When the front wiper arms (5) are close to the reversing position, switch off ignition and turn wiper switch back to position "0".
2 Disconnect electrical connector (1) from wiper motor (M6/1)
3 Adjust windshield washer nozzle for windshield (2) according to the shown diagram
4 Adjust windshield washer nozzle for rear window (3) in case of MODEL 451.3 To prevent scratching the rear window, do not allow rear wiper blade (4) to run dry. The windshield washer nozzle for rear window (3) cannot be aligned to certain points since it moves along with the wiper arm. It should spray onto the rear window in the center area in front of the rear wiper blade (4).
Fig 3: Identifying Windshield Washer Nozzle For Rear Window (Model 451.3) And Rear Wiper Blade Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
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1 Remove left front headlamp unit * not for USA AR82.10-P- 4730MCC * for USA only AR82.10-P- 4730MCU 2 Remove radio With code (C50) smart radio 10 or Code (C57) smart radio 9 or Code (516) RADIO WITH USB INTERFACE or code (527) High-Line radio
- not for USA AR82.60-P- 7502MCC
- for USA only AR82.60-P- 7502MCU 3 Remove antenna cable (1) from antenna base (2)
4.1 Remove antenna cable (1) from body in area of upper door hinge Without code (460) Canada version, without code (494) USA version or without code (498) Japan version
4.2 Detach antenna amplifier (3) from body With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version
Fig 2: Identifying Antenna Cable Remove/Install Components - Shown On Vehicle With Code (494) USA Version Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove adhesive tape (4)¶
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5 Remove adhesive tape (4) from protective tube (5) and push protective tube (5) back until main wiring harness is exposed
6 Expose antenna cable (1) at main wiring harness and cut off (arrow A) Cut off antenna cable (1) directly at the pushed back protective tube (5).
7 Expose antenna amplifier supply line (6) at main wiring harness and cut off (arrow A) With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version Cut off antenna amplifier supply line (6) approx. 5 cm before the pushed back protective tube (5).
8 Make cable hole at grommet (8) Cut off pin (7).
9 Cut off antenna cable (1) in radio recess (arrow B)
Install
10 Remove adhesive tape (9) from new antenna cable (1)
11.1 Clip antenna cable (1) into body in area of upper door hinge Without code (460) Canada version,without code (494) USA version orwithout code (498) Japan version
11.2 Clip antenna amplifier (3) into body With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version
12 Screw antenna cable (1) onto antenna base (2) by hand
13 Route antenna cable (1) along main wiring harness and guide through grommet (8) into interior Expanding pliers *450589123700 14 Route new antenna amplifier supply line (6.1) along antenna cable (1) to antenna amplifier supply line (6) at main wiring harness
15 Cut new antenna amplifier supply line (6.1) to length and connect to antenna amplifier supply line (6) using solder connector (10) With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version Use solder connector (10) with Ø 2.4 mm. AR00.19-P- 0100A 16 Push protective tube (5) forward and fix in place
Shown on vehicle with code (494) USA version¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1333 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Antenna Cable Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1334 · Applies to: 450, 451, 452, 454
1 Remove left front headlamp unit * not for USA AR82.10-P- 4730MCC * for USA only AR82.10-P- 4730MCU 2 Remove radio With code (C50) smart radio 10 orCode (C57) smart radio 9 orCode (516) RADIO WITH USB INTERFACE or code (527) High-Line radio
- not for USA AR82.60-P- 7502MCC
- for USA only AR82.60-P- 7502MCU 3 Remove antenna cable (1) from antenna base (2)
4.1 Remove antenna cable (1) from body in area of upper door hinge Without code (460) Canada version, without code (494) USA version or without code (498) Japan version
4.2 Detach antenna amplifier (3) from body With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version
Remove adhesive tape (4) Fig 2: Identifying Antenna Cable Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
from protective tube (5)¶
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5 from protective tube (5) and push protective tube (5) back until main wiring harness is exposed
6 Expo e antenna cable (1) at main wiring harness and cut off (arrow A) Cut off antenna cable (1) directly at the pushed back protective tube (5).
7 Expose antenna amplifier supply line (6) at main wiring harness and cut off (arrow A) With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version Cut off antenna amplifier supply line (6) approx. 5 cm before the pushed back protective tube (5).
8 Make cable hole at grommet (8) Cut off pin (7).
9 Cut off antenna cable (1) in radio recess (arrow B)
Install
10 Remove adhesive tape (9) from new antenna cable (1)
11.1 Clip antenna cable (1) into body in area of upper door hinge Without code (460) Canada version,without code (494) USA version orwithout code (498) Japan version
11.2 Clip antenna amplifier (3) into body With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version
12 Screw antenna cable (1) onto antenna base (2) by hand
13 Route antenna cable (1) along main wiring harness and guide through grommet (8) into interior Expanding pliers *450589123700 14 Route new antenna amplifier supply line (6.1) along antenna cable (1) to antenna amplifier supply line (6) at main wiring harness
15 Cut new antenna amplifier supply line (6.1) to length and connect to antenna amplifier upply line (6) using solder connector (10) With code (460) Canada versionWith code (494) USA version orWith code (498) Japan version Use solder connector (10) with Ø 2.4 mm. AR00.19-P- 0100A 16 Push protective tube (5) forward and fix in place using suitable insulation
Remove/install¶
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1 Remove antenna rod (3)
2 Open left door, press edge guard (5) to one side in area of fender cover (1) and remove expansion clip (4)
3 Push fender cover (1) slightly upwards and remove
4 Remove bolts (7, 8) Installation: Check whether guide sleeve of bolt (8) is properly seated. 5 Remove bolt (9) from antenna base (2)
6 Slightly press CBS front (6) to one side and carefully take antenna base (2) up and out until the antenna cable (11) is accessible Pay attention to routing of antenna cable (11). 7 Unscrew union nut (10) of antenna cable (11) and remove antenna base (2) Installation: Screw on union nut (10) finger-tight and continue turning a quarter turn using suitable pliers. 8 Install in the reverse order
Fig 1: Identifying Antenna Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Injury hazard from pinching and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1341 · Applies to: 450, 451, 452, 454
crushing, in extreme cases extremities can even be cut off when caught in windshield wiper mechanism. MODEL all AS82.30-Z-0001-01A Risk of death caused by high voltage at xenon headlamps. Risk of explosion/risk of fire caused by highly flammable materials in the vicinity of damaged xenon bulbs. Risk of injury caused by UV light, hot components at xenon headlamps and glass splinters produced by bursting xenon bulbs. Risk of poisoning caused by inhalation of mercury vapors and by toxic salts and mercury compounds being ingested or coming into contact with skin MODEL all... AS82.10-Z-0001-01A Risk of fire and explosion caused by ignition of window washing fluid or antifreeze and their vapors. Risk of poisoning caused by swallowing window washing fluid or antifreeze or inhaling their vapors. Risk of injury or physical irritations caused by contact of window washing fluid or antifreeze with eyes, mucous membranes or skin. MODEL all AS82.35-Z-0001-01A The demagnetizing coil presents a lethal hazard for persons with active electronic implants (e.g. heart pacemakers). MODEL 140 with CODE (350a) Communikations- Navigations-System (CNS) with CODE (498) Japan-Ausfuhrung AS82.85-Z-0001-01A SAFETY PRECAUTIONS > INJURY HAZARD FROM PINCHING AND CRUSHING, IN EXTREME CASES EXTREMITIES CAN EVEN BE CUT OFF WHEN CAUGHT IN WINDSHIELD WIPER MECHANISM. - AS82.30-Z-0001-01A > Always remove ignition key before working on windshield wiper mechanism. Injury hazard When working in the area of the windshield wiper mechanism with the ignition key in position "1" or "2" the wiper arm or wiper linkage can be pushed out of its end position and start running unintentionally . This can result in severe injuries by cutting, pinching or crushing body parts. Rules of behavior/protective measures
Always remove ignition key before working on windshield wiper mechanism.¶
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Secure operating range of mechanism against reaching in. Keep sufficient distance away from moving parts. Supervise hazard area. Wear tight fitting clothing and hair net. SAFETY PRECAUTIONS > RISK OF FIRE AND EXPLOSION CAUSED BY IGNITION OF WINDOW WASHING FLUID OR ANTIFREEZE AND THEIR VAPORS. RISK OF POISONING CAUSED BY SWALLOWING WINDOW WASHING FLUID OR ANTIFREEZE OR INHALING THEIR VAPORS. RISK OF INJURY OR PHYSICAL IRRITATIONS CAUSED BY CONTACT OF WINDOW WASHING FLUID OR ANTIFREEZE WITH EYES, MUCOUS MEMBRANES OR SKIN. - AS82.35-Z-0001-01A > Wear protective clothing and tight fitting safety glasses. No fire, open light or ignition sources. Avoid contact with eyes, mucous membranes and skin. When working with window washing fluids or antifreeze, do not eat, drink, or smoke. Do not inhale vapors and ensure sufficient ventilation in the working area. Store window washing fluid and antifreeze leakfree in safely closed original containers and out of childrens' reach only. Potential risks Risk of fire and explosion Window washing fluids and antifreeze are highly flammable. Vapors in contact with air can ignite and spontaneously combust in an explosion. Risk of poisoning Window washing fluids and antifreeze are a health hazard and can cause dizziness, nausea and symptoms of poisoning when swallowed. Window washing fluid vapors and antifreeze vapors are a health hazard and can cause dizziness, nausea and symptoms of poisoning when inhaled. Risk of injury Window washing fluids and antifreeze cause physical irritations when coming in contact with eyes, mucous membranes or skin. Safety precautions and rules of conduct Observe manufacturer's operating instructions and safety notes. Wear protective clothing and tight fitting safety glasses. No fire, open light or ignition sources. Avoid contact with eyes, mucous membranes and skin. When working with window washing fluids or antifreeze, do not eat, drink, or smoke. Do not inhale vapors of window washing fluid or antifreeze, and ensure sufficient ventilation in the working area.
Store window washing fluid and antifreeze leakfree in safely closed original containers and out of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1343 · Applies to: 450, 451, 452, 454 · AR: AZ82.10-P-0003MCC
childrens' reach only. First aid measures Burns Treat burns with plenty of cold water and cover with sterile dressings. Consult a physician. Eye contact Rinse eye immediately for several minutes, preferably with lukewarm water while keeping the eyelid open. Consult an eye doctor. Skin contact Immediately remove any wetted clothing. Wash off window washing fluid splashed onto skin thoroughly with plenty of soap and water. Swallowing Do not induce vomiting. Give plenty of water to drink in small amounts at a time. Keep the person warm and comfortable at a quiet place. Consult a physician. Inhalation of vapors Take the affected person out into the fresh air. If the situation may result in the person becoming unconscious, the patient must be at rest and transported in recovery position. If necessary, apply artificial respiration to affected person and ensure adequate supply of oxygen, warmth and quietness. Consult a physician. RETROFITTING & CONVERSION > RETROFIT CENTER HIGH-MOUNTED STOP LAMP - AZ82.10-P-0003MCC > MODEL 451.3 /4 Remove
1 Remove center high- mounted brake lamp
AR82.10- P- Fig 1: Identifying Center High-Mounted Stop Lamp, Electrical Connector And Foam Grommet Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(E21)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1344 · Applies to: 450, 451, 452, 454 · AR: AZ82.10-P-0010MCC
5375MCC Install
2 Install new center high- mounted brake lamp (E21) Installation: Slide foam grommet (2) over the electrical connector (1) of the center high-mounted brake lamp (E21). AR82.10- P- 5375MCC 3 Perform function test of center high-mounted brake lamp (E21)
RETROFITTING & CONVERSION > RETROFIT FRONT FOG LAMP - AZ82.10-P-0010MCC > MODEL 451.3 /4 Fig 1: Identifying SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Locating Wiring Harness For Front Fog Lamps¶
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Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Left And Right Fog Lamps Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Cockpit Switch Group Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
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4.11.10 Note on part numbers changed Operation step 2 Check
1 Unclip covers (1) and check whether the wiring harness for front fog lamps (2) is installed The left front fog lamp (E5/1) and right front fog lamp (E5/2) can only be retrofitted when the required wiring harness for front fog lamps (2) is already installed.
2 Using part number (arrow) of SAM control unit (N10/10), check whether this is suitable for front fog lamp retrofitting With one of the following part numbers A 451 540 12 50, A 451 540 19 50, A 451 900 78 00, A 451 906 10 00 retrofitting the front fog lamp is not possible.In this case, SAM control unit (N10/10) must be replaced.See: ↓Remove/install front SAM control unit (N10/10)
- For USA only AR54.21- P- 1254MCU
- Not for USA AR54.21- P- 1254MCC Remove
3 Detach wiring harness for front fog lamps (2) from brackets (arrows)
4 Remove cockpit switch group (S6/1)
AR54.25- P- 1000MCC Install
5 Install left fog lamp (E5/1) and right fog lamp (E5/2) The covers (1) are to be replaced with new front fog lamp covers with code (V07) Front fog lamp (FFO).
- For USA only AR82.10- P- 5103MCU
- Not for USA AR82.10- P- 5103MCC 6 Install new cockpit switch group (S6/1) with integrated front fog The new cockpit switch group (S6/1) must also be provided with code (V07) Front fog AR54.25- P-
lamp switch¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1347 · Applies to: 450, 451, 452, 454
lamp (FFO). 1000MCC 7 Perform function test on left front fog lamp (E5/1) and right front fog lamp (E5/2)
8 Adjust left fog lamp (E5/1) and right fog lamp (E5/2) * For USA only AP82.10- P- 8260MCU * Not for USA AP82.10- P- 8260MCC 9 Add special equipment to the vehicle data card and to the online vehicle data card Add code (V07) Front fog lamp (FFO).
PARTS ORDERING NOTES Part no. Designation Quantity DG 82 (see EPC) Upper control panel switch 1 DG 82 (see EPC) Left front fog lamp 1 DG 82 (see EPC) Right fog lamp 1 DG 88 (see EPC) Left front fog lamp cover 1 DG 88 (see EPC) Right front fog lamp cover 1 RETROFITTING & CONVERSION > RETROFIT AMBIANCE ILLUMINATION WIRING HARNESS - AZ82.20-P-0010-01MCC > Connection diagram Fig 1: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The dashed brown/gray line (br/gr), yellow/black line (ge/sw) and yellow/white line (ge/ws) show the original¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1348 · Applies to: 450, 451, 452, 454
installation of lines in the vehicle; the continuous lines show the retrofit. The black continuous lines show the adapter lines. Routing diagram Fig 2: Ambiance Illumination Wiring Harness - Connection Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Route inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1349 · Applies to: 450, 451, 452, 454
harness (16) from SAM control unit (N10/10), as shown, along vehicle wiring harness behind instrument panel (17) to top of A-pillar. Only route the 1700 mm long branch-off line of the inside rearview mirror ambiance illumination to the top of the A-pillar. The three black 2-pin couplings and the fuse carrier with fuse of the ambiance illumination wiring harness (16) must be located in the area of the SAM control unit (N10/10). They will be connected to the SAM control unit (N10/10) at a later point. Fig 3: Ambiance Illumination Wiring Harness - Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Inside Rearview Mirror Ambiance Illumination Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Route inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring¶
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harness (16), as shown, along vehicle wiring harness to installation location of inside rearview mirror (4). 3. Fix inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring harness (16) in place using cable tie (18) at vehicle wiring harness. 4. Slide inside rearview mirror (4) onto bracket on windshield. 5. Connect black 2-pin connector (21) of inside rearview mirror ambiance illumination wiring harness (22) to black 2-pin coupling (20) of ambiance illumination wiring harness (16). 6. Form a loop with excess length of inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring harness (16) and fix in place using cable tie (19). 7. Route footwell branch-off line of ambiance illumination wiring harness (16), as shown, along vehicle wiring harness behind instrument panel and fix in place using cable tie. Do not tighten cable tie yet. The black 2-pin couplings at the footwell branch-off line of ambiance illumination wiring harness (16) must be positioned centrally in the driver and front passenger footwell. Fig 5: Identifying Ambiance Illumination Wiring Harness, Black 2-Pin Connector And Inside Rearview Mirror Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Release coupling "N11-5" and disconnect at SAM control unit (N10/10).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1351 · Applies to: 450, 451, 452, 454
Coupling "N11-5" is located in the marked slot (arrow). Fig 6: Footwell Branch-Off Line Of Ambiance Illumination Wiring Harness Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. Unplug pin (5.8) of brown/gray line (br/gr) from slot 8 of coupling "N11-5" (5).¶
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- Plug pin of brown/gray line (br/gr) of adapter line into slot 8 of coupling "N11-5" (5). Fig 7: Locating Marked Slot Of Coupling "N11-5" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Plug brown/gray line (br/gr) unplugged from slot 8 of coupling "N11-5" (5) into slot 1 of black 2-pin¶
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coupling (6). 12. Connect black 2-pin coupling (6) to black 2-pin connector (7) of adapter line. 13. Connect coupling "N11-5" (5) at control unit (N10/10). Fig 8: Identifying Pin Of Brown/Gray Line And Coupling N11-5 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
14. Connect black 2-pin connector (9) of gray/blue line (gr/bl) of adapter line to black 2-pin coupling¶
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(10) of gray/blue line (gr/ bl) of ambiance illumination wiring harness (16). 15. Release coupling "N11-8" and disconnect at SAM control unit (N10/10). Coupling "N11-8" is located in the marked slot (arrow A). Fig 9: Identifying Black 2-Pin Coupling, Connector And Blue/Gray Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 10: Identifying Black 2-Pin Coupling Of Ambiance Illumination Wiring Harness And 2-Pin Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
16. Remove white insert (8a) from coupling "N11-8" (8).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1355 · Applies to: 450, 451, 452, 454
- Unplug pin (8.4) of yellow/white line (ge/ws) from slot 4 of white insert (8a).
- Plug pin of yellow/white adapter line (ge/ws) into slot 4 of white insert (8a). Fig 11: Locating Marked Slot Of Coupling "N11-8" Courtesy of MERCEDES BENZ OF NORTH AMERICA Fig 12: Identifying White Insert Of Coupling N11-8 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
19. Plug yellow/white line (ge/ws) unplugged from slot 4 of white insert (8a) into slot 4 of black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1356 · Applies to: 450, 451, 452, 454
coupling (12) of yellow/white line (ge/ws) of ambiance illumination wiring harness (16). 20. Connect black 2-pin coupling (12) of ambiance illumination wiring harness (16) to black 2-pin connector (11) of yellow/white adapter line (ge/ws). 21. Unplug pin (8.19) of yellow/black line (ge/sw) from slot 19 of white insert (8a). 22. Plug pin of yellow/black adapter line (ge/sw) into slot 19 of white insert (8a). Fig 13: Identifying Pin Of Yellow/White Line And White Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
23. Plug yellow/black line (ge/sw) unplugged from slot 19 of white insert (8a) into slot 19 of black 2-pin¶
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coupling (14) of yellow/black line (ge/sw) of ambiance illumination wiring harness (16). 24. Connect black 2-pin coupling (14) of ambiance illumination wiring harness (16) to black 2-pin connector (13) of yellow/black adapter line (ge/sw). 25. Install white insert (8a) in coupling "N11-5" (8). 26. Connect coupling "N11-5" (8) at SAM control unit. 27. Insert fuse carrier with fuse (15) at SAM control unit (N10/10). The slot and the fuse carrier with fuse (15) are coded. The fuse has a fuse rating of 10 A. Fig 14: Identifying Pin Of Yellow/White Line, White Insert And 2-Pin Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 15: Identifying White Insert Of Coupling N11-8 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
28. Screw on brown line (br) of ambiance illumination wiring harness to left interior floor ground (W14).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1358 · Applies to: 450, 451, 452, 454
- Clip SAM control unit (N10/10) into rear area (arrow B) and screw on using screws/bolts (23). RETROFITTING & CONVERSION > RETROFIT AMBIANCE ILLUMINATION WIRING HARNESS - AZ82.20-P-0010-01MCD > Fig 16: Identifying SAM Control Unit And Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connection diagram¶
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Fig 2: Identifying Hot-Air Gun (450 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Wiring Harness Repair Kit (452 589 02 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The dashed yellow/black line (ge/sw) and yellow/white line (ge/ws) show the original installation of lines in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1360 · Applies to: 450, 451, 452, 454
the vehicle; the continuous lines show the retrofit. The black continuous lines show the adapter lines. Routing diagram Fig 4: Ambiance Illumination Wiring Harness - Connection Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Route inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1361 · Applies to: 450, 451, 452, 454
harness (16) from SAM control unit (N10/10), as shown, along vehicle wiring harness behind instrument panel (17) to top of A-pillar. Only route the 1700 mm long branch-off line of the inside rearview mirror ambiance illumination to the top of the A-pillar. The three black 2-pin couplings and the fuse carrier with fuse of the ambiance illumination wiring harness (16) must be located in the area of the SAM control unit (N10/10). They will be connected to the SAM control unit (N10/10) at a later point. Fig 5: Ambiance Illumination Wiring Harness - Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Inside Rearview Mirror Ambiance Illumination Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Route inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1362 · Applies to: 450, 451, 452, 454
harness (16), as shown, along vehicle wiring harness to installation location of inside rearview mirror (4). 3. Fix inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring harness (16) in place using cable tie (18) at vehicle wiring harness. 4. Slide inside rearview mirror (4) onto bracket on windshield. 5. Connect black 2-pin connector (21) of inside rearview mirror ambiance illumination wiring harness (22) to black 2-pin coupling (20) of ambiance illumination wiring harness (16). 6. Form a loop with excess length of inside rearview mirror ambiance illumination branch-off line of ambiance illumination wiring harness (16) and fix in place using cable tie (19). 7. Route footwell branch-off line of ambiance illumination wiring harness (16), as shown, along vehicle wiring harness behind instrument panel and fix in place using cable tie. Do not tighten cable tie yet. The black 2-pin couplings at the footwell branch-off line of ambiance illumination wiring harness (16) must be positioned centrally in the driver and front passenger footwell. Fig 7: Identifying Ambiance Illumination Wiring Harness, Black 2-Pin Connector And Inside Rearview Mirror Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Operation steps 8 and 9 on vehicles with BRABUS twin headlamps.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1363 · Applies to: 450, 451, 452, 454
- Connect individual black 2-pin coupling (24) to free gray/blue line (gr/bl) of BRABUS twin headlamp wiring harness (25).
- Connect black 2-pin coupling (24) of gray/blue line (gr/bl) of BRABUS twin headlamp wiring harness (25) to black 2-pin connector (10) of gray/blue line (gr/bl) of ambiance illumination wiring harness (16). Fig 8: Identifying Ambiance Illumination Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 9: Identifying 2-Pin Coupling, Connector And Gray/Blue Line Of Ambiance Illumination Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Operation steps 10 to 13 on vehicles with daytime running light headlamps.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1364 · Applies to: 450, 451, 452, 454
- Cut off black 2-pin connector (10) of gray/blue line (gr/bl) of ambiance illumination wiring harness (16).
- Slide heat-shrinkable tube over gray/blue line (gr/bl) of ambiance illumination wiring harness (16).
- Crimp together gray/blue line (gr/bl) of ambiance illumination wiring harness (16) and gray/blue line (gr/bl) of daytime running light headlamp wiring harness. The daytime running light headlamp wiring harness is connected to the gray/blue line (gr/bl) of the adapter line in exactly the same manner as the BRABUS twin headlamp wiring harness (25). But because the branch-off line for connection of the black 2-pin coupling (24) is missing, the gray/blue line (gr/bl) of the ambiance illumination wiring harness (16) must be connected by means of a crimped connection to the gray/blue line (gr/bl) of the daytime running light headlamp wiring harness.
- Protect crimped connection with heat-shrinkable tube.
- Release coupling "N11-8" and disconnect at SAM control unit (N10/10). Coupling "N11-8" is located in the marked slot (arrow A).
- Remove white insert (8a) from coupling "N11-8" (8). Fig 10: Locating Marked Slot Of Coupling "N11-8" Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
16. Unplug pin (8.4) of yellow/white line (ge/ws) from slot 4 of white insert (8a).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1365 · Applies to: 450, 451, 452, 454
- Plug pin of yellow/white adapter line (ge/ws) into slot 4 of white insert (8a).
- Plug yellow/white line (ge/ws) unplugged from slot 4 of white insert (8a) into slot 4 of black 2-pin coupling (12) of yellow/white line (ge/ws) of ambiance illumination wiring harness (16).
- Connect black 2-pin coupling (12) of ambiance illumination wiring harness (16) to black 2-pin connector (11) of yellow/white adapter line (ge/ws).
- Unplug pin (8.19) of yellow/black line (ge/sw) from slot 19 of white insert (8a).
- Plug pin of yellow/black adapter line (ge/sw) into slot 19 of white insert (8a). Fig 11: Identifying White Insert Of Coupling N11-8 Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 12: Identifying Pin Of Yellow/White Line And White Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
22. Plug yellow/black line (ge/sw) unplugged from slot 19 of white insert (8a) into slot 19 of black 2-pin¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1366 · Applies to: 450, 451, 452, 454
coupling (14) of yellow/black line (ge/sw) of ambiance illumination wiring harness (16). 23. Connect black 2-pin coupling (14) of ambiance illumination wiring harness (16) to black 2-pin connector (13) of yellow/black adapter line (ge/sw). 24. Install white insert (8a) in coupling "N11-8" (8). 25. Connect coupling "N11-8" (8) at SAM control unit. 26. Insert fuse carrier with fuse (15) at SAM control unit (N10/10). The slot and the fuse carrier (15) are coded. The fuse has a fuse rating of 10 A. Fig 13: Identifying Pin Of Yellow/White Line, White Insert And 2-Pin Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 14: Identifying White Insert Of Coupling N11-8 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
27. Screw on brown line (br) of ambiance illumination wiring harness to left interior floor ground (W14).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1367 · Applies to: 450, 451, 452, 454
- Clip SAM control unit (N10/10) into rear area (arrow B) and screw on using screws/bolts (23). RETROFITTING & CONVERSION > RETROFIT AMBIANCE ILLUMINATION IN FOOTWELL - AZ82.20-P-0010-02MCC >
- Clip lamps (2, 3) into driver footwell lighting strip (4).
- Clip lamps (2, 3) into front passenger footwell lighting strip (1). Fig 15: Identifying SAM Control Unit And Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Remove bolt (5) from vertical strut paneling (9)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1368 · Applies to: 450, 451, 452, 454
- Carefully push down vertical strut paneling (9) and position driver footwell lighting strip (4) behind vertical strut paneling (9). Fig 1: Identifying Lamps Of Driver Footwell Lighting Strip Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Bolt Of Vertical Strut Paneling And Driver Footwell Lighting Strip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Screw driver footwell lighting strip (4) in position using bolts (7).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1369 · Applies to: 450, 451, 452, 454
- Position front passenger footwell lighting strip (1) at lower section of instrument panel and tighten using screws/bolts (7).
- Create all four electrical connections (8) between the ambiance illumination main wiring harness (6) and the lamps (2, 3). The connectors and couplings of the electrical connectors (8) are coded.
- Tighten bolt (5) of vertical strut paneling (9).
- Fasten main ambiance illumination wiring harness (6) in place at driver footwell lighting strip (4) and front passenger footwell lighting strip (1) using cable ties. RETROFITTING & CONVERSION > RETROFIT AMBIANCE ILLUMINATION IN INSIDE REARVIEW MIRROR - AZ82.20-P-0010-03MCC > Fig 1: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Drill hole in marked area (arrow) at inside rearview mirror (1) with a diameter of 4.5 mm.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1370 · Applies to: 450, 451, 452, 454
Hand drill 2. Lead wiring harness (2) through hole and clip bracket with ambiance illumination (3) into inside rearview mirror (1). 3. Plug pin of brown wire (2.1) into slot 1 and pin of gray/blue line (2.2) into slot 2 of connector (4). The slots in the connector (4) are marked. 4. Install inside rearview mirror (1). 5. Create electrical connections (5) between wiring harness (2) and main ambiance illumination wiring harness (6). Fig 2: Identifying Inside Rearview Mirror, Wiring Harness And Ambiance Illumination Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT AMBIANCE ILLUMINATION - AZ82.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1371 · Applies to: 450, 451, 452, 454
0010MCC > MODEL 451.3 /4 up to 30.8.10 Fig 3: Identifying Inside Rearview Mirror, Electrical Connections And Main Ambiance Illumination Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Inside Rearview Mirror/Footwell Ambiance And Entrance Illuminations Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT IPOD INTERFACE WIRING HARNESS -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1374 · Applies to: 450, 451, 452, 454
AZ82.60-P-0001-01MCC > Connection scheme Fig 3: Identifying Hot-Air Gun (450 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Wiring Harness Repair Kit (452 589 02 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Drill hole with diameter of 9 mm, as shown, at instrument panel (arrow).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1375 · Applies to: 450, 451, 452, 454
Cordless drill/driver Ensure that the components behind this are not damaged as otherwise these must be replaced. Fig 1: iPod Interface Wiring Harness - Connection Scheme Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Locating Hole On Instrument Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Lead electrical wiring harness for iPod adapter (4) through the hole (arrow) and route in the front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1376 · Applies to: 450, 451, 452, 454
passenger footwell as shown. 3. Fix electrical wiring harness for iPod adapter (4) in area of instrument panel and in area of front passenger footwell with cable ties and felt tape. 4. Wrap iPod adapter (A34/8) with felt tape included in the installation kit. Ensure that all connections to iPod adapter (A34/8) remain accessible. 5. Detach Bluetooth module (A34/7) at crossmember below instrument panel and place in front passenger footwell with connected electrical lines. 6. Connect electrical wiring harness for iPod adapter (4) to iPod adapter (A34/8) as shown. Fig 3: Fixing Electrical Wiring Harness Of iPod Adapter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Unplug electrical wiring harness for display (5) at Bluetooth module (A34/7) and connect to iPod¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1377 · Applies to: 450, 451, 452, 454
adapter (A34/8) as shown. Electrical wiring harness for Bluetooth microphone (1) and electrical wiring harness for Bluetooth module (6) remain at Bluetooth module (A34/7) and are not plugged in somewhere else. 8. Connect electrical lines (2, 3) to Bluetooth module (A34/7) and iPod adapter (A34/8) as shown. The slot next to the electrical wiring harness for Bluetooth microphone (1) is to be used for the electrical line (3). 9. Fasten iPod adapter (A34/8) together with previously removed Bluetooth module in front passenger footwell at crossmember below instrument panel with cable ties as shown. Ensure that the connected electrical wiring harnesses are not damaged by chafing, pinching or crushing as otherwise these must be replaced. Fig 4: Identifying iPod Adapter, Bluetooth Module And Electrical Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT RADIO - AZ82.60-P-0003MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1378 · Applies to: 450, 451, 452, 454 · AR: AZ82.60-P-0003MCC
MODEL 451.3 /4 up to 30.8.10 with CODE (C08) Radio preinstallation incl. rod antenna (FFO) Fig 5: Identifying iPod Adapter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Parts scope for smart Entry radio (A2/3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1380 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Center Console And Radio Recess Cover, Smart Entry Radio Wiring Harness And Cable Tie Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Operating Instructions, Center Stowage Compartment, Console Cover And Smart Entry Radio 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. 1381 · Applies to: 450, 451, 452, 454
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
Insert wiring harness (8) with the external connector connecting point (X115) and the external audio 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 Entry radio (A2/3).If a glove box (10) is also to be installed in
Fig 3: Identifying External USB Connector Connecting Point, Glove Compartment And Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
source connecting point¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1382 · Applies to: 450, 451, 452, 454 · AR: AZ82.60-P-0003MCD
5 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) 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
DG 82 (see EPC) Wiring harness with external USB connector connecting point 1
and external audio source connecting point¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1383 · Applies to: 450, 451, 452, 454 · AR: AZ82.60-P-0014MCC
DG 68 (see EPC) Passenger-side instrument panel lower section (note equipment variants) 1
Also for retrofitting glove box
DG 68 (see EPC) Glove compartment 1 RETROFITTING & CONVERSION > RETROFIT IPOD INTERFACE - AZ82.60-P-0014MCC > MODEL 451.3 /4 up to 30.8.10 with CODE (C50) smart radio 10 Telephone system/Bluetooth hands- free system with display retrofitted MODEL 451.3 /4 up to 30.8.10 with CODE (C57) smart radio 9 Telephone system/Bluetooth hands- free system with display retrofitted MODEL 451.3 /4 as of 31.8.10 with CODE (516) RADIO WITH USB INTERFACE Telephone system/Bluetooth hands-free system with display retrofitted Package contents of iPod kit Fig 1: Identifying iPod Adapter, Wiring Harness And Electrical Lines Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Checking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1384 · Applies to: 450, 451, 452, 454
1 Check whether Bluetooth handsfree system is installed
Install
2 Move front passenger seat toward rear
3 Retrofit electrical wiring harness for iPod adapter (4), iPod adapter (A34/8) and electrical lines (2, 3) Rechargeable drill / screwdriver AZ82.60-P-0001- 01MCC 4 Reset front passenger seat to original position
5 Perform function test of iPod
PARTS ORDERING NOTES Part no. Designation Quantity DG 98 (see EPC) Installation kit/iPod 1 RETROFITTING & CONVERSION > RETROFIT COMMUNICATION CONTROL UNIT - AZ82.60-P-0021-02MCC > Fig 2: iPod Kit Connection Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Move right seat toward rear.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1385 · Applies to: 450, 451, 452, 454
- Insert communication control unit (N4) into lower area (arrow) on the crossmember under the instrument panel (2).
- Route connector (1) from crossmember beneath dashboard (2) into radio recess.
- Plug connector (1) of communication control unit (N4) into top left slot on the smart radio 9 (A2/1) or on the smart radio 10 (A2/2). The slots are coded and cannot be interchanged.
- Attach connectors (4) and antenna plug (3) to smart radio 9 (A2/1) or smart radio 10 (A2/2) and insert smart radio 9 (A2/1) or smart radio 10 (A2/2) into radio recess. The slots for the connectors (4) are coded and cannot be interchanged.
- Move right seat back to its default position. RETROFITTING & CONVERSION > CONNECT AUDIO COMPONENTS ONTO THE COMMUNICATION CONTROL UNIT - AZ82.60-P-0021-03MCC >
- Move right seat toward rear.
- Attach connector (1) of retrofitted audio component to the communication control unit (N4).
- Connect external audio source separation point to slot (arrow A).
- Connect handsfree system to slot (arrow B).
- Connect PND (personal navigation device) holder to slot (arrow C). Fig 1: Identifying Communication Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Move right seat back to its default position.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1386 · Applies to: 450, 451, 452, 454 · AR: AZ82.62-P-0002MCC
RETROFITTING & CONVERSION > RETROFIT SOUND SYSTEM - AZ82.62-P-0002MCC > MODEL 451.3 /4 except CODE (P02) car2go with CODE (C08) Radio preinstallation incl. rod antenna (FFO) Fig 1: View Of Connecting Audio Components Onto Communication Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1389 · Applies to: 450, 451, 452, 454
1 Remove left seat (1) * not for USA AR91.10- P- 1000MCC * for USA only AR91.10- P- 1010MCU Install
2 Lift up front floor covering (3) and the route electrical connector for subwoofer (2) upwards through opening in front floor covering (3)
3 Fold back front floor covering (3) in marked area (arrows B) and position subwoofer (H4/29) at attachment points (arrows A) of left seat (1)
4 Connect electrical connector for subwoofer (2) to subwoofer (H4/29)
5 Perform function test on subwoofer (H4/29)
6 Install left seat (1) * not for USA AR91.10- P- 1000MCC *for USA only AR91.10- P- 1010MCU Fig 1: Identifying Subwoofer, Seat, Electrical Connector And Front Floor Covering Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Add special equipment to the vehicle data card and to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1390 · Applies to: 450, 451, 452, 454
7 Add special equipment to the vehicle data card and to the online vehicle data card Add code (C55) Active bass speaker (subwoofer).
RETROFITTING & CONVERSION > RETROFIT HANDS-FREE SYSTEM WIRING HARNESS - AZ82.70-P-0005-02MCC > Connection scheme Ensure that electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) are not damaged by chafing, pinching or crushing as otherwise they must be replaced. Electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) are coded and cannot be swapped. 1. Route electrical wiring harness for display (3) from display (A15p5) along radio recess in front passenger footwell as shown. Fig 1: Hands-Free System Wiring Harness - Connection Scheme Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Route electrical wiring harness for Bluetooth module (1) from radio recess in front passenger¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1391 · Applies to: 450, 451, 452, 454
footwell as shown. 3. Fix electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) in place with cable ties at vehicle wiring harness. RETROFITTING & CONVERSION > RETROFIT HANDS-FREE SYSTEM WIRING HARNESS - AZ82.70-P-0005-02MCD > Connection scheme Fig 2: Electrical Wiring Harness For Display Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Ensure that electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1392 · Applies to: 450, 451, 452, 454
microphone (2) and electrical wiring harness for display (3) are not damaged by chafing, pinching or crushing as otherwise they must be replaced. Electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) are coded and cannot be swapped. 1. Route electrical wiring harness for display (3) from display (A15p5) along radio recess in front passenger footwell as shown. Fig 1: Hands-Free System Wiring Harness - Connection Scheme Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Route electrical wiring harness for Bluetooth module (1) from communications control unit (N4) to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1393 · Applies to: 450, 451, 452, 454
Bluetooth module (A34/7) as shown. 3. Fix electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) in place with cable ties at vehicle wiring harness. RETROFITTING & CONVERSION > RETROFIT HANDS-FREE SYSTEM CONTROL UNIT - AZ82.70-P-0005-04MCD > Ensure that electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) are not damaged by chafing, pinching or crushing as otherwise they must be replaced. 1. Stick on Bluetooth module (A34/7) with felt tape included in the installation kit. 2. Connect electrical wiring harness for Bluetooth microphone (2) to Bluetooth module (A34/7) as shown. 3. Connect electrical wiring harness for display (3) to Bluetooth module (A34/7) as shown. Fig 2: Electrical Wiring Harness For Display Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Connect electrical wiring harness for Bluetooth module (1) to Bluetooth module (A34/7) as shown.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1394 · Applies to: 450, 451, 452, 454
- Fix electrical wiring harness for Bluetooth microphone (2) in place with a cable tie at Bluetooth module (A34/7) to prevent loosening of the connector.
- Fasten Bluetooth module (A34/7) in front passenger footwell at crossmember below instrument panel with cable ties as shown. Fig 1: Identifying Connection Of Electrical Wiring Harness For Bluetooth Microphone To Bluetooth Module Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT MICROPHONE FOR HANDS-FREE SYSTEM¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1395 · Applies to: 450, 451, 452, 454
- AZ82.70-P-0005-08MCD >
- Make a mark at the front roof frame panel (12) according to the dimensions "a" and "b". Dimensions: Fig 2: Identifying Bluetooth Module Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill hole with a diameter of 9 mm according to marking made beforehand at front roof frame panel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1396 · Applies to: 450, 451, 452, 454
(12). Cordless drill/driver 3. Route electrical wiring harness for Bluetooth microphone through drilled hole. 4. Clean bonding surface of front roof frame panel (12) in area of drilled hole with suitable cleaning agent (not corrosive toward plastic). Bonding surface must be dry and free of dust and grease to avoid adhesion problems. 5. Remove carrier foil at bracket (9) and glue bracket (9) onto front roof frame panel (12) as shown. 6. Tighten bracket (9) using screw/bolt (8). 7. Clip Bluetooth microphone into bracket (9). Fig 1: Identifying Front Roof Frame Panel Dimensions For Making Mark Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Route electrical wiring harness for Bluetooth microphone (2) as shown in above picture and fix in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1397 · Applies to: 450, 451, 452, 454
place with fabric tape to front roof frame panel (12). 9. Position front roof frame panel (12) in vehicle and secure against falling out with two screws/bolts. Ensure that electrical wiring harness for Bluetooth microphone (2) is not damaged by chafing, pinching or crushing as otherwise it must be replaced with Bluetooth microphone. 10. Route electrical wiring harness for Bluetooth microphone (2) along right A-pillar as shown in following picture and fix in place with fabric tape. Fig 2: Identifying Bracket On Front Roof Frame Panel And Screw/Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Route electrical wiring harness for Bluetooth microphone (2) between instrument panel and A-pillar¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1398 · Applies to: 450, 451, 452, 454
in front passenger footwell. The electrical wiring harness for Bluetooth microphone (2) will be connected to the Bluetooth control unit at a later time. RETROFITTING & CONVERSION > RETROFIT ADDITIONAL INSTRUMENT OF HANDS- FREE SYSTEM - AZ82.70-P-0005-10MCC > On vehicles without code (V31) Cockpit clock and tachometer package, the display of the hands-free system can be attached to the left or the right of the additional instruments bracket in accordance with the customer request. Installation on vehicles without code (V31) Cockpit clock and tachometer package is shown as an example on the right side. 1. Remove cover (13) from clock (A15p3). On vehicles with code (V31) Cockpit clock and tachometer package. Fig 3: Identifying Bluetooth Microphone On Front Roof Frame Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Remove screws/bolts (16) and remove clock from additional instruments bracket (15).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1399 · Applies to: 450, 451, 452, 454
On vehicles with code (V31) Cockpit clock and tachometer package. The clock is no longer needed. Fig 1: Identifying Cover Of Clock Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Instruments Bracket And Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Saw off unnecessary right or left arm (15.1) of new additional instruments bracket (15) along broken¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1400 · Applies to: 450, 451, 452, 454
line. On vehicles without code (V31) Cockpit clock and tachometer package. The display of the hands-free system can be attached to the left or right of the additional instruments bracket (15) in accordance with the customer request. 4. Install display (A15p5) at additional instruments bracket (15) and tighten with screws/bolts (16). 5. Make a cutout at additional instruments bracket (15) along broken line for leading through electrical wiring harness for display (3). 6. Route electrical wiring harness for display (3) in cutout made as shown. 7.1 Install cover removed from clock at display (A15p5). On vehicles with code (V31) Cockpit clock and tachometer package. 7.2 Install new cover at display (A15p5). On vehicles without code (V31) Cockpit clock and tachometer package. Fig 3: Identifying Right Or Left Arm Of Instruments Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8 Position additional instruments bracket (15) at instrument panel.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1401 · Applies to: 450, 451, 452, 454
9 Route electrical wiring harness for display (3) along broken line. 10 Tighten additional instruments bracket (15) with screws/bolts (17). Fig 4: Identifying Additional Instruments Bracket With Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Additional Instruments Bracket With Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11 Form cutouts (18.1 or 18.2) at cover (18) according to perforation (arrow A or arrow B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1402 · Applies to: 450, 451, 452, 454
On vehicles without code (V31) Cockpit clock and tachometer package. The cutout is only to be formed on the side on which the display of the hands-free system was installed. RETROFITTING & CONVERSION > RETROFIT ADDITIONAL INSTRUMENT OF HANDS- FREE SYSTEM - AZ82.70-P-0005-10MCD > 1. Remove cover (13) from clock (A15p3). 2. Remove screws/bolts (16) and remove clock (A15p3) from additional instruments bracket (15). The clock (A15p3) is no longer needed. Fig 6: Locating Perforation On Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Cover Of Clock Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Attach display (A15p5) on additional instruments bracket (15).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1403 · Applies to: 450, 451, 452, 454
- Remove stay at bracket (17) in marked area (arrows A) until coupling (3.1) of display wiring harness (3) can be guided through.
- Guide display wiring harness (3) through bracket (17).
- Tighten display (A15p5) and bracket (17) at additional instruments bracket (15) using screws/bolts (16). Fig 2: Identifying Clock Of Additional Instruments Bracket With Screws/Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Fix display wiring harness (3) in place in the guide (arrow B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1404 · Applies to: 450, 451, 452, 454
- Install cover removed from clock at display (A15p5).
- Position additional instruments (A15) at the instrument panel.
- Route display wiring harness (3) in accordance with routing of additional instruments wiring harness (A15) in slot of smart Entry radio. Fig 3: Identifying Display On Additional Instruments Bracket And Coupling Of Display Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT HANDS-FREE SYSTEM OPERATING UNIT -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1405 · Applies to: 450, 451, 452, 454
AZ82.70-P-0005-11MCU > 1. Twist lower section (11.2) of push button for central operation (11) toward left and remove. 2. Insert battery (12) into lower section (11.2) of push button for central operation (11) as shown. Note polarity of battery (12). 3. Place lower section (11.2) on push button for central operation (11), twist toward right and lock. Fig 4: Identifying Display And Additional Instruments Wiring Harnesses Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Agree on the exact placement of the push button for central operation (11) with the customer¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1406 · Applies to: 450, 451, 452, 454
before installation. 4. Clean bonding surface of cockpit switch group (S6/1) with suitable cleaning agent (not corrosive toward plastic). Bonding surface must be dry and free of dust and grease to avoid adhesion problems. 5. Remove carrier foil (11.1) and glue push button for central operation (11) to cockpit switch group (S6/1) as shown. Fig 1: Twisting Lower Section Of Push Button For Central Operation Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Switch on ignition and at the same time press both control buttons at push button for central¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1407 · Applies to: 450, 451, 452, 454 · AR: AZ82.70-P-0005MCD
operation (11) until green LED at push button for central operation (11) lights up. The push button for central operation (11) has been taught in. RETROFITTING & CONVERSION > RETROFIT HANDSFREE CONVERSATION EQUIPMENT - AZ82.70-P-0005MCD > MODEL 451.3 /4 up to 30.8.10 with CODE (C50) smart radio 10 Installation of a telephone system/Bluetooth handsfree system with display MODEL 451.3 /4 up to 30.8.10 with CODE (C57) smart radio 9 Installation of a telephone system/Bluetooth hands-free system with display MODEL 451.3 /4 as of 31.8.10 with CODE (516) RADIO WITH USB INTERFACE installation of a telephone system/Bluetooth hands-free system with display Package contents of handsfree system Fig 2: Identifying Carrier Foil And Cockpit Switch Group Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Routing diagram for:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1408 · Applies to: 450, 451, 452, 454
Vehicles up to 30.8.10 without code (41Z) AUX jack or without code (C15) Navigation unit (DFO/FFO) or without code (C60) Portable smart navigation system or without code (C54) Sound system 2 Vehicles as of 31.8.10 Fig 1: Identifying Package Contents Of Handsfree System Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Routing diagram for:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1409 · Applies to: 450, 451, 452, 454
Vehicles up to 30.8.10 with code (41Z) AUX jack or with code (C15) Navigation unit (DFO/FFO) or with code (C60) Portable smart navigation system or with code (C54) Sound system 2 Fig 2: Routing Diagram For Handsfree System Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1410 · Applies to: 450, 451, 452, 454
1 Move front passenger seat toward rear
2 Remove smart radio 9 (A2/1), smart radio 10 (A2/2) or smart Entry radio (A2/3) * not for USA AR82.60- P- 7502MCC * for USA only AR82.60- P- 7502MCU 3 Remove 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 Fig 3: Routing Diagram For Handsfree System Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove paneling on right¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1411 · Applies to: 450, 451, 452, 454
4 Remove paneling on right A-pillar * not for USA AR68.30- P- 4050MCC * for USA only AR68.30- P- 4050MCU 5 Remove additional instrument On vehicles up to 30.8.10 with code (V31) Cockpit clock and tachometer package AR54.30- P- 6080MCC Vehicles as of 31.8.10 with code (V31) Cockpit and tachometer package AR54.30- P- 6080MCF Install
6 Retrofit communication control unit (N4) In vehicles up to 30.8.10with code (41Z) AUX jack orwith code (C15) Navigation unit (DFO/FFO) orwith code (C60) Portable smart navigation system orwith code (C54) Sound system 2 AZ82.60- P-0021- 02MCC 7 Install Bluetooth microphone (B25/3) and route electrical wiring harness for Bluetooth microphone (2) in front passenger footwell Cordless drill/driver gotis://G_58.0_01.1 AZ82.70- P-0005- 08MCD 8 Retrofit display (A15p5) Vehicles up to 30.8.10 On vehicles without code (V31) Cockpit clock and tachometer package, the display (A15p5) can be attached to the left or right of the additional instruments bracket in accordance with the customer request. AZ82.70- P-0005- 10MCC Vehicles as of 31.8.10 AZ82.70- P-0005- 10MCD 9.1 Install additional instruments On vehicles as of 31.8.10 with code (V31)Cockpit and tachometer package AR54.30- P- 6080MCF 9.2 Retrofit additional instruments On vehicles as of 31.8.10 without code (V31) Cockpit and tachometer package AZ54.30- P- 0001MCD 10 Retrofit electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) Ensure that electrical wiring harness for Bluetooth module (1), electrical wiring harness for Bluetooth microphone (2) and electrical wiring harness for display (3) are not damaged by chafing, pinching or crushing as otherwise these must be replaced.
Vehicles up to 30.8.10without code (41Z) AUX jack orwithout code (C15) Navigation unit (DFO/ FFO) orwithout code (C60) Portable smart navigation system orwithout code (C54) Sound system AZ82.70- P-0005- 02MCC
2Vehicles as of 31.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1412 · Applies to: 450, 451, 452, 454
Vehicles up to 30.8.10with code (41Z) AUX jack orwith code (C15) Navigation unit (DFO/FFO) orwith code (C60) Portable smart navigation y tem orwith code (C54) Sound y tem 2 AZ82.70- P-0005- 02MCD 11 Connect electrical wiring harness for Bluetooth module (1) to communications control unit (N4) In vehicles up to 30.8.10with code (41Z) AUX jack orwith code (C15) Navigation unit (DFO/FFO) orwith code (C60) Portable smart navigation system orwith code (C54) Sound system 2 The electrical wiring harness for Bluetooth module (1) is to be connected to slot intended for the handsfree system. AZ82.60- P-0021- 03MCC 12 Retrofit Bluetooth module (A34/7)
AZ82.70- P-0005- 04MCD 13 Install smart radio 9 (A2/1), smart radio 10 (A2/2) or smart Entry radio (A2/3) * not for USA AR82.60- P- 7502MCC * for USA only AR82.60- P- 7502MCU 14 Install trim at right A-pillar Ensure that electrical wiring harness for Bluetooth microphone (2) is not damaged by chafing, pinching or crushing as otherwise electrical wiring harness for Bluetooth microphone (2) must be replaced with Bluetooth microphone (B25/3).
- not for USA AR68.30- P- 4050MCC
-
for USA only AR68.30- P- 4050MCU 15 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 AR68.30-
* for USA only¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1413 · Applies to: 450, 451, 452, 454
P- 4450MCV 16 Retrofit push button for central operation (11) Agree on the exact position of the push button for central operation (11) with the customer before in tallation
- not for USA AZ82.70- P-0005- 11MCC
- for USA only AZ82.70- P-0005- 11MCU 17 Reset front passenger seat to original position
18 Carry out handsfree system function test
PARTS ORDERING NOTES Part no. Designation Quantity DG 98 (see EPC) Telephone system/Bluetooth handsfree system 1
In vehicles as of 31.8.10
DG 98 (see EPC) Wiring harness for telephone system/Bluetooth hands-free system 1
In vehicles up to 30.8.10 without code (V31) Cockpit clock and tachometer package
DG 98 (see EPC) Retaining plate/handsfree system 1 DG 54 (see EPC) Additional instruments trim 1
In vehicles up to 30.8.10 with code (41Z) AUX jack or with code (C15) Navigation unit (DFO/FFO) or with code (C60) Portable smart navigation system or with code (C54) Sound system 2
DG 98 (see EPC) Communication control unit 1
In vehicles as of 31.8.10 without code (V31) Cockpit clock and tachometer package
DG 54 (see EPC) Additional instruments 1 DG 54 (see EPC) Screw 1 DG 54 (see EPC) Cover 1 RETROFITTING & CONVERSION > RETROFIT TELEPHONE CONSOLE - AZ82.70-P- 0010MCU > MODEL 451.3 /4 up to 30.8.10
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1414 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Template, Lower Section Of Dashboard And Center Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
switch¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1417 · Applies to: 450, 451, 452, 454
19 Add special equipment to the vehicle data card and to the online vehicle data card Enter code (C10) Telephone console (DFO).
RETROFITTING & CONVERSION > RETROFIT IPHONE KIT WIRING HARNESS - AZ82.70- P-0013-01MCC > Connection scheme Fig 3: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: iPhone Kit Wiring Harness - Connection Scheme Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Route iPhone kit wiring harness (6) behind the instrument panel (3) from the iPhone kit control unit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1418 · Applies to: 450, 451, 452, 454
(4) into the radio recess. 2. Connect black connector (6.2) of iPhone-kit wiring harness (6) to iPhone-kit control unit (4). 3. Strap down 6-pin coupling (8) of AUX connection connector and fix in position on the vehicle wiring harness with a cable tie. Up to 30.8.10, the 6-pin coupling (8) is yellow. As of 31.8.10, the 6-pin coupling (8) is blue. The multicolored connector (6.1) is connected when installing the radio. RETROFITTING & CONVERSION > RETROFIT IPHONE-KIT CONTROL UNIT - AZ82.70-P- 0013-02MCC > Fig 2: Identifying Iphone Kit Wiring Harness, Control Unit And 6-Pin Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fix iPhone-kit control unit (4) in position, as shown, in the rear front passenger footwell behind the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1419 · Applies to: 450, 451, 452, 454
instrument panel (3) with two cable ties (5). RETROFITTING & CONVERSION > RETROFIT IPHONE-KIT MICROPHONE - AZ82.70-P- 0013-03MCC > 1. Carefully separate out the two front webs (arrow) on the grill of the front roof frame lining (9) on the driver-side using side cutting pliers. 2. Guide microphone wiring harness (7.1) through the opening made in the front roof frame lining (9). 3. Position microphone (7) above the opening made in the front roof frame lining (9) and route microphone wiring harness (7.1) on the front roof frame lining (9) and fix in position with fabric adhesive tape (10). Fig 1: Identifying iPhone-Kit Control Unit, Instrument Panel And Cable Ties Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Microphone, Wiring Harness And Front Roof Frame Lining Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Screw down metal brackets contained in the scope of supply in the hatched area (10) on the front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1420 · Applies to: 450, 451, 452, 454
roof frame lining (9). 5. Bond microphone (7) onto the metal bracket. The contact surfaces on the microphone (7) and on the metal bracket must be free of dust and grease otherwise paint adhesion problems can occur. 6. Put down the front roof frame mounting (9) in the vehicle. 7. Route microphone wiring harness (7.1), as shown, along the A-pillar and fix in position with fabric Fig 2: Identifying Microphone, Fabric Adhesive Tape & Roof Frame Lining Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Microphone Wiring Harness Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
adhesive tape (11).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1421 · Applies to: 450, 451, 452, 454
Route microphone wiring harness (7.1) so that the installation of the right A-pillar lining is not obstructed. 8. Route microphone wiring harness (7.1) along the A-pillar under the instrument panel and fix in position with cable tires. 9. Connect black 2-pin connector (6.4) of iPhone-kit wiring harness (6) with the black 2-pin connector (7.2) of the microphone wiring harness (7.1) 10. Fix the microphone wiring harness (7.1) and iPhone-kit wiring harness (6) at suitable positions with cable ties RETROFITTING & CONVERSION > RETROFIT IPHONE-KIT CRADLE - AZ82.70-P-0013- 04MCC > 1. Insert counterholder (12) from behind in the cover of the center console (2) and align with the guides (2.1). 2. Transfer bore holes (arrows) to the cover of the center console (2) and remove counterholder (12) 3. Make bores corresponding to the previously applied markings with a diameter of 4 mm in the cover of the center console (2). Rechargeable drill / screwdriver Fig 1: Identifying Counterholder, Center Console And Guides Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Carefully enlarge center bore at center console cover (2) (arrow A) until transparent couplings (1.2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1422 · Applies to: 450, 451, 452, 454
of iPhone kit mount wiring harness (1.1) can be guided through. Only enlarge the bore enough that it can be concealed by the retaining plate (13) later. In the event of contravention the cover of the center console (2) must be replaced. 5. Guide iPhone-kit mount wiring harness (1.1) through the opening in the retaining plate (13). Observe installation position of retaining plate (13). 6. Guide iPhone-kit mount wiring harness (1.1) through the opening in the center console made previously in the cover of the center console (2). 7 In ert counterholder (12) from behind in the cover of the center con ole (2) and align 8. Attach retaining plate (13) from above and fix in position with the bolts (14) and nuts contained in the scope of supply together with the counterholder (12) on the cover of the center console (2). Fig 2: Locating Center Bore Of Center Console Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Iphone-Kit Mount Wiring Harness, Retaining Plate, Counterholder And Center Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. Clip bracket of the iPhone-kit cradle (1), as shown, into the retaining plate installed previously¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1423 · Applies to: 450, 451, 452, 454
- Route iPhone-kit mount wiring harness (1.1) through the right opening (arrow B) next to the smart Radio 9 (A2/1) or the smart Radio 10 (A2/2) under the instrument panel to the iPhone-kit control unit installed previously.
- Put down cover of center console (2) with iPhone-kit cradle (1) on the center console. Put down the cover of center console (2) so that it cannot fall down.
- Connect transparent couplings (1.2) of iPhone kit mount wiring harness (1.1) to iPhone kit control unit (4)
- Fix iPhone kit cradle wiring harness (1.1) with cable ties at suitable points. Fig 4: Identifying iPhone Kit Cradle Wiring Harness, Control Unit And Coupling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT IPHONE-KIT CRADLE - AZ82.70-P-0013-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1424 · Applies to: 450, 451, 452, 454
04MCD > 1. Insert counterholder (12) from behind in the cover of the center console (2) and align with the guides (2.1). 2. Transfer bore holes (arrows) to the cover of the center console (2) and remove counterholder (12) 3. Make bores corresponding to the previously applied markings with a diameter of 4 mm in the cover of the center console (2). Fig 5: Identifying Couplings, Wiring Harness & iPhone Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Center Bore Of Center Console Cove Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rechargeable drill / screwdriver¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1425 · Applies to: 450, 451, 452, 454
- Carefully enlarge center bore at center console cover (2) (arrow A) until transparent couplings (1.2) of iPhone kit mount wiring harness (1.1) can be guided through. Only enlarge the bore enough that it can be concealed by the retaining plate (13) later. In the event of contravention the cover of the center console (2) must be replaced.
- Guide iPhone-kit mount wiring harness (1.1) through the opening in the retaining plate (13). Observe installation position of retaining plate (13).
- Guide iPhone-kit mount wiring harness (1.1) through the opening in the center console made previously in the cover of the center console (2). Fig 2: Locating Center Bore Of Center Console Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying iPhone Kit Mount Wiring Harness, Retaining Plate And Center Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Insert counterholder (12) from behind in the cover of the center console (2) and align.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1426 · Applies to: 450, 451, 452, 454
- Attach retaining plate (13) from above and fasten with the screws/bolts (14) and nuts (15) contained in the delivery contents together with the counterholder (12) on the center console cover (2).
- Drill hole (arrow C) with a diameter of 2.5 mm according to the dimensions (a and b) on the right side of the center console cover (2). Dimensions: Fig 4: Identifying Hole Dimensions On Right Side Of Center Console Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
10. Clip bracket (16) of the iPhone kit mount (1), as shown, into the retaining plate (13) installed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1427 · Applies to: 450, 451, 452, 454
previously 11. Open cover (18) of glove compartment. On vehicles with code (I63) Glove compartment. 12. Route iPhone kit mount wiring harness (1.1) through right opening (arrow B) between installation opening (17) of smart Entry radio and right instrument panel lower section (19) below instrument panel to previously installed iPhone kit control unit. The iPhone kit mount wiring harness (1.1) must be routed through the top right opening (arrow B) in the slot of the smart Entry radio, otherwise the iPhone kit mount wiring harness (1.1) may be damaged upon installation of the center console cover (2). 13. Put down cover of center console (2) with iPhone-kit cradle (1) on the center console. Put down the cover of center console (2) so that it cannot fall down. 14. Connect transparent couplings (1.2) of iPhone kit mount wiring harness (1.1) to iPhone kit control unit (4) 15. Fix wiring harness for iPhone-kit cradle (1.1) with cable ties at suitable points. Fig 5: Identifying Bracket Of iPhone Kit Mount Into Retaining Plate And Center Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT IPHONE KIT - AZ82.70-P-0013MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1428 · Applies to: 450, 451, 452, 454 · AR: AZ82.70-P-0013MCC
MODEL 451.3 /4 (except 451.39 /49) up to 30.8.10 with CODE (C50) smart radio 10 with CODE (C57) smart radio 9 MODEL 451.3 /4 (except 451.39 /49) as of 31.8.10 with CODE (516) RADIO WITH USB INTERFACE Shown on vehicle up to 30.8.10 Vehicle as of 31.8.10 Fig 6: Identifying Couplings Of iPhone Kit Mount Wiring Harness And Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying iPhone Kit Mount, Center Console Cover And Smart Radio Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Part no.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1431 · Applies to: 450, 451, 452, 454
Designation Quantity see Odus iPhone kit delivery contents 1 RETROFITTING & CONVERSION > RETROFIT NAVIGATION SYSTEM - AZ82.85-P- 2000MCC > MODEL 451.3 /4 as of 31.8.10 with CODE (C08) Radio preinstallation incl. rod antenna (FFO) Parts scope for smart Premium radio (A2/4) Fig 1: Identifying Center Console Cover, Smart Entry Radio Wiring Harness, Cable Tie And Radio Recess Cover 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. 1432 · Applies to: 450, 451, 452, 454
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. 1433 · Applies to: 450, 451, 452, 454
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
Enter special equipment¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1434 · Applies to: 450, 451, 452, 454 · AR: AZ82.85-P-2000MCC
10 Enter special equipment on the vehicle data card and the online vehicle data card Add code (527) High-Line radio.
11 Disconnect Star Diagnosis
AD00.00- P-2000- 04MCC 12 Enter security code of smart Premium radio (A2/4), change if necessary The security code is set to "0000" by default at the factory. If the security code is to be changed, it must be documented in writing.
13 Document retrofitted equipment using vehicle documentation (VeDoc) Attach note "smart Premium radio (A2/4) retrofitted as per AZ82.85-P-2000MCC " as well as serial number of smart Premium radio (A2/4) under field organization texts to design group 82.
PARTS ORDERING NOTES Part no. Designation Quantity
smart Premium radio retrofit scope
DG 82 (see EPC) smart Premium radio 1 DG 82 (see EPC) Operator's manual for smart Premium radio 1 DG 82 (see EPC) GPS antenna 1
Also for retrofitting external USB connector connecting point and external audio source connecting point
DG 82 (see EPC) Wiring harness with external USB connector connecting point and external audio source connecting point 1 DG 68 (see EPC) Passenger-side instrument panel lower section (note equipment variants) 1
Also for retrofitting glove box
DG 68 (see EPC) Glove compartment 1 RETROFITTING & CONVERSION > RETROFIT NAVIGATION SYSTEM - AZ82.85-P- 2000MCD > MODEL 451.3 /4 as of 31.8.10 with CODE (516) RADIO WITH USB INTERFACE Parts scope for smart Premium radio A2/4
documented in writing.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1436 · Applies to: 450, 451, 452, 454 · AR: AZ82.85-P-2000MCD, BA82.00-Z-9999CZ
9 Document retrofitted equipment using vehicle documentation (VeDoc) Attach note "smart Premium radio (A2/4) retrofitted as per AZ82.85-P-2000MCD " as well as serial number of smart Premium radio (A2/4) under field organization texts to design group 82.
PARTS ORDERING NOTES Part no. Designation Quantity DG 82 (see EPC) smart Premium radio 1 DG 82 (see EPC) Operator's manual for smart Premium radio 1 DG 82 (see EPC) GPS antenna 1 DG 68 (see EPC) Center console cover 1 TORQUE SPECIFICATIONS INDEX > TIGHTENING TORQUES: SMART: ELECTRICAL SYSTEM BODY - BA82.00-Z-9999CZ > MODEL all Headlamp unit MODEL 450.3 /4 BA82.10-P-1000-06B Speaker MODEL 450.3 /4 BA82.62-P-1000-04A Windshield wiper MODEL 454.0 BA82.30-P-1000-01G Windshield wiper MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA82.30-P-1000-01F TORQUE SPECIFICATIONS INDEX > WINDSHIELD WIPER - BA82.30-P-1000-01F > Model 450, 451, 452 MODIFICATION NOTES 25.1.07 Nut for wiper arm on wiper shaft Type 451.3 Nut for wiper arm on wiper shaft Model 451.4 WINDSHIELD WIPER Number De ignation Model 450 3/4 Model 451 3 Model 451 4 Model 452 3/4 BA82.30-P- 1001-01F Wiper motor to clamping plate Nm 10 10 10 10 BA82.30-P- Nut for wiper arm on wiper Nm 18 20 20 18
1002-01F¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1437 · Applies to: 450, 451, 452, 454
shaft BA82.30-P- 1003-01F Nut for wiper shaft on body Nm 12 - - - BA82.30-P- 1004-01F Nut, tailgate wiper arm to wiper shaft Nm 14 12 - - BA82.30-P- 1005-01F Bolt, wiper motor to tailgate Nm 2 - - - BA82.30-P- 1006-01F Bolt, wiper drive to body Nm - - - 5 BA82.30-P- 1007-01F Bolt, wiper linkage to body Nm - 10 10 - BASIC KNOWLEDGE > EXTERIOR LIGHTS, LOCATION OF COMPONENTS - GF82.10-P- 0003-02MCU > Fig 1: Locating Exterior Lights Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > BLOCK DIAGRAM OF EXTERIOR LIGHTS - GF82.10-P-0003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1438 · Applies to: 450, 451, 452, 454
03MCU > Fig 2: Locating Exterior Lights Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Auto on/off driving lights (with code (V54) Rain/light sensor)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1440 · Applies to: 450, 451, 452, 454
Turn signal light actuation Turn signaling Hazard warning flashing Hazard warning flashing when airbag deployed Ambient illumination actuation (with code (V54) Rain/light sensor) Stop lamp actuation Front fog lamp actuation (with code (V07) Front fog lamps (FFO)) Backup lamp actuation The SAM control unit (N10/10) is a subscriber in the Controller Area Network (data bus/CAN bus) (CAN) and the master control unit for the exterior lights and all flashing functions. The following switches are read in directly by the SAM control unit: Combination switch (S4) Cockpit switch group (S6/1) Stop lamp switch (S9/1) The following sensor is read in by the SAM control unit via the Local interconnect network, interior 1 (LIN B): Rain sensor / light sensor (B38) (with code (V54) Rain/light sensor) The following information is read in and transmitted by the SAM control unit via CAN: Crash signal from the restraint systems control unit (N2/7) Feedback to the instrument cluster (A1) The SAM control unit actuates the following components: Left front lamp unit (E1) Right front lamp unit (E2) Left taillamp (E3) Right taillamp (E4) Center high-mounted stop lamp (E21) Left additional turn signal lamp (E22/1) Right additional turn signal lamp (E22/2) Left license plate lamp (E19/1) Right license plate lamp (E19/2) Left front fog lamp (E5/1) (with code (V07) (Front fog lamps (FFO))
Turn signaling is requested by pushing the combination switch down or up past the actuation point.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1449 · Applies to: 450, 451, 452, 454
The SAM control unit registers the respective position of the combination switch and actuates the following lamps: Left turn signal light in left front lamp unit (E1) Left brake light/turn signal light in left taillamp (E3) Left additional turn signal lamp or Right turn signal light in right front lamp unit (E2) Right brake light/turn signal light in right taillamp (E4) Right additional turn signal lamp Stop turn signaling Turn signaling is stopped by means of countersteering (automatic return of switch), manually returning the combination switch or activating the hazard warning flasher function. One-touch turn signaling During one-touch turn signaling the combination switch is only briefly moved to the required signaling position. If the turn combination switch is not engaged into place in the signaling position, a sequence of three turn-signal cycles is triggered. The SAM control unit registers the respective position of the combination switch and actuates the following lamps: Left turn signal light in left front lamp unit Left brake light/turn signal light in left taillamp Left additional turn signal lamp or Right turn signal light in right front lamp unit Right brake light/turn signal light in right taillamp Right additional turn signal lamp One-touch turn signaling is stopped by activating the hazard warning flasher function. Turn signaling and one-touch turn signaling feedback The activated function is signaled to the instrument cluster by the SAM control unit via the CAN. The instrument cluster actuates the relevant turn signal indicator lamp as visual feedback. Acoustic feedback is also output on the speaker in the instrument cluster in the form of a turn signal sound indicator. If one of the turn signal lamps fails, the flashing frequency of the indicator lamps, the flashing frequency of the other turn signal lamps and the frequency of the turn signal sound indicator is doubled. Activating the hazard warning flasher using the hazard warning flasher switch The status of the hazard warning flasher switch is registered by the SAM control unit, which actuates the turn signal lamps in the front lamp units, the brake lights/turn signal lights in the taillamps and the additional turn
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1453 · Applies to: 450, 451, 452, 454
The interior illumination system implements the illumination of the vehicle interior. The master control unit for this is the SAM control unit. The following operations are possible Switching on and off manually Switching on automatically Automatic switch off Switching on and off manually by operating the interior lamp witch Switching on automatically when unlocking the vehicle via the transmitter key when opening the driver or front passenger door when opening the top rear-end door (with model 451.3) when opening the bottom rear-end door (with model 451.4) when an alarm is triggered (with code (V01) Anti-theft alarm system (FFO)) The interior lamp is only automatically switched on if the interior lamp switch has been pushed towards the rear. Automatically switched on when the vehicle is unlocked using the transmitter key Fig 1: Interior Illumination Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The "unlock central locking system" request from the transmitter key is read in by the SAM control unit. This¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1454 · Applies to: 450, 451, 452, 454
then actuates the interior lamp. Automatically switched on when a door is opened The opening of the driver or front passenger side door is detected by the relevant rotary tumbler switch. The SAM control unit reads in the rotary tumbler switch signals and then actuates the interior lamp. Automatically switched on when the rear-end door is opened The opening of the rear-end door is detected by the rear-end door handle switch (with model 451.4) or the trunk lid rotary tumbler microswitch (with model 451.3). The SAM control unit reads in the signals and then actuates the interior lamp. Automatically switched off after a door has been opened immediately if circuit 15 on after 15 s when the door is closed and circuit 15 is off after 10 min if the door is open Automatically switched off after locking/unlocking using the transmitter key if circuit 15 is on 12 s after locking 30 s after unlocking if the doors remain closed
Interior illumination (IBL), location of components
GF82.20-P-0002- 01MCC Wiring diagram interior illumination * not for USA PE82.20-P- 2000MCC Model 451.3## /4## ## up to 013644
-
not for USA PE82.20-P- 2000MCD Model 451.3## /4## ## as of 013645
-
for USA only PE82.20-P- 2000MCU
Interior lamp, component description E15/4 GF82.20-P- 5221MCC
Component description for the SAM control unit N10/10
- not for USA GF54.21-P- 4157MCC
- for USA only GF54.21-P- 4157MCU BASIC KNOWLEDGE > CONTENTS, FUNCTION DESCRIPTION OF INTERIOR
BASIC KNOWLEDGE > WIPER SYSTEM (WSA) BLOCK DIAGRAM - GF82.30-P-0003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1459 · Applies to: 450, 451, 452, 454
04MCC > Fig 1: Locating Wiper System Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Wiper System Block Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Function requirements:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1463 · Applies to: 450, 451, 452, 454
Circuit 15 On Functions Wiping Wiping with washer fluid Intermittent wipe Wiping When the wiper switch is moved upwards, the wiper can be activated at 2 different speeds. In position 1 wiping takes place at slow speed, and in position 2 wiping takes place at fast speed. The request is read in by the SAM control unit, which actuates the wiper motor directly. The next slower wiping speed is selected if the vehicle is stationary. The wiper is actuated in accordance with the request at speeds of 5 km/h and above. Switching back to po ition 0 deactivate the wiper function If deactivation take place during a wiper operation, the wiper motor is not switched off until the park position has been reached. Park position feedback is provided by a signal contact integrated in the wiper motor. Wiping with washer fluid Fig 1: Windshield Wiper System Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1465 · Applies to: 450, 451, 452, 454
The combination switch is mounted on the steering column. Task The combination switch is used to read in the following requests: High beam Low beam Headlight flasher Turn signals Auto on/off driving lights (with code (V54) Rain/light sensor) Daytime running lights activation (with code (K06) Daytime running lights) Daytime running lights deactivation (with code (K06) Daytime running lights) Headlamp range adjustment The headlamp range adjustment is actuated directly at the left headlamp range adjustment motor (E1m1) and the right headlamp range adjustment motor (E2m1). All other operating requests are read in by the SAM control unit. Control of the individual functions: Turn signal The turn signal is switched on by pressing the combination switch upward for the right side and downward for the left side beyond the detent point. One-touch turn signaling One-touch turn signaling is activated by briefly pressing the combination switch upward for the right side and downward for the left side as far as the detent point. The turn signal flashes 3 times. Standing light The standing light is activated by rotating the combination switch to the first detent point. Fig 1: View Of Combination Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Low beam¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1466 · Applies to: 450, 451, 452, 454
The low beam is activated by rotating the combination switch to the second detent point. High beam The high beam is activated by pressing the combination switch forward. The high beam is deactivated by pulling the combination switch back to the home position. Headlamp flasher The headlamp flasher is activated for as long as the combination switch is pulled to the rear. Auto on/off driving lights (with code (V54) Rain/light sensor) The auto on/off driving lights are activated by rotating the combination switch to the third detent point. Daytime running lights (with code (K06) Daytime running lights) The daytime running lights are activated and deactivated by pulling back the combination switch and simultaneously operating the lock button on the transmitter key. Headlamp range adjustment The incline angle is adapted using switch settings 0, 1 and 2 on the selector wheel of the combination switch. BASIC KNOWLEDGE > WIPER SWITCH, COMPONENT DESCRIPTION - GF82.30-P- 5002MCC > MODEL 451.3 /4 Location The wiper switch is located on the steering column. Task The wiper switch is used to activate the following requests: Fig 1: View Of Right Wiper Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Windshield¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1467 · Applies to: 450, 451, 452, 454
Wipe at slow speed Wipe at fast speed Wipe with washer fluid Intermittent wipe Rear window (with model 451.3) Intermittent wipe Wipe with washer fluid The windshield washer fluid pump (M5/1) is actuated directly via the wiper switch. Operation of individual functions (windshield) Wipe Pressing the wiper switch upwards beyond the first catch point activates a wipe at a slow speed. Pressing the wiper switch upwards beyond the second catch point activates a wipe at a faster speed. Wipe with washer fluid Pulling the wiper switch backwards and holding it there directly actuates the windshield washer fluid pump. The position of the wiper switch is read in by the SAM control unit, which then actuates the wiper motor. After releasing the wiper switch, another 3 wipe cycles are performed. Intermittent wipe If the wiper switch is pressed downward beyond the catch point, the intermittent wipe is activated. The intermittent wipe is executed to match the vehicle speed or to match the amount of moisture on the windshield (with code (V54) Rain/light sensor). Operation of individual functions (rear window) (on model 451.3) Intermittent wipe If the wiper witch i pre ed forward beyond the catch point, the intermittent wipe i activated for the rear window. Wipe with washer fluid Pressing the wiper switch forwards and holding it there directly actuates the windshield washer fluid pump. BASIC KNOWLEDGE > WIPER MOTOR - COMPONENT DESCRIPTION - GF82.30-P- 5010MCC > MODEL 451.3 /4
E5/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1472 · Applies to: 450, 451, 452, 454
Left front fog lamp 27L E5/2 Right fog lamp 29L E6/13 Left standing light 33L E6/14 Right standing light 31L E19/1 Left license plate lamp 43L E19/2 Right license plate lamp 45L N10/10 SAM control unit 4A12A20A28A N10/10f5 Fuse 5 26A N10/10f6 Fuse 6 30A N10/10f7 Fuse 7 32A N10/10f12 Fuse 12 2A N10/10f22 Fuse 22 15A N10/10f23 Fuse 23 21A N10/10f25 Fuse 25 23A N10/10f26 Fuse 26 17A N15/5 Electronic selector lever module control unit 39A S4 Combination witch 8L S6/1 Cockpit switch group 25L S6/1s8 Front fog lamps switch 25K U114 Valid for front fog lamps 25A W6 Ground (left wheelhouse in luggage compartment) 35G44G W7 Ground (right wheelhouse in luggage compartment) 40G W9 Ground (left front, at lamp unit) 3G6E W43 Ground (outside left fire wall) 15G18G21G23G27G31G32G Z29/4 Circuit 58R (fused) connector sleeve 30G40G42G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 1G10E Z78 Cockpit LIN connector sleeve 2G WIRING DIAGRAMS > EXTERIOR LIGHTS WIRING DIAGRAM - PE82.10-P-2000-97MCU > Code: Designation: Position: B38 Rain sensor/light sensor 2L E1 Left front headlamp unit 16L
E19/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1473 · Applies to: 450, 451, 452, 454
Left license plate lamp 43L E19/2 Right license plate lamp 45L E1e1 Left high beam
E1e2 Left low beam
E1m1 Left headlamp range adjustment motor 15L E2 Right front headlamp unit 21L E2e1 Right high beam
E2e2 Right low beam
E2m1 Right headlamp range adjustment motor 20L E3 Left taillamp 36L E3e2 Left tail light
E3e3 Left backup lamp
E4 Right taillamp 40L E4e2 Right taillamp
E4e3 Right backup lamp
E5/1 Left fog lamp 27L E5/2 Right fog lamp 29L E6/13 Left standing lamp 33L E6/14 Right standing lamp 31L N10/10 SAM control unit 20A N10/10 SAM control unit 12A N10/10 SAM control unit 28A N10/10 SAM control unit 4A N10/10f12 Fuse 12 2A N10/10f22 Fuse 22 15A N10/10f23 Fuse 23 22A N10/10f25 Fuse 25 23A N10/10f26 Fuse 26 17A N10/10f5 Fuse 5 27A N10/10f6 Fuse 6 31A N10/10f7 Fuse 7 33A N15/5 Electronic selector lever module control module 39A S4 Combination switch 8L S6/1 Cockpit switch group 25L
S6/1s8¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1474 · Applies to: 450, 451, 452, 454
Fog lamps switch
U114 Valid for fog lights 25A W43 Ground (outside left fire wall) 32G W43 Ground (outside left fire wall) 31G W43 Ground (outside left fire wall) 27G W43 Ground (outside left fire wall) 23G W43 Ground (outside left fire wall) 15G W43 Ground (outside left fire wall) 18G W43 Ground (outside left fire wall) 21G W6 Ground (left wheelhousing in trunk) 35G W6 Ground (left wheelhousing in trunk) 44G W7 Ground (right wheelhousing in trunk) 40G W9 Ground (at left headlamp unit) 6E W9 Ground (at left headlamp unit) 3G Z29/4 Circuit 58R (fused) connector sleeve 41G Z29/4 Circuit 58R (fused) connector sleeve 42G Z29/4 Circuit 58R (fused) connector sleeve 30G Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 10E Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 2G Z78 Cockpit LIN connector sleeve 2G
Fig 1: Exterior Lights Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1475 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Exterior Lights Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1476 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1001-27MC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1478 · Applies to: 450, 451, 452, 454
Abbreviations for wiring diagrams
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 PE26.00-P- 1100MCU
Further wiring diagrams PE26.00-P- 1100MCU PE54.00-P- 1100MCU
Further wiring diagrams PE54.00-P- 1100MCU WIRING DIAGRAMS > EXTERIOR LIGHTS WIRING DIAGRAM - PE82.10-P-2000-99MCU > Code: Designation: Position: B38 Rain sensor/light sensor 2 L E1 Left front headlamp unit 16 L E19/1 Left license plate lamp 43 L E19/2 Right license plate lamp 45 L E1e1 Left high beam 17 L E1e2 Left low beam 16 L E1m1 Left headlamp range adjustment motor 15 L E2 Right front headlamp unit 21 L E2e1 Right high beam 22 L E2e2 Right low beam 22 L E2m1 Right headlamp range adjustment motor 20 L E3 Left taillamp 35 L E3e2 Left tail light 34 L E3e3 Left backup lamp 37 L E4 Right taillamp 40 L E4e2 Right taillamp 41 L E4e3 Right backup lamp 38 L E5/1 Left fog lamp 27 L
E5/2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1479 · Applies to: 450, 451, 452, 454
Right fog lamp 28 L E6/13 Left standing lamp 32 L E6/14 Right standing lamp 31 L N10/10 SAM control unit 4 A N10/10 SAM control unit 12 A N10/10 SAM control unit 20 A N10/10 SAM control unit 28 A N10/10f12 Fuse 12 2 A N10/10f22 Fuse 22 15 A N10/10f23 Fuse 23 21 A N10/10f25 Fuse 25 23 A N10/10f26 Fuse 26 17 A N10/10f5 Fuse 5 26 A N10/10f6 Fuse 6 30 A N10/10f7 Fuse 7 32 A N15/5 Electronic selector lever module control module 39 A S4 Combination switch 8 L S6/1 Cockpit switch group 25 L S6/1s8 Fog lamps switch 25 L U114 Valid for fog lights 24 A W43 Ground (outside left fire wall) 15 G W43 Ground (outside left fire wall) 18 G W43 Ground (outside left fire wall) 21 G W43 Ground (outside left fire wall) 23 G W43 Ground (outside left fire wall) 27 G W43 Ground (outside left fire wall) 31 G W43 Ground (outside left fire wall) 32 G W6 Ground (left wheelhousing in trunk) 35 G W6 Ground (left wheelhousing in trunk) 44 G W7 Ground (right wheelhousing in trunk) 40 G W9 Ground (at left headlamp unit) 3 G W9 Ground (at left headlamp unit) 6 E Z29/4 Circuit 58R (fused) connector sleeve 30 H
Z29/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1480 · Applies to: 450, 451, 452, 454
Circuit 58R (fused) connector sleeve 40 H Z29/4 Circuit 58R (fused) connector sleeve 42 H Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 1 H Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 10 E Z78 Cockpit LIN connector sleeve 2 H Fig 1: Exterior Lights Wiring Diagram (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Exterior Lights Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1481 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
OV00.01-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1483 · Applies to: 450, 451, 452, 454
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 WIRING DIAGRAMS > WIRING DIAGRAM OF BRAKE LIGHTS AND TURN SIGNAL/HAZARD WARNING FLASHER - PE82.10-P-2220-97MCU > Code: Designation: Position: E1 Left front headlamp unit 7L E1e5 Left turn signal lamp
E2 Right front headlamp unit 17L E21 Center high-mounted stop lamp 43L E21 Center high-mounted stop lamp 39L E22/1 Left auxiliary turn signal lamp 9L E22/2 Right auxiliary turn signal lamp 19L E2e5 Right turn signal lamp
E3 Left taillamp 15L E3e11 Left brake/turn signal light
E4 Right taillamp 24L E4e11 Right brake/turn signal light
K52/11 Left turn signal/stop lamp relay 12L K52/12 Right turn signal/stop lamp relay 21L N10/10 SAM control unit 20A N10/10 SAM control unit 10A N10/10 SAM control unit 28A N10/10 SAM control unit 4A N10/10f12 Fuse 12 13A N10/10f38 Fuse 38
N47-5 ESP control module 35L S4 Combination switch 4L
S6/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1484 · Applies to: 450, 451, 452, 454
Cockpit switch group 27L S6/1s1 Hazard flasher switch
S9/1 Stop lamp switch (4-pin) 31L U23 Valid for cabriolet 41B U606 Valid for all except convertibles 38B W10 Ground (battery) 31G W10 Ground (battery) 27G W43 Ground (outside left fire wall) 18G W43 Ground (outside left fire wall) 17G W43 Ground (outside left fire wall) 8G W6 Ground (left wheelhousing in trunk) 44B W6 Ground (left wheelhousing in trunk) 40B W6 Ground (left wheelhousing in trunk) 15G W7 Ground (right wheelhousing in trunk) 24G W9 Ground (at left headlamp unit) 2E X18/19 Trunk lid connector 40E X18/19 Trunk lid connector 38G X23/7 Soft top connector 42E Z40 Stop lamp signal connector sleeve 39E Z40 Stop lamp signal connector sleeve 42C Z40 Stop lamp signal connector sleeve 32H Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 21H Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 12H Z6/16 Soft top ground connector sleeve 43H Z6/20 Trunk lid ground connector sleeve 40H
Fig 1: Exterior Lights Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1485 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Exterior Lights Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1486 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
N10/10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1489 · Applies to: 450, 451, 452, 454
SAM control unit 4A N10/10 SAM control unit 11A N10/10f15 Fuse 15 3A S87/6 Right door rotary tumbler microswitch 14L S87/7 Left door rotary tumbler microswitch 12L U101 Valid up to 02/2009 9E U102 Valid as of 03/2009 7E U102 Valid as of 03/2009 1E W43 Ground (outside left fire wall) 14C W43 Ground (outside left fire wall) 12C W9 Ground (left front, at lamp unit) 2H W9 Ground (left front, at lamp unit) 9F X35/1 Left door separation point 12E X35/2 Right door separation point 14E Z6/35 Left door ground connector sleeve 12G Z6/36 Right door ground connector sleeve 14G Z7/59 Tml. 30 connector sleeve 3G Z7/59 Tml. 30 connector sleeve 8G
WIRING DIAGRAMS > WIRING DIAGRAM INTERIOR ILLUMINATION - PE82.20-P-2000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1490 · Applies to: 450, 451, 452, 454
97MCV > Code: Designation: Position: E13/15 Driver door pocket ambiance illumination 6L E13/15 Driver door pocket ambiance illumination
E13/16 Front passenger door pocket ambiance illumination 4L E13/16x1 Front passenger door pocket ambiance illumination connector
E17/16 Left front footwell lamp 16L E17/16 Left front footwell lamp 18L E43/1 Left cockpit ambiance illumination 9L E43/1x1 Left cockpit ambiance illumination connector
E43/2 Center cockpit ambiance illumination 10L E43/2x1 Center cockpit ambiance illumination connector
E43/3 Right cockpit ambiance illumination 12L Fig 1: Interior Illumination Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
E43/3x1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1491 · Applies to: 450, 451, 452, 454
Right cockpit ambiance illumination connector
E43/9 Overhead control panel (OCP) ambiance illumination 13L E43/9x1 Overhead control panel (OCP) ambiance illumination connector
N10/10 SAM control unit 4A N10/10 SAM control unit 12A N10/10 SAM control unit 19A W9 Ground (left front, at lamp unit) 15G X35/1 Left door separation point 6H X35/2 Right door separation point 4H Z232 Ambiance illumination supply connector sleeve 8E Z54/6 Circuit 30 footwell lamp connector sleeve 18E Z54/7 Footwell lamps connector sleeve 16E Z6/35 Left door ground connector sleeve 6G Z6/36 Right door ground connector sleeve 4G Fig 1: Interior Illumination Wiring Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Windshield Wiper Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1495 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Windshield Wiper Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1496 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM OF WINDSCREEN WIPER - PE82.30-P-2000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1497 · Applies to: 450, 451, 452, 454
97MCU > Code: Designation: Position: B38 Rain sensor/light sensor 22L M5/1 Windshield washer fluid pump 2L M6/1 Wiper motor 13L M6/4 Tailgate wiper motor 18L N10/10 SAM control unit 12A N10/10 SAM control unit 4A N10/10 SAM control unit 19A N10/10f12 Fuse 12
N10/10f17 Fuse 17
N10/10f2 Fuse 2
N10/10f20 Fuse 20
S4/4 Right wiper switch 7L Fig 3: Windshield Wiper Wiring Diagram (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
U606¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1498 · Applies to: 450, 451, 452, 454
Valid for all except convertibles 15A U606 Valid for all except convertibles 5E W43 Ground (outside left fire wall) 15E W6 Ground (left wheelhou ing in trunk) 19C W9 Ground (at left headlamp unit) 22E W9 Ground (at left headlamp unit) 5E X18/19 Trunk lid connector 19E X18/19 Trunk lid connector 16G Z3/44 Instrument cluster - radio circuit 15 connector sleeve (fused) 6E Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 23E Z6/20 Trunk lid ground connector sleeve 19G Z78 Cockpit LIN connector sleeve 21E Fig 1: Windscreen Wiper Wiring Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM OF WINDSCREEN WIPER - PE82.30-P-2000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1499 · Applies to: 450, 451, 452, 454
99MCU > Code: Designation: Position: B38 Rain sensor/light sensor 22 L M5/1 Windshield washer fluid pump 2 L Fig 2: Windscreen Wiper Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
M6/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1500 · Applies to: 450, 451, 452, 454
Wiper motor 13 L M6/4 Tailgate wiper motor 18 L N10/10 SAM control unit 4 A N10/10 SAM control unit 12 A N10/10 SAM control unit 19 A N10/10f12 Fuse 12 22 A N10/10f17 Fuse 17 17 A N10/10f2 Fuse 2 13 A N10/10f20 Fuse 20 6 A S4/4 Right wiper switch 7 L U606 Valid for all except convertibles 5 E U606 Valid for all except convertibles 15 A W43 Ground (outside left fire wall) 14 E W6 Ground (left wheelhousing in trunk) 19 C W9 Ground (at left headlamp unit) 5 E W9 Ground (at left headlamp unit) 22 E X18/19 Trunk lid connector 16 H X18/19 Trunk lid connector 18 E Z3/44 Instrument cluster - radio circuit 15 connector sleeve (fused) 6 E Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 22 E Z6/20 Trunk lid ground connector sleeve 18 H Z78 Cockpit LIN connector sleeve 20 E
Fig 1: Windscreen Wiper Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1501 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A2/3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1504 · Applies to: 450, 451, 452, 454
smart Entry radio 20A A2/3 smart Entry radio 28A A2/3 smart Entry radio 36A A2/3 smart Entry radio 43A H4/10 Right front speaker 25L H4/29 Subwoofer 32L H4/33 Left tweeter 37L H4/34 Right tweeter 35L H4/9 Left front speaker 27L N10/10 SAM control unit 19L N10/10f15 Fuse 15 20L N10/10f20 Fuse 20 18L N15/6 Automated manual transmission control unit 5L N47-5 ESP control unit 10L S12 Parking brake indicator switch 8L U1 Valid for {{USA}} 3E U12 Valid for left-hand drive vehicles 32D U13 Valid for right-hand drive vehicles 32D U50 Valid for {{USA}} {{Japan}} 21D U58 Valid for ECE 7E U863 Valid for external audio source 40C U90 Valid for Sound System 29A U97 Not valid for model 451.334/380/480 13K U97 Not valid for model 451.334/380/480 17K U98 Valid for model 451.334/380/480 13L U98 Valid for model 451.334/380/480 17K W10 Ground (battery) 33E W12 Ground (center console) 19E W14 Left floor interior compartment ground 32E W7 Ground (right wheelhouse in luggage compartment) 8G X115 USB connection connector 42L X35/1 Left door separation point 26E X35/2 Right door separation point 24E
N47-5¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1507 · Applies to: 450, 451, 452, 454
ESP control unit 9L S12 Parking brake indicator switch 7L U1 Valid for {{USA}} 2E U12 Valid for left-hand drive vehicles 21D U13 Valid for right-hand drive vehicles 21D U58 Valid for ECE 20G U58 Valid for ECE 6E U863 Valid for external audio source 51C U97 Not valid for model 451.334/380/480 13K U97 Not valid for model 451.334/380/480 17K U98 Valid for model 451.334/380/480 13L U98 Valid for model 451.334/380/480 17K W10 Ground (battery) 22F W12 Ground (center console) 18E W14 Left floor interior compartment ground 22E W7 Ground (right wheelhouse in luggage compartment) 7G X115 USB connection connector 52L X134/1 Sound connecting point 1 23G X134/2 Sound connecting point 2 28H X35/1 Left door separation point 43F X35/2 Right door separation point 39F X39/45 External audio source separation point 55L Z28/5 Left door speaker group connector sleeve (+) 44H Z28/6 Left door speaker group connector sleeve (-) 43H Z28/7 Right door speaker group connector sleeve (+) 41H Z28/8 Right door speaker group connector sleeve (-) 39H Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve 17F Z37/42 CAN bus (low) connector sleeve 3H Z81 Circuit 58d connector sleeve 15F
Fig 1: Radio Wiring Diagram (1 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1508 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Radio Wiring Diagram (2 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1509 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Radio Wiring Diagram (3 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1510 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
OV00.01-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1512 · Applies to: 450, 451, 452, 454
1901- 03MCC Use of wiring diagrams
OV00.01-P- 1901- 03MCC OV00.01-P- 1901MCC Search aid for all wiring diagram groups * not for USA OV00.01-P- 1901MCC OV00.01-P- 1901MCU Search aid for all wiring diagram groups * for USA only 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- 1000MCC Location and assignment of line and plug connectors * not for USA GF00.19-P- 1000MCC GF00.19-P- 1000MCU Location and assignment of line and plug connectors * for USA only GF00.19-P- 1000MCU GF00.19-P- 2000MCC Location and assignment of ground points * not for USA GF00.19-P- 2000MCC GF00.19-P- 2000MCU Location and assignment of ground points * for USA only GF00.19-P- 2000MCU GF00.19-P- 3000MCC Location and assignment of Z connector sleeves (line connectors in wiring harness) * not for USA GF00.19-P- 3000MCC GF00.19-P- 3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) * for USA only GF00.19-P- 3000MCU PE54.00-P- 1100MCC
-
not for USAFurther wiring diagrams PE54.00-P- 1100MCC PE54.00-P- 1100MCU
-
only for USAFurther wiring diagrams PE54.00-P- 1100MCU WIRING DIAGRAMS > WIRING DIAGRAM RADIO - PE82.60-P-2000-97MCG > Code: Designation: Position: A1 Instrument cluster 13L A2/20 Radio antenna 50L A2/23 GPS antenna 48L A2/4 smart Premium radio 6A A2/4 smart Premium radio 11A A2/4 smart Premium radio 20A A2/4 smart Premium radio 29A A2/4 smart Premium radio 37A
A2/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1513 · Applies to: 450, 451, 452, 454
smart Premium radio 45A A2/4 smart Premium radio 53A H4/29 Subwoofer 20L H4/29 Subwoofer 47L H4/29 Subwoofer 34L H4/33 Left tweeter 40L H4/34 Right tweeter 41L H4/64 Left door sound system woofer 43L H4/65 Right door sound system woofer 35L H4/68 Left door sound system tweeter 45L H4/69 Right door sound system tweeter 37L H4/7 Left rear speaker 38L H4/8 Right rear speaker 42L N10/10 SAM control unit 17L N10/10f15 Fuse 15 18L N10/10f20 Fuse 20 16L N15/6 Automated manual transmission control unit 3L N47-5 ESP control unit 8L S12 Parking brake indicator switch 6L U1 Valid for {{USA}} 1E U12 Valid for left-hand drive vehicles 19D U13 Valid for right-hand drive vehicles 19D U58 Valid for ECE 6E U863 Valid for external audio source 51C U97 Not valid for model 451.334/380/480 12K U97 Not valid for model 451.334/380/480 16K U98 Valid for model 451.334/380/480 12L U98 Valid for model 451.334/380/480 16K W10 Ground (battery) 20F W12 Ground (center console) 17E W14 Left floor interior compartment ground 20E W7 Ground (right wheelhouse in luggage compartment) 8G X115 USB connection connector 52L X134/1 Sound connecting point 1 21G
Code:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1515 · Applies to: 450, 451, 452, 454
Designation: Position: A1 Instrument cluster 8L A2/1 smart radio 9 19A A2/1 smart radio 9 11A A2/1 smart radio 9 4A A2/1 smart radio 9 28A A2/2 smart radio 10 20A A2/2 smart radio 10 12A A2/2 smart radio 10 5A A2/2 smart radio 10 29A A2/20 Radio antenna 25L H4/10 Right front speaker 11L H4/29 Subwoofer loudspeaker 18L H4/33 Left tweeter speaker 23L H4/34 Right tweeter speaker 22L H4/9 Left front speaker 14L N10/10 SAM control unit 3L N10/10f15 Fuse 15 5L N10/10f20 Fuse 20 2L N4 Communication control unit 29L U18 Valid for communication systems 27E U90 Valid for Sound System 15A W14 Left floor interior compartment ground 19G W26 Ground (transmission tunnel) 3E X35/1 Left door separation point 13E X35/2 Right door separation point 11E Z28/18 Sound system/antenna control connector sleeve 7G Z3/44 Instrument cluster - radio circuit 15 connector sleeve (fused) 2G Z81 Circuit 58d connector sleeve 8G
Fig 1: Radio Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1516 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Radio Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1517 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GF00.19-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1520 · Applies to: 450, 451, 452, 454
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 PE82.00-P- 1100MCU
Further wiring diagrams PE82.00-P- 1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF COMMUNICATIONS INTERFACE (KOM) - PE82.85-P-2002-97MCU > Code: Designation: Position: A2/1 smart radio 9 3L A2/2 smart radio 10 4L A34/16 PND (personal navigation device) holder 13L A34/7 Bluetooth module 19L B25/3 Bluetooth microphone 22D N4 Communication control unit 12A N4 Communication control unit 4A N4 Communication control unit 20A U16 Valid for Bluetooth
U3 Valid for PND (Personal Navigation Device) 10C U863 Valid for external audio source 7C X39/45 External audio source separation point 8L X9 Bluetooth microphone connector 21G
Fig 1: Communications Interface Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1521 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM OF CAN BUS - PE00.19-P-2150-97MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1522 · Applies to: 450, 451, 452, 454
Document number: Document title: Code: Designation: Position: A1 Instrument cluster 44A A1 Instrument cluster 28A A1 Instrument cluster 52A A1 Instrument cluster 37A A1 Instrument cluster 4A A1 Instrument cluster 20A A1 Instrument cluster 12A Fig 2: Communications Interface Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
B24/15¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1523 · Applies to: 450, 451, 452, 454
Yaw rate, lateral and longitudinal acceleration sensor 30L N10/10 SAM control unit 8L N110 Weight Sensing System (WSS) control unit 47L N15/5 Electronic selector lever module control unit 23L N15/6 Automated manual transmission control unit 19L N2/7 Restraint systems control unit 43L N23 Heater/AC operating unit 38L N3/10 ME-SFI [ME] control unit 3L N47-5 ESP control unit 34L N49 Steering angle sensor 26L N68 Steering assist control unit 14L N88 TPM [RDK] control unit 54L U1012 Valid up to 30/08/2010 41K U1012 Valid up to 30/08/2010 46K U1013 Valid as of 31/08/2010 41L U1013 Valid as of 31/08/2010 46L U492 Valid for power steering 10D U493 Not valid for power steering 8D U87 Valid for air conditioning 37D X11/4 Data link connector 51L X55/4 Front passenger seat connector block 46G Z37/2 CAN engine bus (low) connector sleeve 55E Z37/2 CAN engine bus (low) connector sleeve 23E Z37/2 CAN engine bus (low) connector sleeve 51E Z37/2 CAN engine bus (low) connector sleeve 43E Z37/2 CAN engine bus (low) connector sleeve 40E Z37/2 CAN engine bus (low) connector sleeve 27E Z37/2 CAN engine bus (low) connector sleeve 34E Z37/3 CAN engine bus (high) connector sleeve 54E Z37/3 CAN engine bus (high) connector sleeve 22E Z37/3 CAN engine bus (high) connector sleeve 50E Z37/3 CAN engine bus (high) connector sleeve 42E Z37/3 CAN engine bus (high) connector sleeve 38E
Z37/3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1524 · Applies to: 450, 451, 452, 454
CAN engine bus (high) connector sleeve 26E Z37/3 CAN engine bus (high) connector sleeve 33E Z37/4 Power steering CAN bus connector sleeve (low) 11F Z37/41 CAN databus (high) connector sleeve 18E Z37/41 CAN databus (high) connector sleeve 33G Z37/41 CAN databus (high) connector sleeve 30E Z37/42 CAN bus (low) connector sleeve 19E Z37/42 CAN bus (low) connector sleeve 34G Z37/42 CAN bus (low) connector sleeve 31E Z37/5 Power steering CAN bus connector sleeve (high) 10F Fig 1: CAN Bus Wiring Diagram (1 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: CAN Bus Wiring Diagram (2 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1525 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: CAN Bus Wiring Diagram (3 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1526 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 001 589 38 33 00 PULLER - WS82.00-N-3001B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1527 · Applies to: 450, 451, 452, 454
FG 82/Set B MODEL all Use: Puller for wiper arms Fig 4: CAN Bus Wiring Diagram (4 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 25 63 00 PULLER - WS82.00-P-0104B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1528 · Applies to: 450, 451, 452, 454
FG 82/Set B MODEL 450, 451, 452, 454 Use: Puller for routing wiring harnesses. NOTE: smart no.: 7028 V000Q001 0000 00. SPECIAL TOOLS > SPECIAL TOOLS: SMART: ELECTRICAL SYSTEM BODY - WS82.00-Z- 9999CZ > Fig 1: Identifying Puller (001 589 38 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Puller (450 589 25 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1529 · Applies to: 450, 451, 452, 454
000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P-0007B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P-0006Z 001 589 38 33 00 Puller FG 82/Set B WS82.00-N-3001B 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P-0027K 220 589 04 99 00 New passenger car wiring harne repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P-0006B 450 589 06 99 00 Tool kit for retrofitting AC system FG 82/Set B WS82.00-P-0030B 450 589 06 99 01 Modu 4 blade FG82/Set B WS82.00-P-0030- 01B 450 589 06 99 02 Multilock blade FG82/Set B WS82.00-P-0030- 02B 450 589 06 99 03 MDK/DFK blade FG82/Set B WS82.00-P-0030- 03B 450 589 06 99 04 AFK/AFS blade FG82/Set B WS82.00-P-0030- 04B 450 589 06 99 05 Hand pliers FG82/Set B WS82.00-P-0030- 05B 450 589 06 99 06 Blade holder FG82/Set B WS82.00-P-0030- 06B 450 589 25 63 00 Puller FG 82/Set B WS82.00-P-0104B 450 589 26 63 00 Adapter cable SAM St.8 FG 82/Set B WS82.00-P-0108B 450 589 27 63 00 Adapter cable SAM St.9 FG 82/Set B WS82.00-P-0109B 452 589 00 07 00 Removal/installation tool FG 82/Set B WS82.00-P-0033B 452 589 00 63 00 Adapter cable FG 82/set B WS82.00-P-0102B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P-0012K
GENERAL INFORMATION > INFORMATION ON PREVENTING DAMAGE TO ELECTRONIC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1530 · Applies to: 450, 451, 452, 454
COMPONENTS DUE TO ELECTROSTATIC DISCHARGE - AH54.00-P-0001-01A > All models Electrostatic charge Every contact and each physical separation of materials or any movement of solid substances, fluids or particulate loaded gases can generate electrostatic charges. Plastics generally produce the highest electrostatic charge. We come across electrostatic charge or discharge in lots of everyday situations, e.g. with: Combs Walking on carpets or plastic floors Putting on and removing textiles made with synthetic fiber Disembarking from the vehicle Contact between various electrostatically chargeable packaging materials in shelves or in the transport container The following electrostatic discharge (E lectro S tatic D ischarge (ESD)) can be so strong that a small electric shock is detected. Even the smallest discharges which people cannot detect can cause lasting damage to electronic components and control units. Effects and consequences of ESD Electronic components and control units are very sensitive to ESD. The damage is often not immediately obvious, but becomes apparent some time later. In order to avoid failures and damage due to ESD in vehicle electronics, various procedures and safety precautions must be taken into account and followed. Risks of damage occur during transport, handling, testing, removal and installation of electronic components in production as well as during repair work. The following electronic components listed as an example can be damaged by ESD: Airbag components Control units, in particular their bus connections (Control Area Network (data bus/CAN bus) (CAN), local interconnect network (LIN) etc.) Sensors Mechatronic components (actuators etc.) Antenna amplifier Receivers and displays (Radio, TV, GPS, telephone etc.) Modes of behavior and safety precautions
Electrostatic discharge from the fitter (e.g. due to brief contact with the vehicle body).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1531 · Applies to: 450, 451, 452, 454
Suitable clothing, e.g. made of cotton. Wear ESD safety shoes with conductive soles. Keep workplace clean, remove unnecessary objects such as common plastics. Special anti-static seat cushion protectors must be used when performing repair work inside a vehicle. Leave replacement parts in the original packaging for as long as possible, Do not cut open seals, but cut open carefully. The ESD workplace must conform to the ESD guidelines. ESD protection gotis://E 82 04.0 Before unpacking, discharge ESD protective packaging at the ESD workplace. Avoidance of contact with electrostatic chargeable materials such as PE, PVC, styrofoam. Use only original packaging or specially labeled and defined packaging and transport materials. Electronic components which have been removed must be put down on an ESD workplace. Touch connectors on electronic components and in the wiring harness on the housing only. Do not touch the pins and contacts! Electronic components must be installed before they are connected so that potential equalization with the body can take place. Shelves and worktables must stand directly on the floor, there must not be any insulating materials between the base of the shelves/feet and the floor. If the above mentioned insulators cannot be removed, the shelves and work tables must be grounded (e.g. low-resistance electrical connection/line from metal shelf to a heating pipe). Put down conductive transport container/box in a non insulated manner (e.g. on a wooden pallet), otherwise no potential equalization takes place. Do not place control units and electronic components removed from the vehicle on electrostatically chargeable materials, such as PE, PVC, styrofoam. The electrostatic charge is transferred to the control unit or electronic component. An ESD service kit or a connected ESD table mat must be used. Training We strongly advise that each company should appoint a trained ESD officer in accordance with DIN EN 61340-5-1. The ESD officer can hold employee training courses. The objective of the training course measures is to familiarize the employees with the essential difficulties and effects of ESD: Creation of discharging Reasoning behind safety precautions
Effects and consequences of ESD¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1532 · Applies to: 450, 451, 452, 454
ESD rules of conduct and safety precautions Returning electronic components in warranty and goodwill cases When returning electronic components it is absolutely essential to observe the procedure and safety precautions listed. Electrostatic charge or discharge mean the original fault can be falsified or overlaid. This can lead to distorted fault symptoms in the case of the fault analysis of the component concerned. GENERAL INFORMATION > NOTES ON BATTERY - AH54.10-P-0001-01A > All models General information on batteries Do not store batteries over a longer period at a storage point with direct solar radiation. Discharged or defective batteries can freeze, therefore store free from frost. Avoid polarity reversal and short-circuits. Do not place tool or other conducting objects on the battery (risk of short-circuit). Before removal and installation of batteries all switchable current consumers should be switched off, as well as the engine switched off so that inadvertent arcing is ruled out. Always disconnect the negative terminal first and always connect the positive terminal first. Only charge batteries with DC, 10 % of the capacity is recommended as charging current for slow charging and 50 % of the capacity recommended for fast charging. Only switch on the charger after connecting to the terminals and switch off before disconnecting. We recommend greasing the batteries slightly with battery terminal grease. If the battery is to remain in the parked vehicle for a longer time, the negative terminal should be disconnected. If possible batteries should be kept clean and dry. Batteries should not be stored over a longer period without recharging. Notes on lead-gel batteries (additional battery for special bodies) Lead-gel batteries are free from gassing, acid does not run out of them and are completely independent of position and maintenance free. When fast charging ensure that the housing of the lead-gel battery does not heat up excessively otherwise a pressure relief valve will be opened and the lead-gel battery will be defective. Notes on lead acid batteries Always store lead lead-acid batteries horizontally to prevent acid leaking out and do not tilt during transportation. When fast charging ensure that the housing of the lead-acid battery does not heat up excessively. GENERAL INFORMATION > NOTES ON SCN CODING OF CONTROL UNITS - AH54.21-P-
0004-01X >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1533 · Applies to: 450, 451, 452, 454
Model 129, 163, 164, 168, 169, 170, 171, 199, 203, 204, 208, 209, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251 Model 461, 463 Model 450, 451, 452, 454 Model 636, 639 Model 906 The "Software Calibration Number" (SCN) is specified by law in Europe and USA for all control units relevant to exhaust emission as of model year 2002. Accordingly the software and coding of such a control unit must be clearly identifiable by means of the SCN. As a number the SCN consists of 16 numbers. The first 10 places correspond to the object number to be coded (mostly object number of control unit software). The next 2 places designate the manufacturing plant or field organization, in which the vehicle has been coded. The last 4 places are a number of the variants of the coding string of the vehicle-specific as-built configuration. This number is serially numbered for each newly formed variant. If special equipment has been installed or removed in the vehicle (e.g. retrofitting a telephone), these retrofit codes must be added to the central system before requesting the SCN coding data. The appropriate national organization must be contacted (MPC) for this. MAINTENANCE > BATTERIES - CHECKING AND CORRECTING FLUID LEVEL - AP54.10- P-5410MCC > MODEL 451.3 (except 451.334) MODEL 451.3 (except 451.380) MODEL 451.4 (except 451.480) Removing
Risk of explosion caused by No fire, sparks, open AS54.10-Z-0001- Fig 1: Identifying Battery Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Adaptation of audio settings added¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1538 · Applies to: 450, 451, 452, 454
13.1.11 Adaptation of audio settings added Step 9
Remove/install
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 Risk of death when touching components on vehicles with high-voltage system Do not touch components and open lines of high-voltage system. Persons with electronic implants (e.g. cardiac pacemakers) must never work on high- voltage systems. AS54.00- Z-0001- 02MEV 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 Notes on battery
AH54.10- P-0001- 01A Notes on AGM battery Model 451.334/380/480 AH54.10- P-0002- 01MCC
On vehicles with code (527) High-Line radio, before the ground line (1) is disconnected, it must be ensured that the radio code is available to allow the radio to be put into operation at a later stage.
1 Check condition of battery (G1), if necessary replace battery (G1) Only with model 451.391/491 if during the further course of work, work is to be conducted on the high voltage vehicle electric system. The high voltage system cannot be enabled if the battery (G1) is defective: Before replacing the battery (G1) on model 451.391/491 no further work may be performed on the high-voltage vehicle electrical system. AR54.10- P- 1129MCC Carry out disconnection of Only with model 451.391/491 if during the further course of work, work is to be AR54.10-
approx. 1.5 cm with pliers (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1542 · Applies to: 450, 451, 452, 454
3 Remove bolts (3)
4 Swivel the trim of the vertical strut (1) backwards in the lower area and remove until the electrical connector (5) of the interior socket (X58/1) as well as the electrical connector (4) of the data link connector (X11/4) are accessible
5 Separate the electrical connector (5) of the interior socket (X58/1) and electrical connector (4) of the data link connector (X11/4)
6 Remove vertical strut paneling (1)
7 Unclip interior socket (X58/1) from rear of vertical strut paneling (1) and remove toward front Installation: Before installing in the trim of the vertical strut, pull out the metal insert of the interior socket (X58/1) (1) using the pliers (2).
8 Install in the reverse order
TESTING & REPAIR > CHECK QUIESCENT CURRENT CONSUMPTION - AR54.10-P- 1030MCE > MODEL 451.3/4 Fig 2: Identifying Pliers (169 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
con umer (e g charger ,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1544 · Applies to: 450, 451, 452, 454
MP3 player, amplifier etc.) 8 Open doors and liftgate
9 Lock rotary tumblers on doors and liftgate The interior illumination in the vehicle must go out.
10 Lock the vehicle using the central locking with open doors and liftgate A waiting time of at least 6 mins. must be waited after locking the vehicle.
Measure
11 Set multimeter to highest possible current measurement range Standard digital multimeter gotis://E_15/54_06.0
12 Connect multimeter between ground line (1) and negative terminal on battery (G1) without any interruption To prevent any voltage reset, the current flow must not be interrupted. When fitting the multimeter, bridge the negative terminal of the battery (G1) beforehand.
13 Measure no-load current
14 Remove fuses one by one from the SAM control unit and localize the faulty control unit or defective consumer If the value for the no-load current measurement: On vehicles without code (V01) Antitheft alarm system (FFO) exceeds 40 mA. On vehicles with code (V01) Antitheft alarm system (FFO) exceeds 50 mA. Wait in each case for at least 6 mins. until the next measurement to enable the activated bus to return to idle.If the fuse of the defective consumer or control unit is removed, the no-load current drops immediately The fu e and relay assignment enables the increased no-load current consumption to be restricted to specific control units and con umer To re trict the increased no-load current consumption yet further, the
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1546 · Applies to: 450, 451, 452, 454
70 Ah VRLA 74 AH 80 Ah VRLA 84 AH BE54.10-P-1002- 01A Cold test current as per EN A 760 680 800 700 TEST AND ADJUSTMENT VALUES FOR THE BATTERY Number Designation 90 Ah VRLA 95 Ah VRLA 100 Ah BE54.10-P-1002- 01A Cold test current as per EN A 950 850 760 On model 414 the battery has to be disconnected for the tests to avoid any damage. Perform test for remaining vehicles with battery installed and connected where possible. Do not connect tester to jump start or charging terminal point, always connect it directly with the battery. Battery tester gotis://E_15/54_02. 0 All test steps and entries must be performed thoroughly, otherwise the test result will be distorted. Test prerequisites: Tester with software release 2.0 Ignition off Rotary light switch in position "0" If the message "Surface voltage" is displayed during the test, the tester has detected that the battery voltage is apparently too high. This increased voltage can be reduced as follows: Battery installed: Decrease increased voltage as per the specifications of the tester (e.g. switch on driving lights). Battery removed: reduce increased voltage using a suitable volt/amp(s) tester (load battery for approx. 60 s with 20 A to 30 A amps). As an example, the test procedure for passenger cars is described below. Audio component (e.g. radio) switched off Battery voltage higher than 12.4 V Good contact of the tester on the battery 1. Clip tester (1) on to battery. Once the tester is connected the current measured battery voltage is displayed for approx. 2 s. If a so-called "System noise" is detected by the tester, check whether all consumers are switched off and wait (for approx. 2 min), until the quiescent current is minimized and the bus systems are switched off.
2. Follow the menu and select according to the situation:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1547 · Applies to: 450, 451, 452, 454
- In vehicle (battery connected to on-board electrical system)
- Not in vehicle (battery disconnected from on-board electrical system) Confirm selection with "Enter". Fig 1: View Of Clip Tester Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Display Battery Selection Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Follow the menu and select according to the situation:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1548 · Applies to: 450, 451, 452, 454
- 12-114 AH (battery capacity 12-114 Ah)
- AH > (battery capacity ≥115 Ah) Confirm selection with "Enter".
- Follow menu and select battery type:
- Normal
- VRLA Confirm selection with "Enter".
- Follow the menu selection and select the test standard for the cold cranking amps. The test standard is printed on behind the specification of the cold cranking amps. If the imprint of the test standard is not available, select the cold cranking amps "EN". Example: 12 V 46 Ah 420 A → Select EN. Fig 3: Display Battery Selection - Battery Capacity Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Display Battery Selection - Battery Type Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Confirm selection with "Enter".¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1549 · Applies to: 450, 451, 452, 454
- Read off cold cranking amps and enter in tester. Example: 12 V 46 Ah 420 cold cranking amps → 420 A. Confirm input with "Enter". The battery test starts after confirmation of the cold cranking amps entry. The test result or one of the following messages appears after approx. 15 s:
- Test code → Step 7
- Vehicle model → Step 9
- Temperature > 0°C/< 0°C → Step 10
- Before charging/After charging → Step 11
- Surface voltage DETECTED (see above) Fig 5: Display Selection Of Battery Testing For Cold Cranking Amps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Read off test code with "Enter" and continue accordingly:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1550 · Applies to: 450, 451, 452, 454
- "Battery in good condition": No further measures required.
- "Charge and test": Fully charge battery and retest (battery voltage > 12.4 V).
- Print out test code and file in a tamperproof manner.
- "Replace battery": Replace battery if this message appears.
- Follow the menu and select test mode:
- Cars
- Taxi Confirm selection with "Enter". Fig 6: Display Test Result Of Cold Cranking Amps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
10. Follow the menu and select test mode:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1551 · Applies to: 450, 451, 452, 454
-
0°C
- < 0°C Confirm selection with "Enter". If this message appears, the battery condition cannot be evaluated.
- Follow the menu and select test mode:
- BEFORE CHARGE
- AFTER CHARGE Confirm selection with "Enter". Fig 7: Display Selection Of Test Mode - Cars And Taxi Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Display Selection Of Test Mode - Above 0°C And Below 0°C Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.4 with code (I01)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1559 · Applies to: 450, 451, 452, 454
Air conditioning Plus Fig 2: Identifying Electrical Line, Grommet, Bracket And Brake Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.4 with code (I01)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1560 · Applies to: 450, 451, 452, 454
Air conditioning Plus
Remove/install
1 Disconnect ground line of battery (G1)
AR54.10- P- 0003MCC 2 Remove cover (2)
3 Unscrew nut (4) and place electrical line (3) to one side
4 Detach positive terminal (6) of electrical line (1) to the battery (G1)
5 Unclip holder (5) of electrical line (1) on battery tray The brackets (5, 8, 14, 15) and the bracket (arrow A) as well as the protective covers on the electrical line (1) are present on the new electrical line (1), when reusing the old electrical line (1) ensure that it is not damaged.
Risk of death Fig 3: Identifying Electrical Line, Nuts, Brackets, Generator And Starter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
cau ed by vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1561 · Applies to: 450, 451, 452, 454
slipping or toppling off of the lifting platform. Align vehicle between column of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00 00 Z-0010- 01A 6 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver gotis://G_58.0_01.1
7 Release rear drive module
AR01.00- P- 3050MCU 8 Release grommet (7) of electrical line (1) from battery recess Installation: Ensure that grommet (7) is seated correctly.
9 Mark the position of brackets (5, 8, 14, 15), the bracket (arrow A) as well as the bracket (11) and bracket (arrow B) on the electrical line (1)
10 Unclip bracket (8) and bracket (arrow A) of electrical line (1) on underfloor
11 Unclip electrical line (1) from holder (9) on brake line (10)
12 Unclip electrical line (1) from bracket (11) and bracket (arrow B)
13 Unscrew nut (12) on starter (M1) and remove electrical line (1)
14 Unclip bracket (14) of electrical line (1) on intake manifold
15 Unclip holder (15) of electrical line
Unscrew nut (13)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1562 · Applies to: 450, 451, 452, 454
(1) 16 Unscrew nut (13) on alternator (G2) and remove electrical line (1)
17 Route electrical line (1) out and then remove Route electrical line (1) accurately, as otherwise the line may suffer from chafing and crushing. Installation: Replace damaged bracket (5, 8, 14, 15) and bracket (arrow A). The new brackets (5, 8, 14, 15) as well as bracket (arrow A) should be attached in exactly the same position of the electrical line (1).Make sure that the new holders (5, 8, 14, 15) and the holder (arrow A) are not twisted through 180° when secured to the electrical line (1).
18 Transfer all markings made to the electrical line (1) to the new electrical line (1) When replacing the electrical line (1). This ensures that the brackets (5, 8, 14, 15), the bracket (arrow A) as well as the bracket (11) and bracket (arrow B) are positioned at exactly the same point on the new electrical line (1), their position should be corrected if necessary.
19 Install in the reverse order
TESTING & REPAIR > REPAIR WIRING HARNESS BY MEANS OF AXIAL SOLDER CONNECTORS - AR54.18-P-0100-06A > 1. Expose damaged cable or plug/coupling in easily accessible position and cut off. Separate cores in wiring harness offset by approx. 45 mm. 2. Cut new section of cable to match old cable. 3. Remove 15 mm of insulation at end of cables. Pull cut-off insulation off the line while turning. Fig 1: Identifying Wiring Harness Offset Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Select axial solder connector by means of cable cross-section.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1563 · Applies to: 450, 451, 452, 454
- Push the axial solder connector on line beyond the solder point. Push on the thinner side of the axial solder connector first.
- Twist the line ends together.
- Push back the axial solder connector on the transposition while turning. Fig 2: Identifying Cable Insulation Dimensions Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Pushing On Axial Solder Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Heat up axial solder connector with a preheated hot air blower (with electronic temperature control)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1564 · Applies to: 450, 451, 452, 454
to 400°C. Hot air blower gotis://E 15/54 12. 0 Use welding bead catcher in the vehicle interior in order to avoid damage due to liquid solder. Until the soldering ring has dissolved and the covering has positioned itself properly around the lines. 9. Check soldered point. It must not be possible to see the soldering ring of the axial soldered connector any more. The covering must contact the lines properly. Fig 4: Twisting Line Ends Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Heating Axial Solder Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Select menu "Systems" in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1566 · Applies to: 450, 451, 452, 454
3 Select menu "Systems" in main menu and confirm with "Button F3"
4 Select the control unit to be flashed in the "systems" menu and confirm with the "F3 button" The following control units can be flashed: N3/10 (ME-SFI [ME] control unit) N10/10 (SAM control unit) N15/6 (Sprintshift control module) N47-5(ESP control unit)
5 Select the "Control unit adaptations" in the selected menu of the corresponding control unit and confirm with the "F3 button"
6 Select the submenu "Program control unit" in the "Control unit adaptations" menu and confirm with the "F3 button"
7 Select the "hard drive menu: Version Month/ Year (year/month/day)" and confirm with the "F3 button" The information on the flashing systems appears in the display.
8 Start the flashing process by pressing the "F3 button" Programming lasts about 3 minutes.
9 Select the "online (networked STAR DIAGNOSIS unit)" menu or "offline (no networked STAR DIAGNOSIS unit)" menu and start SCN coding by confirming with the "F3 button" Only if the SCN coding command appears in the display. We recommend always performing SCN coding with SDflash online. Only perform Offline SCN coding with a non-networked STAR DIAGNOSIS.
SCN coding with SDflash Online AR54.21-P-0013- 02MCC
Offline SCN coding AR54.21-P-0013- 04MCC Notes on SCN coding of control units
AH54.21-P-0004-01X
Close STAR DIAGNOSIS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1567 · Applies to: 450, 451, 452, 454
10 Close STAR DIAGNOSIS
TESTING & REPAIR > SCN CODING WITH SDFLASH ONLINE - AR54.21-P-0013-02MCC > The following work instructions describes the procedure for Online SCN coding with "SDflash". "SDflash" is the product designation of the program for determining the SCN coding and parameterization data. Prerequisite for Online SCN coding with "SDflash": Networked STAR DIAGNOSIS diagnosis system Access to "SDflash" with corresponding rights SCN coding with "SDflash" 1. Confirm note on sequence of SCN coding with the "F2 button". 2. Select "Operation step 1: Determine vehicle data for online SCN coding from the vehicle" menu and confirm with the "F3 button". 3. Confirm the correct vehicle identification number with the "F3 button". The note that the vehicle data determination was successful appears in the display. 4. Select "Operation step 2: online query SDflash" menu and confirm with the "F3 button". 5. Press "F2 button" for starting the online query. 6. Press "F2 button" for starting the web browser. The web page of the aftersales platform appears in the display. 7. Select the symbol (house) which is located in the top third of the web page. 8. Enter user name and password and select logging on symbol. The applications available appear in the display. 9. Select "SDflash" in the display. 10. Select symbol (Start) in the display. The message that the SCN coding and the coding string formation has been successfully finished appears in the display. 11. After "When the inquiry about the coding data has finished, proceed with the F2 button" appears in the display, press the "F2 button". 12. Select "Operation step 2: Perform SCN coding" menu and confirm with "F3 button". 13. Confirm the correct vehicle identification number with the "F3 button". 14. Press "F3 button" and transfer coding data to the control unit. 15. Once "Switch on ignition" appears in the display, switch on ignition. The coding process starts automatically and lasts about 10 seconds.
16. Once "Switch off ignition" appears in the display, switch off ignition.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1568 · Applies to: 450, 451, 452, 454
- After the coding process has finished the order event log for the documentation of the SCN repair order appears. This order event log must be filled in completely, then printed out with the "F11 button" and enclosed with the repair order.
- Finish SCN coding by pressing the "F2 button". The online SCN coding of the control unit is thus successfully completed. TESTING & REPAIR > OFFLINE SCN CODING - AR54.21-P-0013-04MCC > The following work instructions describe the procedure for offline SCN coding. Precondition for offline SCN coding: STAR DIAGNOSIS diagnosis system with printer and fax machine Correct adjustment of date and time in STAR DIAGNOSIS Special equipment which was subsequently installed in or removed from the vehicle, must be redocumented in the vehicle documentation system (FDOK). Offline SCN coding
- Confirm note on sequence of SCN coding with the "F2 button".
- Prepare the inquiry form by pressing the "F4 button".
- Print out inquiry form by pressing the "F11 button".
- Send the printed-out inquiry form to fax number +49 180511 6373. The inquiry result must be faxed back immediately.
- Enter "coding string", "SCN" and "check digit [2]" in the corresponding input fields in the diagnosis assistance system and confirm with the "F3 button".
- Once the coding process has finished the event log on the documentation of the repair order appears. This event log must be filled in completely, then printed out with the "F11 button" and enclosed with the repair order.
- Finish SCN coding by pressing the "F2 button". SCN coding of the control unit is thus successfully concluded. TESTING & REPAIR > PERFORM INITIAL STARTUP OF CONTROL UNITS - AR54.21-P- 0018MCE > MODEL 451.3/4
Startup
1 Connect Star Diagnosis
AD00.00-P-2000- 04MCC 2 Enter vehicle identification number in Diagnosis Assistance system (DAS) and
open main menu with "F2"¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1569 · Applies to: 450, 451, 452, 454
button 3 Select menu "Systems" in main menu and confirm with "Button F3"
4 In the "Systems" menu, select the control unit for initial startup and confirm with the "F3" button An "initial startup" is required when replacing the following control units: Instrument cluster (A1) Weight Sensing System (WSS) control unit (N110) with code (494) USA version Starter- alternator control unit (N129) with model 451.334/380/480 Electronic selector lever module control unit (N15/5) Restraint systems control unit (N2/7) Heater and A/C operating unit (N23) with code (I01) A/C Plus CDI control unit (N3/9) with engine 660 ME-SFI [ME] control unit (N3/10) with engine 132 SAM control unit (N10/10) Automated manual transmission control unit (N15/6) ESP control unit (N47-5) Steering assist control unit (N68) TPM [RDK] control unit (N88) with code (494) USA version
5 In the menu for the selected control unit, choose the "Initial startup" menu item and confirm
with the "F3" button¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1570 · Applies to: 450, 451, 452, 454
6 Confirm "Notes for initial startup of control unit" with "F2" button
7 Select the "online (networked STAR DIAGNOSIS unit)" menu or "offline (no networked STAR DIAGNOSIS unit)" menu and start by pressing the "F3" button
8 Follow the further instructions in DAS.
9 Close Star Diagnosis
TESTING & REPAIR > REMOVE/INSTALL FRONT SAM CONTROL UNIT - AR54.21-P- 1254MCU > MODEL 451.3/4 Remove/install
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Fig 1: Identifying Front SAM Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1572 · Applies to: 450, 451, 452, 454
1 Remove steering column cover
AR68.30-P- 2000MCC 2 Unclip catch hook (3) on right wiper switch (S4/4)
3 Lift right wiper switch (S4/4) upwards from the guides (4) and remove to one side until the electrical connector (1) is accessible
4 Detach electrical connector (1) on the right wiper switch (S4/4) and remove the right wiper switch (S4/4)
5 Release cap (2) by applying suitable knife to right wiper switch (S4/4) and remove When replacing right wiper switch (S4/4).
6 Install in the reverse order
7 Conduct function test of right wiper switch (S4/4)
TESTING & REPAIR > REMOVE/INSTALL COCKPIT SWITCH GROUP - AR54.25-P- 1000MCC > MODEL 451.3/4 Fig 1: Identifying Wiper Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1574 · Applies to: 450, 451, 452, 454
1 Remove transponder coil and put to one side with electrical line connected
AR80.35-P- 4515MCU 2 Remove clamp (2)
3 Insert transmitter key (3) into the lock cylinder of the ignition/starter switch (1) and switch on ignition (circuit 15) Ensure that the selector lever is located in position "P".
4 Slide in feeler gauge (4), on the left side as shown, between the lock cylinder of the ignition/starter switch (1) and electronic selector lever module control unit (N15/5) Use blade of feeler gauge (4) with the thickness of 0.15 mm.
5 Pull out lock cylinder of ignition/starter switch (1) with transmitter key (3) upwards If necessary move the feeler gauge (4) slightly, so that the locking device (5) is released from the bracket (arrow).
Install
6 Insert lock cylinder of ignition/starter switch (1) with transmitter key (3) in the electronic selector lever module control unit (N15/5) Ensure that the selector lever is located in position "P".The lock cylinder of the ignition/starter switch (1) must engage audibly in the
Fig 1: Identifying Ignition/Starter Switch Lock Cylinder Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1577 · Applies to: 450, 451, 452, 454
Remove/install
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Pull the instrument cluster (A1) in the direction of the arrow out of the dashboard upper section until the connector (2) on the instrument cluster (A1) is accessible Check position of clamps (1). When removing the instrument cluster (A1) there is the danger that the clamps (1) can fall through the openings (arrows A) in the instrument cluster (A1).
2 Unlock connector (2) on the instrument cluster (A1), detach and remove instrument cluster (A1) backwards Clamps (1), which have fallen into instrument cluster (A1) when removing, must be got out again otherwise a short circuit in the instrument cluster can occur (A1). This must only take place through the opening a (arrow A). Disassembling the instrument cluster (A1) is not permissible.
3 Remove clamps (1) on top part of dashboard or on instrument cluster (A1) Installation: The clamps (1) are to be replaced by the clamps (1) listed in the Parts ordering notes table. Insert new clamps (1) in the top part of the dashboard.
Fig 1: Identifying Instrument Cluster, Clips And Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install in the reverse order¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1578 · Applies to: 450, 451, 452, 454
4 Install in the reverse order
5 Set clock in the instrument cluster (A1)
PARTS ORDERING NOTES Part no. Designation Quantity A 203 988 28 78 Clamp 2 TESTING & REPAIR > REMOVE/INSTALL ADDITIONAL INSTRUMENTS - AR54.30-P- 6080MCC > MODEL 451.3/4 as of 31.8.10 with CODE (V31) Cockpit clock and tachometer package Remove/install
1 Remove instrument cluster (A1) * not for USA AR54.30- P- 6015MCC * for USA only AR54.30- P- 6015MCU 2 Remove covering (2) of additional instruments (A15)
3 Remove bolt (3) of additional instruments (A15)
Fig 1: Identifying Additional Instruments Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Adjust driver seat to the rear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1579 · Applies to: 450, 451, 452, 454
4 Adjust driver seat to the rear
5 Unhook wiring harness for additional instruments (1) from holders (arrows) at bottom of instrument panel upper section The wiring harness additional instrument (1) can be accessed from the driver footwell.
6 Detach the additional instrument connector (A15x1) located in the installation opening of the IC (A1)
7 Remove additional instruments (A15)
8 Install in the reverse order
9 Set clock of additional instruments (A15)
TESTING & REPAIR > REMOVE/INSTALL ADDITIONAL INSTRUMENTS - AR54.30-P- 6080MCF > MODEL 451.3/4 as of 31.8.10 with CODE (V31) Cockpit clock and tachometer package Remove/install
1 Remove instrument cluster (A1) * not for USA AR54.30- P- 6015MCC
- for USA only AR54.30- P- 6015MCU Fig 1: Identifying Additional Instruments Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1581 · Applies to: 450, 451, 452, 454 · AR: AS54.00-Z-9999ZZ
1 Remove front CBS
AR88.00- P- 1010MCC 2 Disconnect electrical connectors from horn (H2) Installation: Carry out a function test after connecting the electrical connectors to the horn (H2).
3 Unscrew bolt (1) and remove horn (H2)
4 Install in the reverse order
SAFETY PRECAUTIONS > SAFETY INFORMATION: ELECTRICAL SYSTEM, EQUIPMENT AND INSTRUMENTS - AS54.00-Z-9999ZZ > MODEL all Risk of death when touching components on vehicles with high- voltage on-board electrical system MODEL all AS54.00-Z-0001- 01A Risk of death when touching components on vehicles with high- voltage system MODEL 451.391/491 AS54.00-Z-0001- 02MEV Risk of explosion from gas. Risk of poisoning and burns from swallowing battery electrolyte. Risk of injury to eyes and skin as result of caustic burns from battery electrolyte or from handling damaged lead-acid batteries. MODEL all AS54.10-Z-0001- 01A Risk of injury caused by contact with battery gel when handling damaged lead-gel batteries MODEL all AS54.10-Z-0001- 02A Fig 1: Identifying Horn And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SAFETY PRECAUTIONS > RISK OF EXPLOSION FROM GAS. RISK OF POISONING AND¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1582 · Applies to: 450, 451, 452, 454
BURNS FROM SWALLOWING BATTERY ELECTROLYTE. RISK OF INJURY TO EYES AND SKIN AS RESULT OF CAUSTIC BURNS FROM BATTERY ELECTROLYTE OR FROM HANDLING DAMAGED LEAD-ACID BATTERIES. - AS54.10-Z-0001-01A > No fire, sparks, naked flames or smoking. Wear acid-resistant gloves, clothing and eye protection. Pour battery electrolyte only into suitable and appropriately marked containers. Possible hazards Risk of explosion A highly explosive gas mixture is produced when charging lead-acid batteries. Risk of poisoning If battery electrolyte is swallowed , this can result in manifestations of poisoning such as headaches, dizziness, stomach pain, respiratory paralysis, unconsciousness, vomiting and cramps. Battery electrolyte mist causes caustic burns to the eyes. If swallowed, this can result in caustic burns to the mucous membranes and respiratory passages. The absorption of lead in the body can cause damage to blood, nerves and kidneys; in addition, lead compounds are considered to represent a reproductive hazard. Injury hazard Battery electrolyte contains sulfuric acid which can cause severe caustic burns to skin and eyes. Strict caution is required when handling damaged lead-acid batteries (removing from vehicle damaged in accident) because of the sharp edges on the fractured housing and direct contact with the lead plates. Protective measures/rules of conduct Charge lead-acid batteries only in well ventilated areas. No fire, sparks, naked flames or smoking. Do not place any tool or other conducting objects onto the lead-acid battery (risk of short-circuit). Disconnect and remove lead-acid batteries for charging. Always disconnect negative terminal first of all; always connect positive terminal first of all. Do not switch on the charger until after it has been connected to the terminals; switch it off before disconnecting. Keep lead-acid batteries and battery electrolyte away from unauthorized persons. Pour battery electrolyte only into suitable and appropriately marked containers. Always store lead-acid batteries horizontally. Ensure the gassing line is properly connected. Ensure the gassing line does not have any kinks and is not blocked at any point. Pay attention to instructions for use of the particular lead-acid battery and the operating instructions of the vehicle.
Wear acid-resistant clothing and eye protection with side guards.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1583 · Applies to: 450, 451, 452, 454
First-aid measures Eye contact Rinse out eyes immediately with plenty of water. Skin contact Take off moistened clothing. Immediately neutralize acid splashes on skin or clothing with acid converter or soap suds and rinse off with plenty of water. Inhaling battery electrolyte mist Take the affected person out into the fresh air. Swallowing battery electrolyte Have the person affected drink plenty of water with the addition of activated charcoal. As a general rule, the person affected should consult a medical service or doctor after first-aid has been rendered. Fire protection measures Suitable extinguishing agents CO and dry extinguishing agent Warning instructions for lead-acid batteries SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY CONTACT WITH BATTERY GEL WHEN HANDLING DAMAGED LEAD-GEL BATTERIES - AS54.10-Z-0001-02A > 2 Fig 1: Identifying Warning Instructions For Lead-Acid Batteries Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1584 · Applies to: 450, 451, 452, 454
glasses. Potential risks Risk of poisoning If battery gel is swallowed this can cause poisoning symptoms such as headaches, dizziness, stomach aches, respiratory paralysis, unconsciousness, vomiting, caustic burns and cramps. The absorption of lead in the body can cause damage to blood, nerves and kidneys; in addition, lead compounds are considered to represent a reproductive hazard. Risk of injury Battery electrolyte gel is just as caustic as normal electrolyte fluid and can cause serious caustic burns to the skin and eyes. Strict caution is required when handling damaged lead-gel batteries (e.g. when removing from a vehicle damaged in an accident) due to the sharp edges on a broken housing and direct contact with the lead plates. Safety precautions and rules of conduct No fires, sparks, open flames or smoking. Keep tools and other conductive objects away from lead-gel batteries (risk of short-circuit). Disconnect and remove lead-gel batteries for charging. Always disconnect negative terminal before positive terminal and always connect positive terminal before negative terminal Switch on the charging equipment only after connecting to the terminals and switch off the charging equipment before disconnecting from the terminals. Keep lead-gel batteries away from unauthorized persons (especially children). Observe the instructions of the particular lead-gel battery and the operator's manual of the vehicle. Wear acid-resistant clothing and eye protection with side guards. Only fill gel into suitable and appropriately marked containers. First aid measures Eye contact Rinse out eyes immediately with plenty of water. Skin contact Remove affected clothing. Immediately neutralize acid or gel on skin or clothing with acid converter or soap suds and rinse off with plenty of water. Swallowing battery gel Have the person affected drink plenty of water with the addition of activated charcoal. As a general rule, always consult a medical service or doctor after first-aid has been rendered.
Fire protection measures¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1585 · Applies to: 450, 451, 452, 454
Suitable extinguishing agents CO and dry extinguishing agent RETROFITTING & CONVERSION > RETROFIT ADDITIONAL INSTRUMENTS - AZ54.30-P- 0001MCC > MODEL 451.3/4 up to 30.8.10 Remove
1 Remove cover (1) on center console
AR68.20-P- 2350MCC Install
2 Make the cutouts (2) to
2 Fig 1: Identifying Cover And Cutouts Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Additional Instruments Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
match the perforation¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1586 · Applies to: 450, 451, 452, 454
(arrows) on the cover (1) 3 Position additional instruments (A15) on dashboard upper section and fasten in place using the bolts (3)
4 Connect additional instruments connector (A15x1) The plug for the additional instrument connector (A15x1) is located in the attachment between the air vents. If the plug for the additional instrument connector (A15x1) has not been clipped into the attachment, then the wiring harness is to be tied back and down in a loop.
5 Fit cover (1) onto center console
AR68.20-P- 2350MCC 6 Set clock of additional instruments (A15)
7 Add special equipment to the vehicle data card and to the online vehicle data card Code (V31) Cockpit clock and tachometer package to be added.
RETROFITTING & CONVERSION > RETROFIT ADDITIONAL INSTRUMENTS - AZ54.30-P- 0001MCD > MODEL 451.3/4 as of 31.8.10 Parts scope for additional instrument (A15) Fig 1: Identifying Cover, Screw And Additional Instruments Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Detach covering (3) with clip¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1588 · Applies to: 450, 451, 452, 454
3 Detach covering (3) with clip remover, as shown, and remove Clip remover *452589016300 Install
4 Slide wiring harness for additional instruments (6) through the left opening and under the covering (3) towards the instrument cluster
5 Clip additional instruments (A15) into instrument panel
6 Bend into the footwell and route wiring harness for additional instrument (6) at the bottom of the instrument panel upper section towards the instrument cluster
7 Hook wiring harness for additional instruments (6) into holders (arrow C and B) at bottom on instrument panel upper section
8 Detach black, 3-pin connector (5) from vehicle wiring harness in area of instrument cluster (A1)
9 Connect black, 3-pin connector (5) and black, 3-pin coupling (6.1) of wiring harness for additional instruments (6) The additional instruments connector (A15x1) is now complete.
10 Use bolt (1) to tighten additional instruments (A15)
11 Clip cover (2) over the bolt (1) on the additional instruments (A15)
12 Move driver seat back to its default position
13 Install in the reverse order
14 Set clock of additional instruments (A15)
15 Connect Star Diagnosis
AD00.00-P-2000- 04MCC 16 Enter special equipment on the vehicle data card and the online vehicle data card Code (V31) Cockpit clock and tachometer package to be added.
17 Disconnect Star Diagnosis
AD00.00-P-2000- 04MCC 18 Document retrofitted equipment using vehicle documentation (VeDoc) Attach "Additional instruments (A15) retrofitted as per
BE54.10-P-1000-01A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1590 · Applies to: 450, 451, 452, 454
All MODIFICATION NOTES 24.2.06 Cold test current 12 AH
TEST AND ADJUSTMENT VALUES FOR THE BATTERY Number Designation 12 AH 30 AH 35 Ah 42 AH BE54.10- P-1001- 01A Battery test at 20°C Acid density kg/dm - ≥1,24 ≥1,24 - Maximum permissible difference between individual battery cells kg/dm - 0,04 0,04 - Load current A - 90 100 - Load time s - 10 10 - Voltage VV - ≈10 ≈10 - BE54.10- P-1002- 01A Cold test current as per EN A 170 540 520 340 TEST AND ADJUSTMENT VALUES FOR THE BATTERY Number Designation 46 AH 60 Ah VRLA 60 AH 61 AH BE54.10- P-1001- 01A Battery test at 20°C Acid density kg/dm ≥1,24 - - - Maximum permissible difference between individual battery cells kg/dm 0,04 - - - Load current A 140 - - - Load time s 10 - - - Voltage VV ≈10 - - - BE54.10- P-1002- 01A Cold test current as per EN A 420 680 510 540 TEST AND ADJUSTMENT VALUES FOR THE BATTERY Number Designation 62 AH 70 Ah VRLA 74 AH 80 Ah VRLA 3 3 3 3
BE54.10-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1591 · Applies to: 450, 451, 452, 454
P-1001- 01A Battery test at 20°C Acid density kg/dm ≥1,24 - ≥1,24 - Maximum permissible difference between individual battery cells kg/dm 0,04 - 0,04 - Load current A 190 - 265 - Load time s 10 - 10 - Voltage VV ≈10 - ≈10 - BE54.10- P-1002- 01A Cold test current as per EN A 480 760 680 800 TEST AND ADJUSTMENT VALUES FOR THE BATTERY Number Designation 84 AH 90 Ah VRLA 95 Ah VRLA 100 Ah BE54.10- P-1001- 01A Battery test at 20°C Acid density kg/dm - - - ≥1,24 Maximum permissible difference between individual battery cells kg/dm - - - 0,04 Load current A - - - 300 Load time s - - - ≈10 Voltage VV - - - ≈10 BE54.10- P-1002- 01A Cold test current as per EN A 700 950 850 760 BASIC KNOWLEDGE > FUSE AND RELAY BOX, AS-BUILT CONFIGURATION - GF54.15-P- 0800MCU > MODEL 451.3/4 3 3 3 3
Fuse and relay assignment of SAM control unit (N10/10) (back side)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1593 · Applies to: 450, 451, 452, 454
Position Fuse Identification color Fused function Fuse rating in amperes (A) Fig 1: Identifying Fuse Sockets Of Front Side SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Fuse Sockets And Electrical Connectors Of Back Side SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
N10/10f1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1594 · Applies to: 450, 451, 452, 454
1 N10/10f1 transparent Starter (M1) 25 2 N10/10f2 transparent Wiper motor (M6/1) 25 3 N10/10f3 Yellow Power window convenience feature control unit (N57/2) (with code (V43) Power window) 20 4 N10/10f4 transparent Blower motor (M2) 25 5 N10/10f5 red Left front fog lamp (E5/1) (with code (V07) front fog lamp (FFO))Right front fog lamp (E5/2) (with code (V07) Front fog lamp (FFO)) 10 6 N10/10f6 brown Right taillight (E4e2)Right parking lamp (E6/14)Left license plate lamp (E19/1)Right license plate lamp (E19/2) 7.5 7 N10/10f7 brown Left taillight (E3e2)Left parking light (E6/13) 7.5 8 N10/10f8 transparent Secondary air injection pump relay (K64)ME-SFI [ME] control unit (N3/10)Electronic selector lever module control unit (N15/5)Automated manual transmission control unit (N15/6)Cylinder 1 ignition coil (T1/1)Cylinder 2 ignition coil (T1/2)Cylinder 3 ignition coil (T1/3) 25 9 N10/10f9 brown O2 sensor downstream of CAT (G3/1)Adjustable camshaft timing solenoid (Y49)External air shutoff valve (Y50)Activated charcoal canister shutoff valve (Y58) 7.5 10 N10/10f10 blue O2 sensor upstream of CAT (G3/2)Secondary air injection pump switchover valve (Y32)Cylinder 1 fuel injection valve (Y62/1)Cylinder 2 fuel injection valve (Y62/2)Cylinder 3 fuel injection valve (Y62/3) 15 11 N10/10f11 transparent ESP control unit (N47-5) 25 12 N10/10f12 red Instrument cluster (A1)Additional instruments (A15)Microwave sensor (B32) (with code (V01) Vehicle theft alarm (FFO))Rain sensor / light sensor (B38) (with code (V54) Rain/light sensor)Alarm siren with inclination sensor (H3/2) (with code (V01) Vehicle theft alarm (FFO))Left turn signal lamps/brake light relay (K52/11)Right turn signal lamps/brake light relay (K52/12)Mirror heater relay (K97)Automated manual transmission control unit (N15/6)TPM [RDK] control unit (N88)Combination switch 10
(S4)Cockpit switch group (S6/1)Data link¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1595 · Applies to: 450, 451, 452, 454
connector (X11/4) 13 N10/10f13 blue Spare fuse 15 14 N10/10f14 blue Refrigerant compressor (A9) (with code (I01) Air conditioning Plus)Charge air fan motor (M44) 15 15 N10/10f15 blue smart radio 9 (A2/1) (with code (C57) smart radio 9)smart radio 10 (A2/2) (with code (C50) smart radio 10)Front interior lamp (E15/4) (with vehicles up to production date 1.9.10)Soft top OPEN relay (K66/1) (on model 451.4)Soft top CLOSE relay (K66/2) (on model 451.4) 15 16 N10/10f16 blue Fuel pump with fuel gauge sensor (M3/3)ME-SFI [ME] control unit (N3/10) 15 17 N10/10f17 blue Rear-end door wiper motor (M6/4) (with model 451.3) 15 18 N10/10f18 red Instrument cluster (A1)Yaw rate sensor for lateral and longitudinal acceleration (B24/15)Seat occupied recognition pressure sensor (B48/4)Automatic child seat recognition airbag OFF indicator lamp (E16)Restraint systems control unit (N2/7)ESP control unit (N47-5)Steering angle sensor (N49)Steering assist control unit (N68) (with code (V26) Power steering, EPS (FFO))Driver side seat belt buckle restraint systems switch (S68/3)Front passenger-side seat belt buckle restraint systems switch (S68/4) 10 19 N10/10f19 Brown ME-SFI [ME] control unit (N3/10)Automated manual transmission control unit (N15/6)Data link connector (X11/4)TPM [RDK] control unit (N88) 7,5 20 N10/10f20 red smart radio 9 (A2/1) (with code (C57) smart radio 9)smart radio 10 (A2/2) (with code (C50) smart radio 10)Heater/air conditioning operating unit (N23) (for code (I01)Air conditioning Plus)Front seat heater (SIH) control unit (N25/5) (with code (S17) Seat heater (FFO))Right wiper switch (S4/4)Outside mirror adjustment switch (S50)(with code (V21) Electrically adjustable and heated outside mirrors (FFO))Soft top operation (S84) (on model 451.4) 10 21 N10/10f21 blue Interior socket (X58/1) 15 22 N10/10f22 brown Left low beam (E1e2) 7.5
N10/10f23¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1596 · Applies to: 450, 451, 452, 454
23 N10/10f23 brown Right low beam (E2e2) 7.5 24 N10/10f24 blue Electronic selector lever module control unit (N15/5) 15 25 N10/10f25 brown Right high beam (E2e1) 7.5 26 N10/10f26 brown Left high beam (E1e1) 7.5 27 N10/10f27 brown ME-SFI [ME] control unit (N3/10) 7.5 28 N10/10f28 orange Heated rear window (R1) 40 29 N10/10f29 green Soft top OPEN relay (K66/1) (on model 451.4)Soft top CLOSE relay (K66/2) (on model 451.4) 30 30 N10/10f30 orange Automated manual transmission control unit (N15/6) 40 31 N10/10f31 Yellow Horn (H2)Right door CL motor (M14/5)Left front door central locking motor (M14/6)Rear-end door CL [ZV] motor (M14/7)Fuel filler flap CL [ZV] motor (M14/10)Horn switch (S4/2) 20 32 - - vacant - 33 N10/10f33 red Ignition/starter switch (S2/1) 50 34 N10/10f34 orange ESP control unit (N47-5) 40 35 N10/10f35 green Steering assist control unit (N68) (with code (V26) Power steering, EPS (FFO)) 30 36 N10/10f36 orange Secondary air injection pump (M33)
R1¶
brown Mirror heater relay (K97) (with code (V21) Electrically adjustable and heated outside mirrors (FFO)) 7.5 R2 - brown Stop light switch (S9/1) 7.5 R3 - - VACANT - R4 - - vacant - R5 - - vacant - R6 - - vacant - R7 - - Front interior lamp (E15/4) (with vehicles as of production date 2.9.10) - R8 - Yellow Sound system amplifier (for vehicles as of production date 2.9.10 with code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO)) 20 R9 - transparent Front seat heater (SIH) control unit (N25/5) (with code (S17) Seat heater (FFO)) 25
BASIC KNOWLEDGE > FUSE AND RELAY BOX RELAY ASSIGNMENT - GF54.15-P-1255-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1597 · Applies to: 450, 451, 452, 454
21MCU > Position Relay Switched function A K52/11 Left turn signal/stop lamp relay B K52/12 Right turn signal/stop lamp relay C K97 Mirror heater relay (with code (V21) Electrically adjustable and heated outside mirrors (FFO)) BASIC KNOWLEDGE > FUSE ASSIGNMENT OF FUSES IN THE INTERIOR ON PASSENGER SIDE - GF54.15-P-1256-24MCU > Fig 1: Identifying SAM Control Unit And Relay Sockets Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The SAM control unit controls the following functions:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1599 · Applies to: 450, 451, 452, 454
Drive authorization Central locking Exterior lighting Interior lighting Wiper system Rear window defroster Heated outside mirror (with code (V21) Electrically adjustable and heated outside mirror (FFO)) Anti-theft alarm system (with code (V01) Anti-theft alarm system (FFO)) Soft top (with model 451.4) Requests are conveyed to the SAM control unit via data bus systems or via read-in switches and sensors. The SAM control unit is a subscriber on the Controller Area Network (data bus/CAN bus) (CAN). The following components are read in to control the functions: Via local interconnect network interior 1 (LIN B): Rain sensor / light sensor (B38) (with code (V54) Rain/light sensor) Tachometer (A15p4) (with code (V31) Cockpit clock and tachometer package) Via local interconnect network interior 2 (LIN C): Fig 1: Locating SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Alarm siren with inclination sensor (H3/2) (with code (V01) Vehicle theft alarm (FFO))¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1600 · Applies to: 450, 451, 452, 454
Microwave sensor (B32) (with code (V01) Vehicle theft alarm (FFO)) Components read in directly: Transmitter key Transponder coil (L11) Wiper motor (M6/1) Rear-end door wiper motor (M6/4) (on model 451.3) Heated rear window switch (N23s1) Ignition/starter switch (S2/1) Combination switch (S4) Fanfare horns switch (S4/2) (except code (I75) Leather sport steering wheel incl. steering wheel rocker switch system) Right wiper switch (S4/4) Hazard flasher switch (S6/1s1) Front fog lamp switch (S6/1s8) (with code (V07) Front fog lamp (FFO)) (S6/1s9TPM [RDK] switch) Tow-away protection /Interior protection switch (S6/1s10) (with code (V01) Vehicle theft alarm (FFO)) Inside unlock CL (ZV) switch (S6/1s11) Inside lock CL (ZV) switch (S6/1s12) Stop light switch (S9/1) Remote trunk opening switch (S15) (on model 451.3) Trunk lid rotary tumbler microswitch (S17/8) (on model 451.4) Soft top operation (S84) (on model 451.4) Soft top microswitch (S84/37) (on model 451.4) Left roof cassette microswitch (S84/38) (on model 451.4) Right roof cassette microswitch (S84/40) (on model 451.4) Right door rotary tumbler microswitch (S87/6) Left door rotary tumbler microswitch (S87/7) Right rear soft top microswitch (S84/39) (on model 451.4) Left rear soft top microswitch (S84/41) (on model 451.4) Tailgate handle switch (S88/9)
The following components are actuated directly to carry out the functions:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1601 · Applies to: 450, 451, 452, 454
Refrigerant compressor (A9) (with code (I01) Air conditioning Plus) Left front lamp unit (E1) Left high beam (E1e1) Left low beam (E1e2) Left turn signal lights (E1e5) Left standing lights (E6/13) Right front lamp unit (E2) Right high beam (E2e1) Right low beam (E2e2) Right turn signal lights (E2e5) Right standing lights (E6/14) Left taillamp (E3) Left turn signal lights (E3e11) Left taillight (E3e2) - Left brake light Right taillamp (E4) Right brake light/turn signal lights (E4e11) Right taillight (E4e2) Left front fog lamp (E5/1) (with code (V07) front fog lamp (FFO)) Right front fog lamp (E5/2) (with code (V07) Front fog lamp (FFO)) Front interior lamp (E15/4) Left license plate lamp (E19/1) Right license plate lamp (E19/2) Center high-mounted stop lamp (E21) Left auxiliary turn signal lamp (E22/1) Right auxiliary turn signal lamp (E22/2) Horn (H2) Open soft top relay (K66/1) (model 451.4) Close soft top relay (K66/2) (model 451.4) Left turn signal lamps/brake light relay (K52/11) Right turn signal lamps/brake light relay (K52/12)
Blower motor (M2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1602 · Applies to: 450, 451, 452, 454
Fuel pump with fuel gauge sensor (M3/3) Wiper motor (M6/1) Rear-end door wiper motor (M6/4) (model 451.3) Electrical soft top motor (M12/6) (model 451.4) Left soft top drive (M12/7) (model 451.4) Right soft top drive (M12/8) (model 451.4) Right door CL motor (M14/5) Left front door central locking motor (M14/6) Rear-end door CL [ZV] motor (M14/7) Fuel filler flap CL [ZV] motor (M14/10) Mirror heater (M21/1r1) (with code (V21) Electrically adjustable and heated outside mirror (FFO)) Mirror heater (M21/2r1) (with code (V21) Electrically adjustable and heated outside mirror (FFO)) Heated rear window (R1) BASIC KNOWLEDGE > RAIN/LIGHT SENSOR, COMPONENT DESCRIPTION - GF54.21-P- 6000MCC > MODEL 451.3/4 with CODE (V54) Rain/light sensor Fig 1: Locating Rain Sensor/Light Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1603 · Applies to: 450, 451, 452, 454
The rain/light sensor is located on the inside of the windshield below the inside rearview mirror. Task To measure the light intensity and degree of wetting of the windshield Function principle of rain sensor Infrared light is radiated from the infrared transmitter unit and led to the windshield. The intensity of the light reflected at the windshield is measured by the infrared receiver unit If the windshield is dry in the area of the rain/light sensor (picture A), then the light is reflected almost completely and the infrared receiver unit measures a high light intensity If the windshield is wetted in the area of the rain/light sensor (picture B), then part of the light is scattered from the windshield glass. As a result the intensity of the reflected light reduces and the infrared receiver unit measures a lower light intensity. The light intensity measured by the infrared receiver unit represents a measure for the degree of wetting of the windshield. The smaller the measured light intensity the greater the degree of wetting of the windshield. Function principle of light sensor The light sensor measures the light intensity striking it from outside. The resistance in the light sensor drops as the light intensity reduces. The information from the rain/light sensor is passed on to the SAM control unit (N10/10) via the local interconnect network interior 1 (LIN B). BASIC KNOWLEDGE > DATA LINK CONNECTOR COMPONENT DESCRIPTION - GF54.22- P-2200MCC > MODEL 451.3/4 Fig 2: Identifying Rain Sensor Principle Function Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1605 · Applies to: 450, 451, 452, 454
The cockpit switch group is located in the center console. Task The cockpit switch group reads in the switching requirements and passes these on to the following control units: Front HS [SIH] control unit (N25/5) (with code (S17) Seat heaters (FFO)) Left seat heater switch Right seat heater switch SAM control unit (N10/10) Hazard warning flasher switch Inside unlock CL [ZV] switch Inside lock CL [ZV] switch Rear fog lamp switch - Front fog lamps switch Towing-away protection switch BASIC KNOWLEDGE > INSTRUMENT CLUSTER (IC [K]), DISPLAY INSTRUMENT AND WARNING SYSTEMS - GF54.30-P-0002-08MCU > Fig 1: Identifying Cockpit Switch Group Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1607 · Applies to: 450, 451, 452, 454
The instrument cluster has the following tasks: Vehicle speed display Output of the important operating condition of the vehicle Warning at critical vehicle operating conditions (visual and acoustic) Information display for various systems Display for maintenance interval display Fig 1: Instrument Cluster Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Networking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1608 · Applies to: 450, 451, 452, 454
The instrument cluster functions as a gateway between CAN and CAN-B. Display elements Left turn signal indicator lamp Right turn signal indicator lamp High beam indicator lamp Alternator charge monitoring and warning lamp Brake fluid and parking brake warning lamp Seat belt warning lamp Airbag indicator and warning lamp ABS indicator lamp Electric steering indicator lamp "CHECK ENGINE" MIL Oil pressure warning lamp ESP warning lamp Coolant temperature warning lamp Tire pressure monitor warning lamp Low beam indicator lamp Electronic speedometer (A1p8) Multifunction display (A1p13) Tank cap monitoring warning lamp All indicator and warning lamps are light emitting diodes. Operation The lower left button in the instrument cluster can be used to switchover the multifunction displays. The lower right button in the instrument cluster can adjust the instrument cluster illumination at circuit 15 ON and circuit 58 ON in five dimmer stages to match individual requirements. Activate Circuit 15 ON activates the instrument cluster. The multifunction display shows the current content at any given time, switches on the instrument cluster illumination and the needle for the speed display is shown on the display field. After circuit 15 OFF the instrument cluster remains active for another 30 s. The speed display needle disappears from the display field behind a cover. For circuit 15 OFF the instrument cluster can be activated under the following preconditions:
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1611 · Applies to: 450, 451, 452, 454
Various alternatives are available to the instrument cluster for the output of messages: Visual indicator/warning message via Indicator/warning lamps Multifunction display Acoustic indicator/warning messages via internal tone signal generator Visual indicator/warning messages via indicator/warning lamps Turn signal indicator lamps These are activated differently according to function: Turn signaling Hazard warning flasher The turn signal flasher is always accompanied by an acoustic clicking sound generated in the same rhythm. Turn signaling: Fig 1: Identifying Indicator/Warning Messages Displays Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
During turn signaling the corresponding turn signal indicator lamp is actuated. Actuation takes place via the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1612 · Applies to: 450, 451, 452, 454
Controller Area Network (data bus/CAN bus) (CAN) by the SAM control unit (N10/10). If one of the following lamps malfunctions, the corresponding turn signal indicator lamp is then actuated at doubled-up frequency by the SAM control unit. Left turn signal lamp (E1e5) Right turn signal lamp (E2e5) Left additional turn signal lamp (E22/1) Right additional turn signal lamp (E22/2) Left brake/turn signal lights (E3e11) Right brake/turn signal lights (E4e11) Hazard warning flasher: When the hazard warning flashers are on the two turn signal indicator lamps in the instrument cluster are actuated. High beam indicator lamp Actuation is conducted when the high beam is switched on over CAN by the SAM control unit. Alternator charge indicator/warning lamp If there is a fault in the alternator (G2) the alternator charge monitoring and warning lamp is actuated. Actuation take place via the CAN from the ME control unit (N3/10). Brake fluid and parking brake warning lamp Actuation takes place over the CAN under the following preconditions: From the SAM control unit for an actuated parking brake From the ESP control unit (N47-5) at a minimum brake fluid level in the reservoir From the ESP control unit for a fault of the Electronic Stability Program (Electronic-Stability- Program) Seat belt warning lamp The seat belt warning lamp lights permanently for t = 6s when at circuit 15 ON the driver seat belt buckle restraint systems switch (S68/3) is not closed. A warning tone is also emitted for t = 6 s. As from a vehicle speed of 25 km/h the seat belt warning lamp starts to flash on and off for t = 60 s, when the driver seat belt buckle restraint systems switch or the front passenger seat belt buckle restraint system switch (S68/4) (when front passenger occupied) is not closed. A warning tone is emitted in parallel. The warning tone is emitted in three phases, whereby the frequency changes every 20 s. After this, only the seat belt warning lamp is permanently actuated. The seat belt reminder warning (optical and acoustic) is terminated, as soon as the seat belt buckle restraint system switches are closed by putting on the seat belts. Furthermore, the seat belt reminder warning is also canceled, when the vehicle speed is 0 km/h and the driver door open. The cycle is restarted: If at v > 25 km/h one of the seat belts which is being applied is removed again and as a result one
of the seat belt buckle restraint systems switch is opened¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1613 · Applies to: 450, 451, 452, 454
when the driver door is closed again and the vehicle speed is > 25 km/h The signal for activating the seat belt warning lamp comes from the restraint systems control unit (N2/7) via CAN-B. Airbag indicator and warning lamp The airbag indicator and warning lamp is actuated when there is a fault in the supplemental restraint system (SRS) or the supplemental restraint system has been triggered. Actuation takes place by the restraint systems control unit via CAN. ABS indicator lamp The ABS indicator lamp is actuated when a malfunction occurs in the antilock brake system. Actuation takes place over CAN by the ESP control unit. Electric steering indicator lamp The electric steering indicator lamp is activated, when a malfunction in the electric steering is given. Actuation takes place by the power steering control unit via CAN (N68). "CHECK ENGINE" indicator lamp The CHECK ENGINE indicator lamp is actuated if a fault is present in the injection system, ignition system or exhaust emission system. Actuation takes place by the ME control unit via CAN. Oil pressure warning lamp The oil pressure warning lamp is actuated, if there is no or little oil pressure built up in the engine's oil circuit. Actuation takes place by the ME control unit via CAN. ESP warning lamp Actuation takes place over CAN by the ESP control unit under the following preconditions: The ESP warning lamp flashes on and off during a system control intervention at a frequency of 2.5 Hz. The ESP warning lamp comes on when there is a system fault or when the system is switched off Coolant temperature warning lamp The warning lamp is actuated, when the coolant temperature is too high. Actuation takes place by the ME control unit via CAN. Tire pressure monitor warning lamp Actuation takes place via CAN from the TPM [RDK] control unit (N88) under the following preconditions: when a manual reset has taken place or when a pressure loss was determined A manual reset is indicated by repeated flashing of the tire pressure monitor warning lamp, a pressure loss through the lamp being permanently on.
Low beam indicator lamp¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1614 · Applies to: 450, 451, 452, 454
Actuation is conducted when the low beam is switched on over CAN by the SAM control unit. Tank cap monitoring warning lamp If the ME control unit detects a tank cap which is not closed, it sends a corresponding signal on the. The instrument cluster receives the signal and actuates the tank cap monitoring warning lamp constantly. Indicator lamp test An indicator lamp test is carried out for "terminal 15 ON". In doing so all indicator and warning lamps are actuated with the exception of the following lamps: Left tern signal indicator lamp Right turn signal indicator lamp High beam indicator lamp The indicator lamp test is terminated as soon as an engine speed of > 480 RPM is reported by the ME control unit via CAN. Visual indicator/warning messages via the multifunction display The multifunction display's gear indicator shows the following warning message when the instrument cluster is actuated: Drive authorization system: The system is activated or a malfunction has occurred. Actuation takes place over CAN by the SAM control unit. CAN failure: flashes when the CAN is inoperative. Actuation takes place, when the instrument cluster does not receive any data or only implausible data from the CAN. Shifting system: A malfunction has occurred in the shifting system. Actuation takes place by the automated manual transmission control unit via CAN. Acoustic indicator/warning message over internal tone signal generator The acoustic warning and information signals are produced by an internal tone signal generator. An acoustic feedback occurs for the following function states: Flasher ON With direction flashing and warning flashing, in parallel with the visual feedback, an acoustic feedback takes place in the form of flasher clicking. Actuation takes place via the SAM control unit. Lights on reminder warning (warning tone) If the driver door is opened when the standing light or low beams are switched on, a warning tone
3041MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1617 · Applies to: 450, 451, 452, 454
MODEL 451.3/4 Shown on code (K07) Speedometer (miles) Gear indicator in manual mode The gear indicator displays the current gear engaged. The corresponding information from the automated manual transmission control unit (N15/6) is read in over the Controller Area Network (data bus/CAN bus) (CAN) from the instrument cluster. If the automated manual transmission control unit establishes that a higher gear would be better for the current engine speed, accelerator pedal position and vehicle speed, a gear change is suggested in the gear indicator: Arrow up: Shift up one gear Arrow down: Shift down one gear The gearshift recommendation is oriented towards a consumption-specific driving style. Gear indicator in automatic mode The selected driving stage is shown in the gear indicator. The following displays are possible: "P": Parking position "R": Reverse gear "N": Neutral "D": Drive position The corresponding information from the automated manual transmission control unit is read in over CAN by the instrument cluster. Fuel level and reserve indicator Fig 1: Identifying Indicator Displays Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The fuel supply is shown to the driver over the fuel level and reserve indicator by means of eight segments.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1618 · Applies to: 450, 451, 452, 454
The data sent from the fuel level sensor (M3/3b1) to the ME-SFI [ME] control unit (N3/10) is read in over the CAN by the instrument cluster. The reserve area is equivalent to an amount of 1 gal. If the reserve area is reached, the fuel pump symbol starts to flash on and off and the remaining fuel is displayed in increments of 0.13 gal in the multifunction display. In the event of any malfunction the segments in the fuel level and reserve indicator start to flash on and off. Maintenance interval display The maintenance interval display draws the driver's attention to a service that is due soon. Roughly one month beforehand and every time the engine is started, the maintenance interval display is displayed for 10 seconds, and the line of the main odometer shows the remaining distance or remaining time. Meaning of maintenance interval displays: One wrench = Oil service plus Two wrenches = Maintenance The left button on the instrument cluster can be used to confirm the display on the maintenance interval display. The maintenance interval display is shown for 10 s by briefly pressing the button in the right of the instrument cluster twice. Trip odometer The display area for the trip odometer is 0 to 9999.9 kilometers or miles (with code (K07) Speedometer (miles)). Once the maximum reading is reached the display is automatically reset to zero. Manual reset: Keep pressing the left button until the trip odometer appears in the multifunction display. After pressing the left button again for 1 s the display starts to flash on and off. Continue to press and hold the left button. The display is reset to zero. The trip distance remains stored even when the battery (G1) is disconnected. Odometer The main odometer reading is shown either in kilometers or miles, as soon as the instrument cluster is activated. The range for the main odometer is from 0 to 999,999 kilometers or miles. If the maximum mileage is reached, the counter is not reset to zero. In this case, the instrument cluster should be replaced. The internal counter continues to operate however. The main odometer reading is stored for at least 10 years, even if the voltage supply is disconnected. Outside temperature indicator The instrument cluster takes the following data into consideration when determining the outside temperature value:
Outside temperature value directly from outside temperature display temperature sensor (B14)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1619 · Applies to: 450, 451, 452, 454
Internal vehicle speed signal from instrument cluster Coolant temperature value via CAN from the ME-SFI [ME] control unit Engine running time over CAN from ME-SFI [ME] control unit The instrument cluster processes this data and actuates the outside temperature indicator accordingly. The dependency of the outside temperature indicator on the speed, the engine running time and the coolant temperature prevents too high a temperature being displayed through radiant heat when the vehicle is stationary or moving slowly. Falling temperature values are always allowed. The display's response pattern varies as temperature rises, according to coolant temperature and engine running time: Coolant temperature < 60°C: The current outside temperature value is always displayed when the instrument cluster is activated. Coolant temperature > 60°C: When the instrument cluster is activated rising outside temperature values are displayed with a delay. Coolant temperature > 60°C and circuit 15 OFF: The last measured temperature value is stored for a period of t = 60 min. When the instrument cluster is activated, the stored temperature value is shown in the outside temperature display. If the coolant temperature sensor (B11/4) is defective or if it provides implausible coolant temperature value, the ME-SFI [ME] control unit sends a corresponding message over CAN to the instrument cluster. A coolant temperature of ≥ 60°C is assumed. Set the time After pressing the left button on the instrument cluster for > 5 s the colon in the time display starts to flash on and off. Now the left button or the right button can be used to set the time. If one of the two buttons is not pressed again within the next 5 s, the set value is stored and the colon stops flashing. Instrument cluster, component description A1 GF54.30-P- 6000MCU Outside air temperature sender component description B14 GF83.57-P- 4000MCC ME-SFI [ME] control unit, component description N3/10 GF07.61-P- 6000MCU SAM control unit, component description N10/10 GF54.21-P- 4157MCU Automated manual transmission control unit, component description N15/6Transmission 717.482 GF26.19-P- 1010MCU
BASIC KNOWLEDGE > INSTRUMENT CLUSTER, COMPONENT DESCRIPTION - GF54.30-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1620 · Applies to: 450, 451, 452, 454
P-6000MCU > MODEL 451.3/4 Shown on code (K07) Speedometer (miles) Location The instrument cluster is located in the dashboard on the driver-side. Task The instrument cluster has the following tasks: Gateway between Controller Area Network (data bus/CAN bus) (CAN) and Controller Area Network bus Class B (interior) (CAN-B) Receive the input signals from the CAN and CAN-B for the various displays and warning messages Reading in of the paddle shift for steering wheel gearshift (SAL) (S112) over the fanfare horns and airbag clock spring contact (A45) (with code (I75) Leather sport steering wheel with steering wheel rocker switch system) Reading in the outside temperature display temperature sensor (B14) Fig 1: Identifying Instrument Cluster Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
N10/10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1623 · Applies to: 450, 451, 452, 454
SAM control unit 4L N10/10f12 Fuse 12 2L N10/10f19 Fuse 19 6L W26 Ground (transmission tunnel) 6E X11/4 Data link connector 11A X11/4 Data link connector 4A Z3/24 Circuit 15 (fused) connector sleeve, function 5E Z37/2 CAN engine bus (low) connector sleeve 9E Z37/3 CAN engine bus (high) connector sleeve 8E Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 2E BASIC KNOWLEDGE > WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000- 97MCV > Code: Designation: Position: Fig 1: Data Link Connector/Diagnostic Socket - Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A2/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1624 · Applies to: 450, 451, 452, 454
smart radio 9 24L A2/2 smart radio 10 25L A2/3 smart Entry radio 24L A2/4 smart Premium radio 25L E1 Left front lamp unit 54L E15/4 Front interior lamp 32L E1e1 Left high beam
E1e2 Left low beam
E2 Right front lamp unit 57L E2e1 Right high beam
E2e2 Right low beam
E3 Left taillamp 53L E3e2 Left taillamp
E6/13 Left standing lamp 51L E6/14 Right standing lamp 50L K116 Relay for shutoff-capable interior lamp 29L K52/11 Left turn signal/stop lamp relay 60L K52/12 Right turn signal/stop lamp relay 61L K61 Blower motor relay 1 18L K62 Blower motor relay 2 20L K66/1 Open soft top relay 37L K66/2 Close soft top relay 39L K87/1 Rear fog lamp relay 79L M2 Blower motor 16L M4/2 Coolant fan motor 48L N10/10 SAM control unit 76A N10/10 SAM control unit 19A N10/10 SAM control unit 61A N10/10 SAM control unit 52A N10/10 SAM control unit 44A N10/10 SAM control unit 11A N10/10 SAM control unit 68A N10/10 SAM control unit 4A N10/10 SAM control unit 28A
N10/10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1625 · Applies to: 450, 451, 452, 454
SAM control unit 37A N10/10f11 Fuse 11 70A N10/10f15 Fuse 15 24A N10/10f20 Fuse 20 12A N10/10f22 Fuse 22 N10/10f23 Fuse 23 N10/10f24 Fuse 24 75A N10/10f25 Fuse 25 N10/10f26 Fuse 26 54A N10/10f28 Fuse 28 46A N10/10f29 Fuse 29 40A N10/10f3 Fuse 3 13A N10/10f34 Fuse 34 67A N10/10f35 Fuse 35 64A N10/10f37 Fuse 37 (slot R2) 59A N10/10f4 Fuse 4 N10/10f42 Fuse 42 (slot R7) 31A N10/10f6 Fuse 6 N10/10f7 Fuse 7 51A N10/10k1 Heated rear window relay
N10/10k11 Heater blower relay
N10/10k12 Standing lamps relay
N10/10k2 Soft top "open" and soft top "closed" relay
N10/10k2 Soft top "open" and soft top "closed" relay
N10/10k6 High beam relay
N10/10k8 Low beam headlamp relay
N15/5 Electronic selector lever module control unit 71L N15/5 Electronic selector lever module control unit 75L N23 Heater/AC operating unit 6L N47-5 ESP control unit 68L N57/2 Power window convenience feature control unit 13L N68 Steering assist control unit 64L R1 Heated rear window 47L R1 Heated rear window 45L
Combination switch¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1626 · Applies to: 450, 451, 452, 454
S4 Combination switch 2L S4/4 Right wiper switch 10L S84 Power soft top switch 43L S84/37 Soft top microswitch 40L S84/38 Left roof cassette microswitch 41L S84/39 Right rear soft top microswitch 44L S9/1 Stop lamp switch 59L S9/1 Stop lamp switch 78L U1000 Valid for model 451.391/491 17E U1000 Valid for model 451.391/491 73F U1001 Not valid for model 451.391/491 15E U1001 Not valid for model 451.391/491 77F U1001 Not valid for model 451.391/491 70F U101 Valid up to 02/2009 36E U101 Valid up to 02/2009 34E U1010 Valid for radio with Premium sound system 22K U1012 Valid up to 30/08/2010 35E U1012 Valid up to 30/08/2010 32E U1012 Valid up to 30/08/2010 23K U1013 Valid as of 31/08/2010 36E U1013 Valid as of 31/08/2010 31E U1013 Valid as of 31/08/2010 23K U102 Valid as of 03/2009 35E U102 Valid as of 03/2009 32E U102 Valid as of 03/2009 26C U14 Valid for rain/light sensor 79G U23 Valid for convertibles 35D U492 Valid for power steering 62A U606 Valid for all except convertibles 46D U606 Valid for all except convertibles 8E U656 Valid for interior lights package 27L U861 Valid for versions without interior light package 27K U865 Valid for Entry radio 22K
Ground (outside left fire wall)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1627 · Applies to: 450, 451, 452, 454
W43 Ground (outside left fire wall) 48G W43 Ground (outside left fire wall) 52G W43 Ground (outside left fire wall) 50G W9 Ground (left front, at lamp unit) 48F X18/19 Trunk lid connector 46G X23/7 Soft top connector 43G X23/7 Soft top connector 40G X85/10 Heating or air conditioning connector 16H Z29/4 Circuit 58R (fused) connector sleeve 49G Z29/4 Circuit 58R (fused) connector sleeve 18G Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve 11G Z7/59 Tml. 30 connector sleeve 33F Z7/59 Tml. 30 connector sleeve 35F Z7/59 Tml. 30 connector sleeve 31F Fig 1: Electrical Center - Wiring Diagram (1 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Electrical Center - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1628 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Electrical Center - Wiring Diagram (3 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1629 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Electrical Center - Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1630 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MISCELLANEOUS NOTES > DISPOSE OF BATTERY - OS54.10-P-0001-01Z >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1631 · Applies to: 450, 451, 452, 454
All models Information on recycling and disposing of lead-acid batteries and lead-gel batteries Old lead batteries up to 31.12.1998 are not classed as recyclable waste requiring special monitoring and control. They bear the ISO symbol for return and recycling. Fig 5: Electrical Center - Wiring Diagram (5 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A15x1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1634 · Applies to: 450, 451, 452, 454
Additional instruments connector
A6/1 STH radio remote control receiver 32L K61 Blower motor relay 1 66L M3/3 Fuel pump with fuel level sensor 69L M4/9 Battery cooling fan motor 22L M6/1 Wiper motor 14L M6/4 Tailgate wiper motor 17L N10/10 SAM control unit 45A N10/10 SAM control unit 36A N10/10 SAM control unit 68A N10/10 SAM control unit 53A N10/10 SAM control unit 28A N10/10 SAM control unit 61A N10/10 SAM control unit 76A N10/10 SAM control unit 12A N10/10 SAM control unit 20A N10/10 SAM control unit 5A N10/10f1 Fuse 1 4A N10/10f10 Fuse 10 8A N10/10f12 Fuse 12 34A N10/10f16 Fuse 16 73A N10/10f17 Fuse 17 17A N10/10f18 Fuse 18 42A N10/10f19 Fuse 19 1A N10/10f2 Fuse 2 14A N10/10f27 Fuse 27 2A N10/10f30 Fuse 30 21A N10/10f44 Fuse 44 (slot R9) 60A N10/10f8 Fuse 8 7A N10/10f9 Fuse 9
N10/10k10 Front wiper relay
N10/10k13 Rear wiper relay
N10/10k3 Starter relay
N10/10k4 Electric fuel pump relay
N10/10k7¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1635 · Applies to: 450, 451, 452, 454
Main relay
N10/10k9 Automated manual transmission relay
N15/6 Automated manual transmission control unit 20L N3 EVCM electric vehicle control unit 37L N3 EVCM electric vehicle control unit 75L N3 EVCM electric vehicle control unit 24L N3/10 ME-SFI [ME] control unit 72L N47/5 ESP control unit 42L N65/3 Brake booster vacuum pump control unit 63L S6/1 Cockpit switch group 53L S6/1s1 Hazard warning flasher switch
S6/1s10 Tow-away protection/interior protection switch
S6/1s11 Inside unlock CL [ZV] switch
S6/1s12 Inside lock CL [ZV] switch
S6/1s3 Left seat heater switch
S6/1s4 Right seat heater switch
S6/1s8 Front fog lamps switch
S6/1s9 TPM [RDK] switch
U1000 Valid for model 451.391/491 6G U1000 Valid for model 451.391/491 30G U1000 Valid for model 451.391/491 44F U1000 Valid for model 451.391/491 61D U1000 Valid for model 451.391/491 65G U1000 Valid for model 451.391/491 74G U1000 Valid for model 451.391/491 45L U1000 Valid for model 451.391/491 21F U1001 Not valid for model 451.391/491 1G U1001 Not valid for model 451.391/491 46F U1001 Not valid for model 451.391/491 68G U1001 Not valid for model 451.391/491 55E U1001 Not valid for model 451.391/491 45K U1001 Not valid for model 451.391/491 44F U1012 Valid up to 30/08/2010 26H U1012 Valid up to 30/08/2010 43G
U1013¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1636 · Applies to: 450, 451, 452, 454
Valid as of 31/08/2010 41G U114 Valid for front fog lamps 50F U21 Valid for heated seats 55D U30 Valid for diesel engines 18F U492 Valid for power steering 44E U493 Not valid for power steering 46E U606 Valid for all except convertibles 15D U75 Valid for gasoline engines 70G U75 Valid for gasoline engines 26H U75 Valid for gasoline engines 18G W10 Ground (battery) 50G W10 Ground (battery) 22G X11/4 Data link connector 39L X18/19 Trunk lid connector 16H X99/3 Vehicle wiring harness connector 62H Y19/1 Interior air conditioning expansion valve 34L Y19/3 Battery air conditioning expansion valve 35L Z3/17 Circuit 15 (fused) connector sleeve 42E Z37/4 Power steering CAN bus connector sleeve (low) 45G Z37/5 Power steering CAN bus connector sleeve (high) 46G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 34G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 20G Z7/24 Circuit 87/1 connector sleeve 18G Z78 Cockpit LIN connector sleeve 27G Z81 Circuit 58d connector sleeve 48G
Fig 1: Electrical Center - Wiring Diagram (1 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1637 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Electrical Center - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1638 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Electrical Center - Wiring Diagram (3 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1639 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Electrical Center - Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1640 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000-97MCW¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1641 · Applies to: 450, 451, 452, 454
Code: Designation: Position: A45 Fanfare horns and airbag clock spring contact 26L A9 Refrigerant compressor 15L B32 Microwave sensor 73L Fig 5: Electrical Center - Wiring Diagram (5 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Charger feed socket indicator LED¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1642 · Applies to: 450, 451, 452, 454
E34 Charger feed socket indicator LED 47H E5/1 Left front fog lamp 65L E5/2 Right fog lamp 66L F90 12 V charge line prefuse 3H F91 SAM prefuse 8H G1 Battery 7L G1 Battery 5L G1 Battery 9L H2 Horn 17L H3/2 Alarm siren with inclination sensor 71L K97 Mirror heater relay 61L L11 Transponder coil 76L M14/10 Fuel filler flap CL [ZV] motor 18L M14/6 Left door CL [ZV] motor 20L M21/1 Left electrically adjustable and heated outside mirror 57L M21/1x1 Left electrically adjustable and heated exterior mirror connector
M21/2 Right electrically adjustable and heated outside mirror 58L M21/2x1 Right electrically adjustable and heated exterior mirror connector
M44 Charge air fan motor 14L M57/4 Trunk lid opening assist motor 1 (cabriolet) 23L M57/5 Trunk lid opening assist motor 2 (cabriolet) 24L M57/6 Trunk lid opening assist motor (cabriolet) 21L M6/1 Wiper motor 52L M6/4 Tailgate wiper motor 55L N10/10 SAM control unit 20A N10/10 SAM control unit 27A N10/10 SAM control unit 36A N10/10 SAM control unit 44A N10/10 SAM control unit 52A N10/10 SAM control unit 62A N10/10 SAM control unit 69A
N10/10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1643 · Applies to: 450, 451, 452, 454
SAM control unit 12A N10/10 SAM control unit 76A N10/10 SAM control unit 4A N10/10f14 Fuse 14 13A N10/10f17 Fuse 17 55A N10/10f2 Fuse 2 53A N10/10f21 Fuse 21 51A N10/10f31 Fuse 31 22A N10/10f33 Fuse 33 8A N10/10f36 Fuse 36 (slot R1) 61A N10/10f39 Fuse 39 (slot R4) 78A N10/10f39 Fuse 39 (slot R4) 60A N10/10f40 Fuse 40 (slot R5) 40A N10/10f41 Fuse 41 (slot R6) 68A N10/10f42 Fuse 42 (slot R7) 33A N10/10f43 Fuse 43 (slot R8) 30A N10/10f5 Fuse 5 65A N10/10k10 Front wiper relay
N10/10k13 Rear wiper relay
N10/10k14 Front fog lamp relay
N10/10k820 Charge air fan motor and horn relay
N10/10k820 Charge air fan motor and horn relay
N10/10k830 CL [ZV] "open" and CL [ZV] "locked" relay
N10/10k830 CL [ZV] "open" and CL [ZV] "locked" relay
N10/10k840 Rear-end door/trunk lid CL [ZV] relay
N116/5 High-voltage distributor control unit 30L N116/5 High-voltage distributor control unit 79L N145 Electric motor control unit 33L N145 Electric motor control unit 3L N24/3 High-voltage AC/DC battery charger control unit 41L N24/4 Smart battery charger control unit 44L N3 EVCM electric vehicle control unit 47L N3 EVCM electric vehicle control unit 68L N82/2 Battery management system control unit 37L
S2/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1644 · Applies to: 450, 451, 452, 454
Ignition/starter switch 11L U100 Valid as of 12/2008 59F U1000 Valid for model 451.391/491 28A U1000 Valid for model 451.391/491 66E U1000 Valid for model 451.391/491 1C U1001 Not valid for model 451.391/491 6C U1001 Not valid for model 451.391/491 8C U1012 Valid up to 30/08/2010 73E U1012 Valid up to 30/08/2010 6C U1012 Valid up to 30/08/2010 60C U1013 Valid as of 31/08/2010 74E U1013 Valid as of 31/08/2010 8C U1013 Valid as of 31/08/2010 61C U114 Valid for front fog lamps 64A U180 Valid for ATA [EDW] with siren 70D U23 Valid for convertibles 20G U606 Valid for all except convertibles 54D U606 Valid for all except convertibles 22G U75 Valid for gasoline engines 13G U99 Valid up to 12/2008 57C W10 Ground (battery) 6G W10 Ground (battery) 71G W10 Ground (battery) 51G W10 Ground (battery) 5G W10 Ground (battery) 73F W10 Ground (battery) 75E W10 Ground (battery) 9G W12 Ground (center console) 12F W43 Ground (outside left fire wall) 17G W43 Ground (outside left fire wall) 53G W6 Ground (left wheelhouse in luggage compartment) 14G W6 Ground (left wheelhouse in luggage compartment) 23G
Ground (left wheelhouse in luggage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1645 · Applies to: 450, 451, 452, 454
W6 Ground (left wheelhouse in luggage compartment) 24G W6 Ground (left wheelhouse in luggage compartment) 21G W9 Ground (left front, at lamp unit) 17F W9 Ground (left front, at lamp unit) 27D X18/19 Trunk lid connector 54H X26 Interior/engine connector 13F X35/1 Left door separation point 57H X35/1 Left door separation point 19G X35/2 Right door separation point 58H X58/1 Interior socket 50L X99/3 Vehicle wiring harness connector 29H Z17 Connector sleeve 9 74G Z19/1 CL [ZV] "open" connector sleeve 18G Z19/2 CL [ZV] "closed" connector sleeve 17G Z212 Circuit 30 supply connector sleeve 68G Z4/3 Tml. 30 connector sleeve 40E Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 60G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 73H Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 71G Z78/1 ATA [EDW] LIN connector sleeve 72G
Fig 1: Electrical Center - Wiring Diagram (1 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1646 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Electrical Center - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1647 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Electrical Center - Wiring Diagram (3 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1648 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Electrical Center - Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1649 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000-99MCV¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1650 · Applies to: 450, 451, 452, 454
Code: Designation: Position: A2/1 smart radio 9 24 L A2/2 smart radio 10 25 L E1 Left front headlamp unit 52 L Fig 5: Electrical Center - Wiring Diagram (5 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
E15/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1651 · Applies to: 450, 451, 452, 454
Front interior lamp 27 L E1e1 Left high beam 51 L E1e2 Left low beam 52 L E2 Right front headlamp unit 54 L E2e1 Right high beam 54 L E2e2 Right low beam 55 L E3 Left taillamp 50 L E3e2 Left tail light 49 L E6/13 Left standing lamp 48 L E6/14 Right standing lamp 46 L K52/11 Left turn signal/stop lamp relay 58 L K52/12 Right turn signal/stop lamp relay 60 L K66/1 Open soft top relay 30 L K66/2 Close soft top relay 32 L M2 Blower motor 22 L M21/1 Left electrically adjustable and heated exterior mirror 15 L M21/1x1 Left electrically adjustable and heated exterior mirror connector 15 K M21/2 Right electrically adjustable and heated exterior mirror 16 L M21/2x1 Right electrically adjustable and heated exterior mirror connector 16 K M4/2 Coolant fan motor 44 L N10/10 SAM control unit 4 A N10/10 SAM control unit 12 A N10/10 SAM control unit 20 A N10/10 SAM control unit 28 A N10/10 SAM control unit 36 A N10/10 SAM control unit 44 A N10/10 SAM control unit 52 A N10/10 SAM control unit 61 A N10/10 SAM control unit 68 A N10/10 SAM control unit 75 A N10/10f11 Fuse 11 70 A
N10/10f15¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1652 · Applies to: 450, 451, 452, 454
Fuse 15 24 A N10/10f20 Fuse 20 14 A N10/10f22 Fuse 22 52 A N10/10f23 Fuse 23 55 A N10/10f24 Fuse 24 72 A N10/10f25 Fuse 25 54 A N10/10f26 Fuse 26 50 A N10/10f28 Fuse 28 40 A N10/10f29 Fuse 29 32 A N10/10f3 Fuse 3 18 A N10/10f34 Fuse 34 67 A N10/10f35 Fuse 35 64 A N10/10f37 Fuse 37 16 A N10/10f38 Fuse 38 57 A N10/10f4 Fuse 4 21 A N10/10f6 Fuse 6 46 A N10/10f7 Fuse 7 49 A N10/10k1 Rear window defroster relay module 41 C N10/10k11 Heater blower relay 19 C N10/10k12 Standing lamps relay 46 B N10/10k2 Soft top "open" and soft top "closed" relay 30 C N10/10k2 Soft top "open" and soft top "closed" relay 32 C N10/10k6 High beam relay 50 C N10/10k8 Low beam headlamp relay 52 B N15/5 Electronic selector lever module control module 72 L N23 Heater/AC operating unit 7 L N47-5 ESP control module 68 L N57/2 Power window convenience feature control unit 19 L N68 Steering assist control module 64 L R1 Heated rear window 40 L R1 Heated rear window 42 L S4 Combination switch 3 L S4/4 Right wiper switch 12 L S84 Power soft top switch 37 L
S84/37¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1653 · Applies to: 450, 451, 452, 454
Soft top microswitch 33 L S84/38 Roof cassette microswitch 35 L S84/39 Rear soft top microswitch 38 L S9/1 Stop lamp switch (4-pin) 57 L U23 Valid for cabriolet 29 D U492 Valid for power steering 62 A U606 Valid for all except convertibles 11 F U606 Valid for all except convertibles 41 D W43 Ground (outside left fire wall) 44 G W9 Ground (at left headlamp unit) 43 G X18/19 Trunk lid connector 41 H X23/7 Soft top connector 33 H X23/7 Soft top connector 38 H X35/1 Left door separation point 15 H X35/2 Right door separation point 16 H X85/10 Heating or air conditioning connector 21 H Z29/4 Circuit 58R (fused) connector sleeve 45 H Z3/44 Instrument cluster - radio circuit 15 connector sleeve (fused) 13 H
Fig 1: Electrical Center - Wiring Diagram (1 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1654 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Electrical Center - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1655 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Electrical Center - Wiring Diagram (3 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1656 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Electrical Center - Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1657 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A1e2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1662 · Applies to: 450, 451, 452, 454
Right turn signal indicator lamp 30A A1e26 "CHECK ENGINE" MIL 31A A1e3 High beam indicator lamp 12A A1e30 Oil pressure warning lamp 20A A1e41 ESP warning lamp 22A A1e5 Alternator charge monitoring and warning lamp 24A A1e54 Coolant temperature warning lamp 32A A1e66 Tire pressure monitor warning lamp 26A A1e67 Low beam indicator lamp 10A A1e7 Brake fluid and parking brake warning lamp 14A A1e8 Instrument illumination 3A A1e9 Seat belt warning lamp 23A A1p13 Multifunction display 18A A1p8 Electronic speedometer 19A A2/1 smart radio 9 21L A2/2 smart radio 10 22L A2/3 smart Entry radio 25L A2/4 smart Premium radio 26L A45 Fanfare horns and airbag clock spring contact 32L A45 Fanfare horns and airbag clock spring contact 44L B14 Outside temperature display temperature sensor 18L N10/10 SAM control unit 9L N10/10f12 Fuse 12 7L N10/10f18 Fuse 18 6L N23 Heater/AC operating unit 36L S111/2 Right steering wheel pitman arm 3L S6/1 Cockpit switch group 30L U1010 Valid for radio with Premium sound system 25K U1011 Valid for radio without Premium sound system 25L U1012 Valid up to 30/08/2010 4E U1012 Valid up to 30/08/2010 20G U1012 Valid up to 30/08/2010 38K U1013 Valid as of 31/08/2010 2E
U1013¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1663 · Applies to: 450, 451, 452, 454
Valid as of 31/08/2010 24G U1013 Valid as of 31/08/2010 31G U1013 Valid as of 31/08/2010 38K U492 Valid for power steering 10E U493 Not valid for power steering 12E U494 Valid for SAL 42E U865 Valid for Entry radio 25K W9 Ground (left front, at lamp unit) 9G Z3/17 Circuit 15 (fused) connector sleeve 5G Z37/4 Power steering CAN bus connector sleeve (low) 11G Z37/5 Power steering CAN bus connector sleeve (high) 11G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 7G Z81 Circuit 58d connector sleeve 29E Fig 1: Large Instrument (Instrument Cluster) - Wiring Diagram (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Large Instrument (Instrument Cluster) - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1664 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 00/42/54/91 / Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1669 · Applies to: 450, 451, 452, 454
MODEL all Use: 126-pin socket box for contacting electrical systems in combination with model-specific test cable sets.
SPECIAL TOOLS > 220 589 00 99 00 ELECTRICAL CONNECTION KIT - WS54.00-P-0050B
FG 00 FG 01/13/15/20/25/42/43/47/54/72/Set B MODEL all MODIFICATION NOTES 22.11.04 Replacement for 201 589 00 99 00
6.8.07 Replaced by 220 589 05 99 00 WS00.00-P-0279Z Part 220 589 00 99 01 Adapter line
WS54.00-P-0050- 01B Part 220 589 00 99 02 Adapter line
WS54.00-P-0050- 02B Part 220 589 00 99 03 Adapter line
WS54.00-P-0050- 03B Part 220 589 00 99 04 Adapter line
WS54.00-P-0050- 04B Part 220 589 00 99 05 Adapter line
WS54.00-P-0050- 05B Part 220 589 00 99 06 Adapter line
WS54.00-P-0050- Fig 1: Identifying 126-Pin Socket Box (129 589 00 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Part¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1670 · Applies to: 450, 451, 452, 454
06B Part 220 589 00 99 07 Adapter line FG 25/42/43/54/Set B WS54.00-P-0050- 07B Part 220 589 00 99 08 Adapter line
WS54.00-P-0050- 08B Part 220 589 00 99 09 Adapter line
WS54.00-P-0050- 09B Part 220 589 00 99 10 Adapter line
WS54.00-P-0050- 10B Part 220 589 00 99 11 Adapter line
WS54.00-P-0050- 11B Part 220 589 00 99 12 Adapter line
WS54.00-P-0050- 12B Part 220 589 00 99 13 Adapter line
WS54.00-P-0050- 13B Part 220 589 00 99 20 Test cable FG 25/42/43/54/Set B WS54.00-P-0050- 14B Part 220 589 00 99 21 Alligator clip
WS54.00-P-0050- 15B Part 220 589 00 99 22 Safety clamp FG 25/42/43/54/Set B WS54.00-P-0050- 16B Part 220 589 00 99 23 Clamp test probe
WS54.00-P-0050- 17B Part 220 589 00 99 24 Connector
WS54.00-P-0050- 18B Part 220 589 00 99 25 Empty case FG54/Set B WS54.00-P-0050- 26B Part 220 589 00 99 30 Adapter cable
WS54.00-P-0050- 19B Part 220 589 00 99 31 Adapter cable
WS54.00-P-0050- 20B Part 220 589 00 99 33 Safety cable
WS54.00-P-0050- 22B
140 589 12 21 00 Baseline current draw test adapter 1
WS54.00-P-0015B
140 589 13 21 00 Quiescent current test adapter 2
WS54.00-P-0016B
000 581 06 54 Pliers
Further use FG 42/Set B WS42.00-N-3062B
Further use FG 43/Set B WS43.00-N-3053B Use:
Electrical connection kit for contacting during voltage/current/resistance measurements and for connection of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1671 · Applies to: 450, 451, 452, 454
the compression tester.
SPECIAL TOOLS > 450 589 01 63 00 HOT AIR BLOWER - WS54.00-P-0062B > FG 54/Set B MODEL 450, 451, 452, 454 Use: Hot air blower for soldering cable connection at solder connectors. NOTE: Hot air blowerSmart No. 0005029. Fig 1: Identifying Electrical Connection Kit (220 589 00 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Hot Air Blower (450 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 04 63 01 MEASURING RESISTOR - WS54.00-P-0064-01B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1672 · Applies to: 450, 451, 452, 454
FG54/Set B MODEL 450, 451, 452 Use: Precision resistor for fault limitation with e.g faulty lines, control units or triggering components e.g. a simulation of a sidebag. NOTE: Separate part for 450 589 04 63 00 SPECIAL TOOLS > 450 589 04 63 02 PROBE - WS54.00-P-0064-02B > FG54/Set B MODEL 450, 451, 452 Use: Probe for contacting measuring points. NOTE: Separate part for 450 589 04 63 00 Fig 1: Identifying Measuring Resistor (450 589 04 63 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 04 63 00 CABLE SET WITH DIAGNOSIS CASE - WS54.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1673 · Applies to: 450, 451, 452, 454
0064B > FG 54/Set B MODEL 450, 451, 452 Part 450 589 04 63 01 Measuring resistor FG54/Set B WS54.00-P-0064-01B Part 450 589 04 63 02 Probe FG54/Set B WS54.00-P-0064-02B Use: Cable set with diagnosis case for contacting measuring instruments and design of measuring circuits, including decade resistor. NOTE: Cable set with diagnosis case incl. decade resistor Smart No. 0005111. Fig 1: Identifying Probe (450 589 04 63 02) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 15 21 00 BATTERY TESTER - WS54.00-P-0066A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1674 · Applies to: 450, 451, 452, 454
FG 54/Set A MODEL 450, 451, 452, 454 Use: Battery tester for checking battery voltage. NOTE: Battery testerSmart no. 0006967. SPECIAL TOOLS > 169 589 00 37 00 PLIERS - WS54.00-P-0073B > FG 54/Set B MODEL 163, 164, 168, 169, 170, 171, 172, 197, 203, 204, 207, 208, 209, 210, 211, 212, 216, 218, 219, Fig 1: Identifying Cable Set With Diagnosis Case (450 589 04 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Battery Tester (450 589 15 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1675 · Applies to: 450, 451, 452, 454 · AR: WS54.00-Z-9999CZ
221, 230, 245, 251, 451 Use: Pliers for removing 12V sockets and cigar lighters with an SAE standard
SPECIAL TOOLS > SPECIAL TOOLS: SMART: ELECTRICAL SYSTEM, EQUIPMENT AND INSTRUMENTS - WS54.00-Z-9999CZ > MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P-0007B 000 589 13 99 10 MCP 2.8 ELA crimping set FG00/54/Set B WS00.19-P-0007- 10B 000 589 13 99 30 MCP 2.8 / Fl. blade 2.8 / JPT / SPT FG00/54/83/Set B WS00.19-P-0007- 30B 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P-0111B 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K 129 589 00 21 00 126-pin socket box FG 00/42/54/91 / Set B WS54.00-P- 0008B 156 589 00 31 00 Guide pins FG 54/Set B WS54.00-P-0081B 169 589 00 37 00 Pliers FG 54/Set B WS54.00-P- 0073B 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P- 0050B 220 589 01 99 05 JPT crimping set FG 00/54/83/Set B WS00.19-P-0001- 05B Fig 1: Identifying Pliers (169 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
220 589 01 99 10 Crimp pliers¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1676 · Applies to: 450, 451, 452, 454
FG 00/14/54/83/Set B WS00.19-P-0001- 09B 220 589 01 99 20 Unlocking device with RK 1.5 ejector FG00/54/Set B WS00.19-P-0001- 18B 220 589 01 99 30 Unlocking device with RK 2.5 ejector FG00/14/54/Set B WS00.19-P-0001- 20B 220 589 01 99 40 Wire stripper FG 00/54/83/Set B WS00.19-P-0001- 22B 220 589 01 99 41 Reflector FG 00/54/83/Set B WS00.19-P-0001- 23B 220 589 01 99 42 Adapter FG 00/54/83/Set B WS00.19-P-0001- 24B 220 589 01 99 50 Blade holder with clamping pliers FG00/14/54/83/Set B WS00.19-P-0001- 25B 220 589 01 99 60 MQS blade FG00/54/Set B WS00.19-P-0001- 35B 220 589 01 99 82 JPT ELA crimp set FG00/54/Set B WS00.19-P-0002- 08B 220 589 01 99 85 MQS crimping set FG00/54/Set B WS00.19-P-0002- 11B 220 589 01 99 86 MQS ELA crimping set FG00/54/Set B WS00.19-P-0002- 12B 220 589 02 99 00 Wiring harness repair kit FG 00 FG 54/83/Set B WS00.19-P-0002B 220 589 04 99 00 New passenger car wiring harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P-0006B 450 589 00 63 00 Press-out pin FG 54/Set B WS54.00-P-0060B 450 589 01 63 00 Hot air blower FG 54/Set B WS54.00-P- 0062B 450 589 04 63 00 Cable set with diagnosis case FG 54/Set B WS54.00-P- 0064B 450 589 04 63 01 Measuring resistor FG54/Set B WS54.00-P-0064- 01B 450 589 04 63 02 Probe FG54/Set B WS54.00-P-0064- 02B 450 589 04 99 00 Cable repair set FG 54/Set B WS54.00-P-0063B 450 589 05 37 00 Pliers FG 54/Set B WS54.00-P-0061B 450 589 07 21 07 Adapter FG 01/20/54/Set B WS01.00-P-0074- 07B 450 589 12 63 00 Measuring FG 54/Set B WS54.00-P-0065B
instrument/tester¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1677 · Applies to: 450, 451, 452, 454
450 589 15 21 00 Battery tester FG 54/Set A WS54.00-P- 0066A 450 589 19 21 00 Pin socket box 126- pin FG 54/Set B WS54.00-P-0071B 452 589 02 99 00 Wiring harness repair kit FG 00/54/77/83/ Set B WS00.00-P-0243B 452 589 02 99 01 Crimper 0.35 - 1.0 FG00/54/Set B WS00.00-P-0243- 01B 452 589 02 99 02 Crimper 1.5 - 2.5 FG00/54/Set B WS00.00-P-0243- 02B 452 589 02 99 03 Crimper 4.0 - 6.0 FG00/54/Set B WS00.00-P-0243- 03B 452 589 02 99 04 Wire stripper FG00/54/Set B WS00.00-P-0243- 04B 452 589 02 99 05 Box with connectors 0.35 - 1.0 FG00/54/Set B WS00.00-P-0243- 05B 452 589 02 99 06 Box with connectors 1.5 - 2.5 FG00/54/Set B WS00.00-P-0243- 06B 452 589 02 99 07 Box with connectors 4.0 - 6.0 FG00/54/Set B WS00.00-P-0243- 07B 452 589 02 99 08 Small box with heat- shrinkable tubes 5.75 mm FG00/54/Set B WS00.00-P-0243- 08B 930 589 00 99 00 Supplemental truck wiring harness repair kit FG 00/14/54/67 / Set B WS00.19-N-0004B 930 589 00 99 07 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N-0004- 13B 930 589 00 99 08 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N-0004- 14B 930 589 00 99 25 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N-0004- 15B 930 589 00 99 26 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N-0004- 16B
GENERAL INFORMATION > INFORMATION ON PREVENTING DAMAGE TO ELECTRONIC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1678 · Applies to: 450, 451, 452, 454
COMPONENTS DUE TO ELECTROSTATIC DISCHARGE - AH54.00-P-0001-01A > All models Electrostatic charge Every contact and each physical separation of materials or any movement of solid substances, fluids or particulate loaded gases can generate electrostatic charges. Plastics generally produce the highest electrostatic charge. We come across electrostatic charge or discharge in lots of everyday situations, e.g. with: Combs Walking on carpets or plastic floors Putting on and removing textiles made with synthetic fiber Disembarking from the vehicle Contact between various electrostatically chargeable packaging materials in shelves or in the transport container The following electrostatic discharge (E lectro S tatic D ischarge (ESD)) can be so strong that a small electric shock is detected. Even the smallest discharges which people cannot detect can cause lasting damage to electronic components and control units. Effects and consequences of ESD Electronic components and control units are very sensitive to ESD. The damage is often not immediately obvious, but becomes apparent some time later. In order to avoid failures and damage due to ESD in vehicle electronics, various procedures and safety precautions must be taken into account and followed. Risks of damage occur during transport, handling, testing, removal and installation of electronic components in production as well as during repair work. The following electronic components listed as an example can be damaged by ESD: Airbag components Control units, in particular their bus connections (Control Area Network (data bus/CAN bus) (CAN), local interconnect network (LIN) etc.) Sensors Mechatronic components (actuators etc.) Antenna amplifier Receivers and displays (Radio, TV, GPS, telephone etc.) Modes of behavior and safety precautions
Electrostatic discharge from the fitter (e.g. due to brief contact with the vehicle body).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1679 · Applies to: 450, 451, 452, 454
Suitable clothing, e.g. made of cotton. Wear ESD safety shoes with conductive soles. Keep workplace clean, remove unnecessary objects such as common plastics. Special anti-static seat cushion protectors must be used when performing repair work inside a vehicle. Leave replacement parts in the original packaging for as long as possible, Do not cut open seals, but cut open carefully. The ESD workplace must conform to the ESD guidelines. ESD protection Before unpacking, discharge ESD protective packaging at the ESD workplace. Avoidance of contact with electrostatic chargeable materials such as PE, PVC, styrofoam. Use only original packaging or specially labeled and defined packaging and transport materials. Electronic components which have been removed must be put down on an ESD workplace. Touch connectors on electronic components and in the wiring harness on the housing only. Do not touch the pins and contacts! Electronic components must be installed before they are connected so that potential equalization with the body can take place. Shelves and worktables must stand directly on the floor, there must not be any insulating materials between the base of the shelves/feet and the floor. If the above mentioned insulators cannot be removed, the shelves and work tables must be grounded (e.g. low-resistance electrical connection/line from metal shelf to a heating pipe). Put down conductive transport container/box in a non insulated manner (e.g. on a wooden pallet), otherwise no potential equalization takes place. Do not place control units and electronic components removed from the vehicle on electrostatically chargeable materials, such as PE, PVC, styrofoam. The electrostatic charge is transferred to the control unit or electronic component. An ESD service kit or a connected ESD table mat must be used. Training We strongly advise that each company should appoint a trained ESD officer in accordance with DIN EN 61340-5-1. The ESD officer can hold employee training courses. The objective of the training course measures is to familiarize the employees with the essential difficulties and effects of ESD: Creation of discharging Reasoning behind safety precautions Effects and consequences of ESD ESD rules of conduct and safety precautions
Returning electronic components in warranty and goodwill cases¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1680 · Applies to: 450, 451, 452, 454
When returning electronic components it is absolutely essential to observe the procedure and safety precautions listed. Electrostatic charge or discharge mean the original fault can be falsified or overlaid. This can lead to distorted fault symptoms in the case of the fault analysis of the component concerned. GENERAL INFORMATION > NOTES ON BATTERY - AH54.10-P-0001-01A > All models General information on batteries Do not store batteries over a longer period at a storage point with direct solar radiation. Discharged or defective batteries can freeze, therefore store free from frost. Avoid polarity reversal and short-circuits. Do not place tool or other conducting objects on the battery (risk of short-circuit). Before removal and installation of batteries all switchable current consumers should be switched off, as well as the engine switched off so that inadvertent arcing is ruled out. Always disconnect the negative terminal first and always connect the positive terminal first . Only charge batteries with DC, 10 % of the capacity is recommended as charging current for slow charging and 50 % of the capacity recommended for fast charging. Only switch on the charger after connecting to the terminals and switch off before disconnecting. We recommend greasing the batteries slightly with battery terminal grease. If the battery is to remain in the parked vehicle for a longer time, the negative terminal should be disconnected. If possible batteries should be kept clean and dry. Batteries should not be stored over a longer period without recharging. Notes on lead-gel batteries (additional battery for special bodies) Lead-gel batteries are free from gassing, acid does not run out of them and are completely independent of position and maintenance free. When fast charging ensure that the housing of the lead-gel battery does not heat up excessively otherwise a pressure relief valve will be opened and the lead-gel battery will be defective. Notes on lead acid batteries Always store lead lead-acid batteries horizontally to prevent acid leaking out and do not tilt during transportation. When fast charging ensure that the housing of the lead-acid battery does not heat up excessively. GENERAL INFORMATION > NOTES ON SCN CODING OF CONTROL UNITS - AH54.21-P- 0004-01X >
Model 129, 163, 164, 168, 169, 170, 171, 199, 203, 204, 208, 209, 211, 215, 216, 219, 220, 221, 230, 240,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1681 · Applies to: 450, 451, 452, 454
245, 251 Model 461, 463 Model 450, 451, 452, 454 Model 636, 639 Model 906 The "Software Calibration Number" (SCN) is specified by law in Europe and USA for all control units relevant to exhaust emission as of model year 2002. Accordingly the software and coding of such a control unit must be clearly identifiable by means of the SCN. As a number the SCN consists of 16 numbers. The first 10 places correspond to the object number to be coded (mostly object number of control unit software). The next 2 places designate the manufacturing plant or field organization, in which the vehicle has been coded. The last 4 places are a number of the variants of the coding string of the vehicle-specific as-built configuration. This number is serially numbered for each newly formed variant. If special equipment has been installed or removed in the vehicle (e.g. retrofitting a telephone), these retrofit codes must be added to the central system before requesting the SCN coding data. The appropriate national organization must be contacted (MPC) for this. MAINTENANCE > BATTERIES - CHECKING AND CORRECTING FLUID LEVEL - AP54.10- P-5410MCC > MODEL 451.3 (except 451.334) MODEL 451.3 (except 451.380) MODEL 451.4 (except 451.480)
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1682 · Applies to: 450, 451, 452, 454
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 1 Remove footrest on the passenger-side Left-hand drive vehicles AR68.30- P- 1340MCC Right-hand drive vehicles AR68.30- P- 1340MCE 2 Unscrew nut (3)
3 Unclip the retaining clip (2) on the bracket (1) and remove bracket (1) On right-hand drive vehicles the bracket (1) is only raised until the stop plugs (4) are accessible.
Checking
4 Remove stop plugs (4) on the battery (G1) In each cell the fluid must reach the web let into the filler
Fig 1: Identifying Bracket, Retaining Clip, Nut And Plug With Battery Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Di connect/connect battery ground line¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1684 · Applies to: 450, 451, 452, 454
MODEL 451 3 /4 P 0003MCC
Disconnecting and connecting electrical cables from battery MODEL 451.3 /4 AR54.18- P- 0002MCC
Remove/install additional instruments MODEL 451.3 /4 up to 30.8.10 with CODE (V31) Cockpit clock and tachometer package AR54.30- P- 6080MCC
Remove/install additional instruments MODEL 451.3 /4 as of 31.8.10 with CODE (V31) Cockpit clock and tachometer package AR54.30- P- 6080MCF
Remove/install battery MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle AR54.10- P- 0005MCC
Remove/install battery MODEL 451.3## /4## 2# with CODE (RHD) Right-hand drive vehicle AR54.10- P- 0005MCE
Remove/install battery charger of high- voltage battery MODEL 451.391 /491 with ENGINE 780.009 AR54.10- P- 5106MEV
Remove/install battery sensor MODEL 451.334 /380 /480 AR54.10- P- 0002MCC
Remove/install charger feed socket MODEL 451.391 /491 with ENGINE 780.009 AR54.10- P- 5109MEV
Remove/install cockpit switch group MODEL 451.3/ 4 AR54.25- P- 1000MCC
Remove/install combination switch MODEL 451.3/ 4 AR54.25- P- 2800MCC
Remove/install cruise control switch MODEL 451.3 /4 with CODE (V27) Cruise control/Temposet AR54.25- P- 2803MCC
Remove/install electric motor charge line to 12-volt battery MODEL 451.391 /491 with ENGINE 780.009 AR54.10- P- 5107MEV
Remove/install electric power soft top relay MODEL 451.4 AR54.15- P- 1000MCO
Remove/install electrical line from battery to starter/alternator MODEL 451.3 (except 451.380 /391)MODEL 451.4 (except 451.480 /491) AR54.18- P- 0006MCC AR54.18-
Remove/in tall electrical line from battery to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1685 · Applies to: 450, 451, 452, 454
starter/alternator MODEL 451 3 /4 (except 451 391 /491) P- 0006MCU
Remove/install electrical lines from the on- board electrical system battery to the starter-alternator control unit MODEL 451.334 /380 /480 AR54.10- P- 0100MCC
Remove/install external socket communications control unit MODEL 451.391 /491 with ENGINE 780.009 AR54.10- P- 5108MEV
Remove/install fanfare horns MODEL 451.3 /4 with CODE (V55) Twin-tone horn AR54.35- P- 1555MCC
Remove/install front SAM control unit MODEL 451.3 /4 AR54.21- P- 1254MCC
Remove/install front SAM control unit MODEL 451.3 /4 AR54.21- P- 1254MCU
Remove/install high-voltage battery MODEL 451.391/ 491 AR54.10- P- 1140MEV
Remove/install high-voltage distributor MODEL 451.391 /491 with ENGINE 780.009 AR54.10- P- 1400MEV
Remove/install high-voltage line between high-voltage distributor and PTC heater booster MODEL 451.391 /491 with ENGINE 780.009 AR54.10- P- 1402MEV
Remove/install ignition/starter switch lock cylinder MODEL 451.3/ 4 AR54.25- P- 1030MCC
Remove/install ignition/starter switch lock cylinder MODEL 451.3 /4 AR54.25- P- 1030MCU
Remove/install inertia switch MODEL 451.391 /491 with ENGINE 780.009 AR54.10- P- 0050MEV
Remove/install instrument cluster MODEL 451.3 /4 AR54.30- P- 6015MCC
Remove/install instrument cluster MODEL 451.3 /4 AR54.30- P- 6015MCU
Remove/install main fuse of positive line MODEL 451.3 /4 (except 451.391 /491) Starter/alternator prefuse AR54.15- P- 0051MCU MODEL 451.3 /4 Main fuse of SAM AR54.15-
Remove/in tall main fu e of po itive line¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1686 · Applies to: 450, 451, 452, 454
[signal acquisition and actuation module] control unit P- 0051MCV
Remove/install main fuse of positive line MODEL 451.391 /491 with ENGINE 780.009 AR54.15- P- 0051MEV
Remove/install main fuse of secondary air injection pump MODEL 451.3 /4 (except 451.391 /491) AR54.15- P- 0050MCU
Remove/install outside temperature indicator sensor MODEL 451.3/ 4 AR54.30- P- 6341MCC
Remove/install signaling horn MODEL 451.3 /4 except CODE (V55) Twin-tone horn AR54.35- P- 1556MCC
Remove/install signaling horn MODEL 451.3 /4 AR54.35- P- 1556MCU
Remove/install starter-alternator control unit MODEL 451.334 /380 /480 AR54.21- P- 0300MCC
Remove/install start/stop switch MODEL 451.334 /380 /480 AR54.25- P- 4000MCC
Remove/install three-phase line from starter-alternator to control unit MODEL 451.334 /380 /480 AR54.18- P- 2000MCC
Remove/install wiper switch MODEL 451.3 /4 AR54.25- P- 0003MCC
Remove/install 12 Volt socket MODEL 451.3 /4 AR54.10- P- 1000MCC
Replace desiccant cartridge of high-voltage battery MODEL 451.391/ 491 AR54.10- P- 1171MEV
Replace SAM fuses MODEL 451.3/ 4 AR54.15- P- 2001MCC
Treatment of battery if vehicle taken out of service MODEL 451.3 /4 AR54.10- P- 0006MCC TESTING & REPAIR > DISCONNECT/CONNECT BATTERY GROUND LINE - AR54.10-P- 0003MCC > MODEL 451.3 /4
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1687 · Applies to: 450, 451, 452, 454
10.6.10 Check condition of battery and enable high voltage system added Steps 1 and 2
22.9.10 Information on required radio code on vehicles with code (527) High- Line radio, added
13.1.11 Adaptation of audio settings added Step 9
Remove/install
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 Risk of death when touching components on vehicles with high-voltage system Do not touch components and open lines of high-voltage system. Persons with electronic implants (e.g. cardiac pacemakers) must never work on high- voltage systems. AS54.00- Z-0001- 02MEV 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 Notes on battery
AH54.10- P-0001- 01A Notes on AGM battery Model 451.334/380/480 AH54.10- P-0002- 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. 1691 · Applies to: 450, 451, 452, 454
1 Insert pliers (2) into interior socket (X58/1) and turn until pliers (2) arrest Fig 2 2 Carefully pull out metal insert in interior socket (X58/1) approx. 1.5 cm with pliers (2) Fig 2 3 Remove bolts (3)
4 Swivel the trim of the vertical strut (1) backwards in the lower area and remove until the electrical connector (5) of the interior socket (X58/1) as well as the electrical connector (4) of the data link connector (X11/4) are accessible
5 Separate the electrical connector (5) of the interior socket (X58/1) and electrical connector (4) of the data link connector (X11/4)
6 Remove vertical strut paneling (1)
7 Unclip interior socket (X58/1) from rear of vertical strut paneling (1) and remove toward front Installation: Before installing in the trim of the vertical strut, pull out the metal insert of the interior socket (X58/1) (1) using the pliers (2).
8 Install in the reverse order
Fig 1: Identifying 12 Volt Socket Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > CHECK QUIESCENT CURRENT CONSUMPTION - AR54.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1692 · Applies to: 450, 451, 452, 454
1030MCE > MODEL 451.3 /4 Removing
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 Fig 2: Identifying Pliers (169 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Ground Cable And Battery Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on AGM battery¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1693 · Applies to: 450, 451, 452, 454
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 multimeterIf 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 consumers (e.g. chargers, MP3 player, amplifier etc.)
8 Open doors and liftgate
9 Lock rotary tumblers on doors and liftgate The interior illumination in the vehicle must go out.
10 Lock the vehicle using the central locking with open doors and liftgate A waiting time of at least 6 mins. must be waited after locking the vehicle.
Measure
11 Set multimeter to highest possible current measurement range Standard digital multimeter
12 Connect multimeter between ground line (1) and negative To prevent any voltage reset, the current flow must not be interrupted. When fitting the
terminal on battery¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1694 · Applies to: 450, 451, 452, 454
(G1) without any interruption multimeter, bridge the negative terminal of the battery (G1) beforehand. 13 Measure no-load current
14 Remove fuses one by one from the SAM control unit and localize the faulty control unit or defective consumer If the value for the no-load current measurement: On vehicles without code (V01) Antitheft alarm system (FFO) exceeds 40 mA. On vehicles with code (V01) Antitheft alarm system (FFO) exceeds 50 mA. Wait in each case for at least 6 mins. until the next measurement to enable the activated bus to return to idle.If the fuse of the defective consumer or control unit is removed, the no-load current drops immediately.The fuse and relay assignment enables the increased no-load current consumption to be restricted to specific control units and consumers.To restrict the increased no- load current consumption yet further, the consumers and control units protected by the fuse in question must be removed one after the other.
- not for USAFuse and relay box, as-built configuration GF54.15- P- 0800MCC
- for USA onlyFuse and relay box, as-built configuration GF54.15- P- 0800MCU 15 Remove multimeter without breaking the circuit and attach ground line (1) to negative terminal
Install
16 Install foot support on passenger side Left-hand drive vehicles AR68.30- P- 1340MCC Right-hand drive vehicles AR68.30- P- 1340MCE 17 Open vehicle using central locking system
18 Unlock rotary tumblers on doors and liftgate
Connect STAR DIAGNOSIS then read- AD00.00-
out and erase¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1695 · Applies to: 450, 451, 452, 454
19 out and erase diagnostic trouble code memory
P-2000- 04MCC TESTING & REPAIR > CHECK BATTERY - AR54.10-P-1129-01A > AR54.10- P-1129- 01A Check battery
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 TEST AND ADJUSTMENT VALUES FOR BATTERY Number Designation 12 AH 30 AH 35 Ah 42 AH BE54.10-P-1002-01A Cold test current as per EN A 170 540 520 340 TEST AND ADJUSTMENT VALUES FOR BATTERY Number Designation 46 AH 60 Ah VRLA 60 AH 61 AH BE54.10-P-1002-01A Cold test current as per EN A 420 680 510 540 TEST AND ADJUSTMENT VALUES FOR BATTERY Number Designation 62 AH 70 Ah VRLA 74 AH 80 Ah VRLA BE54.10-P-1002- 01A Cold test current as per EN A 480 760 680 800 TEST AND ADJUSTMENT VALUES FOR BATTERY Number Designation 84 AH 90 Ah VRLA 95 Ah VRLA 100 Ah BE54.10-P-1002- 01A Cold test current as per EN A 700 950 850 760 On model 414 the battery has to be disconnected for the tests to avoid any damage. Perform test for remaining vehicles with battery installed and connected where possible. Do not connect tester to jump start or charging terminal point, always connect it directly with the battery. Battery tester All test steps and entries must be performed thoroughly, otherwise the test result will be distorted. Test prerequisites: Tester with software release 2.0
Ignition off¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1696 · Applies to: 450, 451, 452, 454
Rotary light switch in position "0" Audio component (e.g. radio) switched off Battery voltage higher than 12.4 V Good contact of the tester on the battery If the message "Surface voltage" is displayed during the test, the tester has detected that the battery voltage is apparently too high. This increased voltage can be reduced as follows: Battery installed: Decrease increased voltage as per the specifications of the tester (e.g. switch on driving lights). Battery removed: reduce increased voltage using a suitable volt/amp(s) tester (load battery for approx. 60 s with 20 A to 30 A amps). As an example, the test procedure for passenger cars is described below. 1. Clip tester (1) on to battery. Once the tester is connected the current measured battery voltage is displayed for approx. 2 s. If a so-called "System noise" is detected by the tester, check whether all consumers are switched off and wait (for approx. 2 min.), until the quiescent current is minimized and the bus systems are switched off. Fig 1: Identifying Battery Tester Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Follow the menu and select according to the situation:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1697 · Applies to: 450, 451, 452, 454
- In vehicle (battery connected to on-board electrical system)
- Not in vehicle (battery disconnected from on-board electrical system) Confirm selection with "Enter".
- Follow the menu and select according to the situation:
- 12 - 114 AH (battery capacity 12 - 114 Ah)
- 115 AH > (battery capacity ≥ 115 Ah) Confirm selection with "Enter".
- Follow menu and select battery type:
- Normal
- VRLA Confirm selection with "Enter". Fig 2: Display Battery Tester Menu Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Display Battery Tester Selection - Battery Capacity Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Follow the menu selection and select the test standard for the cold cranking amps.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1698 · Applies to: 450, 451, 452, 454
The test standard is printed on behind the specification of the cold cranking amps. If the imprint of the test standard is not available, select the cold cranking amps "EN". Example: 12 V 46 Ah 420 A → Select EN. Confirm selection with "Enter". Fig 4: Display Battery Tester Selection - Battery Type Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Selection Of Battery Testing For Cold Cranking Amps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Read off cold cranking amps and enter in tester.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1699 · Applies to: 450, 451, 452, 454
Example: 12 V 46 Ah 420 cold cranking amps → 420 A. Confirm input with "Enter". The battery test starts after confirmation of the cold cranking amps entry. The test result or one of the following messages appears after approx. 15 s: 1. Test code →Step 7 2. Vehicle model →Step 9 3. Temperature > 0°C / < 0°C →Step 10 4. Before charging / After charging →Step 11 5. Surface voltage DETECTED (see above) 7. Read off test code with "Enter" and continue accordingly: 1. "Battery in good condition": No further measures required. 2. "Charge and test": Fully charge battery and retest (battery voltage > 12.4 V). Fig 6: Display Test Result Of Cold Cranking Amps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. "Replace battery":¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1700 · Applies to: 450, 451, 452, 454
Replace battery if this message appears. 8. Print out test code and file in a tamperproof manner. 9. Follow the menu and select test mode: 1. Cars 2. Taxi Confirm selection with "Enter". 10. Follow the menu and select test mode: 1. > 0°C 2. < 0°C Confirm selection with "Enter" 11. Follow the menu and select test mode: Fig 7: Selection Of Test Mode - Cars And Taxi Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Selection Of Test Mode - Above 0°C And Below 0°C Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove vertical strut paneling (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1704 · Applies to: 450, 451, 452, 454
1 Remove vertical strut paneling (1)
AR68.00-P- 1500MCC 2 Pull fuse of secondary air injection pump (F36) out of fuse holder (2)
3 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL MAIN FUSE OF POSITIVE LINE - AR54.15-P- 0051MCU > MODEL 451.3 /4 (except 451.391 /491) Starter/alternator prefuse Remove/install
1 Disconnect battery ground line
AR54.10-P- 0003MCC 2 Unclip top cover (2) from bottom cover (1) and remove top cover (2) as well as bottom cover (1)
3 Unscrew nuts (3) and remove starter/alternator fuse (F58) Replace self- locking nuts (3).
4 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL MAIN FUSE OF POSITIVE LINE - AR54.15-P- 0051MCV > MODEL 451.3 /4 Main fuse of SAM [signal acquisition and actuation module] control unit Fig 1: Identifying Bottom Cover, Top Cover, Nut And Starter/Alternator Fuse Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3 /4 (except 451.391 /491)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1707 · Applies to: 450, 451, 452, 454
Shown on model 451.4 with code (I01) Air conditioning Plus Fig 1: Identifying Electrical Line, Cover, Nut, Bracket, Positive Terminal And Battery Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Electrical Line, Grommet, Bracket And Brake Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.4 with code (I01)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1708 · Applies to: 450, 451, 452, 454
Air conditioning Plus
Remove/install
1 Disconnect ground line of battery (G1)
AR54.10- P- 0003MCC 2 Remove cover (2)
3 Unscrew nut (4) and place electrical line (3) to one side
4 Detach positive terminal (6) of electrical line (1) to the battery (G1)
5 Unclip holder (5) of electrical line (1) on battery tray The brackets (5, 8, 14, 15) and the bracket (arrow A) as well as the protective covers on the electrical line (1) are present on the new electrical line (1), when reusing the old electrical line (1) ensure that it is not damaged.
Risk of death Fig 3: Identifying Electrical Line, Nuts, Brackets, Generator And Starter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
cau ed by vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1709 · Applies to: 450, 451, 452, 454
slipping or toppling off of the lifting platform. Align vehicle between column of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00 00 Z-0010- 01A 6 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
7 Release rear drive module
AR01.00- P- 3050MCU 8 Release grommet (7) of electrical line (1) from battery recess Installation: Ensure that grommet (7) is seated correctly.
9 Mark the position of brackets (5, 8, 14, 15), the bracket (arrow A) as well as the bracket (11) and bracket (arrow B) on the electrical line (1)
10 Unclip bracket (8) and bracket (arrow A) of electrical line (1) on underfloor
11 Unclip electrical line (1) from holder (9) on brake line (10)
12 Unclip electrical line (1) from bracket (11) and bracket (arrow B)
13 Unscrew nut (12) on starter (M1) and remove electrical line (1)
14 Unclip bracket (14) of electrical line (1) on intake manifold
15 Unclip holder (15) of electrical line
Unscrew nut (13)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1710 · Applies to: 450, 451, 452, 454
(1) 16 Unscrew nut (13) on alternator (G2) and remove electrical line (1)
17 Route electrical line (1) out and then remove Route electrical line (1) accurately, as otherwise the line may suffer from chafing and crushing. Installation: Replace damaged bracket (5, 8, 14, 15) and bracket (arrow A). The new brackets (5, 8, 14, 15) as well as bracket (arrow A) should be attached in exactly the same position of the electrical line (1).Make sure that the new holders (5, 8, 14, 15) and the holder (arrow A) are not twisted through 180° when secured to the electrical line (1).
18 Transfer all markings made to the electrical line (1) to the new electrical line (1) When replacing the electrical line (1). This ensures that the brackets (5, 8, 14, 15), the bracket (arrow A) as well as the bracket (11) and bracket (arrow B) are positioned at exactly the same point on the new electrical line (1), their position should be corrected if necessary.
19 Install in the reverse order
TESTING & REPAIR > REPAIR WIRING HARNESS BY MEANS OF AXIAL SOLDER CONNECTORS - AR54.18-P-0100-06A > 1. Expose damaged cable or plug/coupling in easily accessible position and cut off. Separate cores in wiring harness offset by approx. 45 mm. 2. Cut new section of cable to match old cable. 3. Remove 15 mm of insulation at end of cables. Pull cut-off insulation off the line while turning. Fig 1: Identifying Wiring Harness Offset Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Select axial solder connector by means of cable cross-section.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1711 · Applies to: 450, 451, 452, 454
- Push the axial solder connector on line beyond the solder point. Push on the thinner side of the axial solder connector first.
- Twist the line ends together.
- Push back the axial solder connector on the transposition while turning. Fig 2: Identifying Cable Insulation Dimension Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Pushing Axial Solder Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Heat up axial solder connector with a preheated hot air blower (with electronic temperature control)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1712 · Applies to: 450, 451, 452, 454
to 400°C. Hot air blower Use welding bead catcher in the vehicle interior in order to avoid damage due to liquid solder. Until the soldering ring has dissolved and the covering has positioned itself properly around the lines. 9. Check soldered point. It must not be possible to see the soldering ring of the axial soldered connector any more. The covering must contact the lines properly. Fig 4: View Of Axial Solder Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Holding Axial Solder Connector Using Welding Bead Catcher Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Select the control unit to be¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1714 · Applies to: 450, 451, 452, 454
F3" 4 Select the control unit to be flashed in the "systems" menu and confirm with the "F3 button" The following control units can be flashed: N3/10 (ME-SFI [ME] control unit) N10/10 (SAM control unit) N15/6 (Sprintshift control module) N47-5(ESP control unit)
5 Select the "Control unit adaptations" in the selected menu of the corresponding control unit and confirm with the "F3 button"
6 Select the submenu "Program control unit" in the "Control unit adaptations" menu and confirm with the "F3 button"
7 Select the "hard drive menu: Version Month/ Year (year/month/day)" and confirm with the "F3 button" The information on the flashing systems appears in the display.
8 Start the flashing process by pressing the "F3 button" Programming lasts about 3 minutes.
9 Select the "online (networked STAR DIAGNOSIS unit)" menu or "offline (no networked STAR DIAGNOSIS unit)" menu and start SCN coding by confirming with the "F3 button" Only if the SCN coding command appears in the display. We recommend always performing SCN coding with SDflash online. Only perform Offline SCN coding with a non- networked STAR DIAGNOSIS.
SCN coding with SDflash Online AR54.21- P-0013- 02MCC
Offline SCN coding AR54.21- P-0013- 04MCC Notes on SCN coding of control units
AH54.21- P-0004- 01X 10 Close STAR DIAGNOSIS
TESTING & REPAIR > SCN CODING WITH SDFLASH ONLINE - AR54.21-P-0013-02MCC > The following work instructions describes the procedure for Online SCN coding with "SDflash".
"SDflash" is the product designation of the program for determining the SCN coding and parameterization¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1715 · Applies to: 450, 451, 452, 454
data. Prerequisite for Online SCN coding with "SDflash": Networked STAR DIAGNOSIS diagnosis system Access to "SDflash" with corresponding rights SCN coding with "SDflash" 1. Confirm note on sequence of SCN coding with the "F2 button". 2. Select "Operation step 1: Determine vehicle data for online SCN coding from the vehicle" menu and confirm with the "F3 button". 3. Confirm the correct vehicle identification number with the "F3 button". The note that the vehicle data determination was successful appears in the display. 4. Select "Operation step 2: online query SDflash" menu and confirm with the "F3 button". 5. Press "F2 button" for starting the online query. 6. Press "F2 button" for starting the web browser. The web page of the after sales platform appears in the display. 7. Select the symbol (house) which is located in the top third of the web page. 8. Enter user name and password and select logging on symbol. The applications available appear in the display. 9. Select "SDflash" in the display. 10. Select symbol (Start) in the display. The message that the SCN coding and the coding string formation has been successfully finished appears in the display. 11. After "When the inquiry about the coding data has finished, proceed with the F2 button" appears in the display, press the "F2 button". 12. Select "Operation step 2: Perform SCN coding" menu and confirm with "F3 button". 13. Confirm the correct vehicle identification number with the "F3 button". 14. Press "F3 button" and transfer coding data to the control unit. 15. Once "Switch on ignition" appears in the display, switch on ignition. The coding process starts automatically and lasts about 10 seconds. 16. Once "Switch off ignition" appears in the display, switch off ignition. 17. After the coding process has finished the order event log for the documentation of the SCN repair order appears. This order event log must be filled in completely, then printed out with the "F11 button" and enclosed with the repair order. 18. Finish SCN coding by pressing the "F2 button".
The online SCN coding of the control unit is thus successfully completed.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1716 · Applies to: 450, 451, 452, 454
TESTING & REPAIR > OFFLINE SCN CODING - AR54.21-P-0013-04MCC > The following work instructions describe the procedure for offline SCN coding. Precondition for offline SCN coding: STAR DIAGNOSIS diagnosis system with printer and fax machine Correct adjustment of date and time in STAR DIAGNOSIS Special equipment which was subsequently installed in or removed from the vehicle, must be redocumented in the vehicle documentation system (FDOK). Offline SCN coding 1. Confirm note on sequence of SCN coding with the "F2 button". 2. Prepare the inquiry form by pressing the "F4 button". 3. Print out inquiry form by pressing the "F11 button". 4. Send the printed-out inquiry form to fax number +49 180511 6373. The inquiry result must be faxed back immediately. 5. Enter "coding string", "SCN" and "check digit [2]" in the corresponding input fields in the diagnosis assistance system and confirm with the "F3 button". 6. Once the coding process has finished the event log on the documentation of the repair order appears. This event log must be filled in completely, then printed out with the "F11 button" and enclosed with the repair order. 7. Finish SCN coding by pressing the "F2 button". SCN coding of the control unit is thus successfully concluded. TESTING & REPAIR > PERFORM INITIAL STARTUP OF CONTROL UNITS - AR54.21-P- 0018MCE > MODEL 451.3 /4
Startup
1 Connect Star Diagnosis
AD00.00- P-2000- 04MCC 2 Enter vehicle identification number in Diagnosis Assistance system (DAS) and open main menu with "F2" button
3 Select menu "Systems" in main menu and confirm with "Button F3"
An "initial startup" is required when replacing the following control units:
In the "Systems" menu, select the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1717 · Applies to: 450, 451, 452, 454
4 In the "Systems" menu, select the control unit for initial startup and confirm with the "F3" button Instrument cluster (A1) Weight Sensing System (WSS) control unit (N110) with code (494) USA version Starter- alternator control unit (N129) with model 451.334/380/480 Electronic selector lever module control unit (N15/5) Restraint systems control unit (N2/7) Heater and A/C operating unit (N23) with code (I01) A/C Plus CDI control unit (N3/9) with engine 660 ME-SFI [ME] control unit (N3/10) with engine 132 SAM control unit (N10/10) Automated manual transmission control unit (N15/6) ESP control unit (N47-5) Steering assist control unit (N68) TPM [RDK] control unit (N88) with code (494) USA version
5 In the menu for the selected control unit, choose the "Initial startup" menu item and confirm with the "F3" button
6 Confirm "Notes for initial startup of control unit" with "F2" button
7 Select the "online (networked STAR DIAGNOSIS unit)" menu or "offline (no networked STAR DIAGNOSIS unit)" menu and start by pressing the "F3" button
8 Follow the further instructions in DAS.
9 Close Star Diagnosis
TESTING & REPAIR > REMOVE/INSTALL FRONT SAM CONTROL UNIT - AR54.21-P- 1254MCU >
MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1718 · Applies to: 450, 451, 452, 454
Remove/install
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Turn off ignition
2 Disconnect ground line of battery
AR54.10- P- 0003MCC 3 Adjust the left front seat to the rear
4 Unclip left tweeter from the dashboard and place to one side with the electric line connected Vehicles up to 30.8.10 with code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO) or Vehicles with code (C54) Sound system 2 AR82.62- P- 1000MCC 5 Unclip SAM control unit (N10/10) in the rear area (arrow A) and fold down forwards
6 Unscrew bolts (1) and carefully lower the SAM control unit
Fig 1: Identifying Front SAM Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Lift right wiper switch (S4/4) upwards from the guides (4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1720 · Applies to: 450, 451, 452, 454
3 Lift right wiper switch (S4/4) upwards from the guides (4) and remove to one side until the electrical connector (1) is accessible
4 Detach electrical connector (1) on the right wiper switch (S4/4) and remove the right wiper switch (S4/4)
5 Release cap (2) by applying suitable knife to right wiper switch (S4/4) and remove When replacing right wiper switch (S4/4).
6 Install in the reverse order
7 Conduct function test of right wiper switch (S4/4)
TESTING & REPAIR > REMOVE/INSTALL COCKPIT SWITCH GROUP - AR54.25-P- 1000MCC > MODEL 451.3/ 4 Remove/install
1 Loosen cockpit switch group (S6/1) using assembly wedge (3) and remove until the electrical connector (1) is accessible Fig 2 2 Separate electrical connector (1) and remove cockpit switch group (S6/1) Check retaining clips (2), replace is necessary.
3 Install in the reverse order
Fig 1: Identifying Electrical Connector, Retaining Clamp, Mounting Wedge & Cockpit Switch Group Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
switch (1) and switch on ignition¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1722 · Applies to: 450, 451, 452, 454
3 switch (1) and switch on ignition (circuit 15) located in position "P".
4 Slide in feeler gauge (4), on the left side as shown, between the lock cylinder of the ignition/starter switch (1) and electronic selector lever module control unit (N15/5) Use blade of feeler gauge (4) with the thickness of 0.15 mm.
5 Pull out lock cylinder of ignition/starter switch (1) with transmitter key (3) upwards If necessary move the feeler gauge (4) slightly, so that the locking device (5) is released from the bracket (arrow).
Install
6 Insert lock cylinder of ignition/starter switch (1) with transmitter key (3) in the electronic selector lever module control unit (N15/5) Ensure that the selector lever is located in position "P".The lock cylinder of the ignition/starter switch (1) must engage audibly in the electronic selector lever module (N15/5) control unit.
7 Remove transmitter key (3)
8 Install transponder coil
AR80.35- P- 4515MCU TESTING & REPAIR > REMOVE/INSTALL COCKPIT SWITCH GROUP - AR54.25-P- 1000MCC > MODEL 451.3/ 4 Remove/install
1 Loosen cockpit switch group (S6/1) using assembly wedge (3) and remove until the electrical connector (1) is accessible Figure Fig 1: Identifying Electrical Connector, Retaining Clamp, Mounting Wedge & Cockpit Switch Group Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Separate electrical connector (1) and remove cockpit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1723 · Applies to: 450, 451, 452, 454
2 Separate electrical connector (1) and remove cockpit switch group (S6/1) Check retaining clips (2), replace is necessary.
3 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL CRUISE CONTROL SWITCH - AR54.25-P- 2803MCC > MODEL 451.3 /4 with CODE (V27) Cruise control/Temposet Remove/install
Remove front Fig 2: Identifying Wedge Tool (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Cover, Bolts And Wiring Harness With Left And Right Cruise Control Switches Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1725 · Applies to: 450, 451, 452, 454
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Pull the instrument cluster (A1) in the direction of the arrow out of the dashboard upper section until the connector (2) on the instrument cluster (A1) is accessible Check position of clamps (1). When removing the instrument cluster (A1) there is the danger that the clamps (1) can fall through the openings (arrows A) in the instrument cluster (A1).
2 Unlock connector (2) on the instrument cluster (A1), detach and remove instrument cluster (A1) backwards Clamps (1), which have fallen into instrument cluster (A1) when removing, must be got out again otherwise a short circuit in the instrument cluster can occur (A1). This must only take place through the opening a (arrow A). Disassembling the instrument cluster (A1) is not permissible.
3 Remove clamps (1) on top part of dashboard or on instrument cluster (A1) Installation: The clamps (1) are to be replaced by the clamps (1) listed in the Parts ordering notes table. Insert new clamps (1) in the top part of the dashboard.
4 Install in the reverse order
5 Set clock in the instrument cluster (A1)
PARTS ORDERING NOTES Part no. Designation Quantity A 203 988 28 78 Clamp 2 TESTING & REPAIR > REMOVE/INSTALL ADDITIONAL INSTRUMENTS - AR54.30-P- 6080MCC > MODEL 451.3 /4 up to 30.8.10 with CODE (V31) Cockpit clock and tachometer package
Risk of death when touching components on vehicles with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1728 · Applies to: 450, 451, 452, 454
high-voltage system (MY5) BlueTec Hybrid Z-0001- 02A Risk of death when touching components on vehicles with high-voltage system MODEL 451.391 /491 AS54.00- Z-0001- 02MEV Risk of explosion from gas. Risk of poisoning and burns from swallowing battery electrolyte. Risk of injury to eyes and skin as result of caustic burns from battery electrolyte or from handling damaged lead-acid batteries. MODEL all AS54.10- Z-0001- 01A Risk of injury caused by contact with battery gel when handling damaged lead-gel batteries MODEL all AS54.10- Z-0001- 02A SAFETY PRECAUTIONS > RISK OF EXPLOSION FROM GAS. RISK OF POISONING AND BURNS FROM SWALLOWING BATTERY ELECTROLYTE. RISK OF INJURY TO EYES AND SKIN AS RESULT OF CAUSTIC BURNS FROM BATTERY ELECTROLYTE OR FROM HANDLING DAMAGED LEAD-ACID BATTERIES. - AS54.10-Z-0001-01A > No fire, sparks, naked flames or smoking. Wear acid-resistant gloves, clothing and eye protection. Pour battery electrolyte only into suitable and appropriately marked containers. Possible hazards Risk of explosion A highly explosive gas mixture is produced when charging lead-acid batteries. Risk of poisoning If battery electrolyte is swallowed , this can result in manifestations of poisoning such as headaches, dizziness, stomach pain, respiratory paralysis, unconsciousness, vomiting and cramps. Battery electrolyte mist causes caustic burns to the eyes. If swallowed , this can result in caustic burns to the mucous membranes and respiratory passages. The absorption of lead in the body can cause damage to blood, nerves and kidneys; in addition, lead compounds are considered to represent a reproductive hazard. Injury hazard Battery electrolyte contains sulfuric acid which can cause severe caustic burns to skin and eyes. Strict caution is required when handling damaged lead-acid batteries (removing from vehicle damaged in accident) because of the sharp edges on the fractured housing and direct contact with the lead plates. Protective measures/rules of conduct Charge lead-acid batteries only in well ventilated areas. No fire, sparks, naked flames or smoking. Do not place any tool or other conducting objects onto the lead-acid battery (risk of short-circuit).
Disconnect and remove lead-acid batteries for charging.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1729 · Applies to: 450, 451, 452, 454
Always disconnect negative terminal first of all; always connect positive terminal first of all. Do not switch on the charger until after it has been connected to the terminals; switch it off before disconnecting. Keep lead-acid batteries and battery electrolyte away from unauthorized persons. Pour battery electrolyte only into suitable and appropriately marked containers. Always store lead-acid batteries horizontally. Ensure the gassing line is properly connected. Ensure the gassing line does not have any kinks and is not blocked at any point. Pay attention to instructions for use of the particular lead-acid battery and the operating instructions of the vehicle. Wear acid-resistant clothing and eye protection with side guards. First-aid measures Eye contact Rinse out eyes immediately with plenty of water. Skin contact Take off moistened clothing. Immediately neutralize acid splashes on skin or clothing with acid converter or soap suds and rinse off with plenty of water. Inhaling battery electrolyte mist Take the affected person out into the fresh air. Swallowing battery electrolyte Have the person affected drink plenty of water with the addition of activated charcoal. As a general rule, the person affected should consult a medical service or doctor after first-aid has been rendered. Fire protection measures Suitable extinguishing agents CO and dry extinguishing agent 2
Warning instructions for lead-acid batteries¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1730 · Applies to: 450, 451, 452, 454
SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY CONTACT WITH BATTERY GEL WHEN HANDLING DAMAGED LEAD-GEL BATTERIES - AS54.10-Z-0001-02A > No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Potential risks Risk of poisoning If battery gel is swallowed this can cause poisoning symptoms such as headaches, dizziness, stomach aches, respiratory paralysis, unconsciousness, vomiting, caustic burns and cramps. The absorption of lead in the body can cause damage to blood, nerves and kidneys; in addition, lead compounds are considered to represent a reproductive hazard. Risk of injury Battery electrolyte gel is just as caustic as normal electrolyte fluid and can cause serious caustic burns to the skin and eyes. Strict caution is required when handling damaged lead-gel batteries (e.g. when removing from a vehicle damaged in an accident) due to the sharp edges on a broken housing and direct contact with the lead plates. Safety precautions and rules of conduct No fires, sparks, open flames or smoking. Keep tools and other conductive objects away from lead-gel batteries (risk of short-circuit). Disconnect and remove lead-gel batteries for charging. Fig 1: Identifying Warning Instructions For Lead-Acid Batteries Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Always disconnect negative terminal before positive terminal and always connect positive¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1731 · Applies to: 450, 451, 452, 454
terminal before negative terminal. Switch on the charging equipment only after connecting to the terminals and switch off the charging equipment before disconnecting from the terminals. Keep lead-gel batteries away from unauthorized persons (especially children). Observe the instructions of the particular lead-gel battery and the operator's manual of the vehicle. Wear acid-resistant clothing and eye protection with side guards. Only fill gel into suitable and appropriately marked containers. First aid measures Eye contact Rinse out eyes immediately with plenty of water. Skin contact Remove affected clothing. Immediately neutralize acid or gel on skin or clothing with acid converter or soap suds and rinse off with plenty of water. Swallowing battery gel Have the person affected drink plenty of water with the addition of activated charcoal. As a general rule, always consult a medical service or doctor after first-aid has been rendered. Fire protection measures Suitable extinguishing agents CO and dry extinguishing agent RETROFITTING & CONVERSION > RETROFIT ADDITIONAL INSTRUMENTS - AZ54.30-P- 0001MCC > MODEL 451.3 /4 up to 30.8.10 2
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1732 · Applies to: 450, 451, 452, 454
1 Remove cover (1) on center console
AR68.20- P- 2350MCC Install
2 Make the cutouts (2) to match the perforation (arrows) on the cover (1)
3 Position additional instruments (A15) on dashboard upper section and fasten in place using the bolts (3)
Fig 1: Identifying Cover And Cutout Of Instruments Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Cover, Screw And Additional Instruments With Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connect additional¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1733 · Applies to: 450, 451, 452, 454
4 Connect additional instruments connector (A15x1) The plug for the additional instrument connector (A15x1) is located in the attachment between the air vents. If the plug for the additional instrument connector (A15x1) has not been clipped into the attachment, then the wiring harness is to be tied back and down in a loop.
5 Fit cover (1) onto center console
AR68.20- P- 2350MCC 6 Set clock of additional instruments (A15)
7 Add special equipment to the vehicle data card and to the online vehicle data card Code (V31) Cockpit clock and tachometer package to be added.
RETROFITTING & CONVERSION > RETROFIT ADDITIONAL INSTRUMENTS - AZ54.30-P- 0001MCD > MODEL 451.3 /4 as of 31.8.10 Parts scope for additional instrument (A15) Fig 1: Identifying Cover, Screw And Additional Instruments Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1734 · Applies to: 450, 451, 452, 454
1 Adjust driver seat to the rear
- not for USA AR54.30- P- Fig 2: Removing Additional Instruments Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Additional Instruments Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove instrument cluster (A1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1735 · Applies to: 450, 451, 452, 454
2 Remove instrument cluster (A1) 6015MCC * for USA only AR54.30- P- 6015MCU 3 Detach covering (3) with clip remover, as shown, and remove Clip remover Fig 4 Install
4 Slide wiring harness for additional instruments (6) through the left opening and under the covering (3) towards the instrument cluster
5 Clip additional instruments (A15) into instrument panel
6 Bend into the footwell and route wiring harness for additional instrument (6) at the bottom of the instrument panel upper section towards the instrument cluster
7 Hook wiring harness for additional instruments (6) into holders (arrow C and B) at bottom on instrument panel upper section
8 Detach black, 3-pin connector (5) from vehicle wiring harness in area of instrument cluster (A1)
9 Connect black, 3-pin connector (5) and black, 3-pin coupling (6.1) of wiring harness for additional instruments (6) The additional instruments connector (A15x1) is now complete.
10 Use bolt (1) to tighten additional instruments (A15)
11 Clip cover (2) over the bolt (1) on the additional instruments (A15)
12 Move driver seat back to its default position
13 Install in the reverse order
14 Set clock of additional instruments (A15)
15 Connect Star Diagnosis
AD00.00- P-2000- 04MCC 16 Enter special equipment on the vehicle data card and the online vehicle data card Code (V31) Cockpit clock and tachometer package to be added.
17 Disconnect Star Diagnosis
AD00.00- P-2000- 04MCC
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1737 · Applies to: 450, 451, 452, 454
All MODIFICATION NOTES 24.2.06 Cold test current 12 AH
TEST AND ADJUSTMENT VALUES FOR BATTERY Number Designation 12 AH 30 AH 35 Ah 42 AH BE54.10-P- 1001-01A Battery test at 20°C Acid density kg/dm - ≥1,24 ≥1,24 - Maximum permissible difference between individual battery cells kg/dm - 0,04 0,04 - Load current A - 90 100 - Load time s - 10 10 - Voltage VV - ≈10 ≈10 - BE54.10-P- 1002-01A Cold test current as per EN A 170 540 520 340 TEST AND ADJUSTMENT VALUES FOR BATTERY Number Designation 46 AH 60 Ah VRLA 60 AH 61 AH BE54.10- P-1001- 01A Battery test at 20°C Acid density kg/dm ≥1,24 - - - Maximum permissible difference between individual battery cells kg/dm 0,04 - - - Load current A 140 - - - Load time s 10 - - - Voltage VV ≈10 - - - BE54.10- P-1002- 01A Cold test current as per EN A 420 680 510 540 TEST AND ADJUSTMENT VALUES FOR BATTERY Number Designation 62 AH 70 Ah VRLA 74 AH 80 Ah VRLA BE54.10- P-1001- 01A Battery test at 20°C Acid density kg/dm ≥1,24 - ≥1,24 - Maximum permissible difference between individual battery cells kg/dm 0,04 - 0,04 - Load current A 190 - 265 - 3 3 3 3 3 3
Load time¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1738 · Applies to: 450, 451, 452, 454
s 10 - 10 - Voltage VV ≈10 - ≈10 - BE54.10- P-1002- 01A Cold test current as per EN A 480 760 680 800 TEST AND ADJUSTMENT VALUES FOR BATTERY Number Designation 84 AH 90 Ah VRLA 95 Ah VRLA 100 Ah BE54.10- P-1001- 01A Battery test at 20°C Acid density kg/dm - - - ≥1,24 Maximum permissible difference between individual battery cells kg/dm - - - 0,04 Load current A - - - 300 Load time s - - - ≈10 Voltage VV - - - ≈10 BE54.10- P-1002- 01A Cold test current as per EN A 700 950 850 760 BASIC KNOWLEDGE > FUSE AND RELAY BOX, AS-BUILT CONFIGURATION - GF54.15-P- 0800MCU > MODEL 451.3 /4 3 3
Fuse and relay box fuse assignment¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1739 · Applies to: 450, 451, 452, 454
Engine 132.9 GF54.15-P- 1255-20MCU Engine 780.0 GF54.15-P- 1255-20MEV
Fuse and relay box relay assignment Model 451.3/4 (except 451.391/491) GF54.15-P- 1255-21MCU Model 451.391/491 GF54.15-P- 1255-21MEV
Fuse assignment of fuses in the interior on passenger side Model 451.3/4 (except 451.391/491) GF54.15-P- 1256-24MCU Model 451.391/491 GF54.15-P- 1256-24MEV Wiring diagram electrical center Sheet 1 PE54.25-P- 2000MCU Sheet 2 PE54.25-P- 2000MCV Sheet 3 PE54.25-P- 2000MCW BASIC KNOWLEDGE > FUSE AND RELAY BOX FUSE ASSIGNMENT - GF54.15-P-1255- 20MCU > Fuse and relay assignment of SAM control unit (N10/10) (front side) Fig 1: Identifying SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fuse and relay assignment of SAM control unit (N10/10) (back side)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1740 · Applies to: 450, 451, 452, 454
Position Fuse Identification color Fused function Fuse rating in amperes Fig 1: Identifying Fuse Sockets Of Front Side SAM Control Unit (N10/10) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Fuse Sockets And Electrical Connectors Of Back Side SAM Control Unit (N10/10) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
N10/10f1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1741 · Applies to: 450, 451, 452, 454
(A) 1 N10/10f1 transparent Starter (M1) 25 2 N10/10f2 transparent Wiper motor (M6/1) 25 3 N10/10f3 Yellow Power window convenience feature control unit (N57/2) (with code (V43) Power window) 20 4 N10/10f4 transparent Blower motor (M2) 25 5 N10/10f5 red Left front fog lamp (E5/1) (with code (V07) front fog lamp (FFO))Right front fog lamp (E5/2) (with code (V07) Front fog lamp (FFO)) 10 6 N10/10f6 brown Right taillight (E4e2)Right parking lamp (E6/14)Left license plate lamp (E19/1)Right license plate lamp (E19/2) 7.5 7 N10/10f7 brown Left taillight (E3e2)Left parking light (E6/13) 7.5 8 N10/10f8 transparent Secondary air injection pump relay (K64)ME-SFI [ME] control unit (N3/10)Electronic selector lever module control unit (N15/5)Automated manual transmission control unit (N15/6)Cylinder 1 ignition coil (T1/1)Cylinder 2 ignition coil (T1/2)Cylinder 3 ignition coil (T1/3) 25 9 N10/10f9 brown O2 sensor downstream of CAT (G3/1)Adjustable camshaft timing solenoid (Y49)External air shutoff valve (Y50)Activated charcoal canister shutoff valve (Y58) 7.5 10 N10/10f10 blue O2 sensor upstream of CAT (G3/2)Secondary air injection pump switchover valve (Y32)Cylinder 1 fuel injection valve (Y62/1)Cylinder 2 fuel injection valve (Y62/2)Cylinder 3 fuel injection valve (Y62/3) 15 11 N10/10f11 transparent ESP control unit (N47-5) 25 12 N10/10f12 red Instrument cluster (A1)Additional instruments (A15)Microwave sensor (B32) (with code (V01) Vehicle theft alarm (FFO))Rain sensor / light sensor (B38) (with code (V54) Rain/light sensor)Alarm siren with inclination sensor (H3/2) (with code (V01) Vehicle theft alarm (FFO))Left turn signal lamps/brake light relay (K52/11)Right turn signal lamps/brake light relay (K52/12)Mirror heater relay (K97)Automated manual transmission control unit (N15/6)TPM [RDK] control unit (N88)Combination switch (S4)Cockpit switch group (S6/1)Data link connector (X11/4) 10 13 N10/10f13 blue Spare fuse 15 14 N10/10f14 blue Refrigerant compressor (A9) (with code (I01) Air conditioning Plus)Charge air fan motor (M44) 15 smart radio 9 (A2/1) (with code (C57) smart radio 9)smart radio 10 (A2/2) (with code (C50) smart
N10/10f15¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1742 · Applies to: 450, 451, 452, 454
15 N10/10f15 blue radio 10)Front interior lamp (E15/4) (with vehicles up to production date 1.9.10)Soft top OPEN relay (K66/1) (on model 451.4)Soft top CLOSE relay (K66/2) (on model 451.4) 15 16 N10/10f16 blue Fuel pump with fuel gauge sensor (M3/3)ME-SFI [ME] control unit (N3/10) 15 17 N10/10f17 blue Rear-end door wiper motor (M6/4) (with model 451.3) 15 18 N10/10f18 red Instrument cluster (A1)Yaw rate sensor for lateral and longitudinal acceleration (B24/15)Seat occupied recognition pressure sensor (B48/4)Automatic child seat recognition airbag OFF indicator lamp (E16)Restraint systems control unit (N2/7)ESP control unit (N47-5)Steering angle sensor (N49)Steering assist control unit (N68) (with code (V26) Power steering, EPS (FFO))Driver side seat belt buckle restraint systems switch (S68/3)Front passenger-side seat belt buckle restraint systems switch (S68/4) 10 19 N10/10f19 Brown ME-SFI [ME] control unit (N3/10)Automated manual transmission control unit (N15/6)Data link connector (X11/4)TPM [RDK] control unit (N88) 7,5 20 N10/10f20 red smart radio 9 (A2/1) (with code (C57) smart radio 9)smart radio 10 (A2/2) (with code (C50) smart radio 10)Heater/air conditioning operating unit (N23) (for code (I01)Air conditioning Plus)Front seat heater (SIH) control unit (N25/5) (with code (S17) Seat heater (FFO))Right wiper switch (S4/4)Outside mirror adjustment switch (S50)(with code (V21) Electrically adjustable and heated outside mirrors (FFO))Soft top operation (S84) (on model 451.4) 10 21 N10/10f21 blue Interior socket (X58/1) 15 22 N10/10f22 brown Left low beam (E1e2) 7.5 23 N10/10f23 brown Right low beam (E2e2) 7.5 24 N10/10f24 blue Electronic selector lever module control unit (N15/5) 15 25 N10/10f25 brown Right high beam (E2e1) 7.5 26 N10/10f26 brown Left high beam (E1e1) 7.5 27 N10/10f27 brown ME-SFI [ME] control unit (N3/10) 7.5 28 N10/10f28 orange Heated rear window (R1) 40 29 N10/10f29 green Soft top OPEN relay (K66/1) (on model 451.4)Soft top CLOSE relay (K66/2) (on model 451.4) 30 30 N10/10f30 orange Automated manual transmission control unit (N15/6) 40
N10/10f31¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1743 · Applies to: 450, 451, 452, 454
31 N10/10f31 Yellow Horn (H2)Right door CL motor (M14/5)Left front door central locking motor (M14/6)Rear-end door CL [ZV] motor (M14/7)Fuel filler flap CL [ZV] motor (M14/10)Horn switch (S4/2) 20 32 - - vacant - 33 N10/10f33 red Ignition/starter switch (S2/1) 50 34 N10/10f34 orange ESP control unit (N47-5) 40 35 N10/10f35 green Steering assist control unit (N68) (with code (V26) Power steering, EPS (FFO)) 30 36 N10/10f36 orange Secondary air injection pump (M33)
R1¶
brown Mirror heater relay (K97) (with code (V21) Electrically adjustable and heated outside mirrors (FFO)) 7.5 R2 - brown Stop light switch (S9/1) 7.5 R3 - - VACANT - R4 - - vacant - R5 - - vacant - R6 - - vacant - R7 - - Front interior lamp (E15/4) (with vehicles as of production date 2.9.10) - R8 - Yellow Sound system amplifier (for vehicles as of production date 2.9.10 with code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO)) 20 R9 - transparent Front seat heater (SIH) control unit (N25/5) (with code (S17) Seat heater (FFO)) 25 BASIC KNOWLEDGE > FUSE AND RELAY BOX RELAY ASSIGNMENT - GF54.15-P-1255- 21MCU >
Position¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1744 · Applies to: 450, 451, 452, 454
Relay Switched function A K52/11 Left turn signal/stop lamp relay B K52/12 Right turn signal/stop lamp relay C K97 Mirror heater relay (with code (V21) Electrically adjustable and heated outside mirrors (FFO)) BASIC KNOWLEDGE > FUSE ASSIGNMENT OF FUSES IN THE INTERIOR ON PASSENGER SIDE - GF54.15-P-1256-24MCU > Fig 1: Identifying SAM Control Unit And Relay Sockets Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The SAM control unit controls the following functions:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1746 · Applies to: 450, 451, 452, 454
Drive authorization Central locking Exterior lighting Interior lighting Wiper system Rear window defroster Heated outside mirror (with code (V21) Electrically adjustable and heated outside mirror (FFO)) Anti-theft alarm system (with code (V01) Anti-theft alarm system (FFO)) Soft top (with model 451.4) Requests are conveyed to the SAM control unit via data bus systems or via read-in switches and sensors. The SAM control unit is a subscriber on the Controller Area Network (data bus/CAN bus) (CAN). The following components are read in to control the functions: Via local interconnect network interior 1 (LIN B): Rain sensor / light sensor (B38) (with code (V54) Rain/light sensor) Tachometer (A15p4) (with code (V31) Cockpit clock and tachometer package) Via local interconnect network interior 2 (LIN C): Fig 1: Identifying SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Alarm siren with inclination sensor (H3/2) (with code (V01) Vehicle theft alarm (FFO))¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1747 · Applies to: 450, 451, 452, 454
Microwave sensor (B32) (with code (V01) Vehicle theft alarm (FFO)) Components read in directly: Transmitter key Transponder coil (L11) Wiper motor (M6/1) Rear-end door wiper motor (M6/4) (on model 451.3) Heated rear window switch (N23s1) Ignition/starter switch (S2/1) Combination switch (S4) Fanfare horns switch (S4/2) (except code (I75) Leather sport steering wheel incl. steering wheel rocker switch system) Right wiper switch (S4/4) Hazard flasher switch (S6/1s1) Front fog lamp switch (S6/1s8) (with code (V07) Front fog lamp (FFO)) (S6/1s9TPM [RDK] switch) Tow-away protection /Interior protection switch (S6/1s10) (with code (V01) Vehicle theft alarm (FFO)) Inside unlock CL (ZV) switch (S6/1s11) Inside lock CL (ZV) switch (S6/1s12) Stop light switch (S9/1) Remote trunk opening switch (S15) (on model 451.3) Trunk lid rotary tumbler microswitch (S17/8) (on model 451.4) Soft top operation (S84) (on model 451.4) Soft top microswitch (S84/37) (on model 451.4) Left roof cassette microswitch (S84/38) (on model 451.4) Right roof cassette microswitch (S84/40) (on model 451.4) Right door rotary tumbler microswitch (S87/6) Left door rotary tumbler microswitch (S87/7) Right rear soft top microswitch (S84/39) (on model 451.4) Left rear soft top microswitch (S84/41) (on model 451.4) Tailgate handle switch (S88/9)
The following components are actuated directly to carry out the functions:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1748 · Applies to: 450, 451, 452, 454
Refrigerant compressor (A9) (with code (I01) Air conditioning Plus) Left front lamp unit (E1) Left high beam (E1e1) Left low beam (E1e2) Left turn signal lights (E1e5) Left standing lights (E6/13) Right front lamp unit (E2) Right high beam (E2e1) Right low beam (E2e2) Right turn signal lights (E2e5) Right standing lights (E6/14) Left taillamp (E3) Left turn signal lights (E3e11) Left taillight (E3e2) - Left brake light Right taillamp (E4) Right brake light/turn signal lights (E4e11) Right taillight (E4e2) Left front fog lamp (E5/1) (with code (V07) front fog lamp (FFO)) Right front fog lamp (E5/2) (with code (V07) Front fog lamp (FFO)) Front interior lamp (E15/4) Left license plate lamp (E19/1) Right license plate lamp (E19/2) Center high-mounted stop lamp (E21) Left auxiliary turn signal lamp (E22/1) Right auxiliary turn signal lamp (E22/2) Horn (H2) Open soft top relay (K66/1) (model 451.4) Close soft top relay (K66/2) (model 451.4) Left turn signal lamps/brake light relay (K52/11) Right turn signal lamps/brake light relay (K52/12)
Blower motor (M2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1749 · Applies to: 450, 451, 452, 454
Fuel pump with fuel gauge sensor (M3/3) Wiper motor (M6/1) Rear-end door wiper motor (M6/4) (model 451.3) Electrical soft top motor (M12/6) (model 451.4) Left soft top drive (M12/7) (model 451.4) Right soft top drive (M12/8) (model 451.4) Right door CL motor (M14/5) Left front door central locking motor (M14/6) Rear-end door CL [ZV] motor (M14/7) Fuel filler flap CL [ZV] motor (M14/10) Mirror heater (M21/1r1) (with code (V21) Electrically adjustable and heated outside mirror (FFO)) Mirror heater (M21/2r1) (with code (V21) Electrically adjustable and heated outside mirror (FFO)) Heated rear window (R1) BASIC KNOWLEDGE > RAIN/LIGHT SENSOR, COMPONENT DESCRIPTION - GF54.21-P- 6000MCC > MODEL 451.3 /4 with CODE (V54) Rain/light sensor Fig 1: Identifying Rain Sensor/Light Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1750 · Applies to: 450, 451, 452, 454
The rain/light sensor is located on the inside of the windshield below the inside rearview mirror. Task To measure the light intensity and degree of wetting of the windshield Function principle of rain sensor Infrared light is radiated from the infrared transmitter unit and led to the windshield. The intensity of the light reflected at the windshield is measured by the infrared receiver unit If the windshield is dry in the area of the rain/light sensor (picture A), then the light is reflected almost completely and the infrared receiver unit measures a high light intensity If the windshield is wetted in the area of the rain/light sensor (picture B), then part of the light is scattered from the windshield glass. As a result the intensity of the reflected light reduces and the infrared receiver unit measures a lower light intensity. The light intensity measured by the infrared receiver unit represents a measure for the degree of wetting of the windshield. The smaller the measured light intensity the greater the degree of wetting of the windshield. Function principle of light sensor The light sensor measures the light intensity striking it from outside. The resistance in the light sensor drops as the light intensity reduces. The information from the rain/light sensor is passed on to the SAM control unit (N10/10) via the local interconnect network interior 1 (LIN B). BASIC KNOWLEDGE > DATA LINK CONNECTOR COMPONENT DESCRIPTION - GF54.22- P-2200MCC > MODEL 451.3 /4 Fig 2: Identifying Rain Sensor Principle Function Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1752 · Applies to: 450, 451, 452, 454
The cockpit switch group is located in the center console. Task The cockpit switch group reads in the switching requirements and passes these on to the following control units: Front HS [SIH] control unit (N25/5) (with code (S17) Seat heaters (FFO)) Left seat heater switch Right seat heater switch SAM control unit (N10/10) Hazard warning flasher switch Inside unlock CL [ZV] switch Inside lock CL [ZV] switch Rear fog lamp switch - Front fog lamps switch Towing-away protection switch BASIC KNOWLEDGE > INSTRUMENT CLUSTER (IC [K]), DISPLAY INSTRUMENT AND WARNING SYSTEMS - GF54.30-P-0002-08MCU > Fig 1: Identifying Cockpit Switch Group Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1754 · Applies to: 450, 451, 452, 454
The instrument cluster has the following tasks: Vehicle speed display Output of the important operating condition of the vehicle Warning at critical vehicle operating conditions (visual and acoustic) Information display for various systems Display for maintenance interval display Fig 1: Instrument Cluster Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Networking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1755 · Applies to: 450, 451, 452, 454
The instrument cluster functions as a gateway between CAN and CAN-B. Display elements Left turn signal indicator lamp Right turn signal indicator lamp High beam indicator lamp Alternator charge monitoring and warning lamp Brake fluid and parking brake warning lamp Seat belt warning lamp Airbag indicator and warning lamp ABS indicator lamp Electric steering indicator lamp "CHECK ENGINE" MIL Oil pressure warning lamp ESP warning lamp Coolant temperature warning lamp Tire pressure monitor warning lamp Low beam indicator lamp Electronic speedometer (A1p8) Multifunction display (A1p13) Tank cap monitoring warning lamp All indicator and warning lamps are light emitting diodes. Operation The lower left button in the instrument cluster can be used to switchover the multifunction displays. The lower right button in the instrument cluster can adjust the instrument cluster illumination at circuit 15 ON and circuit 58 ON in five dimmer stages to match individual requirements. Activate Circuit 15 ON activates the instrument cluster. The multifunction display shows the current content at any given time, switches on the instrument cluster illumination and the needle for the speed display is shown on the display field. After circuit 15 OFF the instrument cluster remains active for another 30 s. The speed display needle disappears from the display field behind a cover. For circuit 15 OFF the instrument cluster can be activated under the following preconditions:
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1758 · Applies to: 450, 451, 452, 454
Various alternatives are available to the instrument cluster for the output of messages: Visual indicator/warning message via Indicator/warning lamps Multifunction display Acoustic indicator/warning messages via internal tone signal generator Visual indicator/warning messages via indicator/warning lamps Turn signal indicator lamps These are activated differently according to function: Turn signaling Hazard warning flasher The turn signal flasher is always accompanied by an acoustic clicking sound generated in the same rhythm. Turn signaling: Fig 1: Identifying Indicator/Warning Messages Display Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
During turn signaling the corresponding turn signal indicator lamp is actuated. Actuation takes place via the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1759 · Applies to: 450, 451, 452, 454
Controller Area Network (data bus/CAN bus) (CAN) by the SAM control unit (N10/10). If one of the following lamps malfunctions, the corresponding turn signal indicator lamp is then actuated at doubled-up frequency by the SAM control unit. Left turn signal lamp (E1e5) Right turn signal lamp (E2e5) Left additional turn signal lamp (E22/1) Right additional turn signal lamp (E22/2) Left brake/turn signal lights (E3e11) Right brake/turn signal lights (E4e11) Hazard warning flasher: When the hazard warning flashers are on the two turn signal indicator lamps in the instrument cluster are actuated. High beam indicator lamp Actuation is conducted when the high beam is switched on over CAN by the SAM control unit. Alternator charge indicator/warning lamp If there is a fault in the alternator (G2) the alternator charge monitoring and warning lamp is actuated. Actuation take place via the CAN from the ME control unit (N3/10). Brake fluid and parking brake warning lamp Actuation takes place over the CAN under the following preconditions: From the SAM control unit for an actuated parking brake From the ESP control unit (N47-5) at a minimum brake fluid level in the reservoir From the ESP control unit for a fault of the Electronic Stability Program (Electronic-Stability- Program) Seat belt warning lamp The seat belt warning lamp lights permanently for t = 6s when at circuit 15 ON the driver seat belt buckle restraint systems switch (S68/3) is not closed. A warning tone is also emitted for t = 6 s. As from a vehicle speed of 25 km/h the seat belt warning lamp starts to flash on and off for t = 60 s, when the driver seat belt buckle restraint systems switch or the front passenger seat belt buckle restraint system switch (S68/4) (when front passenger occupied) is not closed. A warning tone is emitted in parallel. The warning tone is emitted in three phases, whereby the frequency changes every 20 s. After this, only the seat belt warning lamp is permanently actuated. The seat belt reminder warning (optical and acoustic) is terminated, as soon as the seat belt buckle restraint system switches are closed by putting on the seat belts. Furthermore, the seat belt reminder warning is also canceled, when the vehicle speed is 0 km/h and the driver door open. The cycle is restarted: If at v > 25 km/h one of the seat belts which is being applied is removed again and as a result one
of the seat belt buckle restraint systems switch is opened¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1760 · Applies to: 450, 451, 452, 454
when the driver door is closed again and the vehicle speed is > 25 km/h The signal for activating the seat belt warning lamp comes from the restraint systems control unit (N2/7) via CAN-B. Airbag indicator and warning lamp The airbag indicator and warning lamp is actuated when there is a fault in the supplemental restraint system (SRS) or the supplemental restraint system has been triggered. Actuation takes place by the restraint systems control unit via CAN. ABS indicator lamp The ABS indicator lamp is actuated when a malfunction occurs in the antilock brake system. Actuation takes place over CAN by the ESP control unit. Electric steering indicator lamp The electric steering indicator lamp is activated, when a malfunction in the electric steering is given. Actuation takes place by the power steering control unit via CAN (N68). "CHECK ENGINE" indicator lamp The CHECK ENGINE indicator lamp is actuated if a fault is present in the injection system, ignition system or exhaust emission system. Actuation takes place by the ME control unit via CAN. Oil pressure warning lamp The oil pressure warning lamp is actuated, if there is no or little oil pressure built up in the engine's oil circuit. Actuation takes place by the ME control unit via CAN. ESP warning lamp Actuation takes place over CAN by the ESP control unit under the following preconditions: The ESP warning lamp flashes on and off during a system control intervention at a frequency of 2.5 Hz. The ESP warning lamp comes on when there is a system fault or when the system is switched off Coolant temperature warning lamp The warning lamp is actuated, when the coolant temperature is too high. Actuation takes place by the ME control unit via CAN. Tire pressure monitor warning lamp Actuation takes place via CAN from the TPM [RDK] control unit (N88) under the following preconditions: when a manual reset has taken place or when a pressure loss was determined A manual reset is indicated by repeated flashing of the tire pressure monitor warning lamp, a pressure loss through the lamp being permanently on.
Low beam indicator lamp¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1761 · Applies to: 450, 451, 452, 454
Actuation is conducted when the low beam is switched on over CAN by the SAM control unit. Tank cap monitoring warning lamp If the ME control unit detects a tank cap which is not closed, it sends a corresponding signal on the. The instrument cluster receives the signal and actuates the tank cap monitoring warning lamp constantly. Indicator lamp test An indicator lamp test is carried out for "terminal 15 ON". In doing so all indicator and warning lamps are actuated with the exception of the following lamps: Left tern signal indicator lamp Right turn signal indicator lamp High beam indicator lamp The indicator lamp test is terminated as soon as an engine speed of > 480 RPM is reported by the ME control unit via CAN. Visual indicator/warning messages via the multifunction display The multifunction display's gear indicator shows the following warning message when the instrument cluster is actuated: Drive authorization system: The system is activated or a malfunction has occurred. Actuation takes place over CAN by the SAM control unit. CAN failure: flashes when the CAN is inoperative. Actuation takes place, when the instrument cluster does not receive any data or only implausible data from the CAN. Shifting system: A malfunction has occurred in the shifting system. Actuation takes place by the automated manual transmission control unit via CAN. Acoustic indicator/warning message over internal tone signal generator The acoustic warning and information signals are produced by an internal tone signal generator. An acoustic feedback occurs for the following function states: Flasher ON With direction flashing and warning flashing, in parallel with the visual feedback, an acoustic feedback takes place in the form of flasher clicking. Actuation takes place via the SAM control unit. Lights on reminder warning (warning tone) If the driver door is opened when the standing light or low beams are switched on, a warning tone
3041MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1764 · Applies to: 450, 451, 452, 454
MODEL 451.3 /4 Shown on code (K07) Speedometer (miles) Gear indicator in manual mode The gear indicator displays the current gear engaged. The corresponding information from the automated manual transmission control unit (N15/6) is read in over the Controller Area Network (data bus/CAN bus) (CAN) from the instrument cluster. If the automated manual transmission control unit establishes that a higher gear would be better for the current engine speed, accelerator pedal position and vehicle speed, a gear change is suggested in the gear indicator: Arrow up: Shift up one gear Arrow down: Shift down one gear The gearshift recommendation is oriented towards a consumption-specific driving style. Gear indicator in automatic mode The selected driving stage is shown in the gear indicator. The following displays are possible: "P": Parking position "R": Reverse gear "N": Neutral "D": Drive position The corresponding information from the automated manual transmission control unit is read in over CAN by the instrument cluster. Fuel level and reserve indicator Fig 1: Identifying Speedometer Operating Condition Display Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The fuel supply is shown to the driver over the fuel level and reserve indicator by means of eight segments.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1765 · Applies to: 450, 451, 452, 454
The data sent from the fuel level sensor (M3/3b1) to the ME-SFI [ME] control unit (N3/10) is read in over the CAN by the instrument cluster. The reserve area is equivalent to an amount of 1 gal. If the reserve area is reached, the fuel pump symbol starts to flash on and off and the remaining fuel is displayed in increments of 0.13 gal in the multifunction display. In the event of any malfunction the segments in the fuel level and reserve indicator start to flash on and off. Maintenance interval display The maintenance interval display draws the driver's attention to a service that is due soon. Roughly one month beforehand and every time the engine is started, the maintenance interval display is displayed for 10 seconds, and the line of the main odometer shows the remaining distance or remaining time. Meaning of maintenance interval displays: One wrench = Oil service plus Two wrenches = Maintenance The left button on the instrument cluster can be used to confirm the display on the maintenance interval display. The maintenance interval display is shown for 10 s by briefly pressing the button in the right of the instrument cluster twice. Trip odometer The display area for the trip odometer is 0 to 9999.9 kilometers or miles (with code (K07) Speedometer (miles)). Once the maximum reading is reached the display is automatically reset to zero. Manual reset: Keep pressing the left button until the trip odometer appears in the multifunction display. After pressing the left button again for 1 s the display starts to flash on and off. Continue to press and hold the left button. The display is reset to zero. The trip distance remains stored even when the battery (G1) is disconnected. Odometer The main odometer reading is shown either in kilometers or miles, as soon as the instrument cluster is activated. The range for the main odometer is from 0 to 999,999 kilometers or miles. If the maximum mileage is reached, the counter is not reset to zero. In this case, the instrument cluster should be replaced. The internal counter continues to operate however. The main odometer reading is stored for at least 10 years, even if the voltage supply is disconnected. Outside temperature indicator The instrument cluster takes the following data into consideration when determining the outside temperature value:
Outside temperature value directly from outside temperature display temperature sensor (B14)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1766 · Applies to: 450, 451, 452, 454
Internal vehicle speed signal from instrument cluster Coolant temperature value via CAN from the ME-SFI [ME] control unit Engine running time over CAN from ME-SFI [ME] control unit The instrument cluster processes this data and actuates the outside temperature indicator accordingly. The dependency of the outside temperature indicator on the speed, the engine running time and the coolant temperature prevents too high a temperature being displayed through radiant heat when the vehicle is stationary or moving slowly. Falling temperature values are always allowed. The display's response pattern varies as temperature rises, according to coolant temperature and engine running time: Coolant temperature < 60°C: The current outside temperature value is always displayed when the instrument cluster is activated. Coolant temperature > 60°C: When the instrument cluster is activated rising outside temperature values are displayed with a delay. Coolant temperature > 60°C and circuit 15 OFF: The last measured temperature value is stored for a period of t = 60 min. When the instrument cluster is activated, the stored temperature value is shown in the outside temperature display. If the coolant temperature sensor (B11/4) is defective or if it provides implausible coolant temperature value, the ME-SFI [ME] control unit sends a corresponding message over CAN to the instrument cluster. A coolant temperature of ≥ 60°C is assumed. Set the time After pressing the left button on the instrument cluster for > 5 s the colon in the time display starts to flash on and off. Now the left button or the right button can be used to set the time. If one of the two buttons is not pressed again within the next 5 s, the set value is stored and the colon stops flashing.
Instrument cluster, component description A1 GF54.30-P- 6000MCU
Outside air temperature sender component description B14 GF83.57-P- 4000MCC
ME-SFI [ME] control unit, component description N3/10 GF07.61-P- 6000MCU
SAM control unit, component description N10/10 GF54.21-P- 4157MCU
Automated manual transmission control unit, component description N15/6Transmission 717.482 GF26.19-P- 1010MCU
BASIC KNOWLEDGE > INSTRUMENT CLUSTER, COMPONENT DESCRIPTION - GF54.30-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1767 · Applies to: 450, 451, 452, 454
P-6000MCU > MODEL 451.3 /4 Shown on code (K07) Speedometer (miles) Location The instrument cluster is located in the dashboard on the driver-side. Task The instrument cluster has the following tasks: Gateway between Controller Area Network (data bus/CAN bus) (CAN) and Controller Area Network bus Class B (interior) (CAN-B) Receive the input signals from the CAN and CAN-B for the various displays and warning messages Reading in of the paddle shift for steering wheel gearshift (SAL) (S112) over the fanfare horns and airbag clock spring contact (A45) (with code (I75) Leather sport steering wheel with steering wheel rocker switch system) Reading in the outside temperature display temperature sensor (B14) Fig 1: Identifying Instrument Cluster Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Determining and displaying the vehicle speed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1768 · Applies to: 450, 451, 452, 454
Illumination of the multifunction display, the dial face, the pointers and displays depending on the dimmer stage Display of dimmer stage over circuit 58d Actuation of warning and indicator lamps Output of acoustic signals Acoustic signals The acoustic warning and information signals and the turn signal indicator clicking are generated by means of an audio signal generator: Turn signal ON (turn signal knocking sound) Light warning (warning tone) Door warning (warning tone) Daytime running lights activated or deactivated (signal tone) (with code (K06) Daytime running lights) Seat belt reminder warning Actuation of stepper motors The electronic speedometer is driven by a stepper motor. Variable displays in the multifunction display The following displays are shown in the multifunction display: Fuel level and reserve indicator Transmission mode display in automatic mode Gear indicator or gearshift recommendation in manual mode Main odometer Multifunction display for remaining fuel, trip odometer and maintenance interval display Time display Ambient temperature display Transmission mode display Display of gear engaged or gearshift recommendation in manual mode
Instrument cluster, component description A1 GF54.30-P- 6000MCU
Outside air temperature sender component description B14 GF83.57-P- 4000MCC
Restraint systems control unit, N2/7 GF91.60-P-
component description¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1769 · Applies to: 450, 451, 452, 454
4048MCU
ME-SFI [ME] control unit, component description N3/10 GF07.61-P- 6000MCU
SAM control unit, component description N10/10 GF54.21-P- 4157MCU
Automated manual transmission control unit, component description N15/6 GF26.19-P- 1010MCU
ESP control unit, component description N47-5 GF42.45-P- 5118MCU
Electric steering control unit, component description N68For vehicles with code (V26) Power steering, EPS (FFO) GF46.35-P- 7100MCU
Tire pressure monitor control unit, component description N88 GF40.15-P- 5124MCU
Table of contents for function description of instrument cluster (IC)
GF54.30-P- 0997MCU MISCELLANEOUS NOTES > DISPOSE OF BATTERY - OS54.10-P-0001-01Z > All models Information on recycling and disposing of lead-acid batteries and lead-gel batteries Old lead batteries up to 31.12.1998 are not classed as recyclable waste requiring special monitoring and control. They bear the ISO symbol for return and recycling. The electrolyte, diluted sulfuric acid or acid gel should never be emptied in a careless manner. This procedure must be carried out by specialist companies. Picture shows ISO symbol for return and recycling Old lead-acid batteries and lead-gel batteries should not be mixed together as this would make recycling more difficult. Fig 1: Identifying ISO Symbol For Return And Recycling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
PE54.30-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1771 · Applies to: 450, 451, 452, 454
P- 2001MEV Wiring diagram large instrument (instrument cluster) MODEL 451.391/ 491 PE54.30-P- 2001MEV PE54.30- P- 2003MCU Wiring diagram of auxiliary instruments MODEL 451 / (except 451.391 /491) up to 30.8.10 PE54.30-P- 2003MCU PE54.30- P- 2051MCU Electrical function diagram for instrument cluster (KI) MODEL 451 PE54.30-P- 2051MCU PE54.35- P- 2000MCU Wiring diagram for signaling system MODEL 451 PE54.35-P- 2000MCU WIRING DIAGRAMS > WIRING DIAGRAM OF ELECTRONIC STABILITY PROGRAM (ESP) - PE42.45-P-2000-97MCU > Code: Designation: Position: A1 Instrument cluster 13L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20L L6/1 Left front wheel speed sensor 26L L6/1x1 Wheel speed sensor connector
L6/2 Right front wheel speed sensor 28L L6/2x1 Wheel speed sensor connector
L6/3 Left rear wheel speed sensor 29L L6/3x1 Wheel speed sensor connector
L6/4 Right rear wheel speed sensor 31L L6/4x1 Wheel speed sensor connector
N10/10 SAM control unit 4L N10/10f11 Fuse 11 2L N10/10f18 Fuse 18 5L N10/10f34 Fuse 34 3L N10/10f38 Fuse 38 7L N47-5 ESP control module 28A N47-5 ESP control module 12A N47-5 ESP control module 20A N47-5 ESP control module 4A N49 Steering angle sensor 17L S11 Brake fluid indicator switch 23L
Parking brake indicator switch¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1772 · Applies to: 450, 451, 452, 454
S12 Parking brake indicator switch 25L S9/1 Stop lamp switch (4-pin) 9L W10 Ground (battery) 11G W10 Ground (battery) 7E W14 Left floor interior compartment ground 22G W43 Ground (outside left fire wall) 24G W7 Ground (right wheelhousing in trunk) 25G W9 Ground (at left headlamp unit) 16G Z3/17 Circuit 15 (fused) connector sleeve 18G Z3/17 Circuit 15 (fused) connector sleeve 5G Z37/2 CAN engine bus (low) connector sleeve 14G Z37/2 CAN engine bus (low) connector sleeve 16E Z37/3 CAN engine bus (high) connector sleeve 12G Z37/3 CAN engine bus (high) connector sleeve 17E Z37/41 CAN databus (high) connector sleeve 12E Z37/41 CAN databus (high) connector sleeve 19E Z37/42 CAN bus (low) connector sleeve 14E Z37/42 CAN bus (low) connector sleeve 21E Z40 Stop lamp signal connector sleeve 9G
Fig 1: Electronic Stability Program (ESP) - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1773 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GF00.19-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1775 · Applies to: 450, 451, 452, 454
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 WIRING DIAGRAMS > WIRING DIAGRAM FOR DATA LINK CONNECTOR/DIAGNOSTIC SOCKET - PE54.22-P-2000-97MCU > Code: Designation: Position: A1 Instrument cluster 9L N10/10 SAM control unit 4L N10/10f12 Fuse 12 2L N10/10f19 Fuse 19 6L W26 Ground (transmission tunnel) 6E X11/4 Data link connector 11A X11/4 Data link connector 4A Z3/24 Circuit 15 (fused) connector sleeve, function 5E Z37/2 CAN engine bus (low) connector sleeve 9E Z37/3 CAN engine bus (high) connector sleeve 8E Z45 ATA {EDW} sensor supply circuit 30 connector sleeve 2E
GF00.19-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1777 · Applies to: 450, 451, 452, 454
P- 1000MCU Location and assignment of line and plug 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 PE07.00- P- 1100MCU
Engine 132Further wiring diagrams PE07.00- P- 1100MCU PE08.00- P- 1100MCC
Engine 780.009Further wiring diagrams PE08.00- P- 1100MCC PE26.00- P- 1100MCU
Transmission 717 (except model 451.391/491)Further wiring diagrams PE26.00- P- 1100MCU PE27.00- P- 1100MCC
Model 451.391 / 491Further wiring diagrams PE27.00- P- 1100MCC PE42.00- P- 1100MCU
Further wiring diagrams PE42.00- P- 1100MCU PE43.00- P- 1100MCC
Model 451.391 / 491Further wiring diagrams PE43.00- P- 1100MCC PE46.00- P- 1100MCU
Further wiring diagrams PE46.00- P- 1100MCU PE54.00- P- 1100MCU
Further wiring diagrams PE54.00- P- 1100MCU PE72.00- P- 1100MCU
Further wiring diagrams PE72.00- P- 1100MCU PE80.00- P- 1100MCU
Further wiring diagrams PE80.00- P- 1100MCU PE82.00- P- 1100MCU
Further wiring diagrams PE82.00- P- 1100MCU PE83.00- P- 1100MCU
Further wiring diagrams PE83.00- P- 1100MCU
PE91.00-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1778 · Applies to: 450, 451, 452, 454
P- 1100MCU
Further wiring diagrams PE91.00- P- 1100MCU WIRING DIAGRAMS > WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000-97MCU
Code: Designation: Position: A1 Instrument cluster 46L A15 Additional instruments 28L A15x1 Additional instruments connector
A6/1 STH radio remote control receiver 32L K61 Blower motor relay 1 66L M3/3 Fuel pump with fuel level sensor 69L M4/9 Battery cooling fan motor 22L M6/1 Wiper motor 14L M6/4 Tailgate wiper motor 17L N10/10 SAM control unit 45A N10/10 SAM control unit 36A N10/10 SAM control unit 68A N10/10 SAM control unit 53A N10/10 SAM control unit 28A N10/10 SAM control unit 61A N10/10 SAM control unit 76A N10/10 SAM control unit 12A N10/10 SAM control unit 20A N10/10 SAM control unit 5A N10/10f1 Fuse 1 4A N10/10f10 Fuse 10 8A N10/10f12 Fuse 12 34A N10/10f16 Fuse 16 73A N10/10f17 Fuse 17 17A N10/10f18 Fuse 18 42A N10/10f19 Fuse 19 1A N10/10f2 Fuse 2 14A N10/10f27 Fuse 27 2A
N10/10f30¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1779 · Applies to: 450, 451, 452, 454
Fuse 30 21A N10/10f44 Fuse 44 (slot R9) 60A N10/10f8 Fuse 8 7A N10/10f9 Fuse 9
N10/10k10 Front wiper relay
N10/10k13 Rear wiper relay
N10/10k3 Starter relay
N10/10k4 Electric fuel pump relay
N10/10k7 Main relay
N10/10k9 Automated manual transmission relay
N15/6 Automated manual transmission control unit 20L N3 EVCM electric vehicle control unit 37L N3 EVCM electric vehicle control unit 75L N3 EVCM electric vehicle control unit 24L N3/10 ME-SFI [ME] control unit 72L N47/5 ESP control unit 42L N65/3 Brake booster vacuum pump control unit 63L S6/1 Cockpit switch group 53L S6/1s1 Hazard warning flasher switch
S6/1s10 Tow-away protection/interior protection switch
S6/1s11 Inside unlock CL [ZV] switch
S6/1s12 Inside lock CL [ZV] switch
S6/1s3 Left seat heater switch
S6/1s4 Right seat heater switch
S6/1s8 Front fog lamps switch
S6/1s9 TPM [RDK] switch
U1000 Valid for model 451.391/491 6G U1000 Valid for model 451.391/491 30G U1000 Valid for model 451.391/491 44F U1000 Valid for model 451.391/491 61D U1000 Valid for model 451.391/491 65G U1000 Valid for model 451.391/491 74G U1000 Valid for model 451.391/491 45L U1000 Valid for model 451.391/491 21F
U1001¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1780 · Applies to: 450, 451, 452, 454
Not valid for model 451.391/491 1G U1001 Not valid for model 451.391/491 46F U1001 Not valid for model 451.391/491 68G U1001 Not valid for model 451.391/491 55E U1001 Not valid for model 451.391/491 45K U1001 Not valid for model 451.391/491 44F U1012 Valid up to 30/08/2010 26H U1012 Valid up to 30/08/2010 43G U1013 Valid as of 31/08/2010 41G U114 Valid for front fog lamps 50F U21 Valid for heated seats 55D U30 Valid for diesel engines 18F U492 Valid for power steering 44E U493 Not valid for power steering 46E U606 Valid for all except convertibles 15D U75 Valid for gasoline engines 70G U75 Valid for gasoline engines 26H U75 Valid for gasoline engines 18G W10 Ground (battery) 50G W10 Ground (battery) 22G X11/4 Data link connector 39L X18/19 Trunk lid connector 16H X99/3 Vehicle wiring harness connector 62H Y19/1 Interior air conditioning expansion valve 34L Y19/3 Battery air conditioning expansion valve 35L Z3/17 Circuit 15 (fused) connector sleeve 42E Z37/4 Power steering CAN bus connector sleeve (low) 45G Z37/5 Power steering CAN bus connector sleeve (high) 46G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 34G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 20G Z7/24 Circuit 87/1 connector sleeve 18G Z78 Cockpit LIN connector sleeve 27G Z81 Circuit 58d connector sleeve 48G
Fig 1: Electrical Center - Wiring Diagram (1 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1781 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Electrical Center - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1782 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Electrical Center - Wiring Diagram (3 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1783 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Electrical Center - Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1784 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
P-1901-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1786 · Applies to: 450, 451, 452, 454
03MCC Use of wiring diagrams
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 plug 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 PE07.00- P- 1100MCU
Engine 132Further wiring diagrams PE07.00- P- 1100MCU PE08.00- P- 1100MCC
Engine 780.009Further wiring diagrams PE08.00- P- 1100MCC PE26.00- P- 1100MCU
Transmission 717 (except model 451.391/491)Further wiring diagrams PE26.00- P- 1100MCU PE27.00- P- 1100MCC
Model 451.391 / 491Further wiring diagrams PE27.00- P- 1100MCC PE42.00- P- 1100MCU
Further wiring diagrams PE42.00- P- 1100MCU PE43.00- P- 1100MCC
Model 451.391 / 491Further wiring diagrams PE43.00- P- 1100MCC PE46.00- P- 1100MCU
Further wiring diagrams PE46.00- P- 1100MCU PE54.00- P- 1100MCU
Further wiring diagrams PE54.00- P- 1100MCU PE72.00- PE72.00-
1100MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1787 · Applies to: 450, 451, 452, 454
P- 1100MCU
Further wiring diagrams P- 1100MCU PE80.00- P- 1100MCU
Further wiring diagrams PE80.00- P- 1100MCU PE82.00- P- 1100MCU
Further wiring diagrams PE82.00- P- 1100MCU PE83.00- P- 1100MCU
Further wiring diagrams PE83.00- P- 1100MCU PE91.00- P- 1100MCU
Further wiring diagrams PE91.00- P- 1100MCU WIRING DIAGRAMS > WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000-97MCV
Code: Designation: Position: A2/1 Smart radio 9 24L A2/2 Smart radio 10 25L A2/3 Smart Entry radio 24L A2/4 Smart Premium radio 25L E1 Left front lamp unit 54L E15/4 Front interior lamp 32L E1e1 Left high beam
E1e2 left low beam
E2 Right front lamp unit 57L E2e1 Right high beam
E2e2 Right low beam
E3 Left taillamp 53L E3e2 Left taillamp
E6/13 Left standing lamp 51L E6/14 Right standing lamp 50L K116 Relay for shutoff-capable interior lamp 29L K52/11 Left turn signal/stop lamp relay 60L K52/12 Right turn signal/stop lamp relay 61L K61 Blower motor relay 1 18L K62 Blower motor relay 2 20L
K66/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1788 · Applies to: 450, 451, 452, 454
Open soft top relay 37L K66/2 Close soft top relay 39L K87/1 Rear fog lamp relay 79L M2 Blower motor 16L M4/2 Coolant fan motor 48L N10/10 SAM control unit 76A N10/10 SAM control unit 19A N10/10 SAM control unit 61A N10/10 SAM control unit 52A N10/10 SAM control unit 44A N10/10 SAM control unit 11A N10/10 SAM control unit 68A N10/10 SAM control unit 4A N10/10 SAM control unit 28A N10/10 SAM control unit 37A N10/10f11 Fuse 11 70A N10/10f15 Fuse 15 24A N10/10f20 Fuse 20 12A N10/10f22 Fuse 22
N10/10f23 Fuse 23
N10/10f24 Fuse 24 75A N10/10f25 Fuse 25
N10/10f26 Fuse 26 54A N10/10f28 Fuse 28 46A N10/10f29 Fuse 29 40A N10/10f3 Fuse 3 13A N10/10f34 Fuse 34 67A N10/10f35 Fuse 35 64A N10/10f37 Fuse 37 (slot R2) 59A N10/10f4 Fuse 4
N10/10f42 Fuse 42 31A N10/10f6 Fuse 6
N10/10f7 Fuse 7 51A N10/10k1 Heated rear window relay
N10/10k11¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1789 · Applies to: 450, 451, 452, 454
Heater blower relay
N10/10k12 Standing lamps relay
N10/10k2 Soft top "open" and soft top "close" relay
N10/10k2 Soft top "open" and soft top "close" relay
N10/10k6 High beam relay
N10/10k8 Low beam headlamp relay
N15/5 Electronic selector lever module control unit 71L N15/5 Electronic selector lever module control unit 75L N23 Heater/AC operating unit 6L N47-5 ESP control unit 68L N57/2 Power window convenience feature control unit 13L N68 Steering Assist control unit 64L R1 Heated rear window 47L R1 Heated rear window 45L S4/4 Right wiper switch 10L S84 Power soft top switch 43L S84/37 Soft-top microswitch 40L S84/38 Left roof cassette microswitch 41L S84/39 Right rear soft top microswitch 44L S9/1 Stop lamp switch 59L S9/1 Stop lamp switch 78L U1000 Valid for model 451.391/491 17E U1000 Valid for model 451.391/491 73F U1001 Not Valid for model 451.391/491 15E U1001 Not Valid for model 451.391/491 77F U1001 Not Valid for model 451.391/491 70F U101 Valid up to 02/2009 36E U101 Valid up to 02/2009 34E U1010 Valid for radio with Premium sound system 22K U1012 Valid up to 30/08/2010 35E U1012 Valid up to 30/08/2010 32E U1012 Valid up to 30/08/2010 23K U1013 Valid as of 31/08/2010 36E U1013 Valid as of 31/08/2010 31E
U1013¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1790 · Applies to: 450, 451, 452, 454
Valid as of 31/08/2010 23K U102 Valid as of 3/2009 35E U102 Valid as of 3/2009 32E U102 Valid as of 3/2009 26C U14 Valid for rain/light sensor 79G U23 Valid for convertibles 35D U492 Valid for power steering 62A U606 Valid for all except convertibles 46D U606 Valid for all except convertibles 8E U656 Valid for interior lights package 27L U861 Valid for versions without interior light package 27K U865 Valid for Entry radio 22K W43 Ground (outside left fire wall) 48G W43 Ground (outside left fire wall) 52G W43 Ground (outside left fire wall) 50G W9 Ground (left front, at lamp unit) 48F X18/19 Trunk lid connector 46G X23/7 Soft top connector 43G X23/7 Soft top connector 40G X85/10 Heating or air conditioning connector 16H Z29/4 Circuit 58R (fused) connector sleeve 49G Z29/4 Circuit 58R (fused) connector sleeve 18G Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve (low) 11G Z7/59 Tml. 30 connector sleeve 33F Z7/59 Tml. 30 connector sleeve 35F Z7/59 Tml. 30 connector sleeve 31F
Fig 1: Electrical Center - Wiring Diagram (1 Of 6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1791 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Electrical Center - Wiring Diagram (2 Of 6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1792 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Electrical Center - Wiring Diagram (3 Of 6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1793 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Electrical Center - Wiring Diagram (4 Of 6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1794 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Electrical Center - Wiring Diagram (5 Of 6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1795 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1901MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1797 · Applies to: 450, 451, 452, 454
P- 1901MCU Search aid for all wiring diagram groups
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 plug 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 PE07.00- P- 1100MCU
Engine 132Further wiring diagrams PE07.00- P- 1100MCU PE08.00- P- 1100MCC
Engine 780.009Further wiring diagrams PE08.00- P- 1100MCC PE26.00- P- 1100MCU
Transmission 717 (except model 451.391/491)Further wiring diagrams PE26.00- P- 1100MCU PE27.00- P- 1100MCC
Model 451.391 / 491Further wiring diagrams PE27.00- P- 1100MCC PE42.00- P- 1100MCU
Further wiring diagrams PE42.00- P- 1100MCU PE43.00- P- 1100MCC
Model 451.391 / 491Further wiring diagrams PE43.00- P- 1100MCC PE46.00- P- 1100MCU
Further wiring diagrams PE46.00- P- 1100MCU PE54.00- P- 1100MCU
Further wiring diagrams PE54.00- P- 1100MCU PE72.00- P- 1100MCU
Further wiring diagrams PE72.00- P- 1100MCU
PE80.00-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1798 · Applies to: 450, 451, 452, 454
P- 1100MCU
Further wiring diagrams PE80.00- P- 1100MCU PE82.00- P- 1100MCU
Further wiring diagrams PE82.00- P- 1100MCU PE83.00- P- 1100MCU
Further wiring diagrams PE83.00- P- 1100MCU PE91.00- P- 1100MCU
Further wiring diagrams PE91.00- P- 1100MCU WIRING DIAGRAMS > WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000-97MCW
Code: Designation: Position: A45 Fanfare horns and airbag clock spring contact 26L A9 Refrigerant compressor 15L B32 Microwave sensor 73L E34 Charger feed socket indicator LED 47H E5/1 Left front fog lamp 65L E5/2 Right fog lamp 66L F90 12 V charge line prefuse 3H F91 SAM prefuse 8H G1 Battery 7L G1 Battery 5L G1 Battery 9L H2 Horn 17L H3/2 Alarm siren with inclination sensor 71L K97 Mirror heater relay 61L L11 Transponder coil 76L M14/10 Fuel filler flap CL [ZV] motor 18L M14/6 Left door CL [ZV] motor 20L M21/1 Left electrically adjustable and heated outside mirror 57L M21/1x1 Left electrically adjustable and heated exterior mirror connector
M21/2 Right electrically adjustable and heated outside mirror 58L M21/2x1 Right electrically adjustable and heated exterior mirror connector
Charge air fan motor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1799 · Applies to: 450, 451, 452, 454
M44 Charge air fan motor 14L M57/4 Trunk lid opening assist motor 1 (cabriolet) 23L M57/5 Trunk lid opening assist motor 2 (cabriolet) 24L M57/6 Trunk lid opening assist motor (cabriolet) 21L M6/1 Wiper motor 52L M6/4 Tailgate wiper motor 55L N10/10 SAM control unit 20A N10/10 SAM control unit 27A N10/10 SAM control unit 36A N10/10 SAM control unit 44A N10/10 SAM control unit 52A N10/10 SAM control unit 62A N10/10 SAM control unit 69A N10/10 SAM control unit 12A N10/10 SAM control unit 76A N10/10 SAM control unit 4A N10/10f14 Fuse 14 13A N10/10f17 Fuse 17 55A N10/10f2 Fuse 2 53A N10/10f21 Fuse 21 51A N10/10f31 Fuse 31 22A N10/10f33 Fuse 33 8A N10/10f36 Fuse 36 (slot R1) 61A N10/10f39 Fuse 39 (slot R4) 78A N10/10f39 Fuse 39 (slot R4) 60A N10/10f40 Fuse 40 (slot R5) 40A N10/10f41 Fuse 41 (slot R6) 68A N10/10f42 Fuse 42 (slot R7) 33A N10/10f43 Fuse 43 (slot R8) 30A N10/10f5 Fuse 5 65A N10/10k10 Front wiper relay
N10/10k13 Rear wiper relay
N10/10k14 Front fog lamp relay
N10/10k820 Charge air fan motor and horn relay
N10/10k820¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1800 · Applies to: 450, 451, 452, 454
Charge air fan motor and horn relay
N10/10k830 CL [ZV] "open" and CL [ZV] "locked" relay
N10/10k830 CL [ZV] "open" and CL [ZV] "locked" relay
N10/10k840 Rear-end door/trunk lid CL [ZV] relay
N116/5 High-voltage distributor control unit 30L N116/5 High-voltage distributor control unit 79L N145 Electric motor control unit 33L N145 Electric motor control unit 3L N24/3 High-voltage AC/DC battery charger control unit 41L N24/4 Smart battery charger control unit 44L N3 EVCM electric vehicle control unit 47L N3 EVCM electric vehicle control unit 68L N82/2 Battery management system control unit 37L S2/1 Ignition/starter switch 11L U100 Valid as of 12/2008 59F U1000 Valid for model 451.391/491 28A U1000 Valid for model 451.391/491 66E U1000 Valid for model 451.391/491 1C U1001 Not valid for model 451.391/491 6C U1001 Not valid for model 451.391/491 8C U1012 Valid up to 30/08/2010 73E U1012 Valid up to 30/08/2010 6C U1012 Valid up to 30/08/2010 60C U1013 Valid as of 31/08/2010 74E U1013 Valid as of 31/08/2010 8C U1013 Valid as of 31/08/2010 61C U114 Valid for front fog lamps 64A U180 Valid for ATA [EDW] with siren 70D U23 Valid for convertibles 20G U606 Valid for all except convertibles 54D U606 Valid for all except convertibles 22G U75 Valid for gasoline engines 13G U99 Valid up to 12/2008 57C
Ground (battery)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1801 · Applies to: 450, 451, 452, 454
W10 Ground (battery) 6G W10 Ground (battery) 71G W10 Ground (battery) 51G W10 Ground (battery) 5G W10 Ground (battery) 73F W10 Ground (battery) 75E W10 Ground (battery) 9G W12 Ground (center console) 12F W43 Ground (outside left fire wall) 17G W43 Ground (outside left fire wall) 53G W6 Ground (left wheelhouse in luggage compartment) 14G W6 Ground (left wheelhouse in luggage compartment) 23G W6 Ground (left wheelhouse in luggage compartment) 24G W6 Ground (left wheelhouse in luggage compartment) 21G W9 Ground (left front, at lamp unit) 17F W9 Ground (left front, at lamp unit) 27D X18/19 Trunk lid connector 54H X26 Interior/engine connector 13F X35/1 Left door separation point 57H X35/1 Left door separation point 19G X35/2 Right door separation point 58H X58/1 Interior socket 50L X99/3 Vehicle wiring harness connector 29H Z17 Connector sleeve 9 74G Z19/1 CL [ZV] "open" connector sleeve 18G Z19/2 CL [ZV] "closed" connector sleeve 17G Z212 Circuit 30 supply connector sleeve 68G Z4/3 Tml. 30 connector sleeve 40E Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 60G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 73H Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 71G Z78/1 ATA [EDW] LIN connector sleeve 72G
Fig 1: Electrical Center - Wiring Diagram (1 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1802 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Electrical Center - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1803 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Electrical Center - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1804 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Electrical Center - Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1805 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
OV00.01-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1807 · Applies to: 450, 451, 452, 454
1901-03MCC Use of wiring diagrams
OV00.01-P- 1901-03MCC OV00.01-P- 1901MC 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 PE07.00-P- 1100MCU
Further wiring diagrams PE07.00-P- 1100MCU PE26.00-P- 1100MCU
Further wiring diagrams PE26.00-P- 1100MCU PE42.00-P- 1100MCU
Further wiring diagrams PE42.00-P- 1100MCU PE46.00-P- 1100MCU
Further wiring diagrams PE46.00-P- 1100MCU PE54.00-P- 1100MCU
Further wiring diagrams PE54.00-P- 1100MCU WIRING DIAGRAMS > WIRING DIAGRAM LARGE INSTRUMENT (INSTRUMENT CLUSTER) - PE54.30-P-2001-97MCU > Code: Designation: Position: A1 Instrument cluster 25A A1 Instrument cluster 5A A1 Instrument cluster 43A A1 Instrument cluster 12A A1 Instrument cluster 36A A1e1 Left tern signal indicator lamp 29A A1e15 Airbag indicator and warning lamp 21A A1e17 ABS indicator lamp 15A
A1e18¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1808 · Applies to: 450, 451, 452, 454
Electric steering indicator lamp 45A A1e2 Right turn signal indicator lamp 30A A1e26 "CHECK ENGINE" MIL 31A A1e3 High beam indicator lamp 12A A1e30 Oil pressure warning lamp 20A A1e41 ESP warning lamp 22A A1e5 Alternator charge monitoring and warning lamp 24A A1e54 Coolant temperature warning lamp 32A A1e66 Tire pressure monitor warning lamp 26A A1e67 Low beam indicator lamp 10A A1e7 Brake fluid and parking brake warning lamp 14A A1e8 Instrument illumination 3A A1e9 Seat belt warning lamp 23A A1p13 Multifunction display 18A A1p8 Electronic speedometer 19A A2/1 smart radio 9 21L A2/2 smart radio 10 22L A2/3 smart Entry radio 25L A2/4 smart Premium radio 26L A45 Fanfare horns and airbag clock spring contact 32L A45 Fanfare horns and airbag clock spring contact 44L B14 Outside temperature display temperature sensor 18L N10/10 SAM control unit 9L N10/10f12 Fuse 12 7L N10/10f18 Fuse 18 6L N23 Heater/AC operating unit 36L S111/2 Right steering wheel pitman arm 3L S6/1 Cockpit switch group 30L U1010 Valid for radio with Premium sound system 25K U1011 Valid for radio without Premium sound system 25L U1012 Valid up to 30/08/2010 4E U1012 Valid up to 30/08/2010 20G U1012 Valid up to 30/08/2010 38K U1013 Valid as of 31/08/2010 2E
U1013¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1809 · Applies to: 450, 451, 452, 454
Valid as of 31/08/2010 24G U1013 Valid as of 31/08/2010 31G U1013 Valid as of 31/08/2010 38K U492 Valid for power steering 10E U493 Not valid for power steering 12E U494 Valid for SAL 42E U865 Valid for Entry radio 25K W9 Ground (left front, at lamp unit) 9G Z3/17 Circuit 15 (fused) connector sleeve 5G Z37/4 Power steering CAN bus connector sleeve (low) 11G Z37/5 Power steering CAN bus connector sleeve (high) 11G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 7G Z81 Circuit 58d connector sleeve 29E Fig 1: Large Instrument (Instrument Cluster) - Wiring Diagram (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Large Instrument (Instrument Cluster) - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1810 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
OV00.01-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1812 · Applies to: 450, 451, 452, 454
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 PE07.00-P- 1100MCU
Further wiring diagrams PE07.00-P- 1100MCU PE26.00-P- 1100MCU
Further wiring diagrams PE26.00-P- 1100MCU PE42.00-P- 1100MCU
Further wiring diagrams PE42.00-P- 1100MCU PE46.00-P- 1100MCU
Further wiring diagrams PE46.00-P- 1100MCU PE54.00-P- 1100MCU
Further wiring diagrams PE54.00-P- 1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF AUXILIARY INSTRUMENTS - PE54.30-P- 2003MCU > MODEL 451 / (except 451.391 /491) up to 30.8.10 PE54.30-P- 2003-97MCU Wiring diagram of auxiliary instruments
PE54.30-P- 2003-97MCU 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 plug connectors
GF00.19-P- 1000MCU GF00.19-P- 2000MCU Location and assignment of ground points
GF00.19-P- 2000MCU
GF00.19-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1813 · Applies to: 450, 451, 452, 454
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 WIRING DIAGRAMS > WIRING DIAGRAM OF AUXILIARY INSTRUMENTS - PE54.30-P-2003- 97MCU > Code: Designation: Position: A15 Additional instruments 11A A15 Additional instruments 6A A15 Additional instruments 3A A15p3 Clock
A15p4 Tachometer
A15p5 Display
A15x1 Additional instruments connector 1D A15x2 Additional instruments connector 10D A34/7 Bluetooth module 11L N10/10 SAM control unit 5L N10/10f12 Fuse 12 2L U31 Valid on vehicles with Bluetooth with display 9A U32 Not valid on vehicles with Bluetooth with display 5A W9 Ground (left front, at lamp unit) 3G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 2G Z78 Cockpit LIN connector sleeve 4G
WIRING DIAGRAMS > LEGEND OF FUNCTION DIAGRAM OF INSTRUMENT CLUSTER (KI)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1814 · Applies to: 450, 451, 452, 454
ELECTRICAL SYSTEM - PE54.30-P-2051-60MCU > MODEL 451 Code Designation Coordinates A1 Instrument cluster 14G A1e1 Left tern signal indicator lamp 15B A1e2 Right turn signal indicator lamp 15C A1e3 High beam indicator lamp 15C A1e5 Alternator charge monitoring and warning lamp 15C A1e7 Brake fluid and parking brake warning lamp 15D A1e8 Instrument lighting 15D A1e9 Seat belt warning lamp 15H A1e15 Airbag indicator and warning lamp 15H A1e17 ABS indicator lamp 15J Fig 1: Auxiliary Instruments - Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
OV00.01-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1817 · Applies to: 450, 451, 452, 454
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 plug 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 WIRING DIAGRAMS > WIRING DIAGRAM FOR SIGNALING SYSTEM - PE54.35-P-2000- 97MCU > Code: Designation: Position: A1 Instrument cluster 12A A45 Fanfare horns and airbag clock spring contact 3L A45 Fanfare horns and airbag clock spring contact 13L H2 Horn 5L N10/10 SAM control unit 5A N10/10f31 Fuse 31 3A U492 Valid for power steering 6E U493 Not valid for power steering 8E U494 Valid for SAL 11C W43 Ground (outside left fire wall) 5G W9 Ground (left front, at lamp unit) 3G Z37/4 Power steering CAN bus connector sleeve (low) 6G Z37/5 Power steering CAN bus connector sleeve (high) 7G
SPECIAL TOOLS > 129 589 00 21 00 126-PIN SOCKET BOX - WS54.00-P-0008B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1818 · Applies to: 450, 451, 452, 454
FG 00/42/54/91 / Set B MODEL all Use: 126-pin socket box for contacting electrical systems in combination with model-specific test cable sets.
Fig 1: Signaling System - Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 220 589 00 99 00 ELECTRICAL CONNECTION KIT - WS54.00-P-0050B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1819 · Applies to: 450, 451, 452, 454
FG 00 FG 01/13/15/20/25/42/43/47/54/72/Set B MODEL all MODIFICATION NOTES 22.11.04 Replacement for 201 589 00 99 00
6.8.07 Replaced by 220 589 05 99 00
WS00.00-P-0279Z Part 220 589 00 99 01 Adapter line
WS54.00-P-0050- 01B Part 220 589 00 99 02 Adapter line
WS54.00-P-0050- 02B Part 220 589 00 99 03 Adapter line
WS54.00-P-0050- 03B Part 220 589 00 99 04 Adapter line
WS54.00-P-0050- 04B Part 220 589 00 99 05 Adapter line
WS54.00-P-0050- 05B Part 220 589 00 99 06 Adapter line
WS54.00-P-0050- 06B Part 220 589 00 99 07 Adapter line FG 25/42/43/54/Set B WS54.00-P-0050- 07B Part 220 589 00 99 08 Adapter line
WS54.00-P-0050- 08B Part 220 589 00 99 09 Adapter line
WS54.00-P-0050- 09B Fig 1: Identifying 126-Pin Socket Box (129 589 00 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Part¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1820 · Applies to: 450, 451, 452, 454
220 589 00 99 10 Adapter line
WS54.00-P-0050- 10B Part 220 589 00 99 11 Adapter line
WS54.00-P-0050- 11B Part 220 589 00 99 12 Adapter line
WS54.00-P-0050- 12B Part 220 589 00 99 13 Adapter line
WS54.00-P-0050- 13B Part 220 589 00 99 20 Test cable FG 25/42/43/54/Set B WS54.00-P-0050- 14B Part 220 589 00 99 21 Alligator clip
WS54.00-P-0050- 15B Part 220 589 00 99 22 Safety clamp FG 25/42/43/54/Set B WS54.00-P-0050- 16B Part 220 589 00 99 23 Clamp test probe
WS54.00-P-0050- 17B Part 220 589 00 99 24 Connector
WS54.00-P-0050- 18B Part 220 589 00 99 25 Empty case FG54/Set B WS54.00-P-0050- 26B Part 220 589 00 99 30 Adapter cable
WS54.00-P-0050- 19B Part 220 589 00 99 31 Adapter cable
WS54.00-P-0050- 20B Part 220 589 00 99 33 Safety cable
WS54.00-P-0050- 22B
140 589 12 21 00 Baseline current draw test adapter 1
WS54.00-P-0015B
140 589 13 21 00 Quiescent current test adapter 2
WS54.00-P-0016B
000 581 06 54 Pliers
Further use FG 42/Set B WS42.00-N-3062B
Further use FG 43/Set B WS43.00-N-3053B Use: Electrical connection kit for contacting during voltage/current/resistance measurements and for connection of the compression tester.
SPECIAL TOOLS > 450 589 01 63 00 HOT AIR BLOWER - WS54.00-P-0062B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1821 · Applies to: 450, 451, 452, 454
FG 54/Set B MODEL 450, 451, 452, 454 Use: Hot air blower for soldering cable connection at solder connectors. NOTE: Hot air blowerSmart No. 0005029. SPECIAL TOOLS > 450 589 04 63 01 MEASURING RESISTOR - WS54.00-P-0064-01B > FG54/Set B MODEL 450, 451, 452 Fig 1: Identifying Electrical Connection Kit (220 589 00 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Hot Air Blower (450 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1822 · Applies to: 450, 451, 452, 454
Precision resistor for fault limitation with e.g faulty lines, control units or triggering components e.g. a simulation of a sidebag. NOTE: Separate part for 450 589 04 63 00 SPECIAL TOOLS > 450 589 04 63 02 PROBE - WS54.00-P-0064-02B > FG54/Set B MODEL 450, 451, 452 Use: Probe for contacting measuring points. NOTE: Separate part for 450 589 04 63 00 Fig 1: Identifying Measuring Resistor (450 589 04 63 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 04 63 00 CABLE SET WITH DIAGNOSIS CASE - WS54.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1823 · Applies to: 450, 451, 452, 454
0064B > FG 54/Set B MODEL 450, 451, 452 Part 450 589 04 63 01 Measuring resistor FG54/Set B WS54.00-P-0064-01B Part 450 589 04 63 02 Probe FG54/Set B WS54.00-P-0064-02B Use: Cable set with diagnosis case for contacting measuring instruments and design of measuring circuits, including decade resistor. NOTE: Cable set with diagnosis case incl. decade resistor Smart No. 0005111. Fig 1: Identifying Probe (450 589 04 63 02) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 589 15 21 00 BATTERY TESTER - WS54.00-P-0066A450 >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1824 · Applies to: 450, 451, 452, 454
FG 54/Set A MODEL 450, 451, 452, 454 Use: Battery tester for checking battery voltage. NOTE: Battery testerSmart no. 0006967. SPECIAL TOOLS > 589 00 37 00 PLIERS - WS54.00-P-0073B169 > FG 54/Set B MODEL 163, 164, 168, 169, 170, 171, 172, 197, 203, 204, 207, 208, 209, 210, 211, 212, 216, 218, 219, Fig 1: Identifying Cable Set With Diagnosis Case (450 589 04 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Battery Tester (450 589 15 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1825 · Applies to: 450, 451, 452, 454 · AR: WS54.00-Z-9999CZ
221, 230, 245, 251, 451 Use: Pliers for removing 12V sockets and cigar lighters with an SAE standard
SPECIAL TOOLS > SPECIAL TOOLS: SMART: ELECTRICAL SYSTEM, EQUIPMENT AND INSTRUMENTS - WS54.00-Z-9999CZ > MODEL all
000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P- 0007B
000 589 13 99 10 MCP 2.8 ELA crimping set FG00/54/Set B WS00.19-P- 0007-10B
000 589 13 99 30 MCP 2.8 / Fl. blade 2.8 / JPT / SPT FG00/54/83/Set B WS00.19-P- 0007-30B
001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P- 0111B
110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P- 0274K
129 589 00 21 00 126-pin socket box FG 00/42/54/91 / Set B WS54.00-P- 0008B
156 589 00 31 00 Guide pins FG 54/Set B WS54.00-P- 0081B
169 589 00 37 00 Pliers FG 54/Set B WS54.00-P- 0073B
220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P- 0050B WS00.19-P- Fig 1: Identifying Pliers (169 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
220 589 01 99 05 JPT crimping set¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1826 · Applies to: 450, 451, 452, 454
FG 00/54/83/Set B 0001-05B
220 589 01 99 10 Crimp pliers FG 00/14/54/83/Set B WS00.19-P- 0001-09B
220 589 01 99 20 Unlocking device with RK 1.5 ejector FG00/54/Set B WS00.19-P- 0001-18B
220 589 01 99 30 Unlocking device with RK 2.5 ejector FG00/14/54/Set B WS00.19-P- 0001-20B
220 589 01 99 40 Wire stripper FG 00/54/83/Set B WS00.19-P- 0001-22B
220 589 01 99 41 Reflector FG 00/54/83/Set B WS00.19-P- 0001-23B
220 589 01 99 42 Adapter FG 00/54/83/Set B WS00.19-P- 0001-24B
220 589 01 99 50 Blade holder with clamping pliers FG00/14/54/83/Set B WS00.19-P- 0001-25B
220 589 01 99 60 MQS blade FG00/54/Set B WS00.19-P- 0001-35B
220 589 01 99 82 JPT ELA crimp set FG00/54/Set B WS00.19-P- 0002-08B
220 589 01 99 85 MQS crimping set FG00/54/Set B WS00.19-P- 0002-11B
220 589 01 99 86 MQS ELA crimping set FG00/54/Set B WS00.19-P- 0002-12B
220 589 02 99 00 Wiring harness repair kit FG 00 FG 54/83/Set B WS00.19-P- 0002B
220 589 04 99 00 New passenger car wiring harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P- 0006B
450 589 00 63 00 Press-out pin FG 54/Set B WS54.00-P- 0060B
450 589 01 63 00 Hot air blower FG 54/Set B WS54.00-P- 0062B
450 589 04 63 00 Cable set with diagnosis case FG 54/Set B WS54.00-P- 0064B
450 589 04 63 01 Measuring resistor FG54/Set B WS54.00-P- 0064-01B
450 589 04 63 02 Probe FG54/Set B WS54.00-P- 0064-02B
450 589 04 99 00 Cable repair set FG 54/Set B WS54.00-P- 0063B
450 589 05 37 00 Pliers FG 54/Set B WS54.00-P- 0061B
450 589 07 21 07 Adapter¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1827 · Applies to: 450, 451, 452, 454
FG 01/20/54/Set B WS01.00-P- 0074-07B
450 589 12 63 00 Measuring instrument/tester FG 54/Set B WS54.00-P- 0065B
450 589 15 21 00 Battery tester FG 54/Set A WS54.00-P- 0066A
450 589 19 21 00 Pin socket box 126- pin FG 54/Set B WS54.00-P- 0071B
452 589 02 99 00 Wiring harness repair kit FG 00/54/77/83/ Set B WS00.00-P- 0243B
452 589 02 99 01 Crimper 0.35 - 1.0 FG00/54/Set B WS00.00-P- 0243-01B
452 589 02 99 02 Crimper 1.5 - 2.5 FG00/54/Set B WS00.00-P- 0243-02B
452 589 02 99 03 Crimper 4.0 - 6.0 FG00/54/Set B WS00.00-P- 0243-03B
452 589 02 99 04 Wire stripper FG00/54/Set B WS00.00-P- 0243-04B
452 589 02 99 05 Box with connectors 0.35 - 1.0 FG00/54/Set B WS00.00-P- 0243-05B
452 589 02 99 06 Box with connectors 1.5 - 2.5 FG00/54/Set B WS00.00-P- 0243-06B
452 589 02 99 07 Box with connectors 4.0 - 6.0 FG00/54/Set B WS00.00-P- 0243-07B
452 589 02 99 08 Small box with heat- shrinkable tubes 5.75 mm FG00/54/Set B WS00.00-P- 0243-08B
930 589 00 99 00 Supplemental truck wiring harness repair kit FG 00/14/54/67 / Set B WS00.19-N- 0004B
930 589 00 99 07 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N- 0004-13B
930 589 00 99 08 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N- 0004-14B
930 589 00 99 25 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N- 0004-15B
930 589 00 99 26 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N- 0004-16B
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1833 · Applies to: 450, 451, 452, 454
Risk of injury to skin and eyes caused by handling hot or glowing objects. Wear safety gloves, protective clothing and safety glasses, if necessary. AS00.00-Z- 0002-01A 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 2 Remove bolts (2) and unhook rear apron (1) from brackets (arrows)
3 Support rear muffler (4) using a transmission jack (6) and removal fixture (5) Removal fixtureTransmission jack gotis://H_00/10_01.0 *450589026200 4 Unhook rear muffler (4) from the rubber retainers (3)
5 Lower rear muffler (4) with transmission jack (6) and removal fixture (5) until the O2 sensor upstream of CAT [KAT] (G3/2) is accessible Removal fixtureTransmission jack gotis://H_00/10_01.0 *450589026200 Fig 1: Locating O2 Sensors Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unclip holder (7) for connector for O2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1834 · Applies to: 450, 451, 452, 454
6 Unclip holder (7) for connector for O2 sensor upstream of CAT [KAT] (G3/2x1) and disconnect connector for O2 sensor upstream of CAT [KAT] (G3/2x1)
7 Unscrew O2 sensor upstream of CAT [KAT] (G3/2) from catalytic converter (1) Use a suitable 22 mm socket wrench. Installation: Coat thread of O2 sensor upstream of CAT [KAT] (G3/2) with paste.
BA14.00-P- 1002-01B Paste BR00.45-Z- 1005-06A 8 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z- 0005-01A 9 Perform engine test run and check exhaust system for leakage in area of O2 sensor upstream of CAT [KAT] (G3/2) O2 SENSOR Number Designation Engine 132.9 BA14.00-P-1002- 01B O2 sensor upstream of CAT [KAT] to catalytic converter Nm 50 REPAIR MATERIALS Number Designation Order number Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1836 · Applies to: 450, 451, 452, 454
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00-P- 0001-01A 1 Turn off ignition
2 Remove right side paneling in trunk
AR68.30- P- 4800MCU 3 Release and disconnect electrical connectors (1)
4 Remove bolts (2) and ME-SFI [ME] control unit (N3/10)
5 Install in the reverse order
6 Flash ME-SFI [ME] control unit (N3/10) When replacing the ME-SFI [ME] control unit (N3/10). AR54.21- P- 0012MCU TESTING & REPAIR > REMOVE/INSTALL THROTTLE VALVE ACTUATOR - AR07.61-P- 1401MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 1: Identifying Injection System Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1837 · Applies to: 450, 451, 452, 454
1 Remove resonance tank
AR09.20- P- 0010MCU 2 Disconnect electrical connector (1) at throttle valve actuator (M16/6)
3 Remove bolts (2) *BA07.61- P-1003- 01B 4 Remove throttle valve actuator (M16/6) from intake manifold (3) Installation: Replace seal between the throttle valve actuator (M16/6) and the intake manifold (3).
5 Install in the reverse order
6 Read out fault memory, erase if necessary When throttle valve actuator valve is replaced (M16/6).
Connect STAR DIAGNOSIS and read out fault memory AD00.00- P-2000- 04MCC ME-SFI [ME] GASOLINE INJECTION AND IGNITION SYSTEM Number Designation Engine 132.9 BA07.61-P-1003- 01B Bolt, throttle valve actuator to intake manifold/ charge air manifold Nm 9 SAFETY PRECAUTIONS > SAFETY INFORMATION: MIXTURE FORMATION - AS07.00-Z- 9999ZZ > Fig 1: Identifying Throttle Valve Actuator Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1838 · Applies to: 450, 451, 452, 454 · AR: BA07.00-Z-9999CZ
Risk of death caused by contact with parts conducting high voltages. ENGINE 642 AS07.16-Z-0002- 01A Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure ENGINE 611, 612, 613, 628, 629, 639, 640, 642, 646, 647, 648, 660, 668, 651 AS07.16-Z-0001- 01A Risk of explosion caused by ignition or explosion of fuel. Risk of injury to skin and eyes caused by fuel jets or leakage. ENGINE 112, 272, 271.942 AS07.70-Z-0001- 01A Risk of explosion caused by test oil being ignited. Risk of injury to skin and eyes caused by test oil streaming out ENGINE 601.942/970, 402.970, 441.980, 446.938, 384, 444.901, 447.903 AS07.03-Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: MIXTURE FORMATION - BA07.00-Z-9999CZ > MODEL all Common rail diesel injection (CDI) ENGINE 639.9 BA07.16-P-1000-01G Common rail diesel injection (CDI) ENGINE 660.940 /950 /951 BA07.16-P-1000-01E Control unit ENGINE 160.910 /920, 660.940 in MODEL 450.3 /4 ENGINE 160.921 /922 /923 in MODEL 452.3 /4 BA07.08-P-1000-01E Fuel distributor ENGINE 132.9, 160.910 /920 /921 /922 /923 BA07.52-P-1000- 01D Fuel distributor ENGINE 122.9, 134.910 /911, 135.930 /950 BA07.52-P-1000-01F ME gasoline injection and ignition system ENGINE 132.9, 160.910 /920 /921 /922 /923 BA07.61-P-1000- 01B ME gasoline injection and ignition system ENGINE 134.910 /911, 135.930 /950 BA07.61-P-1000-01C Sensors ENGINE 160.910 /920 /921 /922 /923 BA07.04-P-1000-01A Sensors ENGINE 639.9, 660.9 BA07.04-P-1000-01J Sensors ENGINE 134.910 /911, 135.930 /950 BA07.04-P-1000-01H Vacuum system ENGINE 639.939, 660.9 BA07.09-P-1000-01A TORQUE SPECIFICATIONS > FUEL DISTRIBUTOR - BA07.52-P-1000-01D > Engine 132, 160
FUEL DISTRIBUTOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1839 · Applies to: 450, 451, 452, 454
Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 BA07.52-P- 1001-01D Bolt, fuel distributor to intake manifold Nm 9 8 8 8 BA07.52-P- 1002-01D Bolt, fuel distributor to charge air distribution pipe Nm 9 - - - FUEL DISTRIBUTOR Number Designation Engine 160.922 Engine 160.923 BA07.52-P-1001- 01D Bolt, fuel distributor to intake manifold Nm 8 8 BA07.52-P-1002- 01D Bolt, fuel distributor to charge air distribution pipe Nm - - TORQUE SPECIFICATIONS > ME GASOLINE INJECTION AND IGNITION SYSTEM - BA07.61-P-1000-01B > Engine 132, 160 ME-SFI [ME] GASOLINE INJECTION AND IGNITION SYSTEM Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 BA07.61-P- 1001-01B Bolt at throttle valve actuator Nm - 9 - - BA07.61-P- 1002-01B Bolt, electronic accelerator adjusting motor to intake manifold Nm - - 9 9 BA07.61-P- 1003-01B Bolt, throttle valve actuator to intake manifold/ charge air manifold Nm 9 - - - ME-SFI [ME] GASOLINE INJECTION AND IGNITION SYSTEM Number Designation Engine 160.922 Engine 160.923 BA07.61-P-1001- 01B Bolt at throttle valve actuator Nm - - BA07.61-P-1002- 01B Bolt, electronic accelerator adjusting motor to intake manifold Nm 9 9 BA07.61-P-1003- 01B Bolt, throttle valve actuator to intake manifold/ charge air manifold Nm - -
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1842 · Applies to: 450, 451, 452, 454
The crankshaft position sensor is located at the bottom right on the cylinder crankcase. Task The crankshaft position sensor detects the crankshaft position and motor speed. Fig 1: Locating Crankshaft Position Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1845 · Applies to: 450, 451, 452, 454
The knock sensor is located on the engine crankcase under the exhaust manifold. Task The knock detects vibrations which are emitted by the cylinders and transmits these in the form of an electrical signal to the ME-SFI [ME] control unit (N3/10). In the event of failure of the knock sensor, the ignition performance map for low quality fuels or fuels with a low octane rating is used by the ME control unit. Design The knock sensor consists of: A seismic mass Piezoceramic perforated disc Thrust sleeve Housing Function The knock sensor is screwed through the thrust sleeve to the crankcase. The vibrations which are coming from the individual combustion chambers are transmitted by the seismic ground to the piezoceramic perforated disc. The piezoceramic generates an electrical voltage signal and passes this on to the ME-SFI [ME] control unit. The piezoceramic consists of crystals on whose surface an electrical voltage is generated through deformation. Fig 1: Locating Knock Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1848 · Applies to: 450, 451, 452, 454
The intake manifold pressure sensor is located on the intake manifold. Task The intake manifold pressure sensor detects the pressure and the air temperature in the intake manifold downstream of the throttle valve and passes this information on in the form of voltage signals to the ME-SFI [ME] control unit (N3/10). Function pressure measurement The pressure applied to the pressure gauge connection distorts a membrane which acts on a piezoresistor. In this way the piezoresistor changes its resistance value and transmits an appropriate voltage signal to the ME-SFI [ME] control unit. Function temperature measurement There is an additional NTC resistor integrated in the intake manifold pressure sensor. This alters its electrical Resistor according to the air temperature in the intake manifold. The ME control unit applies a sensor voltage and evaluates the air temperature in accordance with the signal voltage. BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR O2 SENSOR - GF07.04-P- 6100MCU > ENGINES 132.9 in MODEL 451.3/4 Fig 1: Locating Intake Manifold Pressure Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINE 132.9 in MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1850 · Applies to: 450, 451, 452, 454
General Adjustment of the rotation angle of the intake camshaft alters the point in time of opening and closing of intake valves. This leads to improvement of the gas exchange and reduction of pollutants in the exhaust. At low RPM adjustment in the direction "advanced" causes the intake valves to open earlier. This has the effect: that return flow of the suctioned in fuel/air mixture is prevented there are less damaging exhaust gases a high torque as a result of improved cylinder charge At high RPM adjustment in the direction "retarded" causes the intake valves to open later. This has the effect: long continued flow of the suctioned in fuel/air mixture a high engine output die to an improved cylinder charge Function Adjustment of intake camshafts takes place map-controlled via the ME-SFI [ME] control unit (N3/10) which directly actuates the adjustable camshaft timing solenoid. The adjustable camshaft timing solenoid integrated in the engine oil circuit is supplied via the oil pump with engine oil. The pressure generated by the oil pump is used to actuate the camshaft adjuster in the direction "advanced" (large valve overlap) or "retarded" (low valve overlap). To do this the adjustable camshaft timing solenoid is connected via the oil line "advanced" and the oil line "retarded" with the camshaft adjuster. The oil lines are released or closed off by the adjustable camshaft timing solenoid according to requirements and the intake camshaft is adjusted in the direction "advanced" or "retarded". The adjustment time is dependent on the engine oil pressure, the oil viscosity and the oil temperature. The intake camshafts can be adjusted from "advanced" to "retarded" over a range of 50°. Excess engine oil in the engine oil circuit is passed back via the return on the adjustable camshaft timing solenoid. Fig 1: Camshaft Adjustment Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > (ME-SFI) MOTOR ELECTRONICS FUEL INJECTION AND IGNITION¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1853 · Applies to: 450, 451, 452, 454
SYSTEM, LOCATION OF COMPONENTS - GF07.61-P-0001-01MCU > Fig 1: Locating Motor Electronics Fuel Injection And Ignition System Components (1 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Locating Motor Electronics Fuel Injection And Ignition System Components (2 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1854 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Locating Motor Electronics Fuel Injection And Ignition System Components (3 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1855 · Applies to: 450, 451, 452, 454
SYSTEM CONTROL UNIT, INPUT SIGNALS - GF07.61-P-0001-06MCU > Fig 4: Locating Motor Electronics Fuel Injection And Ignition System Components (4 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Motor Electronics Fuel Injection And Ignition System Control Unit Input Signals Reference Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Driving mode¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1857 · Applies to: 450, 451, 452, 454
idle speed control warm-up control acceleration enrichment deceleration fuel shutoff antiknock control camshaft adjustment fan control maximum engine speed limitation external quantity intervention O2-sensor heater two-sensor control fuel regeneration tank leaktightness monitoring safety fuel shutoff catalytic converter heating secondary air injection ignition system On-board diagnosis readiness code fault detection consequential fault CHECK ENGINE indicator lamp (A1e26) fault memory limp-home mode function chain
(ME-SFI) motor electronics fuel injection and ignition system, location of components GF07.61-P-0001- 01MCU
Motor electronics (ME-SFI) fuel injection and ignition system control unit, input signals GF07.61-P-0001- 06MCU
Motor electronics (ME-SFI) fuel injection and ignition system control unit, output signals GF07.61-P-0001- 07MCU
The driving mode includes the following subfunctions:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1859 · Applies to: 450, 451, 452, 454
Idle speed control: The ME-SFI [ME] control unit regulates a stable idle speed under all operating conditions. Warm-up control: The engine is brought rapidly up to operating temperature. Fig 1: ME-SFI Driving Mode Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Acceleration enrichment¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1860 · Applies to: 450, 451, 452, 454
Dynamic enrichment prevents jerking when accelerating. Overrun fuel shutoff The braking effect of the engine is increased in overrun mode and fuel consumption reduced Antiknock control: The antiknock control guarantees knock-free operation of the engine with various fuel qualities and under all operating conditions. Camshaft adjustment Camshaft adjustment lowers emissions and increases performance Fan control The fan motor is actuated to reduce the coolant temperature Maximum engine speed limitation For protection of the engine and the drive train the engine speed is limited External quantity intervention The injection quantity is adapted to various driving modes. O2 sensor heater: The O2 sensor heater is used to bring the O2 sensors rapidly up to operating temperature. Two-sensor control The effect of the catalytic converter is monitored by the signals from the O2 sensor upstream of CAT and by the signals from the O2 sensor downstream of CAT Fuel regeneration: Fuel vapors are fed to the engine. Moreover, fuel vapors are not allowed to escape into the atmosphere. Checking for leaks in the tank: Gross, fine and very fine leaks are checked by measuring the pressure in the tank. Safety fuel shutoff In the event of a crash, the fuel pump is shut off and the fuel injection valves are actuated briefly Catalytic converter heating The catalytic converter is brought rapidly to the operating temperature Secondary air injection: In addition, fresh air is let into the exhaust flow to improve the exhaust emission values. Ignition system:
A static high-voltage distribution with 3 single-spark ignition coils is used.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1861 · Applies to: 450, 451, 452, 454
Idle speed control The throttle valve actuator controls the idle speed by altering the position of the throttle valve. Actuation is by the ME-SFI [ME] control unit. The ME-SFI [ME] control unit regulates the idle speed according to the input signals for different engine loads (e.g. a switched on refrigerant compressor). The ME-SFI [ME] control unit evaluates signals from the following components for idle speed control: Camshaft Hall sensor Coolant temperature sensor Intake manifold pressure sensor Accelerator pedal sensor Crankshaft position sensor Throttle valve actuator Warming-up control After the start process the fuel-air mixture is further enriched via the warm-up control. The warm-up control compensates for the fuel unavailable for combustion due to precipitation on the cold inner walls of the intake manifold. The engine is assigned an additional fuel quantity by the ME-SFI [ME] control unit according to a performance map. To do this, the actuation period of the fuel injection valves is extended accordingly. Warm-up control is dependent on: Coolant temperature Engine speed Engine load Acceleration enrichment The opening of the throttle valve is dependent on the accelerator pedal sensor. For rapid opening of the throttle valve the mixture goes lean for a short time. Therefore a short-term mixture adaptation takes place in that the ME-SFI [ME] control unit assigns the engine an additional fuel quantity. Acceleration enrichment is dependent on: Coolant temperature Accelerator pedal position Engine speed Engine load
Inertia fuel shutoff¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1862 · Applies to: 450, 451, 452, 454
The braking effect of the engine in the overrun mode is increased and the fuel consumption is reduced by means of the overrun fuel shutoff. In overrun mode, the ME-SFI [ME] control unit switches off the fuel injection valves depending on the temperature and the speed. The fuel injectors are operated again, when the accelerator pedal is depressed or when idle speed is reached, and no further overrun mode exists. Anti-knock control [AKC] The antiknock control ensures knock-free operation of the engine at all engine speeds, for all fuel grades and under all operating conditions. To do this for uncontrolled combustion (knocking) the ignition timing is set to "retard". If knocking continues to occur, the ignition timing (depending on engine speed) continues to be retarded in stages until maximum retardation is achieved. If knock-free combustion is restored, the retardation is reduced in stages after a few ignitions (depending on engine speed) until the normal performance map value is achieved or knocking once again occurs. Input signals for anti-knock control Knock sensor Camshaft Hall sensor Coolant temperature sensor Accelerator pedal sensor Crankshaft position sensor Camshaft adjustment The adjustment of the camshaft takes place electrohydraulically via the camshaft timing solenoid and the camshaft adjuster. Here a control plunger in the adjustable camshaft timing solenoid ensures that the applied engine oil pressure is passed through to the respective connection on the camshaft adjuster. The intake camshaft can now be adjusted by turning the adjuster to "advanced" (large valve overlap) or "retarded" (small valve overlap). The adjustment time is dependent on the engine oil pressure at the adjuster, oil viscosity and oil temperature. Camshaft adjustment is used to reduce pollutants in the exhaust gas and to increase the performance of the engine. In the case of failure of the camshaft Hall sensor, camshaft adjustment is disabled. Fan control The ME-SFI [ME] control unit decides according to a performance map about switching on the coolant fan motor. Depending on the coolant temperature and operation of the air conditioning system, the fan motor is switched on. Actuation takes place via the SAM control unit. Maximum engine speed limitation The ME-SFI [ME] control unit detects the engine speed via the crankshaft position sensor signal. This is
limited to protect the engine and the drive train through retarding the ignition timing and cutting out the fuel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1863 · Applies to: 450, 451, 452, 454
injection valves. The ME-SFI [ME] control unit also asks for the current gear range from the automated manual transmission control unit in order, if necessary, to initiate an upshift. If the throttle valve actuator is defective or signals implausible, the engine speed is also limited. External intervention in the fuel quantity With external quantity intervention, the engine torque is reduced (e.g. for an ESP regulation) by the ME-SFI [ME] control unit. A reduction of the engine torque takes place through reduction of the injection quantity. The ME-SFI [ME] control unit receives appropriate signals for this via the CAN from: Automated manual transmission control unit Shift process ESP control unit ESP regulation O2 sensor heater The O2 sensor downstream of TWC and the O2 sensor upstream of TWC only allow lambda regulation above an operating temperature of about 300°C. In order to reach this temperature as quickly as possible the O2 sensors are fitted with an integral heater. The O2 sensor heater is actuated by the ME-SFI [ME] control unit. Rapid heating of the sensors means a high degree of control is achieved, even at low exhaust temperatures. Two-sensor control The ME control unit uses the signal from the O2 sensor downstream TWC and the O2 sensor upstream TWC to determine the mean Lambda value. This value is compared with a stored value for optimum exhaust emissions. If the deviation is too large after a number of measurements, a correction variable is determined for the lambda control. Using the correction variable aging of the O2 sensor upstream of TWC is compensated for within certain limits. If the correction variable exceeds the limit value, a new O2 sensor upstream of TWC must be installed. The correction values are map-controlled and are implemented by the ME control unit by adapting the fuel injection. If the limits are exceeded or if the plausibility check of the signal from the O2 sensor downstream of TWC and O2 sensor upstream of TWC is negative, the CHECK ENGINE indicator lamp (A1e26) in the instrument cluster lights up. The O2 sensor signal downstream of TWC [KAT] and O2 sensor signal upstream of TWC [KAT] is also used to monitor the effect of the catalytic converter. Fuel regeneration The evaporative emission control system prevents fuel vapors escaping to atmosphere. The fuel vapors are stored in the activated charcoal filter and then sent later to the engine for combustion. The fuel vapors from the fuel tank flow through the purge line and are stored in the activated charcoal filter. In driving mode the tank vent valve opens and the fuel vapors are led to combustion. For a cold engine or a lower air mass (e.g. neutral) the tank vent valve is closed by the ME-SFI [ME] control unit and the combustion of fuel vapors interrupted. This leads to better running characteristics of the engine in partial load operation.
The ME-SFI [ME] control unit requires the following information for actuation of the tank vent valve:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1864 · Applies to: 450, 451, 452, 454
Coolant temperature Intake manifold pressure Fuel tank leak test Test requirements Engine at idle Vehicle stationary Intake air temperature <45°C Coolant temperature for engine start <100°C Drive position "D" or "R" is engaged Fuel level in the fuel tank between approximately 1/4 and 3/4 The fuel system is tested for leaks in three stages (function chain). The leak test detects leaks with a diameter of 0.5 mm and more: Test for gross leaks (equal to or greater than 3 mm) Test for fine leaks (equal to or greater than 1 mm) Test for very fine leaks (equal to or greater than 0.5 mm) Test for gross leak: The outside air shutoff valve is closed and the tank vent valve is opened. Intake manifold vacuum present in fuel tank. This vacuum is measured by the tank pressure sensor. If no vacuum is formed in the fuel tank, there is a larger leakage (for example, open tank cap, loose hose line). The test is interrupted and the fault 'gross leak' is registered. Test for fine leak: The tank vent valve is closed at a vacuum of around -6 mbar. The system is closed and thereby airproof. The vacuum is them measured for approx. 30 seconds. The vacuum must not reduce more rapidly than 0.3 to 0.5 mbar per second (depends on fuel level). If the vacuum drops more rapidly, there is a fine leak. The test is interrupted and the fault 'fine leak' is registered. Test for very fine leak: If no minor leak has been detected, the purge system is briefly enabled and a vacuum of approx. -6 mbar is built up again. The vacuum must not drop any faster than 0.1 to 0.15 mbar per second for a closed system (depending on the level of fuel in the tank). If the vacuum drops more rapidly, the fault 'very fine leak' is registered. The outside air shutoff valve is opened again after the tests. If a gross, fine or a very fine leak is detected, the CHECK ENGINE indicator lamp is actuated by the ME-SFI
[ME] control unit via the CAN.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1865 · Applies to: 450, 451, 452, 454
Safety fuel shutoff If the ME-SFI [ME] control unit receives a crash signal from the restraint systems control unit via the CAN, it switches off the fuel pump with fuel level sensor and actuates the fuel injection valves for a short time to make the fuel system become unpressurized. Catalytic converter heating The catalytic convertor heater rapidly brings the catalytic convertor to the operating temperature In this way the exhaust gas emissions after a cold start are strongly reduced. Controlling of the catalytic converter heating is by the ME-SFI [ME] control unit. The ignition timing is adjusted to 'retarded' in the neutral depending on the coolant temperature in order to increase the exhaust temperature. By delaying the ignition timing point and the resultant combustion in the exhaust tract, the catalytic converter is heated rapidly. The idle speed is adjusted in line with the coolant temperature. Secondary air injection Function requirement Coolant temperature between 7°C and 36°C The secondary air injection causes afterburning of the unburnt hydrocarbons on the exhaust side. As a result, the catalytic converter reaches its operating temperature more quickly after the cold start and the emissions in the exhaust are reduced. The secondary air is provided by the secondary air injection pump, which is actuated by the ME-SFI [ME] control unit via the secondary air injection relay for t = 33 s. The secondary air injection pump switchover valve actuates the secondary air valve via a vacuum, which enables air supply into the exhaust manifold. The secondary air injection pump switchover valve is also actuated by the ME-SFI [ME] control unit. The actuation is aborted by the ME-SFI [ME] control unit at an engine speed of more than 4000 RPM. If the engine speed then falls below 4000 RPM, the secondary air injection is restarted. Ignition system Three single-spark ignition coils are used at the spark plugs (R4). Actuation of ignition coils takes place over the ME-SFI [ME] control unit. Static high-voltage is distributed directly to the spark plugs without an ignition distributor. Advantages of the rotorless high voltage distribution are: significantly lower electromagnetic interference level (no naked sparks) No rotating parts (no wear) Noise reduction No need for ignition lines The ME-SFI [ME] control unit evaluates signals from the following components for actuation of the ignition coils: Knock sensor
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1868 · Applies to: 450, 451, 452, 454
The ME-SFI [ME] control unit is located in the trunk, behind the right side paneling. Task The ME-SFI [ME] control unit controls, monitors and coordinates the entire engine control. Function The ME-SFI [ME] control unit is a subscriber on the Control Area Network (data bus/CAN bus) (CAN) and controls the following systems: Fuel supply Injection control Secondary air injection Lambda control Ignition system Immobilizer Communication with the following components takes place via the CAN: Instrument cluster (A1) Restraint systems control unit (N2/7) SAM control unit (N10/10) Automated manual transmission control unit (N15/6) Heater/air conditioning operating unit (N23) (for code (I01) Air conditioning Plus) ESP control unit (N47-5) Steering assist control unit (N68) (with code (V26) Power steering, EPS (FFO)) The following components are read in directly by the ME-SFI [ME] control unit: Knock sensor (A16) Tank pressure sensor (B4/3) Camshaft Hall sensor (B6/1) Coolant temperature sensor (B11/4) Intake manifold pressure sensor (B28) Accelerator pedal sensor (B37) Alternator (G2) O2 sensor downstream of TWC (G3/1) O2 sensor upstream of TWC (G3/2)
M16/6¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1872 · Applies to: 450, 451, 452, 454
Throttle valve actuator 32L M3/3 Fuel pump with fuel level sensor 10L M3/3b1 Fuel level sensor 12L M33 Secondary air injection pump 19L N10/10 SAM control unit 75A N10/10 SAM control unit 5L N10/10f1 Fuse 1 76A N10/10f10 Fuse 10 73A N10/10f10 Fuse 10 5L N10/10f16 Fuse 16 9L N10/10f19 Fuse 19 3L N10/10f27 Fuse 27 2L N10/10f8 Fuse 8 8L N3/10 ME-SFI [ME] control unit 61A N3/10 ME-SFI [ME] control unit 52A N3/10 ME-SFI [ME] control unit 44A N3/10 ME-SFI [ME] control unit 36A N3/10 ME-SFI [ME] control unit 28A N3/10 ME-SFI [ME] control unit 20A N3/10 ME-SFI [ME] control unit 12A N3/10 ME-SFI [ME] control unit 4A N3/10 ME-SFI [ME] control unit 67A R4 Spark plugs 59L R4 Spark plugs 56L R4 Spark plugs 55L S41/1 Oil pressure switch 42L T1/1 Cylinder 1 ignition coil 55K T1/2 Cylinder 2 ignition coil 57K T1/3 Cylinder 3 ignition coil 59K U4 Valid for cruise control 26F W11 Ground (engine) 79E W11/5 Ground (engine/body) 18G W11/5 Ground (engine/body) 79L
Ground (left wheelhouse in luggage compartment)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1873 · Applies to: 450, 451, 452, 454
W6 Ground (left wheelhouse in luggage compartment) 59E W6 Ground (left wheelhouse in luggage compartment) 55E W7 Ground (right wheelhouse in luggage compartment) 11G W7 Ground (right wheelhouse in luggage compartment) 9E X15 Secondary air injection pump connector 20G X26 Interior/engine connector 70G Y32 Secondary air injection pump switchover valve 53L Y49 Adjustable camshaft timing solenoid 36L Y58/1 Fuel tank vent valve 70A Y58/2 Activated charcoal filter shutoff valve 34L Y62/1 Cylinder 1 fuel injection valve 49L Y62/2 Cylinder 2 fuel injection valve 51L Y62/3 Cylinder 3 fuel injection valve 50L Z3/24 Circuit 15 (fused) connector sleeve, function 2E Z7/3 Circuit 87 connector sleeve, injection valve 1 to 3 61E Z7/3 Circuit 87 connector sleeve, injection valve 1 to 3 53E Z7/3 Circuit 87 connector sleeve, injection valve 1 to 3 72L Z7/3 Circuit 87 connector sleeve, injection valve 1 to 3 50E Z7/35 Circuit 87 M1e connector sleeve 78E Z7/35 Circuit 87 M1e connector sleeve 22E Z7/35 Circuit 87 M1e connector sleeve 5E Z7/36 Circuit 87 M2e connector sleeve 71E Z7/36 Circuit 87 M2e connector sleeve 8E Z7/4 O2 sensor heater, wastegate valve circuit 30 connector sleeve 64E Z7/4 O2 sensor heater, wastegate valve circuit 30 connector sleeve 71L Z7/4 O2 sensor heater, wastegate valve circuit 30 connector sleeve 35E Z7/5 Circuit 87 connector sleeve 78L Z7/5 Circuit 87 connector sleeve 59E Z7/5 Circuit 87 connector sleeve 54E Z7/5 Circuit 87 connector sleeve 57E
Fig 1: Fuel Injection And Ignition System ME-SFI - Wiring Diagram (1 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1874 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Fuel Injection And Ignition System ME-SFI - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1875 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Fuel Injection And Ignition System ME-SFI - Wiring Diagram (3 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1876 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Fuel Injection And Ignition System ME-SFI - Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1877 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINE 132, 160, 660¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1880 · Applies to: 450, 451, 452, 454
Use: Pressure gauge for checking the fuel pressure. NOTE: Fuel pressure gauge 0...10 barSmart No. 0005182. SPECIAL TOOLS > 450 589 18 21 00 VACUUM PUMP - WS07.00-P-0102B > FG 07/Set B MODEL 450, 451, 452 Use: Vacuum pump for inspection of leaktightness and performance of vacuum pump on a diesel engine as well as inspection of leaktightness of vacuum line on a gasoline engine. NOTE: Vacuum pumpSmart No.: 0014669 Fig 1: Identifying Pressure Gauge (450 589 09 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: MIXTURE FORMATION - WS07.00-Z-9999CZ¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1881 · Applies to: 450, 451, 452, 454 · AR: WS07.00-Z-9999CZ
MODEL all 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B 001 589 50 33 00 Puller FG 07/Set B WS07.00-P-0118B 122 589 00 61 00 Valve assembly tool FG 07/Set B WS07.00-P-0122B 450 589 02 10 00 Socket wrench bit FG 07/Set B WS07.00-P-0101B 450 589 09 21 00 Pressure gauge FG 07/Set B WS07.00-P- 0100B 450 589 18 21 00 Vacuum pump FG 07/Set B WS07.00-P- 0102B 454 589 00 03 00 Open double hexagon box wrench FG 07/Set B WS07.00-P-0116B 454 589 01 03 00 Open double hexagon box wrench FG 07/Set B WS07.00-P-0117B 454 589 04 40 00 Counterholder FG 07/Set B WS07.00-P-0123B 611 589 00 03 00 Socket wrench FG 07/Set B WS07.00-N-3070B 640 589 01 33 00 Bell-type puller FG 07/Set B WS07.00-P-0109B SPECIAL TOOLS > SPECIAL TOOLS: SMART: ELECTRICAL DRIVE SYSTEM - WS08.00-Z- 9999CZ > MODEL all Fig 1: Identifying Vacuum Pump (450 589 18 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
001 589 01 91 00 Set of protective¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1882 · Applies to: 450, 451, 452, 454
covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P- 0111B 451 589 08 63 00 Warning label FG 08/Set K WS08.00-P- 0003K
Detach clamp (6) and remove fuel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1885 · Applies to: 450, 451, 452, 454
4 Detach clamp (6) and remove fuel line (7) from fuel distributor (1) Collect the e caping fuel in a suitable container.Use suitable plugs to seal the openings. Installation: Replace clamp (6). Observe correct seating of the fuel line (7) in mounts on the intake manifold (8).
5 Remove bolts (9) for fuel distributor (1) on intake manifold (8) *BA07.52- P-1001- 01D 6 Remove fuel distributor (1) together with fuel injection valves Installation: Replace sealing rings for fuel injection valves and wet slightly with engine oil for easier assembly.
7 Remove fuel injection valves When replacing fuel distributor (1). AR07.03- P- 6522MCU 8 Install in the reverse order
9 Read out fault memory, erase if necessary
Connect STAR DIAGNOSIS and read out fault memory AD00.00- P-2000- 04MCC Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 10 Conduct engine test run and check for leaktightness of fuel system in the area of the fuel distributor (1) FUEL DISTRIBUTOR Number Designation Engine 132.9 BA07.52-P-1001-01D Bolt, fuel distributor to intake manifold Nm 9 TESTING & REPAIR INDEX > REMOVE/INSTALL INJECTION VALVES - AR07.03-P- 6522MCU > ENGINE 132.910 in MODEL 451.3 /4
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1888 · Applies to: 450, 451, 452, 454
Risk of injury to skin and eyes caused by handling hot or glowing objects. Wear safety gloves, protective clothing and safety glasses, if necessary. AS00.00- Z-0002- 01A 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 2 Remove bolts (2) and unhook rear apron (1) from brackets (arrows)
3 Support rear muffler (4) using a transmission jack (6) and removal fixture (5) Removal fixtureTransmission jack Fig 2 4 Unhook rear muffler (4) from the rubber retainers (3)
5 Lower rear muffler (4) with transmission jack (6) and removal fixture (5) until the O2 sensor upstream of CAT [KAT] (G3/2) is accessible Removal fixtureTransmission jack Fig 2 6 Unclip holder (7) for connector for O2 sensor upstream of CAT [KAT] (G3/2x1) and disconnect connector for O2 sensor
Fig 1: Identifying O2 Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
up tream of CAT [KAT] (G3/2 1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1889 · Applies to: 450, 451, 452, 454
7 Unscrew O2 sensor upstream of CAT [KAT] (G3/2) from catalytic converter (1) Use a suitable 22 mm socket wrench. Installation: Coat thread of O2 sensor upstream of CAT [KAT] (G3/2) with paste.
BA14.00- P-1002- 01B Paste BR00.45- Z-1005- 06A 8 Install in the reverse order
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 9 Perform engine test run and check exhaust system for leakage in area of O2 sensor upstream of CAT [KAT] (G3/2) O2 SENSOR Number Designation Engine 132.9 BA14.00-P-1002- 01B O2 sensor upstream of CAT [KAT] to catalytic converter Nm 50 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1005- 06A Paste, hot lubrication 1 kg, DB supply specification 6879.20 A 000 989 76 51 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1892 · Applies to: 450, 451, 452, 454
1 Remove resonance tank
AR09.20- P- 0010MCU 2 Disconnect electrical connector (1) at throttle valve actuator (M16/6)
3 Remove bolts (2) *BA07.61- P-1003- 01B 4 Remove throttle valve actuator (M16/6) from intake manifold (3) Installation: Replace seal between the throttle valve actuator (M16/6) and the intake manifold (3).
5 Install in the reverse order
6 Read out fault memory, erase if necessary When throttle valve actuator valve is replaced (M16/6).
Connect STAR DIAGNOSIS and read out fault memory AD00.00- P-2000- 04MCC ME-SFI [ME] GASOLINE INJECTION AND IGNITION SYSTEM Number Designation Engine 132.9 BA07.61-P-1003- 01B Bolt, throttle valve actuator to intake manifold/ charge air manifold Nm 9 SAFETY PRECAUTIONS > SAFETY INFORMATION: MIXTURE FORMATION - AS07.00-Z- Fig 1: Identifying Throttle Valve Actuator Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9999ZZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1893 · Applies to: 450, 451, 452, 454 · AR: BA07.00-Z-9999CZ
MODEL all Risk of death caused by contact with parts conducting high voltages. ENGINE 642 Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure ENGINE 611, 612, 613, 628, 629, 639, 640, 642, 646, 647, 648, 660, 668, 651 Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure ENGINE 470.9, 471.9, 473.9 Risk of explosion caused by ignition or explosion of fuel. Risk of injury to skin and eyes caused by fuel jets or leakage. ENGINE 112, 272, 271.942 Risk of explosion caused by test oil being ignited. Risk of injury to skin and eyes caused by test oil streaming out ENGINE 601.942 /970, 402.970, 441.980, 446.938, 384, 444.901, 447.903 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: MIXTURE FORMATION - BA07.00-Z-9999CZ > MODEL all Common rail diesel injection (CDI) ENGINE 639.9 BA07.16-P-1000-01G Common rail diesel injection (CDI) ENGINE 660.940 /950 /951 BA07.16-P-1000-01E Control unit ENGINE 160.910 /920, 660.940 in MODEL 450.3 /4 ENGINE 160.921 /922 /923 in MODEL 452.3 /4 BA07.08-P-1000-01E Fuel distributor ENGINE 132.9, 160.910 /920 /921 /922 /923 BA07.52-P-1000-01D Fuel distributor ENGINE 122.9, 134.910 /911, 135.930 /950 BA07.52-P-1000-01F ME gasoline injection and ignition system ENGINE 132.9, 160.910 /920 /921 /922 /923 BA07.61-P-1000-01B ME gasoline injection and ignition system ENGINE 134.910 /911, 135.930 /950 BA07.61-P-1000-01C Sensors ENGINE 160.910 /920 /921 /922 /923 BA07.04-P-1000-01A
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1895 · Applies to: 450, 451, 452, 454
The fuel injection valves are located in the cylinder head upstream of the intake valves. Task The injection valves inject the fuel in the required amount before the intake valve. Design Fig 1: Identifying Fuel Injection Valves Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1897 · Applies to: 450, 451, 452, 454
The crankshaft position sensor is located at the bottom right on the cylinder crankcase. Task The crankshaft position sensor detects the crankshaft position and motor speed. Fig 1: Identifying Crankshaft Position Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1900 · Applies to: 450, 451, 452, 454
The knock sensor is located on the engine crankcase under the exhaust manifold. Task The knock detects vibrations which are emitted by the cylinders and transmits these in the form of an electrical signal to the ME-SFI [ME] control unit (N3/10). In the event of failure of the knock sensor, the ignition performance map for low quality fuels or fuels with a low octane rating is used by the ME control unit. Design The knock sensor consists of: A seismic mass Piezoceramic perforated disc Thrust sleeve Housing Function The knock sensor is screwed through the thrust sleeve to the crankcase. The vibrations which are coming from the individual combustion chambers are transmitted by the seismic ground to the piezoceramic perforated disc. The piezoceramic generates an electrical voltage signal and passes this on to the ME-SFI [ME] control unit. The piezoceramic consists of crystals on whose surface an electrical voltage is generated through deformation. Fig 1: Identifying Knock Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1903 · Applies to: 450, 451, 452, 454
The intake manifold pressure sensor is located on the intake manifold. Task The intake manifold pressure sensor detects the pressure and the air temperature in the intake manifold downstream of the throttle valve and passes this information on in the form of voltage signals to the ME-SFI [ME] control unit (N3/10). Function pressure measurement The pressure applied to the pressure gauge connection distorts a membrane which acts on a piezoresistor. In this way the piezoresistor changes its resistance value and transmits an appropriate voltage signal to the ME-SFI [ME] control unit. Function temperature measurement There is an additional NTC resistor integrated in the intake manifold pressure sensor. This alters its electrical Resistor according to the air temperature in the intake manifold. The ME control unit applies a sensor voltage and evaluates the air temperature in accordance with the signal voltage. BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR O2 SENSOR - GF07.04-P- 6100MCU > ENGINES 132.9 in MODEL 451.3 /4 Fig 1: Identifying Intake Manifold Pressure Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINE 132.9 in MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1905 · Applies to: 450, 451, 452, 454
General Adjustment of the rotation angle of the intake camshaft alters the point in time of opening and closing of intake valves. This leads to improvement of the gas exchange and reduction of pollutants in the exhaust. At low rpms adjustment in the direction "advanced" causes the intake valves to open earlier. This has the effect: that return flow of the suctioned in fuel/air mixture is prevented there are less damaging exhaust gases a high torque as a result of improved cylinder charge At high rpms adjustment in the direction "retarded" causes the intake valves to open later. This has the effect: long continued flow of the suctioned in fuel/air mixture a high engine output die to an improved cylinder charge Function Adjustment of intake camshafts takes place map-controlled via the ME-SFI [ME] control unit (N3/10) which directly actuates the adjustable camshaft timing solenoid. The adjustable camshaft timing solenoid integrated in the engine oil circuit is supplied via the oil pump with engine oil. The pressure generated by the oil pump is used to actuate the camshaft adjuster in the direction "advanced" (large valve overlap) or "retarded" (low valve overlap). To do this the adjustable camshaft timing solenoid is connected via the oil line "advanced" and the oil line "retarded" with the camshaft adjuster. The oil lines are released or closed off by the adjustable camshaft timing solenoid according to requirements and the intake camshaft is adjusted in the direction "advanced" or "retarded". The adjustment time is dependent on the engine oil pressure, the oil viscosity and the oil temperature. The intake camshafts can be adjusted from "advanced" to "retarded" over a range of 50°. Excess engine oil in the engine oil circuit is passed back via the return on the adjustable camshaft timing solenoid. Fig 1: Camshaft Adjustment Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Motor Electronics Fuel Injection And Ignition System Components Location (2 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1909 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Motor Electronics Fuel Injection And Ignition System Components Location (3 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1910 · Applies to: 450, 451, 452, 454
SYSTEM CONTROL UNIT, INPUT SIGNALS - GF07.61-P-0001-06MCU > Fig 4: Motor Electronics Fuel Injection And Ignition System Components Location (4 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Motor Electronics Fuel Injection And Ignition System Control Unit Input Signals Reference Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Driving mode¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1912 · Applies to: 450, 451, 452, 454
idle speed control warm-up control acceleration enrichment deceleration fuel shutoff antiknock control camshaft adjustment fan control maximum engine speed limitation external quantity intervention O2-sensor heater two-sensor control fuel regeneration tank leaktightness monitoring safety fuel shutoff catalytic converter heating secondary air injection ignition system On-board diagnosis readiness code fault detection consequential fault CHECK ENGINE indicator lamp (A1e26) fault memory limp-home mode function chain
(ME-SFI) motor electronics fuel injection and ignition system, location of components GF07.61-P-0001-01MCU
Motor electronics (ME-SFI) fuel injection and ignition system control unit, input signals GF07.61-P-0001-06MCU
Motor electronics (ME-SFI) fuel GF07.61-P-0001-07MCU
ENGINES 132.9 in MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1914 · Applies to: 450, 451, 452, 454
The driving mode includes the following subfunctions: Idle speed control: The ME-SFI [ME] control unit regulates a stable idle speed under all operating conditions. Warm-up control: Fig 1: ME-SFI Driving Mode Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The engine is brought rapidly up to operating temperature.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1915 · Applies to: 450, 451, 452, 454
Acceleration enrichment Dynamic enrichment prevents jerking when accelerating. Overrun fuel shutoff The braking effect of the engine is increased in overrun mode and fuel consumption reduced Antiknock control: The antiknock control guarantees knock-free operation of the engine with various fuel qualities and under all operating conditions. Camshaft adjustment Camshaft adjustment lowers emissions and increases performance Fan control The fan motor is actuated to reduce the coolant temperature Maximum engine speed limitation For protection of the engine and the drive train the engine speed is limited External quantity intervention The injection quantity is adapted to various driving modes. O2 sensor heater: The O2 sensor heater is used to bring the O2 sensors rapidly up to operating temperature. Two-sensor control The effect of the catalytic converter is monitored by the signals from the O2 sensor upstream of CAT and by the signals from the O2 sensor downstream of CAT Fuel regeneration: Fuel vapors are fed to the engine. Moreover, fuel vapors are not allowed to escape into the atmosphere. Checking for leaks in the tank: Gross, fine and very fine leaks are checked by measuring the pressure in the tank. Safety fuel shutoff In the event of a crash, the fuel pump is shut off and the fuel injection valves are actuated briefly Catalytic converter heating The catalytic converter is brought rapidly to the operating temperature Secondary air injection: In addition, fresh air is let into the exhaust flow to improve the exhaust emission values.
Ignition system:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1916 · Applies to: 450, 451, 452, 454
A static high-voltage distribution with 3 single-spark ignition coils is used. Idle speed control The throttle valve actuator controls the idle speed by altering the position of the throttle valve. Actuation is by the ME-SFI [ME] control unit. The ME-SFI [ME] control unit regulates the idle speed according to the input signals for different engine loads (e.g. a switched on refrigerant compressor). The ME-SFI [ME] control unit evaluates signals from the following components for idle speed control: Camshaft Hall sensor Coolant temperature sensor Intake manifold pressure sensor Accelerator pedal sensor Crankshaft position sensor Throttle valve actuator Warming-up control After the start process the fuel-air mixture is further enriched via the warm-up control. The warm-up control compensates for the fuel unavailable for combustion due to precipitation on the cold inner walls of the intake manifold. The engine is assigned an additional fuel quantity by the ME-SFI [ME] control unit according to a performance map. To do this, the actuation period of the fuel injection valves is extended accordingly. Warm-up control is dependent on: Coolant temperature Engine speed Engine load Acceleration enrichment The opening of the throttle valve is dependent on the accelerator pedal sensor. For rapid opening of the throttle valve the mixture goes lean for a short time. Therefore a short-term mixture adaptation takes place in that the ME-SFI [ME] control unit assigns the engine an additional fuel quantity. Acceleration enrichment is dependent on: Coolant temperature Accelerator pedal position Engine speed
Engine load¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1917 · Applies to: 450, 451, 452, 454
Inertia fuel shutoff The braking effect of the engine in the overrun mode is increased and the fuel consumption is reduced by means of the overrun fuel shutoff. In overrun mode, the ME-SFI [ME] control unit switches off the fuel injection valves depending on the temperature and the speed. The fuel injectors are operated again, when the accelerator pedal is depressed or when idle speed is reached, and no further overrun mode exists. Anti-knock control [AKC] The antiknock control ensures knock-free operation of the engine at all engine speeds, for all fuel grades and under all operating conditions. To do this for uncontrolled combustion (knocking) the ignition timing is set to "retard". If knocking continues to occur, the ignition timing (depending on engine speed) continues to be retarded in stages until maximum retardation is achieved. If knock-free combustion is restored, the retardation is reduced in stages after a few ignitions (depending on engine speed) until the normal performance map value is achieved or knocking once again occurs. Input signals for anti-knock control Knock sensor Camshaft Hall sensor Coolant temperature sensor Accelerator pedal sensor Crankshaft position sensor Camshaft adjustment The adjustment of the camshaft takes place electrohydraulically via the camshaft timing solenoid and the camshaft adjuster. Here a control plunger in the adjustable camshaft timing solenoid ensures that the applied engine oil pressure is passed through to the respective connection on the camshaft adjuster. The intake camshaft can now be adjusted by turning the adjuster to "advanced" (large valve overlap) or "retarded" (small valve overlap). The adjustment time is dependent on the engine oil pressure at the adjuster, oil viscosity and oil temperature. Camshaft adjustment is used to reduce pollutants in the exhaust gas and to increase the performance of the engine. In the case of failure of the camshaft Hall sensor, camshaft adjustment is disabled. Fan control The ME-SFI [ME] control unit decides according to a performance map about switching on the coolant fan motor. Depending on the coolant temperature and operation of the air conditioning system, the fan motor is switched on. Actuation takes place via the SAM control unit. Maximum engine speed limitation
The ME-SFI [ME] control unit detects the engine speed via the crankshaft position sensor signal. This is¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1918 · Applies to: 450, 451, 452, 454
limited to protect the engine and the drive train through retarding the ignition timing and cutting out the fuel injection valves. The ME-SFI [ME] control unit also asks for the current gear range from the automated manual transmission control unit in order, if necessary, to initiate an upshift. If the throttle valve actuator is defective or signals implausible, the engine speed is also limited. External intervention in the fuel quantity With external quantity intervention, the engine torque is reduced (e.g. for an ESP regulation) by the ME-SFI [ME] control unit. A reduction of the engine torque takes place through reduction of the injection quantity. The ME-SFI [ME] control unit receives appropriate signals for this via the CAN from: Automated manual transmission control unit Shift process ESP control unit ESP regulation O2 sensor heater The O2 sensor downstream of TWC and the O2 sensor upstream of TWC only allow lambda regulation above an operating temperature of about 300°C. In order to reach this temperature as quickly as possible the O2 sensors are fitted with an integral heater. The O2 sensor heater is actuated by the ME-SFI [ME] control unit. Rapid heating of the sensors means a high degree of control is achieved, even at low exhaust temperatures. Two-sensor control The ME control unit uses the signal from the O2 sensor downstream TWC and the O2 sensor upstream TWC to determine the mean Lambda value. This value is compared with a stored value for optimum exhaust emissions. If the deviation is too large after a number of measurements, a correction variable is determined for the lambda control. Using the correction variable aging of the O2 sensor upstream of TWC is compensated for within certain limits. If the correction variable exceeds the limit value, a new O2 sensor upstream of TWC must be installed. The correction values are map-controlled and are implemented by the ME control unit by adapting the fuel injection. If the limits are exceeded or if the plausibility check of the signal from the O2 sensor downstream of TWC and O2 sensor upstream of TWC is negative, the CHECK ENGINE indicator lamp (A1e26) in the instrument cluster lights up. The O2 sensor signal downstream of TWC [KAT] and O2 sensor signal upstream of TWC [KAT] is also used to monitor the effect of the catalytic converter. Fuel regeneration The evaporative emission control system prevents fuel vapors escaping to atmosphere. The fuel vapors are stored in the activated charcoal filter and then sent later to the engine for combustion. The fuel vapors from the fuel tank flow through the purge line and are stored in the activated charcoal filter. In driving mode the tank vent valve opens and the fuel vapors are led to combustion. For a cold engine or a lower air mass (e.g. neutral) the tank vent valve is closed by the ME-SFI [ME] control unit and the combustion
of fuel vapors interrupted. This leads to better running characteristics of the engine in partial load operation.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1919 · Applies to: 450, 451, 452, 454
The ME-SFI [ME] control unit requires the following information for actuation of the tank vent valve: Coolant temperature Intake manifold pressure Fuel tank leak test Test requirements Engine at idle Vehicle stationary Intake air temperature <45°C Coolant temperature for engine start <100°C Drive position "D" or "R" is engaged Fuel level in the fuel tank between approximately 1/4 and 3/4 The fuel system is tested for leaks in three stages (function chain). The leak test detects leaks with a diameter of 0.5 mm and more: Test for gross leaks (equal to or greater than 3 mm) Test for fine leaks (equal to or greater than 1 mm) Test for very fine leaks (equal to or greater than 0.5 mm) Test for gross leak: The outside air shutoff valve is closed and the tank vent valve is opened. Intake manifold vacuum present in fuel tank. This vacuum is measured by the tank pressure sensor. If no vacuum is formed in the fuel tank, there is a larger leakage (for example, open tank cap, loose hose line). The test is interrupted and the fault 'gross leak' is registered. Test for fine leak: The tank vent valve is closed at a vacuum of around -6 mbar. The system is closed and thereby airproof. The vacuum is them measured for approx. 30 seconds. The vacuum must not reduce more rapidly than 0.3 to 0.5 mbar per second (depends on fuel level). If the vacuum drops more rapidly, there is a fine leak. The test is interrupted and the fault 'fine leak' is registered. Test for very fine leak: If no minor leak has been detected, the purge system is briefly enabled and a vacuum of approx. -6 mbar is built up again. The vacuum must not drop any faster than 0.1 to 0.15 mbar per second for a closed system (depending on the level of fuel in the tank). If the vacuum drops more rapidly, the fault 'very fine leak' is registered. The outside air shutoff valve is opened again after the tests.
If a gross, fine or a very fine leak is detected, the CHECK ENGINE indicator lamp is actuated by the ME-SFI¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1920 · Applies to: 450, 451, 452, 454
[ME] control unit via the CAN. Safety fuel shutoff If the ME-SFI [ME] control unit receives a crash signal from the restraint systems control unit via the CAN, it switches off the fuel pump with fuel level sensor and actuates the fuel injection valves for a short time to make the fuel system become unpressurized. Catalytic converter heating The catalytic convertor heater rapidly brings the catalytic convertor to the operating temperature In this way the exhaust gas emissions after a cold start are strongly reduced. Controlling of the catalytic converter heating is by the ME-SFI [ME] control unit. The ignition timing is adjusted to 'retarded' in the neutral depending on the coolant temperature in order to increase the exhaust temperature. By delaying the ignition timing point and the resultant combustion in the exhaust tract, the catalytic converter is heated rapidly. The idle speed is adjusted in line with the coolant temperature. Secondary air injection Function requirement Coolant temperature between 7°C and 36°C The secondary air injection causes afterburning of the unburnt hydrocarbons on the exhaust side. As a result, the catalytic converter reaches its operating temperature more quickly after the cold start and the emissions in the exhaust are reduced. The secondary air is provided by the secondary air injection pump, which is actuated by the ME-SFI [ME] control unit via the secondary air injection relay for t = 33 s. The secondary air injection pump switchover valve actuates the secondary air valve via a vacuum, which enables air supply into the exhaust manifold. The secondary air injection pump switchover valve is also actuated by the ME-SFI [ME] control unit. The actuation is aborted by the ME-SFI [ME] control unit at an engine speed of more than 4000 rpm. If the engine speed then falls below 4000 rpm, the secondary air injection is restarted. Ignition system Three single-spark ignition coils are used at the spark plugs (R4). Actuation of ignition coils takes place over the ME-SFI [ME] control unit. Static high-voltage is distributed directly to the spark plugs without an ignition distributor. Advantages of the rotorless high voltage distribution are: significantly lower electromagnetic interference level (no naked sparks) No rotating parts (no wear) Noise reduction No need for ignition lines The ME-SFI [ME] control unit evaluates signals from the following components for actuation of the ignition coils:
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1923 · Applies to: 450, 451, 452, 454
The ME-SFI [ME] control unit is located in the trunk, behind the right side paneling. Task The ME-SFI [ME] control unit controls, monitors and coordinates the entire engine control. Function The ME-SFI [ME] control unit is a subscriber on the Control Area Network (data bus/CAN bus) (CAN) and controls the following systems: Fuel supply Injection control Secondary air injection Lambda control Ignition system Immobilizer Communication with the following components takes place via the CAN: Instrument cluster (A1) Restraint systems control unit (N2/7) SAM control unit (N10/10) Fig 1: Identifying ME-SFI (ME) Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Automated manual transmission control unit (N15/6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1924 · Applies to: 450, 451, 452, 454
Heater/air conditioning operating unit (N23) (for code (I01) Air conditioning Plus) ESP control unit (N47-5) Steering assist control unit (N68) (with code (V26) Power steering, EPS (FFO)) The following components are read in directly by the ME-SFI [ME] control unit: Knock sensor (A16) Tank pressure sensor (B4/3) Camshaft Hall sensor (B6/1) Coolant temperature sensor (B11/4) Intake manifold pressure sensor (B28) Accelerator pedal sensor (B37) Alternator (G2) O2 sensor downstream of TWC (G3/1) O2 sensor upstream of TWC (G3/2) Crankshaft position sensor (L5) Throttle valve actuator (M16/6) Oil pressure switch (S41/1) Fuel level sensor (M3/3b1) The following components are actuated directly by the ME-SFI [ME] control unit: Generator Heating O2 sensor downstream of TWC Heating O2 sensor upstream of TWC Secondary air injection pump relay (K64) Throttle valve actuator Cylinder 1 ignition coil (T1/1) Cylinder 2 ignition coil (T1/2) Cylinder 3 ignition coil (T1/3) Secondary air injection pump switchover valve (Y32) Adjustable camshaft timing solenoid (Y49) External air shut-off valve (Y50) Tank vent valve (Y58)
N10/10f19¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1928 · Applies to: 450, 451, 452, 454
Fuse 19 3L N10/10f27 Fuse 27 2L N10/10f8 Fuse 8 8L N3/10 ME-SFI [ME] control unit 61A N3/10 ME-SFI [ME] control unit 52A N3/10 ME-SFI [ME] control unit 44A N3/10 ME-SFI [ME] control unit 36A N3/10 ME-SFI [ME] control unit 28A N3/10 ME-SFI [ME] control unit 20A N3/10 ME-SFI [ME] control unit 12A N3/10 ME-SFI [ME] control unit 4A N3/10 ME-SFI [ME] control unit 67A R4 Spark plugs 59L R4 Spark plugs 56L R4 Spark plugs 55L S41/1 Oil pressure switch 42L T1/1 Cylinder 1 ignition coil 55K T1/2 Cylinder 2 ignition coil 57K T1/3 Cylinder 3 ignition coil 59K U4 Valid for cruise control 26F W11 Ground (engine) 79E W11/5 Ground (engine/body) 18G W11/5 Ground (engine/body) 79L W6 Ground (left wheelhouse in luggage compartment) 59E W6 Ground (left wheelhouse in luggage compartment) 55E W7 Ground (right wheelhouse in luggage compartment) 11G W7 Ground (right wheelhouse in luggage compartment) 9E X15 Secondary air injection pump connector 20G X26 Interior/engine connector 70G Y32 Secondary air injection pump switchover valve 53L Y49 Adjustable camshaft timing solenoid 36L Y58/1 Fuel tank vent valve 70A Y58/2 Activated charcoal filter shutoff valve 34L Y62/1 Cylinder 1 fuel injection valve 49L
Y62/2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1929 · Applies to: 450, 451, 452, 454
Cylinder 2 fuel injection valve 51L Y62/3 Cylinder 3 fuel injection valve 50L Z3/24 Circuit 15 (fused) connector sleeve, function 2E Z7/3 Circuit 87 connector sleeve, injection valve 1 to 3 61E Z7/3 Circuit 87 connector sleeve, injection valve 1 to 3 53E Z7/3 Circuit 87 connector sleeve, injection valve 1 to 3 72L Z7/3 Circuit 87 connector sleeve, injection valve 1 to 3 50E Z7/35 Circuit 87 M1e connector sleeve 78E Z7/35 Circuit 87 M1e connector sleeve 22E Z7/35 Circuit 87 M1e connector sleeve 5E Z7/36 Circuit 87 M2e connector sleeve 71E Z7/36 Circuit 87 M2e connector sleeve 8E Z7/4 O2 sensor heater, wastegate valve circuit 30 connector sleeve 64E Z7/4 O2 sensor heater, wastegate valve circuit 30 connector sleeve 71L Z7/4 O2 sensor heater, wastegate valve circuit 30 connector sleeve 35E Z7/5 Circuit 87 connector sleeve 78L Z7/5 Circuit 87 connector sleeve 59E Z7/5 Circuit 87 connector sleeve 54E Z7/5 Circuit 87 connector sleeve 57E
Fig 1: Fuel Injection And Ignition System ME-SFI Wiring Diagram (1 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1930 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Fuel Injection And Ignition System ME-SFI Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1931 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Fuel Injection And Ignition System ME-SFI Wiring Diagram (3 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1932 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Fuel Injection And Ignition System ME-SFI Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1933 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A1p8¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1936 · Applies to: 450, 451, 452, 454
Electronic speedometer 23B A1p13 Multifunction display 23B A9 Refrigerant compressor 2L A15p4 Tachograph 5J A16 Knock sensor 9H B4/3 Fuel tank pressure sensor 9H B6/1 Camshaft Hall sensor 10J B11/4 Coolant temperature sensor 11K B28 Intake manifold pressure sensor 15H B37 Accelerator pedal sensor 10C G2 Generator 9E G3/1 O2 sensor downstream from catalytic converter 12K G3/2 O2 sensor upstream of CAT 12L K64 Secondary air injection pump relay 16D L5 Crankshaft position sensor 13K M1 Starter 4L M3/3b1 Fuel tank sensor 15H M16/6 Throttle valve actuator 15K M18 Coupling motor 8D M33 Secondary air injection pump 17C N3/10 ME-SFI [ME] control unit 10F N10/10 SAM control unit 1J N15/6 Automated manual transmission control unit 5B N23 Heater/AC operating unit 22L N47-5 ESP control unit 7L N68 Steering assist control unit 18L R4 Spark plugs 17B S41/1 Oil pressure switch 12B T1/1 Cylinder 1 ignition coil 15C T1/2 Cylinder 2 ignition coil 15C T1/3 Cylinder 3 ignition coil 15C U492 Valid for power steering 16J X11/4 Data link connector 2C Y32 Secondary air injection pump switchover valve 13B
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1939 · Applies to: 450, 451, 452, 454 · AR: WS07.00-Z-9999CZ
Vacuum pump for inspection of leaktightness and performance of vacuum pump on a diesel engine as well as inspection of leaktightness of vacuum line on a gasoline engine. NOTE: Vacuum pumpSmart No.: 0014669 SPECIAL TOOLS > SPECIAL TOOLS: SMART: MIXTURE FORMATION - WS07.00-Z-9999CZ
MODEL all 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B 001 589 50 33 00 Puller FG 07/Set B WS07.00-P-0118B 122 589 00 61 00 Valve assembly tool FG 07/Set B WS07.00-P-0122B 450 589 02 10 00 Socket wrench bit FG 07/Set B WS07.00-P-0101B 450 589 09 21 00 Pressure gauge FG 07/Set B WS07.00-P-0100B 450 589 18 21 00 Vacuum pump FG 07/Set B WS07.00-P-0102B 454 589 00 03 00 Open double hexagon box wrench FG 07/Set B WS07.00-P-0116B Fig 1: Identifying Vacuum Pump (450 589 18 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
454 589 01 03 00 Open¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1940 · Applies to: 450, 451, 452, 454
double hexagon box wrench FG 07/Set B WS07.00-P-0117B 454 589 04 40 00 Counterholder FG 07/Set B WS07.00-P-0123B 611 589 00 03 00 Socket wrench FG 07/Set B WS07.00-N-3070B 640 589 01 33 00 Bell-type puller FG 07/Set B WS07.00-P-0109B SPECIAL TOOLS > SPECIAL TOOLS: SMART: ELECTRICAL DRIVE SYSTEM - WS08.00-Z- 9999CZ > MODEL all 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P-0111B 451 589 08 63 00 Warning label FG 08/Set K WS08.00-P-0003K
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1948 · Applies to: 450, 451, 452, 454
Notes on self- locking nuts and bolts
AH00.00-N- 0001-01A 1 Remove left and right front wheel * for USA only AR40.10-P- 1100MCU
- not for USA AR40.10-P- 1100MCC 2 Remove underfloor panels Rechargeable drill / screwdrivergotis://G_58.0_01.1
3 Unscrew nuts (2) and remove retaining clamps (3) from stabilizer bar (4) Installation: The retaining clamps (3) are 2-piece Check rubber mount (5) and replace if necessary. Installation: The opening of the rubber mounts (5) must point in the direction of travel.Insert the retaining clamps (3) at a right angle to the stabilizer bar (4).Position the vehicle on its wheels. Only tighten nuts (2) and bolts (9, 10) when the vehicle is unladen (approx. 75 kg weight on the driver seat and a full tank or approx. 20 kg weight in the front passenger area)
*BA32.20-P- 1003-02I
*BA33.15-P- 1001-01C 4 Pull stabilizer bar (4) forwards and fold away downwards
5 Remove front bulkhead (6) The front bulkhead (6) is bolted on with two nuts.
6 Expose electrical line of RPM sensor connector (L6/1x1) at the brake line (7)
7 Using a suitable tool counterhold the left and right link rod (8) and unscrew the bolts (9, 10) Installation: Screw the bolts (9, 10) all the way in. The bolts on the B-pillar (9, 10) are tightened at a later stage.
8 Loosen link rods (8) on front axle carrier (1) and remove Replace link rods (8).
Loosen left and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1949 · Applies to: 450, 451, 452, 454
9 Loosen left and right transverse control arm (11) on front axle carrier (1)
10 Undo bolts (arrows) of rack- and-pinion steering on front axle carrier (1) from above BA46.20-P- 1001-01G 11 Support front axle carrier (1) using transmission jack and support removal fixture Removal fixtureTransmission jackgotis://H_00.10_01. 450589026200 12 Remove bolts (12) Installation: Screw bolts (12) all the way in, and remove transmission jack with removal fixture.Slide front axle carrier (1) forwards completely and align centrally in this position, then tighten bolts (12).
*BA33.10-P- 1001-01D 13 Remove reinforcements (13) from front axle carrier (1) Observe installation position of reinforcements (13).
14 Lower transmission jack with removal fixture and remove front axle carrier (1)
15 Install in the reverse order
16 Perform wheel alignment check Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20-P- 0200MCC
with recording the vehicle level AR40.20-P- 0200MCE FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1003-02I Nut, stabilizer bar to retaining clamp Nm 95
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1951 · Applies to: 450, 451, 452, 454
11.4.08 Special tool for releasing nut on piston rod, added Step 16 4.11.08 Wheel alignment check with recording of vehicle level, added Step 22 Remove/install
Fig 1: Identifying Front Axle Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front Axle Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on self-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1952 · Applies to: 450, 451, 452, 454
locking nuts and bolts
AH00.00-N- 0001-01A 1 Remove front CBS
AR88.00-P- 1010MCC 2 Remove left and right lamp unit * for USA only AR82.10-P- 4730MCU
except USA AR82.10-P- 4730MCC 3 Remove brake pads from the front axle * for USA only AR42.10-P- 1600MCU
except USA AR42.10-P- 1600MCC 4 Unscrew bolt (1) on left and right brake caliper (2) and hang up brake calipers (2) to one side with brake hose connected *BA42.10-P- 1001-10A 5 Remove bolts (3), and pull left front RPM sensor (L6/1) and right front RPM sensor (L6/2) out of steering knuckle
6 Using a suitable tool unclip bracket (4) on left and right suspension strut, place left front RPM sensor (L6/1) and right front RPM sensor (L6/2) to one side
7 Remove underfloor panels Rechargeable drill / screwdrivergotis://G_58.0_01.1
8 Loosen nut (5) on steering coupling (6) Turn the front wheels onto lock until the nut (5) is accessible.
*BA46.10-P- 1001-01F
Lower vehicle with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1953 · Applies to: 450, 451, 452, 454
9 Lower vehicle with vehicle lift
10 Place the front wheels in the straight-ahead position and block the steering wheel using the holding device Fasten the steering wheel otherwise the fanfare horns and airbag clock spring contact can be damaged.
*129589012100 11 Raise vehicle with vehicle lift
12 Unscrew nut (5) on the steering coupling (6), remove bolt (7) and slide steering coupling (6) upwards and remove from the rack-and-pinion steering (8) Only the bolt (7) and nut (5) approved for model 451 may be used. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. When the nut (5) is released, the cam-shaped bolt (7) rotates approx. half a revolution at the same time. However, the bolt (7) does not have to be counterheld. Check the steering coupling (6) for ease of movement and replace if necessary.
13 Disconnect connector of power steering torque sensor (B23x1) For vehicles with code (V26) Power steering, EPS (FFO)
14 Disconnect power steering connector (M19x1) For vehicles with code (V26) Power steering, EPS (FFO)
15 Ground; disconnect interference suppression of power steering pump (W30/2) For vehicles with code (V26) Power steering, EPS (FFO)
16 Support front axle carrier (9) with transmission jack and removal fixture and secure with tensioning strap Transmission jackgotis://H_00.10_01.0 *450589026200 17 Remove bolts (10) on front axle carrier (9) Installation: Screw in bolts (10) and remove transmission jack with removal fixture.Slide front axle carrier (9) into the foremost position and align centrally in this position, then tighten bolts (10).
*BA33.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1954 · Applies to: 450, 451, 452, 454
1001-01D 18 Unscrew nut (14) on left and right suspension strut Do not turn at the piston rod, otherwise the suspension strut could be damaged. Counterhold the piston rod of the suspension strut using a Torx bit (size T45) and a shank length of 100 mm.If the nut (14) is seized slide back boot, fasten holding device (15) on the piston rod of the suspension strut and counterhold with open end wrench (16).
*BA32.25-P- 1002-04D
*450589010100
*450589089900
*451589006300 19 Raise vehicle with the vehicle lift and pull front axle forward under the vehicle Aid of helper required.
20 Loosen tensioning strap, remove front axle from transmission jack and removal fixture Aid of 2 helpers required.
21 Install in the reverse order
22 Perform wheel alignment check Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20-P- 0200MCC
with recording the vehicle level AR40.20-P- 0200MCE SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1002- 04D Nut, suspension strut at rebound buffer Nm 45 FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491 BA33.10-P-1001- Bolt, front-axle carrier to body Nm 100
FRONT AXLE FLOATING CALIPER¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1955 · Applies to: 450, 451, 452, 454
01D FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1001- 10A Bolt, brake caliper to brake caliper support Nm 30 STEERING SHAFT Number Designation Model 451.3/4 BA46.10-P-1001- 01F Bolt, steering coupling to rack-and-pinion steering Nm 20 Fig 3: Identifying Holding Device (129 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1957 · Applies to: 450, 451, 452, 454
14.10.10 Value changed: Bolt, transverse control arm to front axle carrier *BA33.15-P-1001-01C Remove/install
Notes on self- locking nuts and bolts
AH00.00-N- 0001-01A 1 Remove left or right front wheel * for USA only AR40.10-P- 1100MCU
- not for USA AR40.10-P- 1100MCC 2 Remove underfloor panels Rechargeable drill / screwdrivergotis://G_58.0_01.1
3 Unscrew nut (2) and, using puller, pry flange Press out flange ball joint (3) carefully in order to avoid damage to the rubber boot. Counterhold the threaded pin of the flange ball joint (3) using a Torx wrench (size T40). Installation: Check rubber boot, replace flange ball joint (3), if necessary.Position the
Fig 1: Identifying Front Axle Transverse Control Arm Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ball joint (3) off¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1958 · Applies to: 450, 451, 452, 454
the steering knuckle (4) vehicle on it wheel Only tighten nut (5, 12) and bolt (13) when the vehicle is unladen (approx. 75 kg weight on the driver seat and a full tank or approx. 20 kg weight in the front passenger area)
*BA32.20-P- 1003-02I
*BA33.15-P- 1001-01C
*BA33.25-P- 1001-01D
Puller *454589003300 4 Unscrew nut (5) and remove retaining clamp (6) from stabilizer bar (8) The retaining clamp (6) is 2-piece. Installation: Check rubber mount (7) and replace if necessary.The opening of the rubber mounts (7) must point in the direction of travel.Insert the retaining clamp (6) at a right angle to the stabilizer bar (8).Screw nut (5) all the way on The nut (5) is tightened later on.
5 Unclip retaining clip (9) and RPM sensor connector (L6/1x1) on the brake line (10) When removing the left transverse control arm (1).
6 Using a suitable tool hold the connecting rod (11) steady and unscrew the bolt (13) and nut (12) Installation: Bolt (13) and nut (12) are tightened later on.
7 Loosen link rod (11) from front axle carrier (14) and remove Installation: If the link rod (11) is damaged during removal it has to be replaced.
8 Remove transverse control arm (1)
9 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1003- 02I Nut, stabilizer bar to retaining clamp Nm 95 TRAILING ARMS, WISHBONES
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1960 · Applies to: 450, 451, 452, 454
Notes on self-locking nuts and bolts
AH00.00-N- 0001-01A 1 Remove left or right splash shield of front brake * for USA only AR42.10-P- 0233MCU
- not for USA AR42.10-P- 0233MCC 2 Unscrew nut (2) and unhook link rod (3) from suspension strut (4). Counterhold threaded stud of link rod (3).
Screwdriver bit *126589001000
Tool assortment for stabilizer assembly *450589001700
*BA32.20-P- 1004-02I 3 Unscrew nut (5) and pry tie rod end (6) off teering knuckle (1) Pry off tie rod end (6) carefully in order to avoid damage to the rubber boot.
Fig 1: Identifying Steering Knuckle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
using puller and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1961 · Applies to: 450, 451, 452, 454
unhook Installation: Check rubber boot, replace tie rod end (6), if necessary.
Puller *450589013300
*BA46.40-P- 1001-01F 4 Unscrew screw (7) and pull the left front RPM sensor (L6/1) or right front RPM sensor (L6/2) out of the upright (1)
5 Using a suitable tool unclip the bracket (8) on the suspension strut (4) and place the left front RPM sensor (L6/1) or right front RPM sensor (L6/2) to one side
6 Undo nut (9) and remove bolt (10) from steering knuckle (1) *BA32.25-P- 1003-04D 7 Mount clamping device (11) onto steering knuckle (1), insert retaining pin (12) into the bore in the steering knuckle (1) and spread the steering knuckle (1) using the expansion bolt (13)
Tighten expansion bolt (13) until resistance is felt, do not overtighten, as otherwise the clamping device (11) or the steering knuckle (1) may be damaged. Installation: Push steering knuckle (1) all the way upwards to the end stop.
Tensioning device *451589003100 8 Unscrew nut (14) and, using puller, pry flange ball joint (15) off the steering knuckle (1) Press out flange ball joint (15) carefully in order to avoid damage to the rubber boot. Push transverse control arm on front axle down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged. Counterhold the flange ball joint's threaded pin (15) using a Torx wrench (size T40). Installation: Check rubber boot, replace flange ball joint (15), if necessary.
Puller *454589003300
*BA33.25-P- 1001-01D 9 Detach steering knuckle (1) from suspension strut (4) When replacing the steering knuckle (1) remove the clamping device (11).
and remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1962 · Applies to: 450, 451, 452, 454
10 Install in the reverse order
11 Perform wheel alignment check without recording the vehicle level AR40.20-P- 0200MCC
with recording the vehicle level AR40.20-P- 0200MCE FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1004- 02I Nut, link rod to suspension strut Nm 58 SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1003- 04D Bolt, fastening shackle of suspension strut at swiveling bearing Stage 1 Nm 30 Stage 2 ∠° 180 AXLE HOUSING, STEERING KNUCKLE Number Designation Model 451.3/4 BA33.25-P-1001- 01D Nut, flange ball joint to swivel bearing Nm 50 TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001- 01F Self-locking nut, tie rod to steering knuckle Nm 34 Fig 2: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 00)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1963 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Tensioning Device (451 589 00 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: FRONT AXLE - BA33.00-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1964 · Applies to: 450, 451, 452, 454
Z-9999CZ > MODEL all Axle housing, steering knuckle MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA33.25-P-1000- 01D Front axle carrier MODEL 454.0 BA33.10-P-1000-01F Front axle carrier MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA33.10-P-1000- 01D Input shaft MODEL 454.0 with ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BA33.30-P-1000-07B Trailing arms, wishbones MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA33.15-P-1000- 01C Trailing arms, wishbones MODEL 454.0 with ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BA33.15-P-1000-01D Wheel location, wheel hub MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA33.20-P-1000- 01G TORQUE SPECIFICATIONS > FRONT AXLE CARRIER - BA33.10-P-1000-01D > Model 450, 451, 452 FRONT AXLE CARRIER Number Designation Model 450.3/4 Model 451.3/4 except 451.391/491 Model 451.391/491 BA33.10-P- 1001-01D Bolt, front-axle carrier to body Nm 85 100 100 BA33.10-P- 1002-01D Bolt, support, front axle carrier to front axle carrier Nm - - 23 BA33.10-P- Bolt, support, front axle Nm 85 - 23 Fig 6: Identifying Puller (454 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1003 01D¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1965 · Applies to: 450, 451, 452, 454
carrier to body FRONT AXLE CARRIER Number Designation Model 452.3/4 BA33.10-P-1001- 01D Bolt, front-axle carrier to body Nm 85 BA33.10-P-1002- 01D Bolt, support, front axle carrier to front axle carrier Nm - BA33.10-P-1003- 01D Bolt, support, front axle carrier to body Nm - TORQUE SPECIFICATIONS > TRAILING ARMS, WISHBONES - BA33.15-P-1000-01C > Model 450, 451, 452 MODIFICATION NOTES 12.10.10 Value changed: Nut, transverse control arm to front axle carrier Model 451.3/4 14.10.10 Value changed: Screw/bolt, transverse control arm to front axle carrier Model 451.3/4 TRAILING ARMS, WISHBONES Number Designation Model 450.3/4 up to 7.1.2001 Models 450.3/4 as of 8.1.2001 Model 451.3/4 Model 452.3/4 BA33.15-P- 1001-01C Bolt, wishbone to front axle carrier Nm 120 120 50 120 ∠° - - 90 - BA33.15-P- 1002-01C Self-locking nut, flange joint on wishbone Nm 40 40
40 BA33.15-P- 1003-01C Nut, wishbones to front axle carrier Nm - 120 - - BA33.15-P- 1004-01C Nut, wishbones to front axle carrier Nm - - 50 - ∠° - - 90 - TORQUE SPECIFICATIONS > WHEEL LOCATION, WHEEL HUB - BA33.20-P-1000-01G > Model 450, 451, 452 WHEEL LOCATION, HUB Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA33.20-P-1001- Bolt, wheel bearing at swivel bearing Nm 120 65 120
TORQUE SPECIFICATIONS > AXLE HOUSING, STEERING KNUCKLE - BA33.25-P-1000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1966 · Applies to: 450, 451, 452, 454
01G TORQUE SPECIFICATIONS > AXLE HOUSING, STEERING KNUCKLE - BA33.25-P-1000- 01D > Model 450, 451, 452 MODIFICATION NOTES 17.4.02 Value changed from 48 Nm to 46 Nm Value in series 1001 changed for engine 450.3/4 AXLE HOUSING, STEERING KNUCKLE Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA33.25-P-1001- 01D Nut, flange ball joint to swivel bearing Nm 46 50 46 SPECIAL TOOLS > 450 589 01 09 00 OPEN-ENDED SOCKET WRENCH - WS33.00-P- 0141B > FG 33/Set B MODEL 450, 451, 452 Use: Open-end socket wrench for tightening the nut of the tie rod on the tie rod end (WAF 21), with 14x18 mm torque wrench. NOTE: Open-ended socket tool 21/ for torque wrench (14x18 mm) Smart no. 0005009. Fig 1: Identifying Open-Ended Socket Wrench (450 589 01 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 00 17 00 RANGE OF TOOLS FOR STABILIZER BAR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1967 · Applies to: 450, 451, 452, 454
ASSEMBLY - WS33.00-P-0142B > FG 33/Set B MODEL 450, 451, 452 Use: Range of tools for stabilizer bar assembly for installing and removing stabilizer bar on the front axle. NOTE: Range of tools for stabilizer assemblySmart no. 0005010. SPECIAL TOOLS > 450 589 01 33 00 PULLER - WS33.00-P-0143B > FG 33/Set B MODEL 450, 452, 454, 451 Use: Puller for detaching the tie rod end and supporting joint swivel bearing. NOTE: Ball joint separator, passenger car versionSmart no. 0005149. Fig 1: Identifying Range Of Tools For Stabilizer Bar Assembly (450 589 00 17 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 454 589 00 33 00 PULLER - WS33.00-P-0158B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1968 · Applies to: 450, 451, 452, 454
FG 33/Set B MODEL 451, 454 Use: Puller for pressing out supporting joint on front axle wishbone control arm. SPECIAL TOOLS > 450 589 00 16 00 ACTUATION TOOL - WS33.00-P-0178B > FG 33/Set B MODEL 450, 451, 452, 454 Use: Actuation tool for checking supporting joint on McPherson front axle. Fig 1: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Puller (454 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 221 589 04 33 00 EXTRACTION TOOL - WS33.00-P-0187B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1969 · Applies to: 450, 451, 452, 454
FAG 33/Set B MODEL 204.08 /09 /28 /29 /98 /99, 212.08 /09 /28 /29, 216, 218.39, 221, 451 Use: For extracting the front axle shaft, shaft seals and pinion bearing from the front axle gear. NOTE: In combination with slide hammer puller 602 589 00 33 00.
SPECIAL TOOLS > 602 589 00 33 00 IMPACT EXTRACTOR - WS33.00-P-0189B > FG 26/33/35/Set B Fig 1: Identifying Actuation Tool (450 589 00 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Extraction Tool (221 589 04 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 204.08 /09 /28 /29 /98 /99, 212.08 /09 /28 /29, 216, 218.39, 221¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1970 · Applies to: 450, 451, 452, 454 · AR: WS33.00-Z-9999CZ
MODEL 245.286 with ENGINE 780.991 MODEL 451 MODEL 639 with CODE (MA0) E-CELL 60 kW Use: Impact extractor for pulling out front-axle shafts. In model 639, to pull out drive flange of drive shafts. NOTE: In combination with extraction tool 221 589 04 33 00. For model 639: In combination with adaptation 639 589 01 33 00
SPECIAL TOOLS > SPECIAL TOOLS: SMART: FRONT AXLE - WS33.00-Z-9999CZ > MODEL all 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P-0006Z 221 589 04 33 00 Extraction tool FAG 33/Set B WS33.00-P- 0187B 450 589 00 16 00 Actuation tool FG 33/Set B WS33.00-P- 0178B 450 589 00 17 00 Range of tools for FG 33/Set B WS33.00-P- Fig 1: Identifying Impact Extractor (602 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
tabilizer bar a¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1971 · Applies to: 450, 451, 452, 454
embly 0142B 450 589 01 01 00 Open end wrench FG 33/Set B WS33.00-P- 0144B 450 589 01 09 00 Open-ended socket wrench FG 33/Set B WS33.00-P- 0141B 450 589 01 33 00 Puller FG 33/Set B WS33.00-P- 0143B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P- 0090B 450 589 04 37 00 Pliers FG 33/Set B WS33.00-P- 0140B 454 589 00 33 00 Puller FG 33/Set B WS33.00-P- 0158B 602 589 00 33 00 Impact extractor FG 26/33/35/Set B WS33.00-P- 0189B 639 589 00 61 00 Engine lifting device FG 01/33/Set C WS01.00-N- 3106C
axle carrier¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1973 · Applies to: 450, 451, 452, 454
Remove/install
Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A 1 Remove left and right front wheel * for USA only AR40.10- P- 1100MCU
- not for USA AR40.10- P- 1100MCC 2 Remove underfloor panels Rechargeable drill / screwdriver
3 Unscrew nuts (2) and remove retaining clamps (3) from stabilizer bar (4) Installation: The retaining clamps (3) are 2-piece Check rubber mount (5) and replace if necessary. Installation: The opening of the rubber mounts (5) must point in the direction of travel.Insert the retaining clamps (3) at a right angle to the stabilizer bar (4).Position the vehicle on its wheels. Only tighten nuts (2) and bolts (9, 10) when the vehicle is unladen (approx. 75 kg weight on the driver seat and a full tank or approx. 20 kg weight in the front passenger area)
*BA32.20- P-1003- 02I
*BA33.15- P-1001- 01C 4 Pull stabilizer bar (4) forwards and fold away downwards
5 Remove front bulkhead (6) The front bulkhead (6) is bolted on with two nuts.
6 Expose electrical line of rpm sensor connector (L6/1x1) at the brake line (7)
7 Using a suitable tool counterhold the left and right link rod (8) and Installation: Screw the bolts (9, 10) all the way in. The bolts on the B-pillar (9, 10) are tightened at a later stage.
unscrew the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1974 · Applies to: 450, 451, 452, 454
bolts (9, 10) 8 Loosen link rods (8) on front axle carrier (1) and remove Replace link rods (8).
9 Loosen left and right transverse control arm (11) on front axle carrier (1)
10 Undo bolts (arrows) of rack- and-pinion steering on front axle carrier (1) from above *BA46.20- P-1001- 01G 11 Support front axle carrier (1) using transmission jack and support removal fixture Removal fixtureTransmission jack Fig 2 12 Remove bolts (12) Installation: Screw bolts (12) all the way in, and remove transmission jack with removal fixture.Slide front axle carrier (1) forwards completely and align centrally in this position, then tighten bolts (12).
*BA33.10- P-1001- 01D 13 Remove reinforcements (13) from front axle carrier (1) Observe installation position of reinforcements (13).
14 Lower transmission jack with removal fixture and remove front axle carrier (1)
15 Install in the reverse order
16 Perform wheel alignment check Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20- P- 0200MCC
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1976 · Applies to: 450, 451, 452, 454
11.4.08 Special tool for releasing nut on piston rod, added Step 16 4.11.08 Wheel alignment check with recording of vehicle level, added Step 22 Fig 1: Identifying Front Axle Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front Axle Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1977 · Applies to: 450, 451, 452, 454
Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A 1 Remove front CBS
AR88.00- P- 1010MCC 2 Remove left and right lamp unit * for USA only AR82.10- P- 4730MCU
except USA AR82.10- P- 4730MCC 3 Remove brake pads from the front axle * for USA only AR42.10- P- 1600MCU
except USA AR42.10- P- 1600MCC 4 Unscrew bolt (1) on left and right brake caliper (2) and hang up brake calipers (2) to one side with brake hose connected *BA42.10- P-1001- 10A 5 Remove bolts (3), and pull left front rpm sensor (L6/1) and right front rpm sensor (L6/2) out of steering knuckle
6 Using a suitable tool unclip bracket (4) on left and right suspension strut, place left front rpm sensor (L6/1) and right front rpm sensor (L6/2) to one side
7 Remove underfloor panels Rechargeable drill / screwdriver
8 Loosen nut (5) on steering coupling Turn the front wheels onto lock until the nut (5) is accessible.
*BA46.10-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1978 · Applies to: 450, 451, 452, 454
(6)
*BA46.10- P-1001- 01F 9 Lower vehicle with vehicle lift
10 Place the front wheels in the straight-ahead position and block the steering wheel using the holding device Fasten the steering wheel otherwise the fanfare horns and airbag clock spring contact can be damaged.
Fig 3 11 Raise vehicle with vehicle lift
12 Unscrew nut (5) on the steering coupling (6), remove bolt (7) and slide steering coupling (6) upwards and remove from the rack-and-pinion steering (8) Only the bolt (7) and nut (5) approved for model 451 may be used. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. When the nut (5) is released, the cam- shaped bolt (7) rotates approx. half a revolution at the same time. However, the bolt (7) does not have to be counterheld. Check the steering coupling (6) for ease of movement and replace if necessary.
13 Disconnect connector of power steering torque sensor (B23x1) For vehicles with code (V26) Power steering, EPS (FFO)
14 Disconnect power steering connector (M19x1) For vehicles with code (V26) Power steering, EPS (FFO)
15 Ground; disconnect interference suppression of power steering pump (W30/2) For vehicles with code (V26) Power steering, EPS (FFO)
16 Support front axle carrier (9) with transmission jack and removal fixture and secure with tensioning strap Transmission jack Figure
Remove bolts (10)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1979 · Applies to: 450, 451, 452, 454
17 Remove bolts (10) on front axle carrier (9) Installation: Screw in bolts (10) and remove transmission jack with removal fixture.Slide front axle carrier (9) into the foremost position and align centrally in this position, then tighten bolts (10).
*BA33.10- P-1001- 01D 18 Unscrew nut (14) on left and right suspension strut Do not turn at the piston rod, otherwise the suspension strut could be damaged. Counterhold the piston rod of the suspension strut using a Torx bit (size T45) and a shank length of 100 mm.If the nut (14) is seized slide back boot, fasten holding device (15) on the piston rod of the suspension strut and counterhold with open end wrench (16).
*BA32.25- P-1002- 04D
Fig 4
Fig 6
Fig 7 19 Raise vehicle with the vehicle lift and pull front axle forward under the vehicle Aid of helper required.
20 Loosen tensioning strap, remove front axle from transmission jack and removal fixture Aid of 2 helpers required.
21 Install in the reverse order
22 Perform wheel alignment check Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20- P- 0200MCC
with recording the vehicle level AR40.20- P- 0200MCE SUSPENSION STRUTS Number Designation Model 451.3/4
BA32.25-P-1002-04D¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1980 · Applies to: 450, 451, 452, 454
Nut, suspension strut at rebound buffer Nm 45 FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491 BA33.10-P-1001-01D Bolt, front-axle carrier to body Nm 100 FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1001-10A Bolt, brake caliper to brake caliper support Nm 30 STEERING SHAFT Number Designation Model 451.3/4 BA46.10-P-1001-01F Bolt, steering coupling to rack-and-pinion steering Nm 20 Fig 3: Identifying Holding Device (129 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1982 · Applies to: 450, 451, 452, 454
14.10.10 Value changed: Bolt, transverse control arm to front axle carrier *BA33.15-P-1001-01C Remove/install
Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A 1 Remove left or right front wheel * for USA only AR40.10- P- 1100MCU
- not for USA AR40.10- P- 1100MCC 2 Remove underfloor panels Rechargeable drill / screwdriver
Unscrew nut (2) Press out flange ball joint (3) carefully in order to avoid damage to the rubber boot. Counterhold the threaded pin Fig 1: Identifying Front Axle Transverse Control Arm Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
and, u ing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1983 · Applies to: 450, 451, 452, 454
3 and, u ing puller, pry flange ball joint (3) off the steering knuckle (4) of the flange ball joint (3) u ing a Tor wrench ( ize T40) Installation: Check rubber boot, replace flange ball joint (3), if necessary.Position the vehicle on its wheels. Only tighten nuts (5, 12) and bolt (13) when the vehicle is unladen (approx. 75 kg weight on the driver seat and a full tank or approx. 20 kg weight in the front passenger area)
*BA32.20- P-1003- 02I
*BA33.15- P-1001- 01C
*BA33.25- P-1001- 01D
Puller Fig 2 4 Unscrew nut (5) and remove retaining clamp (6) from stabilizer bar (8) The retaining clamp (6) is 2-piece. Installation: Check rubber mount (7) and replace if necessary.The opening of the rubber mounts (7) must point in the direction of travel.Insert the retaining clamp (6) at a right angle to the stabilizer bar (8).Screw nut (5) all the way on The nut (5) is tightened later on.
5 Unclip retaining clip (9) and rpm sensor connector (L6/1x1) on the brake line (10) When removing the left transverse control arm (1).
6 Using a suitable tool hold the connecting rod (11) steady and unscrew the bolt (13) and nut (12) Installation: Bolt (13) and nut (12) are tightened later on.
7 Loosen link rod (11) from front axle carrier (14) and remove Installation: If the link rod (11) is damaged during removal it has to be replaced.
8 Remove transverse control arm (1)
9 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4
BA32 20 P 1003 02I¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1984 · Applies to: 450, 451, 452, 454
Nut, tabilizer bar to retaining clamp Nm 95 TRAILING ARMS, WISHBONES Number Designation Model 451.3/4 BA33.15-P-1001-01C Bolt, wishbone to front axle carrier Nm 50 ∠° 90 AXLE HOUSING, STEERING KNUCKLE Number Designation Model 451.3/4 BA33.25-P-1001-01D Nut, flange ball joint to swivel bearing Nm 50 TESTING & REPAIR INDEX > REMOVE/INSTALL STEERING KNUCKLE - AR33.25-P- 0400MCC > MODEL 451.3 /4 Fig 2: Identifying Puller (454 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1985 · Applies to: 450, 451, 452, 454
Notes on self-locking nuts and bolts
AH00.00- N-0001- 01A 1 Remove left or right splash shield of front brake * for USA only AR42.10- P- 0233MCU
- not for USA AR42.10- P- 0233MCC 2 Unscrew nut (2) and unhook link rod (3) from suspension strut (4). Counterhold threaded stud of link rod (3).
Screwdriver bit Fig 2
Tool assortment for stabilizer assembly Fig 3
*BA32.20- P-1004- 02I Unscrew nut (5) and pry Fig 1: Identifying Steering Knuckle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
tie rod end (6) off¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1986 · Applies to: 450, 451, 452, 454
3 tie rod end (6) off steering knuckle (1) using puller and unhook Pry off tie rod end (6) carefully in order to avoid damage to the rubber boot. Installation: Check rubber boot, replace tie rod end (6), if necessary.
Puller Fig 4
*BA46.40- P-1001- 01F 4 Unscrew screw (7) and pull the left front rpm sensor (L6/1) or right front rpm sensor (L6/2) out of the upright (1)
5 Using a suitable tool unclip the bracket (8) on the suspension strut (4) and place the left front rpm sensor (L6/1) or right front rpm sensor (L6/2) to one side
6 Undo nut (9) and remove bolt (10) from steering knuckle (1) *BA32.25- P-1003- 04D 7 Mount clamping device (11) onto steering knuckle (1), insert retaining pin (12) into the bore in the steering knuckle (1) and spread the steering knuckle (1) using the expansion bolt (13)
Tighten expansion bolt (13) until resistance is felt, do not overtighten, as otherwise the clamping device (11) or the steering knuckle (1) may be damaged. Installation: Push steering knuckle (1) all the way upwards to the end stop.
Tensioning device Fig 5 8 Unscrew nut (14) and, using puller, pry flange ball joint (15) off the steering knuckle (1) Press out flange ball joint (15) carefully in order to avoid damage to the rubber boot. Push transverse control arm on front axle down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged. Counterhold the flange ball joint's threaded pin (15) using a Torx wrench (size T40). Installation: Check rubber boot, replace flange ball joint (15), if necessary.
Puller Figure
*BA33.25- P-1001- 01D 9 Detach steering knuckle (1) from suspension When replacing the steering knuckle (1) remove the clamping device (11).
trut (4) and remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1987 · Applies to: 450, 451, 452, 454
10 Install in the reverse order
11 Perform wheel alignment check without recording the vehicle level AR40.20- P- 0200MCC
with recording the vehicle level AR40.20- P- 0200MCE FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1004-02I Nut, link rod to suspension strut Nm 58 SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1003- 04D Bolt, fastening shackle of suspension strut at swiveling bearing Stage 1 Nm 30 Stage 2 ∠° 180 AXLE HOUSING, STEERING KNUCKLE Number Designation Model 451.3/4 BA33.25-P-1001-01D Nut, flange ball joint to swivel bearing Nm 50 TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001-01F Self-locking nut, tie rod to steering knuckle Nm 34 Fig 2: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 00)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1988 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Tensioning Device (451 589 00 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: FRONT AXLE - BA33.00-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1989 · Applies to: 450, 451, 452, 454
Z-9999CZ > MODEL all Axle housing, steering knuckle MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA33.25-P-1000-01D Front axle carrier MODEL 454.0 BA33.10-P-1000-01F Front axle carrier MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA33.10-P-1000-01D Input shaft MODEL 454.0 with ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BA33.30-P-1000-07B Trailing arms, wishbones MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA33.15-P-1000-01C Trailing arms, wishbones MODEL 454.0 with ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BA33.15-P-1000-01D Wheel location, wheel hub MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA33.20-P-1000-01G TORQUE SPECIFICATIONS > FRONT AXLE CARRIER - BA33.10-P-1000-01D > Model 450, 451, 452 FRONT AXLE CARRIER Number Designation Model 450.3/4 Model 451.3/4 except 451.391/491 Model 451.391/491 BA33.10-P- 1001-01D Bolt, front-axle carrier to body Nm 85 100 100 BA33.10-P- 1002-01D Bolt, support, front axle carrier to front axle carrier Nm - - 23 Fig 6: Identifying Puller (454 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA33 10 P¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1990 · Applies to: 450, 451, 452, 454
1003-01D Bolt, upport, front a le carrier to body Nm 85 - 23 FRONT AXLE CARRIER Number Designation Model 452.3/4 BA33.10-P-1001-01D Bolt, front-axle carrier to body Nm 85 BA33.10-P-1002-01D Bolt, support, front axle carrier to front axle carrier Nm - BA33.10-P-1003-01D Bolt, support, front axle carrier to body Nm - TORQUE SPECIFICATIONS > TRAILING ARMS, WISHBONES - BA33.15-P-1000-01C > Model 450, 451, 452 MODIFICATION NOTES 12.10.10 Value changed: Nut, transverse control arm to front axle carrier Model 451.3/4 14.10.10 Value changed: Screw/bolt, transverse control arm to front axle carrier Model 451.3/4 TRAILING ARMS, WISHBONES Number Designation Model 450.3/4 up to 7.1.2001 Models 450.3/4 as of 8.1.2001 Model 451.3/4 Model 452.3/4 BA33.15- P-1001- 01C Bolt, wishbone to front axle carrier Nm 120 120 50 120 ∠° - - 90 - BA33.15- P-1002- 01C Self-locking nut, flange joint on wishbone Nm 40 40
40 BA33.15- P-1003- 01C Nut, wishbones to front axle carrier Nm - 120 - - BA33.15- P-1004- 01C Nut, wishbones to front axle carrier Nm - - 50 - ∠° - - 90 - TORQUE SPECIFICATIONS > WHEEL LOCATION, WHEEL HUB - BA33.20-P-1000-01G > Model 450, 451, 452 WHEEL LOCATION, HUB Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA33.20-P-1001- 01G Bolt, wheel bearing at swivel bearing Nm 120 65 120
TORQUE SPECIFICATIONS > AXLE HOUSING, STEERING KNUCKLE - BA33.25-P-1000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1991 · Applies to: 450, 451, 452, 454
01D > Model 450, 451, 452 MODIFICATION NOTES 17.4.02 Value changed from 48 Nm to 46 Nm Value in series 1001 changed for engine 450.3/4 AXLE HOUSING, STEERING KNUCKLE Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA33.25-P-1001- 01D Nut, flange ball joint to swivel bearing Nm 46 50 46 SPECIAL TOOLS > 450 589 01 09 00 OPEN-ENDED SOCKET WRENCH - WS33.00-P- 0141B > FG 33/Set B MODEL 450, 451, 452 Use: Open-end socket wrench for tightening the nut of the tie rod on the tie rod end (WAF 21), with 14x18 mm torque wrench. NOTE: Open-ended socket tool 21/ for torque wrench (14x18 mm) Smart no. 0005009. SPECIAL TOOLS > 450 589 00 17 00 RANGE OF TOOLS FOR STABILIZER BAR Fig 1: Identifying Open-Ended Socket Wrench (450 589 01 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ASSEMBLY - WS33.00-P-0142B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1992 · Applies to: 450, 451, 452, 454
FG 33/Set B MODEL 450, 451, 452 Use: Range of tools for stabilizer bar assembly for installing and removing stabilizer bar on the front axle. NOTE: Range of tools for stabilizer assemblySmart no. 0005010. SPECIAL TOOLS > 450 589 01 33 00 PULLER - WS33.00-P-0143B > FG 33/Set B MODEL 450, 452, 454, 451 Use: Puller for detaching the tie rod end and supporting joint swivel bearing. NOTE: Ball joint separator, passenger car versionSmart no. 0005149. Fig 1: Identifying Range Of Tools For Stabilizer Bar Assembly (450 589 00 17 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 454 589 00 33 00 PULLER - WS33.00-P-0158B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1993 · Applies to: 450, 451, 452, 454
FG 33/Set B MODEL 451, 454 Use: Puller for pressing out supporting joint on front axle wishbone control arm. SPECIAL TOOLS > 450 589 00 16 00 ACTUATION TOOL - WS33.00-P-0178B > FG 33/Set B MODEL 450, 451, 452, 454 Use: Actuation tool for checking supporting joint on McPherson front axle. Fig 1: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Puller (454 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 221 589 04 33 00 EXTRACTION TOOL - WS33.00-P-0187B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1994 · Applies to: 450, 451, 452, 454
FAG 33/Set B MODEL 204.08 /09 /28 /29 /98 /99, 212.08 /09 /28 /29, 216, 218.39, 221, 451 Use: For extracting the front axle shaft, shaft seals and pinion bearing from the front axle gear. NOTE: In combination with slide hammer puller 602 589 00 33 00.
SPECIAL TOOLS > 602 589 00 33 00 IMPACT EXTRACTOR - WS33.00-P-0189B > FG 26/33/35/Set B Fig 1: Identifying Actuation Tool (450 589 00 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Extraction Tool (221 589 04 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 204.08 /09 /28 /29 /98 /99, 212.08 /09 /28 /29, 216, 218.39, 221¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1995 · Applies to: 450, 451, 452, 454 · AR: WS33.00-Z-9999CZ
MODEL 245.286 with ENGINE 780.991 MODEL 451 MODEL 639 with CODE (MA0) E-CELL 60 kW Use: Impact extractor for pulling out front-axle shafts. In model 639, to pull out drive flange of drive shafts. NOTE: In combination with extraction tool 221 589 04 33 00. For model 639: In combination with adaptation 639 589 01 33 00
SPECIAL TOOLS > SPECIAL TOOLS: SMART: FRONT AXLE - WS33.00-Z-9999CZ > MODEL all 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P-0006Z 221 589 04 33 00 Extraction tool FAG 33/Set B WS33.00-P-0187B 450 589 00 16 00 Actuation tool FG 33/Set B WS33.00-P-0178B 450 589 00 17 00 Range of tools for stabilizer bar FG 33/Set B WS33.00-P-0142B Fig 1: Identifying Impact Extractor (602 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
embly¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1996 · Applies to: 450, 451, 452, 454
a embly 450 589 01 01 00 Open end wrench FG 33/Set B WS33.00-P-0144B 450 589 01 09 00 Open- ended socket wrench FG 33/Set B WS33.00-P-0141B 450 589 01 33 00 Puller FG 33/Set B WS33.00-P-0143B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 450 589 04 37 00 Pliers FG 33/Set B WS33.00-P-0140B 454 589 00 33 00 Puller FG 33/Set B WS33.00-P-0158B 602 589 00 33 00 Impact extractor FG 26/33/35/Set B WS33.00-P-0189B 639 589 00 61 00 Engine lifting device FG 01/33/Set C WS01.00-N-3106C
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1998 · Applies to: 450, 451, 452, 454
4.11.08 Wheel alignment check with recording of vehicle level added Step 23 Fig 1: Identifying Axle Tube Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Axle Tube Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1999 · Applies to: 450, 451, 452, 454
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 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 / screwdriver gotis://G_58.0_01.1 2 Remove bulkhead wall On model 451.4
- for USA only AR61.25-P- 6600MCU Except USA AR61.25-P- 6600MCC 3 Remove rear axle crossmember together with bar links
AR35.15-P- 0250MCC 4 Unhook hand brake cables (2) from the pull rod rocker (3), compress locking devices on the hand brake cables (2) and guide hand brake cables (2) out of the support on the frame-type integral support (4) *451589001400 5 Unscrew plastic nut (5), open folding clamp (6) using a suitable tool and take off Observe installation position of brake lines (7) and electrical line for left rear RPM sensor as for the right rear RPM sensor.
6 Expose and disconnect RPM sensor connector (L6/3x1 and L6/4x1)
7 Check bolted connections of brake lines (7) with the brake hoses of the rear axle (8) for color coding Installation: Identify brake lines (7) accordingly. AR42.10-P- 0013-05MCC Collect brake fluid which runs out in a suitable container. Seal brake lines (7) and brake hoses of rear axle (8) using suitable
Undo and disconnect bolted¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2000 · Applies to: 450, 451, 452, 454
8 Undo and disconnect bolted connections of brake lines (7) with brake hoses for rear axle (8) stop plugs. *BA42.10-P- 1002-04E
Installation: If a brake line (7) with red color coding is released, then this brake line (7) has to be replaced. See: ↓Remove/install brake line from the ESP hydraulic unit to the rear axle *450589099904 * for USA only AR42.10-P- 0035MCU Except USA AR42.10-P- 0035MCC 9 Support axle tube (1) with major assembly lifting platform Major assembly lifting platform gotis://A_01_07.
10 Remove left and right rear springs * for USA only AR32.20-P- 0230MCU Except USA AR32.20-P- 0230MCC 11 Counterhold nuts (9) and remove bolt (10) Replace self-locking nut (9).
Replace self-locking nut (9). *BA35.10-P- 1002-01F 12 Lower the major assemblies lifting table with the axle tube (1) and pull forward under the vehicle
13 Unclip hand brake cables (2) and rear brake lines (11) from the corresponding brackets on the axle tube (1) When replacing the axle tube (1).
14 Check bolted connections of rear brake lines (11) with the brake hoses of rear axle (8) for color coding When replacing the axle tube (1). Installation: Mark rear brake lines (11) accordingly. AR42.10-P- 0013-05MCC Loosen and disconnect bolted When replacing the axle tube (1).
Collect brake fluid which runs out in a suitable container. Seal rear brake lines (11) and brake hoses of rear axle (8) using suitable stop plugs.
*BA42.10-P- 1002-04E
Installation: If a rear brake line (11) with red color
connections of the rear brake lines¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2001 · Applies to: 450, 451, 452, 454
15 connections of the rear brake lines (11) with the brake hoses of rear axle (8), detach retaining clamps (12) and remove brake hoses of rear axle (8) coding has been detached, this rear brake line must be replaced (11). Refer to: ↓ *450589099904 Remove/install left rear brake line
-
for USA only AR42.10-P- 0036MCU Except USA AR42.10-P- 0036MCC Remove/install right rear brake line
-
for USA only AR42.10-P- 0037MCU Except USA AR42.10-P- 0037MCC 16 Remove RPM sensor from the rear axle When replacing the axle tube (1).
-
for USA only AR42.30-P- 0714MCU Except USA AR42.30-P- 0714MCC 17 Remove bolts (13) of wheel hubs (14) When replacing the axle tube (1).
*BA35.20-P- 1001-07B 18 Remove complete wheel hubs (14) with wheel brake, hand brake cable (2) and rear brake line (11) When replacing the axle tube (1).
19 Remove holder of hand brake cable (2) and rear brake lines (11) from axle tube (1) When replacing the axle tube (1).
20 Remove covering (15) of rear axle springs from axle tube (1) When replacing the axle tube (1).
21 Install in the reverse order
22 Bleed brake system * for USA only AR42.10-P- 0010MCU Except USA AR42.10-P- 0010MCC 23 Perform wheel alignment check Depending on the workshop equipment, a selection has to be made between the alignment variant with recording of the vehicle level or without recording of vehicle level.
Without recording of vehicle level AR40.20-P-
0200MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2002 · Applies to: 450, 451, 452, 454
With recording of vehicle level AR40.20-P- 0200MCE REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1002- 01F Bolt, axle tube to frame-type integral support Nm 160 WHEEL BEARING Number Designation Model 451.3/4 BA35.20-P-1001- 07B Bolt, wheel bearing to axle tube Nm 65 BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002-04E Brake pipe to brake hose Nm 16 Fig 3: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Sleeve (451 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unscrew nuts (5).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2004 · Applies to: 450, 451, 452, 454
2 Unscrew nuts (5). The bolts (4) remain in the left bar link (3) and right bar link (6).
3 Remove bolts (1)
4 Remove rear axle crossmember (2) together with left bar link (3) and right bar link (6)
5 Remove bolts (4)
6 Drill out rivets (7) and rivet (arrow A) and remove heat shield (8) *450589017000
Rechargeable drill/screwdriver gotis://G_58.0_01.1
7 Remove remainder of rivets
8 Unscrew corresponding bolt (9) and remove left bar link (3) or right bar link (6)
Install
Installation should only be carried out when the vehicle is empty (approx. 75 kg on the driver seat and full tank or approx. 20 kg in front passenger area).
9 Align left bar link (3) or right bar link (6) corresponding to the adjustment dimension of bar link to rear axle crossmember (a) and tighten with bolt (9) Adjustment dimension, bar link to rear axle crossmember *BE35.15-P-1001-01B
*BA35.15-P-1002-02C 10 Position heat shield (8) on rear axle crossmember (2) and press in rivets (7) and rivet (arrow A) using hand riveting tool Hand riveting toolgotis://K_68- 80_06.0
11 Insert bolts (4)
12 Position rear axle crossmember (2) together with left bar link (3) and right bar link (6) on vehicle and tighten bolts (1) *BA35.10-P-1003-01F 13 Rock vehicle several times to settle suspension Ensure that the vehicle is not relieved of load by a lifting platform, axle jack, wheels-free jack, transmission jack,
TESTING & REPAIR > REMOVE/INSTALL REAR AXLE CROSSMEMBER - AR35.15-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2006 · Applies to: 450, 451, 452, 454
0250MCC > MODEL 451.3/4 Fig 3: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Rear Axle Crossmember Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2007 · Applies to: 450, 451, 452, 454
4.11.08 Wheel alignment check with recording of vehicle level added Step 15 Remove
1 Raise vehicle using drive-on lifting platform
2 Unscrew nuts (5). The bolts (4) remain in the left bar link (3) and right bar link (6).
3 Remove bolts (1)
4 Remove rear axle crossmember (2) together with left bar link (3) and right bar link (6)
5 Remove bolts (4)
6 Drill out rivets (7) and rivet (arrow A) and remove heat shield (8) Rechargeable drill / screwdriver gotis://G_58.0_01.1 *450589017000 7 Remove remainder of rivets
8 Remove bolts (9) and take off left bar link (3) and right bar link (6)
Install
Fig 2: Identifying Adjustment Dimension, Bar Link To Rear Axle Crossmember Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2011 · Applies to: 450, 451, 452, 454
26.10.07 Bolt, shock absorber to rear axle *BA32.25-P-1001-03N Remove/install
1 Remove left or right rear wheel
AR40.10-P- 1100MCU 2 Unscrew bolt (2) of rear axle shaft (1) To undo and tighten the bolt (2) screw two wheel bolts (3) into the wheel hub and counterhold wheel hub using a suitable tool. Installation: Replace self-locking bolt (2) of rear axle shaft (1).
BA35.30-P- 1002-01D 3 Support the rear axle crossmember (4) using a transmission jack, unscrew bolts (5) and lower the rear axle crossmember (4) Transmission jack gotis://H_00.10_01. BA35.10-P- 1003-01F Fig 1: Identifying Rear Axle Shaft Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove wheel bolt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2012 · Applies to: 450, 451, 452, 454
4 Remove wheel bolt (3) from wheel hub, position adaptation (6) to line up with the hole circle and attach to the wheel hub with all wheel bolts (3) 451589003400 5 Position the extraction and insertion tool (7) to line up with the hole circle and fasten with bolts (8) to the adapter (6) 451589003400 210589034300 6 Press rear axle shaft (1) out of the wheel hub and detach extraction and insertion tool (7) as well as adapter (6) from the wheel hub 451589003400 *210589034300 7 Support axle tube (9) with major assemblies lifting table or transmission jack If both rear axle shafts (1) are removed simultaneously, the major assemblies lifting table should be used to support the axle tube (9).Major assembly platform lift gotis://A_01_07.1
8 Remove expansion clip on cover (10), remove cover (10)
9 Remove bolt of shock absorber (11) on axle tube (9) *BA32.25-P- 1001-03N 10 Lower the axle tube (9) carefully and guide rear axle shaft (1) out of the wheel hub Ensure that the inner ball joint of the rear axle shaft (1) is not pulled apart as it will be irreparably damaged as a result. When lowering the axle tube (9) ensure that the rear spring does not fall out of its supports. Installation: Observe the correct seat of the rear spring in the supports on the axle tube (9) and on the frame-type integral support. In ert the hock ab orber (11) into the upport on the axle tube (9).
11 Raise the axle tube (9) and attach to the shock absorber (11) Installation: Unscrew bolt on shock absorber (11) and lower the axle tube (9) until the rear axle shaft (1) can be inserted into the wheel hub.In the process ensure that the rear spring does not fall out of its supports.
Undo rear a le haft¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2013 · Applies to: 450, 451, 452, 454
12 Undo rear a le haft (1) using impact extractor and extractor tool (12) on transmission and remove. Afterwards seal the transmission opening with plug Collect e caping tran mi ion oil in a uitable container. Installation: Do not damage radial shaft sealing ring otherwise it may leak. Installation: Replace circlip on the inner joint of the rear axle shaft (1).
221589043300 602589003300 Plug *BR00.45-Z- 1005-15A 13 Install in the reverse order
14 Inspect transmission oil level, adjust to correct level if necessary
AR26.00-P- 0200MCU REAR AXLE SHOCK ABSORBER Number Designation Model 451.3/4 BA32.25-P-1001- 03N Bolt, shock absorber to rear axle Nm 70 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1003- 01F Bolt, crossmember to frame-type integral support Nm 65 REAR AXLE SHAFT Number Designation Model 451.3/4 BA35.30-P-1002- 01D Bolt, rear axle shaft to rear axle shaft flange Stage 1 Nm 45 Stage 2 ∠° 90 Fig 2: Identifying Extraction And Insertion Tool (210 589 03 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Wheel end¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2015 · Applies to: 450, 451, 452, 454
Removing
1 Remove input shaft (6)
AR35.30-P- 0620MCU Disassemble
2 Clamp input shaft (6) in vise (3) using protective jaws
3 Detach clamps (4, 5)
4 Cut open and pull off input shaft boot (2) and detach constant velocity joint (1) in direction of arrow from input shaft (6) Drive the constant velocity joint (1) on the inner spider off the input shaft (6). Use a suitable steel drift.
5 Remove circlip (7)
Clean
6 Clean constant velocity joint (1)
Assembly
7 Push clamp (4) onto input shaft (6)
8 Push new input shaft boot (2) onto input shaft (6)
9 Install new circlip (7).
10 Fill constant velocity joint (1) up to upper edge of inner spider with grease included in package contents
11 Push constant velocity joint (1) onto input shaft (6) The constant velocity joint (1) must
Fig 1: Identifying Input Shaft Boot Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Wheel location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2018 · Applies to: 450, 451, 452, 454
MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA35.20-P-1000-07B TORQUE SPECIFICATIONS > REAR AXLE CARRIER - BA35.10-P-1000-01F > Model 450, 451, 452 REAR AXLE CARRIER Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA35.10-P- 1001-01F Bolt of frame-type integral support to body Nm 100 125 100 BA35.10-P- 1002-01F Bolt, axle tube to frame-type integral support Nm 120 160 120 BA35.10-P- 1003-01F Bolt, crossmember to frame-type integral support Nm 65 65 65 BA35.10-P- 1004-01F Bolt, crossmember to axle tube Nm - 100 - TORQUE SPECIFICATIONS > TRAILING ARMS, WISHBONES - BA35.15-P-1000-02C > Model 450, 451, 452 MODIFICATION NOTES 24.11.06 Bolt, bar-type link to axle tube Model 451.3/4 TRAILING ARMS, WISHBONES Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA35.15-P-1001- 02C Bolt, bar-type link to axle tube Nm 100 90 100 BA35.15-P-1002- 02C Bolt, bar-type link to crossmember Nm 65 65 65 TORQUE SPECIFICATIONS > WHEEL LOCATION - BA35.20-P-1000-07B > Model 450, 451, 452 WHEEL BEARING Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA35.20-P-1001- 07B Bolt, wheel bearing to axle tube Nm 65 65 60 TORQUE SPECIFICATIONS > REAR AXLE SHAFT - BA35.30-P-1000-01D > Model 450, 451, 452
SPECIAL TOOLS > 210 589 03 43 00 EXTRACTION AND INSERTION TOOL - WS35.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2020 · Applies to: 450, 451, 452, 454
0154C > FG 35/Set C MODEL 451, 107, 123, 124, 126, 129, 140, 163, 164, 170, 171, 172, 197, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 251, 414, 636, 639 MODIFICATION NOTES 3.5.95 Replacement for 140 589 03 61 00 Part 210 589 03 43 09 Pin FG 35/Set C WS35.00-P-0154-01C Use: Removal and installation tool for rear axle shafts
SPECIAL TOOLS > 450 589 03 37 00 PLIERS - WS35.00-P-0210B > Fig 1: Identifying Pin (210 589 03 43 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Extraction And Insertion Tool (210 589 03 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 35/Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2021 · Applies to: 450, 451, 452, 454
MODEL 450, 451, 452 Use: Pliers for clamping the clamps on the boots of the side shafts. NOTE: Clamp pliers for joint bootSmart no. 0005006. SPECIAL TOOLS > 450 589 18 63 00 REMOVAL AND INSTALLATION TOOL - WS35.00-P- 0213A > FG 35/Set A MODEL 450, 451, 452 Use: Removal and installation tool for removing and installing hold-down springs at drum brake shoes. NOTE: Removal and installation tool for drum brakeSmart No. 0007349. Fig 1: Identifying Pliers (450 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 221 589 00 62 00 SET OF SPACER BOLTS - WS35.00-P-0250B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2022 · Applies to: 450, 451, 452, 454
FG 35/Set B MODEL 221 MODEL 451.3/4 with CODE (460) Canada version MODEL 451.3/4 with CODE (494) USA version Use: Set of spacer bolts for partial lowering of rear axle carrier when removing/installing rear axle gear. NOTE: For rear axle gear with ring gear Ø240mm.
SPECIAL TOOLS > 451 589 00 62 00 MOUNTING FIXTURE - WS35.00-P-0258B > Fig 1: Identifying Removal And Installation Tool (450 589 18 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Set Of Spacer Bolts (221 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 35/Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2023 · Applies to: 450, 451, 452, 454
MODEL 451 Use: Support for lowering the rear axle module into the service position. NOTE: Only in combination with major assembly lifting platform and universal major assembly support (in combination with major assembly lifting platform).Please refer to GOTIS for procurement and information SPECIAL TOOLS > 451 589 00 34 00 ADAPTATION - WS35.00-P-0264B > FG 35/Set B MODEL 451 Use: Adaptation for pressing the side shaft out of the rear wheel hub. NOTE: Only use in combination with extraction and insertion tool 210 589 03 43 00. Fig 1: Identifying Mounting Fixture (451 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: REAR AXLE - WS35.00-Z-9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2024 · Applies to: 450, 451, 452, 454 · AR: WS35.00-Z-9999CZ
MODEL all 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 210 589 03 43 00 Extraction and insertion tool FG 35/Set C WS35.00-P-0154C 210 589 03 43 09 Pin FG35/Set C WS35.00-P-0154- 01C 221 589 00 62 00 Set of spacer bolts FG 35/Set B WS35.00-P-0250B 450 589 00 09 00 Open-ended socket wrench FG 35/Set B WS35.00-P-0211B 450 589 00 33 00 Puller FG 35/Set B WS35.00-P-0212B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 450 589 03 37 00 Pliers FG 35/Set B WS35.00-P-0210B 450 589 10 09 00 Socket wrench bit (TORX) FG 35/Set B WS35.00-P-0216B 450 589 18 63 00 Removal and installation tool FG 35/Set A WS35.00-P-0213A 451 589 00 34 00 Adaptation FG 35/Set B WS35.00-P-0264B 451 589 00 62 00 Mounting fixture FG 35/Set B WS35.00-P-0258B 602 589 00 33 00 Impact extractor FG 26/33/35/Set B WS33.00-P-0189B Fig 1: Identifying Adaptation (451 589 00 34 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2026 · Applies to: 450, 451, 452, 454
4.11.08 Wheel alignment check with recording of vehicle level added Step 23 Fig 1: Identifying Axle Tube Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Axle Tube Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2027 · Applies to: 450, 451, 452, 454
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 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 / screwdriver 2 Remove bulkhead wall On model 451.4
- for USA only AR61.25- P- 6600MCU Except USA AR61.25- P- 6600MCC 3 Remove rear axle crossmember together with bar links
AR35.15- P- 0250MCC 4 Unhook hand brake cables (2) from the pull rod rocker (3), compress locking devices on the hand brake cables (2) and guide hand brake cables (2) out of the support on the frame-type integral support (4) Fig 4 5 Unscrew plastic nut (5), open folding clamp (6) using a suitable tool and take off Observe installation position of brake lines (7) and electrical line for left rear rpm sensor as for the right rear rpm sensor.
6 Expose and disconnect rpm sensor connector (L6/3x1 and L6/4x1)
7 Check bolted connections of brake lines (7) with the brake hoses of the rear axle (8) for color coding Installation: Identify brake lines (7) accordingly. AR42.10- P-0013- 05MCC Collect brake fluid which runs out in a suitable container. Seal brake lines (7) and brake hoses of
Undo and disconnect bolted¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2028 · Applies to: 450, 451, 452, 454
8 Undo and disconnect bolted connections of brake lines (7) with brake hoses for rear axle (8) rear axle (8) using suitable stop plugs. *BA42.10- P-1002- 04E
Installation: If a brake line (7) with red color coding is released, then this brake line (7) has to be replaced. See: ↓Remove/install brake line from the ESP hydraulic unit to the rear axle Fig 3 * for USA only AR42.10- P- 0035MCU Except USA AR42.10- P- 0035MCC 9 Support axle tube (1) with major assembly lifting platform Major assembly lifting platform
10 Remove left and right rear springs * for USA only AR32.20- P- 0230MCU Except USA AR32.20- P- 0230MCC 11 Counterhold nuts (9) and remove bolt (10) Replace self-locking nut (9).
Replace self-locking nut (9). *BA35.10- P-1002- 01F 12 Lower the major assemblies lifting table with the axle tube (1) and pull forward under the vehicle
13 Unclip hand brake cables (2) and rear brake lines (11) from the corresponding brackets on the axle tube (1) When replacing the axle tube (1).
14 Check bolted connections of rear brake lines (11) with the brake hoses of rear axle (8) for color coding When replacing the axle tube (1). Installation: Mark rear brake lines (11) accordingly. AR42.10- P-0013- 05MCC When replacing the axle tube (1).
Collect brake fluid which runs out in a suitable container. Seal rear brake lines (11) and brake hoses of rear axle (8) using suitable stop plugs.
Loosen and disconnect bolted¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2029 · Applies to: 450, 451, 452, 454
15 Loosen and disconnect bolted connections of the rear brake lines (11) with the brake hoses of rear axle (8), detach retaining clamps (12) and remove brake hoses of rear axle (8) *BA42.10- P-1002- 04E
Installation: If a rear brake line (11) with red color coding has been detached, this rear brake line must be replaced (11). Refer to: ↓ Fig 3 Remove/install left rear brake line
-
for USA only AR42.10- P- 0036MCU Except USA AR42.10- P- 0036MCC Remove/install right rear brake line
-
for USA only AR42.10- P- 0037MCU Except USA AR42.10- P- 0037MCC 16 Remove rpm sensor from the rear axle When replacing the axle tube (1).
-
for USA only AR42.30- P- 0714MCU Except USA AR42.30- P- 0714MCC 17 Remove bolts (13) of wheel hubs (14) When replacing the axle tube (1).
*BA35.20- P-1001- 07B 18 Remove complete wheel hubs (14) with wheel brake, hand brake cable (2) and rear brake line (11) When replacing the axle tube (1).
19 Remove holder of hand brake cable (2) and rear brake lines (11) from axle tube (1) When replacing the axle tube (1).
20 Remove covering (15) of rear axle springs from axle tube (1) When replacing the axle tube (1).
21 Install in the reverse order
- for USA only AR42.10- P- 0010MCU
Bleed brake system¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2030 · Applies to: 450, 451, 452, 454
22 Bleed brake system Except USA AR42.10- P- 0010MCC 23 Perform wheel alignment check Depending on the workshop equipment, a selection has to be made between the alignment variant with recording of the vehicle level or without recording of vehicle level.
Without recording of vehicle level AR40.20- P- 0200MCC With recording of vehicle level AR40.20- P- 0200MCE REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1002-01F Bolt, axle tube to frame-type integral support Nm 160 WHEEL BEARING Number Designation Model 451.3/4 BA35.20-P-1001-07B Bolt, wheel bearing to axle tube Nm 65 BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1002-04E Brake pipe to brake hose Nm 16 Fig 3: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > REMOVE/INSTALL REAR AXLE CROSSMEMBER - AR35.15-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2031 · Applies to: 450, 451, 452, 454
P-0250MCC > MODEL 451.3 /4 Fig 4: Identifying Sleeve (451 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Rear Axle Crossmember Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2032 · Applies to: 450, 451, 452, 454
4.11.08 Wheel alignment check with recording of vehicle level added Step 15 Remove
1 Raise vehicle using drive-on lifting platform
2 Unscrew nuts (5). The bolts (4) remain in the left bar link (3) and right bar link (6).
3 Remove bolts (1)
4 Remove rear axle crossmember (2) together with left bar link (3) and right bar link (6)
5 Remove bolts (4)
6 Drill out rivets (7) and rivet (arrow A) and remove heat shield (8) Rechargeable drill / screwdriver Fig 3 7 Remove remainder of rivets
8 Remove bolts (9) and take off left bar link (3) and right bar link (6)
Install
Installation should only be carried out when the vehicle is empty Fig 2: Identifying Rear Axle Crossmember Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(appro 75 kg on the driver eat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2033 · Applies to: 450, 451, 452, 454
and full tank or approx. 20 kg in front passenger area).
9 Align left bar link (3) and right bar link (6) according to adjustment dimension of bar link relative to rear axle crossmember (a) and secure with bolts (9) Adjustment dimension, bar link to rear axle crossmember BE35.15- P-1001- 01B BA35.15- P-1002- 02C 10 Position heat shield (8) on rear axle crossmember (2) and press in rivets (7) and rivet (arrow A) using hand riveting tool Hand riveting tool
11 Insert bolts (4)
12 Position rear axle crossmember (2) together with left bar link (3) and right bar link (6) on vehicle and tighten bolts (1) *BA35.10- P-1003- 01F 13 Rock vehicle several times to settle suspension Make sure that the vehicle is not resting on a lifting platform, axle jack, wheels-free jack, transmission jack or support block or suchlike.
14 Secure left bar link (3) and right bar link (6) using bolts (4) and nuts (5) *BA35.15- P-1001- 02C 15 Perform wheel alignment check Depending on the workshop equipment, a selection has to be made between the alignment variant with recording of the vehicle level or without recording of vehicle level.
Without recording of vehicle level AR40.20- P- 0200MCC With recording of vehicle level AR40.20- P- 0200MCE TRAILING ARMS, WISHBONES Number Designation Model 451 BE35.15-P-1001-01B Adjustment dimension, bar link to rear axle crossmember mm 130 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1003-01F Bolt, crossmember to frame-type integral support Nm 65
Remove bolts (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2035 · Applies to: 450, 451, 452, 454
3 Remove bolts (2) *BA35.20- P-1001- 07B 4 Remove wheel bearing (1) with wheel hub and support brake anchor plate (3) using transmission jack and removal fixture Make sure that the brake line to the wheel brake cylinder is not bent, as otherwise it will have to be replaced.
Transmission jack Fig 2 5 Install in the reverse order
WHEEL BEARING Number Designation Model 451.3/4 BA35.20-P-1001-07B Bolt, wheel bearing to axle tube Nm 65 TESTING & REPAIR INDEX > REMOVE/INSTALL REAR AXLE SHAFT - AR35.30-P- 0620MCU > MODEL 451.3 /4 Shown on right side of vehicle Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2036 · Applies to: 450, 451, 452, 454
26.10.07 Bolt, shock absorber to rear axle
*BA32.25-P-1001-03N Remove/install
1 Remove left or right rear wheel
AR40.10- P- 1100MCU 2 Unscrew bolt (2) of rear axle shaft (1) To undo and tighten the bolt (2) screw two wheel bolts (3) into the wheel hub and counterhold wheel hub using a suitable tool. Installation: Replace self-locking bolt (2) of rear axle shaft (1).
BA35.30- P-1002- 01D 3 Support the rear axle crossmember (4) using a transmission jack, unscrew bolts (5) and lower the rear axle crossmember Transmission jack BA35.10- P-1003- 01F Fig 1: Identifying Rear Axle Shaft Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove wheel bolts¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2037 · Applies to: 450, 451, 452, 454
(4) 4 Remove wheel bolts (3) from wheel hub, position adaptation (6) to line up with the hole circle and attach to the wheel hub with all wheel bolts (3) Fig 4 5 Position the extraction and insertion tool (7) to line up with the hole circle and fasten with bolts (8) to the adapter (6) Fig 4 Fig 2 6 Press rear axle shaft (1) out of the wheel hub and detach extraction and insertion tool (7) as well as adapter (6) from the wheel hub Fig 4 Fig 2 7 Support axle tube (9) with major assemblies lifting table or transmission jack If both rear axle shafts (1) are removed simultaneously, the major assemblies lifting table should be used to support the axle tube (9).Major assembly platform lift
8 Remove expansion clip on cover (10), remove cover (10)
9 Remove bolt of shock absorber (11) on axle tube (9) *BA32.25- P-1001- 03N 10 Lower the axle tube (9) carefully and guide rear axle shaft (1) out of the wheel hub Ensure that the inner ball joint of the rear axle shaft (1) is not pulled apart as it will be irreparably damaged as a result. When lowering the axle tube (9) ensure that the rear spring does not fall out of its supports. Installation: Observe the correct seat of the rear spring in the supports on the axle tube (9) and on the frame- type integral support. Insert the shock absorber (11) into the support on the axle tube (9).
11 Raise the axle tube (9) and attach to the shock absorber (11) Installation: Unscrew bolt on shock absorber (11) and lower the axle tube (9) until the rear axle shaft (1) can be inserted into the wheel hub.In the process ensure that the rear spring does not fall out of its supports.
Undo rear axle shaft Collect escaping transmission oil in a suitable container. Installation: Do not damage radial shaft sealing ring otherwise it may leak. Installation:
(1) u ing impact¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2038 · Applies to: 450, 451, 452, 454
12 (1) u ing impact extractor and extractor tool (12) on transmission and remove. Afterwards seal the transmission opening with plug Replace circlip on the inner joint of the rear a le haft (1). Fig 3 Fig 5 Plug *BR00.45- Z-1005- 15A 13 Install in the reverse order
14 Inspect transmission oil level, adjust to correct level if necessary
AR26.00- P- 0200MCU REAR AXLE SHOCK ABSORBER Number Designation Model 451.3/4 BA32.25-P-1001-03N Bolt, shock absorber to rear axle Nm 70 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1003-01F Bolt, crossmember to frame-type integral support Nm 65 REAR AXLE SHAFT Number Designation Model 451.3/4 BA35.30-P-1002- 01D Bolt, rear axle shaft to rear axle shaft flange Stage 1 Nm 45 Stage 2 ∠° 90 Fig 2: Identifying Extraction And Insertion Tool (210 589 03 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2039 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1005-15A Cap to transmission housing A 451 261 00 33 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: REAR AXLE - BA35.00-Z- 9999CZ > Fig 3: Identifying Extraction Tool (221 589 04 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Adaptation (451 589 00 34 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Impact Extractor (602 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2040 · Applies to: 450, 451, 452, 454
Hub MODEL 454.0 BA35.20-P-1000-06B Rear axle MODEL 454.0 BA35.10-P-1000-03A Rear axle carrier MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA35.10-P-1000-01F Rear axle shaft MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA35.30-P-1000-01D Trailing arms, wishbones MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA35.15-P-1000-02C Wheel location MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA35.20-P-1000-07B TORQUE SPECIFICATIONS > REAR AXLE CARRIER - BA35.10-P-1000-01F > Model 450, 451, 452 REAR AXLE CARRIER Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA35.10-P- 1001-01F Bolt of frame-type integral support to body Nm 100 125 100 BA35.10-P- 1002-01F Bolt, axle tube to frame-type integral support Nm 120 160 120 BA35.10-P- 1003-01F Bolt, crossmember to frame-type integral support Nm 65 65 65 BA35.10-P- 1004-01F Bolt, crossmember to axle tube Nm - 100 - TORQUE SPECIFICATIONS > TRAILING ARMS, WISHBONES - BA35.15-P-1000-02C > Model 450, 451, 452 MODIFICATION NOTES 24.11.06 Bolt, bar-type link to axle tube Model 451.3/4 TRAILING ARMS, WISHBONES Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA35.15-P-1001- 02C Bolt, bar-type link to axle tube Nm 100 90 100 BA35.15-P-1002- 02C Bolt, bar-type link to crossmember Nm 65 65 65
SPECIAL TOOLS > 210 589 03 43 00 EXTRACTION AND INSERTION TOOL - WS35.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2042 · Applies to: 450, 451, 452, 454
0154C > FG 35/Set C MODEL 451, 107, 123, 124, 126, 129, 140, 163, 164, 170, 171, 172, 197, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 251, 414, 636, 639 MODIFICATION NOTES 3.5.95 Replacement for 140 589 03 61 00 Part 210 589 03 43 09 Pin FG 35/Set C WS35.00-P-0154-01C Use: Removal and installation tool for rear axle shafts
SPECIAL TOOLS > 450 589 03 37 00 PLIERS - WS35.00-P-0210B > Fig 1: Identifying Pin (210 589 03 43 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Extraction And Insertion Tool (210 589 03 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 35/Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2043 · Applies to: 450, 451, 452, 454
MODEL 450, 451, 452 Use: Pliers for clamping the clamps on the boots of the side shafts. NOTE: Clamp pliers for joint bootSmart no. 0005006. SPECIAL TOOLS > 450 589 18 63 00 REMOVAL AND INSTALLATION TOOL - WS35.00-P- 0213A > FG 35/Set A MODEL 450, 451, 452 Use: Removal and installation tool for removing and installing hold-down springs at drum brake shoes. NOTE: Removal and installation tool for drum brakeSmart No. 0007349. Fig 1: Identifying Pliers (450 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 221 589 00 62 00 SET OF SPACER BOLTS - WS35.00-P-0250B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2044 · Applies to: 450, 451, 452, 454
FG 35/Set B MODEL 221 MODEL 451.3 /4 with CODE (460) Canada version MODEL 451.3 /4 with CODE (494) USA version Use: Set of spacer bolts for partial lowering of rear axle carrier when removing/installing rear axle gear. NOTE: For rear axle gear with ring gear Ø240mm.
SPECIAL TOOLS > 451 589 00 62 00 MOUNTING FIXTURE - WS35.00-P-0258B > Fig 1: Identifying Removal And Installation Tool (450 589 18 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Set Of Spacer Bolts (221 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 35/Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2045 · Applies to: 450, 451, 452, 454
MODEL 451 Use: Support for lowering the rear axle module into the service position. NOTE: Only in combination with major assembly lifting platform and universal major assembly support (in combination with major assembly lifting platform). SPECIAL TOOLS > 451 589 00 34 00 ADAPTATION - WS35.00-P-0264B > FG 35/Set B MODEL 451 Use: Adaptation for pressing the side shaft out of the rear wheel hub. NOTE: Only use in combination with extraction and insertion tool 210 589 03 43 00. Fig 1: Identifying Mounting Fixture (451 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: REAR AXLE - WS35.00-Z-9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2046 · Applies to: 450, 451, 452, 454 · AR: WS35.00-Z-9999CZ
MODEL all 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 210 589 03 43 00 Extraction and insertion tool FG 35/Set C WS35.00-P-0154C 210 589 03 43 09 Pin FG35/Set C WS35.00-P-0154-01C 221 589 00 62 00 Set of spacer bolts FG 35/Set B WS35.00-P-0250B 450 589 00 09 00 Open- ended socket wrench FG 35/Set B WS35.00-P-0211B 450 589 00 33 00 Puller FG 35/Set B WS35.00-P-0212B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 450 589 03 37 00 Pliers FG 35/Set B WS35.00-P-0210B 450 589 10 09 00 Socket wrench bit (TORX) FG 35/Set B WS35.00-P-0216B 450 589 18 63 00 Removal and installation tool FG 35/Set A WS35.00-P-0213A 451 589 00 34 00 Adaptation FG 35/Set B WS35.00-P-0264B 451 589 00 62 00 Mounting fixture FG 35/Set B WS35.00-P-0258B 602 589 00 33 00 Impact extractor FG 26/33/35/Set B WS33.00-P-0189B Fig 1: Identifying Adaptation (451 589 00 34 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: PROPELLER SHAFT - WS41.00-Z-9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2047 · Applies to: 450, 451, 452, 454 · AR: WS41.00-Z-9999CZ
MODEL all 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 450 589 04 15 00 Drift FG 41/Set B WS41.00-P-0016B
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2050 · Applies to: 450, 451, 452, 454
Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1 Set steering and turn signal switch to center If the steering and turn signal switch are not in the center position for removal/ installation of the steering wheel (2), the fanfare horns and airbag clock spring contact (A45) and the turn signal canceling cam may be
Fig 1: Identifying Steering Wheel Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
po ition¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2051 · Applies to: 450, 451, 452, 454
damaged Calibration of the teering angle en or in the fanfare horns and airbag clock spring contact (A45) remains impossible. 2 Disconnect battery ground line
AR54.10- P- 0003MCC 3 Remove lower steering column trim (1)
AR68.30- P- 2000MCC 4 Detach clock spring contact and airbag connector (A45x1)
5 Undo bolt (3) from below on the steering wheel (2) The steering wheel (2) may only be rotated using the tightened bolt (3), to avoid damaging the fanfare horns and airbag clock spring contact (A45). The bolt (3) remains on the steering wheel (2).
*BA46.10- P-1001- 02D 6 Remove steering wheel (2) The steering wheel (2) may only be rotated using the tightened bolt (3), to avoid damaging the fanfare horns and airbag clock spring contact (A45). When removing the steering wheel (2) from the steering column, the fanfare horns and airbag clock spring contact (A45) is blocked against any inadvertent turning. Installation: Mount steering wheel (2) so that the locking pins (arrows A) line up with the fixtures (arrows B) of the fanfare horns and airbag clock spring contact (A45). Ensure that the front wheels are in the straight-ahead position before installing the steering wheel (2).
7 Remove clock spring contact Only when replacing the steering wheel (2).
- not for USA AR46.10- P- 0200MCC
- for USA only AR46.10- P- 0200MCU 8 Install in the reverse order
STEERING WHEEL Number Designation Model 451.3/4 BA46.10-P-1001- 02D Bolts, steering wheel to steering shaft Nm 27
TESTING & REPAIR > REMOVE/INSTALL STEERING WHEEL SPOKE COVERS - AR46.10-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2052 · Applies to: 450, 451, 452, 454
P-0105MCC > MODEL 451.3/4 Shown on the steering wheel with code (I75) Leather sport steering wheel with steering wheel rocker switch system Remove/install
1 Remove steering wheel (2)
AR46.10- P- 0100MCC 2 Remove bolts (1) For vehicles without code (I75) Leather sport steering wheel with steering wheel rocker switch system the bolts (1) are screwed on immediately at the rear covering (3).
3 Remove the steering wheel gear shifter PLUS (S112s1) and steering wheel gear shifter MINUS (S112s2) until the electrical connector (7) is accessible For vehicles with code (I75) Leather sport steering wheel with steering wheel rocker switch system
Detach electrical Fig 1: Identifying Steering Wheel Spoke Cover Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2054 · Applies to: 450, 451, 452, 454
1 Remove airbag unit from steering wheel (1)
AR91.60- P- 0660MCC 2 Detach electrical connector (6) at fanfare horns and airbag clock spring contact The electrical connector (arrow C) of the driver airbag unit must not be disconnected, otherwise the fanfare horns and airbag clock spring contact has to be renewed.
3 Release the catch on the plug (5) and detach the plug (5) and the ground line (4) from the steering wheel (1) After disconnecting the plug (5) from the steering wheel (1), the wiring harness (3) gas to be replaced.For vehicles as of 31.8.10, the connector (5) must not be detached from the steering wheel (1). The new steering wheel (1) is delivered with the corresponding wiring harness and a connector (5) already fitted.
4 Route plug for steering wheel rocker switch system (2) through the opening on the steering wheel (1) For vehicles with code (I75) Leather sport steering wheel with steering wheel rocker switch system
5 Release wiring harness (3) from holders (arrows A) on steering wheel (1) For vehicles with code (I75) Leather sport steering wheel with steering wheel rocker switch system
6 Release and remove wiring harness (3) from holders (arrows B) on steering wheel (1) Observe installation position of wiring harness (3). Installation: Renew wiring harness (3).
7 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL CLOCK SPRING CONTACT - AR46.10-P- 0200MCU > MODEL 451.3/4
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2056 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Jacket Tube Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Jacket Tube Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2057 · Applies to: 450, 451, 452, 454
22.8.07 Bolt, steering coupling to rack-and-pinion steering *BA46.10-P-1001-01F
Remove/install
Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A 1 Remove bottom paneling for instrument panel on driver side Installation: Before installing the steering wheel ensure that the rack-and-pinion steering (1) is in the center position (front wheels straight ahead). AR68.10- P- 1501MCU 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 2 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver http://gotis.aftersales.mercedes-benz.com
3 Loosen nut (3) on steering coupling (2) Turn the front wheels until the nut (3) is accessible.
4 Move the rack- and-pinion steering (1) into the center position (front wheels straight
Fig 3: Identifying Jacket Tube Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ahead)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2058 · Applies to: 450, 451, 452, 454
5 Unscrew nut (3) on the steering coupling (2), remove bolt (4) and slide steering coupling (2) upwards off the rack-and- pinion steering (1) Replace nut (3) and bolt (4).Only the bolt (4) and nut (3) approved for model 451 may be used. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. When the nut (3) is released, the cam-shaped bolt (4) rotates approx. half a revolution at the same time. However, the bolt (4) does not have to be counterheld. Check the steering coupling (2) for ease of movement and replace if necessary. Installation: Turn the jacket tube (8) relative to the rack-and-pinion steering (1) until the steering coupling (2) can be assembled.
*BA46.10- P-1001- 01F 6 Lower vehicle with lifting platform
7 Remove bolts (5) on SAM control unit (N10/10)
8 Loosen locking device (arrow A) in the rear area of the SAM control unit (N10/10) and place SAM control unit (N10/10) to one side with electrical lines connected
9 Unscrew bolts (9) and remove top bearing cap (7) Replace bolts (9). Installation: The top bearing (10) must close flush with the cutouts (arrows C) of the crossmember under the dashboard (14).The bolts (9) are self-tapping, therefore a thread must not be precut.In each case tighten bolts (9) in steps of one revolution.
*BA46.10- P-1002- 01F 10 Unscrew bolts (13) and remove bottom bearing cap (6) Install new bolts (13). Installation: The bottom bearing (11) must be flush with the bottom area (arrow B) of the crossmember below the dashboard (14) otherwise the specified installation position of the jacket tube (8) will not be reached. The bolts (13) are self-tapping; therefore a thread must not be precut.In each case tighten bolts (13) in steps of one revolution.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2060 · Applies to: 450, 451, 452, 454
1 Remove steering wheel (1)
AR46.10- P- 0100MCC 2 Remove bolts (2)
3 Remove the steering wheel gear shifter PLUS (S112s1) or the steering wheel gear shifter MINUS (S112s2) until the electrical connector (3) is accessible
4 Detach electrical connector (3) and remove steering wheel gear shifter PLUS (S112s1) or the steering wheel gear shifter MINUS (S112s2)
5 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL RUBBER MOUNT OF RACK-AND-PINION MOUNTING - AR46.20-P-0600-02SM > REPAIR MATERIALS Number Designation Order number BR00.45-Z-1002- 06A Lubricating paste, rubber parts 2.5 kg, DB supply specification 6867.00 A 000 989 01 60 Removing 1. Using a suitable tool, press rubber mounts (2, 3) downwards out of the supports on the on the rack- and-pinion steering (1). Fig 1: Identifying Paddle Shift Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
On vehicles with code (V26) EPS power steering (FFO) the bolt (4) on the power steering motor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2061 · Applies to: 450, 451, 452, 454
can only be removed after the rubber mount (1) has been pressed out. Install 2. Rub rubber mounts (2, 3) from outside with antifriction paste. 3. Using a rubber hammer, hammer rubber mounts (2, 3) into the supports on the rack-and-pinion steering (1) and press into the final installation position using a suitable tool. On vehicles with code (V26) EPS power steering (FFO) the rubber mount (2) on the power steering motor must be inserted together with the bolt (4) of the rack-and-pinion steering (1). TESTING & REPAIR > REMOVE/INSTALL RACK-AND-PINION STEERING - AR46.20-P- 0600MCB > MODEL 451.3/4 with CODE (V26) Power steering, EPS (FFO) Fig 1: Identifying Rubber Mounts Of Rack-And-Pinion Mounting Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2062 · Applies to: 450, 451, 452, 454
3.9.08 "Detach/attach wheels" added in accordance with new repair method Operation step 9, 24
"Remove/install rubber mounts to replace rack-and-pinion steering bolts" added Operation step 16, 18 4.11.08 Wheel alignment check with recording of vehicle level, added Step 37 Removing
Notes on self-locking nuts and bolts
AH00.00-N-0001-01A Evaluating steering rack when repairing accident vehicles
AH46.20-P-9409- 01SM 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 using the vehicle lift and remove Rechargeable drill / screwdriver
Fig 1: Identifying Rack-And-Pinion Steering Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
underfloor paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2063 · Applies to: 450, 451, 452, 454
gotis://G 58.0 01.1 2 Remove front bulkhead The front bulkhead is attached with two nuts.
3 Loosen nut (3) on steering coupling (2) until it can be turned by hand Do not unscrew the nut (3) completely otherwise the bolt (4) may fall out and the steering coupling (2) become separated. The consequence of this is that with the front wheels in the straight ahead position the fanfare horns and airbag clock spring contact may be damaged. Turn the front wheels onto lock until the nut (3) is accessible.
4 Lower vehicle with vehicle lift
5 Place the front wheels in the straight-ahead position and block the steering wheel using the holding device Hold the steering wheel firmly otherwise the fanfare horns and airbag clock spring contact may be damaged.
*129589012100 6 Raise vehicle with vehicle lift
7 Unscrew nut (3) on the steering coupling (2), remove bolt (4) and slide steering coupling (2) upwards off the rack-and- pinion steering (1) Only use the bolt (4) and nut (3) approved for model 451. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. When the nut (3) is loosened, the cam-shaped bolt (4) rotates with it approx. half a revolution. However, the bolt (4) does not have to be counterheld.Check the steering coupling (2) for ease of movement and replace if necessary.
8 Disconnect connector of power steering torque sensor (B23x1)
9 Disconnect power steering connector (M19x1)
TIE ROD¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2067 · Applies to: 450, 451, 452, 454
Number Designation Model 451.3/4 BA46.40-P-1001- 01F Self-locking nut, tie rod to steering knuckle Nm 34 REPAIR MATERIALS Fig 2: Identifying Holding Device (129 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2068 · Applies to: 450, 451, 452, 454
Designation Order number BR00.45-Z-1002- 06A Lubricating paste, rubber parts 2.5 kg, DB supply specification 6867.00 A 000 989 01 60 TESTING & REPAIR > REMOVE/INSTALL RACK-AND-PINION STEERING - AR46.20-P- 0600MCC > MODEL 451.3/4 except CODE (V26) Power steering, EPS (FFO) Fig 1: Identifying Rack-And-Pinion Steering Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2069 · Applies to: 450, 451, 452, 454
Notes on self-locking nuts and bolts
AH00.00-N-0001-01A Evaluating steering rack when repairing accident vehicles
AH46.20-P-9409- 01SM 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 using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver gotis://G_58.0_01.1
2 Remove front bulkhead The front bulkhead is attached with two nuts.
3 Loosen nut (3) on steering coupling (2) until it can be turned by hand Do not unscrew the nut (3) completely otherwise the bolt (4) may fall out and the steering coupling (2) become separated. The consequence of this is that with the front wheels in the straight ahead position the fanfare horns and airbag
Fig 2: Identifying Rack-And-Pinion Steering Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
teering¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2073 · Applies to: 450, 451, 452, 454
01F teering STEERING GEAR Number Designation Model 451.3/4 BA46.20-P-1001- 01G Bolt, rack-and-pinion steering to front axle carrier Stage 1 Nm 70 Stage 2 ∠° - TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001- 01F Self-locking nut, tie rod to steering knuckle Nm 34 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1002- 06A Lubricating paste, rubber parts 2.5 kg, DB supply specification 6867.00 A 000 989 01 60 Fig 3: Identifying Holding Device (129 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2075 · Applies to: 450, 451, 452, 454
30.7.07 Remove front bulkhead, added Step 2
22.8.07 Bolt, steering coupling to rack-and-pinion steering
*BA46.10-P-1001- 01F Fig 1: Identifying Power Steering Electric Motor Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Power Steering Electric Motor Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Wheel alignment check with recording of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2076 · Applies to: 450, 451, 452, 454
4.11.08 Wheel alignment check with recording of vehicle level, added Step 18
Remove/install
Notes on self- locking nuts and bolts
AH00.00-N- 0001-01A 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 using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver gotis://G_58.0_01.1
2 Remove front bulkhead The front bulkhead is attached with two nuts.
3 Loosen nut (3) on steering coupling (2) Do not unscrew the nut (3) completely otherwise the bolt (4) may fall out and the steering coupling (2) become separated. The consequence of this is that with the front wheels in the straight ahead position the fanfare horns and airbag clock spring contact may be damaged. Turn the front wheels until the nut (3) is accessible.
*BA46.10-P- 1001-01F 4 Lower vehicle with vehicle lift
5 Place the front wheels in the straight-ahead position and block the steering wheel using the holding device Fasten the steering wheel otherwise the fanfare horns and airbag clock spring contact can be damaged.
*129589012100 6 Raise vehicle with vehicle lift
7 Unscrew nut (3) on the steering coupling (2), remove bolt (4) and slide steering coupling Replace nut (3) and bolt (4). Only the bolt (4) and nut (3) approved for model 451 may be used. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. When the nut (3) is loosened, the cam-shaped bolt (4) rotates with it approx. half
(2) upwards off¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2077 · Applies to: 450, 451, 452, 454
the rack-and- pinion steering (1) a revolution. However, the bolt (4) does not have to be counterheld. Installation: Check steering coupling (2) for ease of movement, replace if necessary. 8 Disconnect connector of power steering torque sensor (B23x1)
9 Disconnect power steering connector (M19/1)
10 Ground; disconnect interference suppression of power steering pump (W30/2)
11 Support front axle carrier (5) with transmission jack and removal fixture Transmission jack gotis://H_00.10_01.0 *450589026200 12 Remove bolts (6) on front axle carrier (5) Installation: Screw in bolts (6) and remove transmission jack with removal fixture.Slide front axle carrier (5) forwards completely and align centrally in this position, then tighten bolts (6).
*BA33.10-P- 1001-01D 13 Lower the front axle carrier (5) carefully using transmission jack until the power steering motor (M19) is accessible
14 Remove cable ties (10) and place electrical line (11) to one side Observe routing of electrical line (11). Installation: Replace cable ties (10).
15 Remove bolts (12) on power steering motor (M19) Observe installation position of contact lug (13).
*BA46.20-P- 1005-01G
Remove power¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2078 · Applies to: 450, 451, 452, 454
16 Remove power steering motor (M19) from rack- and-pinion steering (1) Ensure that no dirt reaches the power steering motor (M19) and the rack-and-pinion steering (1). Check seal ring (14) for condition and seat. Installation: To facilitate assembly of the power steering motor (M19) grease the seal ring (14) lightly.
Syntheso GLK 1 grease *BR00.45-Z- 1059-06A 17 Install in the reverse order
18 Perform wheel alignment check Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20-P- 0200MCC with recording the vehicle level AR40.20-P- 0200MCE FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491 BA33.10-P-1001- 01D Bolt, front-axle carrier to body Nm 100 STEERING SHAFT Number Designation Model 451.3/4 BA46.10-P-1001- 01F Bolt, steering coupling to rack-and-pinion steering Nm 20 STEERING GEAR Number Designation Model 451.3/4 BA46.20-P-1005- 01G Bolt, electric motor to rack-and-pinion steering Nm 25
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2080 · Applies to: 450, 451, 452, 454
4.11.08 Wheel alignment check with recording of vehicle level, added Step 6
Remove/install
Notes on self-locking nuts and bolts
AH00.00-N- 0001-01A 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
2 Counterhold left or right tie rod (2) and loosen nut (3) Mark installation position of tie rod end (1) on tie rod (2) or count the threads when unscrewing the tie rod end (1).
*BA46.40-P- 1002-01F 3 Unscrew nut (4) and pry tie rod end (1) off steering knuckle (5) using puller and unhook Pry off tie rod end (1) carefully in order to avoid damage to the rubber boot. Installation: Check rubber boot; replace tie rod end (1) if necessary.
450589013300 BA46.40-P- 1001-01F 4 Unscrew tie rod end (1) from the tie rod (2) Counterhold tie rod (2). Installation: Check tie rod end (1) for play, replace if necessary.
5 Install in the reverse order
6 Perform wheel alignment check Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20-P- 0200MCC with recording the vehicle level AR40.20-P- 0200MCE TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001- 01F Self-locking nut, tie rod to steering knuckle Nm 34
Loosen clamp (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2082 · Applies to: 450, 451, 452, 454 · AR: AS46.00-Z-9999ZZ
3 Loosen clamp (2) and click-model clamp (3) on boot (1) and remove model clamp (3). Installation: The shackle on the clamp (2) and on the click-model clamp (3) must point downwards otherwise the coolant hose may be damaged.
450589063700 450589073700 4 Remove boot (1) from the tie rod Installation: Pay attention to correct seat of bellows (1).
5 Install in the reverse order
SAFETY PRECAUTIONS > SAFETY INFORMATION: STEERING - AS46.00-Z-9999ZZ > MODEL all Danger of injury to eyes caused by steering oil emerging at high pressure. Danger of poisoning caused by swallowing steering oil MODEL 372, 397, 405, 436, 437, 461, 463, 613,667,668,670,671,684... AS46.00-Z-0001- 01A RETROFITTING & CONVERSION > INSTALL STEERING WHEEL WITH PADDLE SHIFT - Fig 2: Identifying Pliers (450 589 06 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Pliers (450 589 07 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2085 · Applies to: 450, 451, 452, 454
13.12.06 Bolt, steering coupling to rack-and-pinion steering Model 451.3/4 22.8.07 Bolt, steering coupling to rack-and-pinion steering Model 451.3/4 STEERING SHAFT Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA46.10-P-1001- 01F Bolt, steering coupling to rack-and- pinion steering Nm 27 20 27 BA46.10-P-1002- 01F Bolt to upper bearing shell Nm 25 25 25 BA46.10-P-1003- 01F Bolt to lower bearing shell Nm 25 25 25 TORQUE SPECIFICATIONS > STEERING WHEEL - BA46.10-P-1000-02D > Model 450, 451, 452 MODIFICATION NOTES 12.12.06 Bolts, steering wheel to steering shaft Model 451.3/4 STEERING WHEEL Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA46.10-P-1001- 02D Bolts, steering wheel to steering shaft Nm 30 27 30 TORQUE SPECIFICATIONS > STEERING GEAR - BA46.20-P-1000-01G > Model 450, 451, 452 MODIFICATION NOTES 11.2.08 Value modified: Bolt, rack-and-pinion steering to front axle carrier, Stage 1 Model 451.3/4
Value modified: Bolt, rack-and-pinion steering to front axle carrier, Stage 2 Model 451.3/4 STEERING GEAR Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA46.20-P- 1001-01G Bolt, rack-and-pinion steering to front axle carrier Stage 1 Nm 46 70 46
Stage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2086 · Applies to: 450, 451, 452, 454
2 ∠° - - - BA46.20-P- 1002-01G Bolt, steering damper to rack-and- pinion steering Nm 15 - - BA46.20-P- 1003-01G Bolt, steering damper to driver Nm 15 - - BA46.20-P- 1004-01G Union nut to rack-and-pinion steering Nm 45 - - BA46.20-P- 1005-01G Bolt, electric motor to rack-and-pinion steering Nm 16 25 16 TORQUE SPECIFICATIONS > TIE ROD - BA46.40-P-1000-01F > Model 450, 451, 452 TIE ROD Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA46.40-P-1001- 01F Self-locking nut, tie rod to steering knuckle Nm 40 34 40 BA46.40-P-1002- 01F Lock nut to tie rod Nm 50 50 50 BASIC KNOWLEDGE > ELECTRIC STEERING, LOCATION OF COMPONENTS - GF46.35-P- 0002-01MCU > Fig 1: Locating Electric Steering Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
S112s1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2093 · Applies to: 450, 451, 452, 454
Steering wheel gear shifter PLUS 11A S112s1 Steering wheel gear shifter PLUS 38A S112s2 Steering wheel gear shifter MINUS 8A S112s2 Steering wheel gear shifter MINUS 34A S112s3 Fanfare horn system button 4A S112s3 Fanfare horn system button 22A S112s4 Left cruise control switch 27A S112s5 Right cruise control switch 30A U1012 Valid up to 30/08/2010 1A U1013 Valid as of 31/08/2010 19A U1014 Valid for steering wheel shifting 7A U1014 Valid for steering wheel shifting 33A U4 Valid for cruise control 25A U4 Valid for cruise control 27H W110 Ground on steering wheel 3D W110 Ground on steering wheel 21D W110 Ground on steering wheel 32B W9 Ground (left front, at lamp unit) 4J W9 Ground (left front, at lamp unit) 21J Z81 Circuit 58d connector sleeve 34H
Fig 1: Steering Wheel - Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2094 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Steering Wheel - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2095 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM OF ELECTRIC STEERING - PE46.35-P-2000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2096 · Applies to: 450, 451, 452, 454
97MCU > Code: Designation: Position: A1 Instrument cluster 7L B23 Power steering torque sensor 10L B23x1 Power steering torque sensor connector
Fig 3: Steering Wheel - Wiring Diagram (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Power steering engine¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2097 · Applies to: 450, 451, 452, 454
M19 Power steering engine 13L M19x1 Power steering connector
N10/10 SAM control unit 3L N10/10f18 Fuse 18 4L N10/10f35 Fuse 35 2L N68 Steering assist control module 11A N68 Steering assist control module 4A W30/2 Ground; power steering pump noise suppression 14C W43 Ground (outside left fire wall) 3G W43 Ground (outside left fire wall) 9C Z20/29 Shield end insulated from outer shield 9H Z20/73 Screening connector sleeve 13H Z3/17 Circuit 15 (fused) connector sleeve 4H Z37/4 Power steering CAN bus connector sleeve (low) 6H Z37/5 Power steering CAN bus connector sleeve (high) 7H Z83/11 Screening connector sleeve 9E
WIRING DIAGRAMS > WIRING DIAGRAM OF ELECTRIC STEERING - PE46.35-P-2000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2100 · Applies to: 450, 451, 452, 454
99MCU > Code: Designation: Position: A1 Instrument cluster 7 L B23 Power steering torque sensor 10 L B23x1 Power steering torque sensor connector 9 J M19 Power steering engine 13 L M19x1 Power steering connector 12 J N10/10 SAM control unit 3 L N10/10f18 Fuse 18 4 L N10/10f35 Fuse 35 2 L N68 Steering assist control module 4 A N68 Steering assist control module 11 A W30/2 Ground; power steering pump noise suppression 13 C W43 Ground (outside left fire wall) 3 H W43 Ground (outside left fire wall) 9 C Z20/29 Shield end insulated from outer shield 8 H Z20/73 Screening connector sleeve 13 H Z3/17 Circuit 15 (fused) connector sleeve 4 H Z37/4 Power steering CAN bus connector sleeve (low) 6 H Z37/5 Power steering CAN bus connector sleeve (high) 7 H Z83/11 Screening connector sleeve 8 E
SPECIAL TOOLS > 126 589 00 10 00 SCREWDRIVER BIT - WS46.00-P-0033B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2102 · Applies to: 450, 451, 452, 454 · AR: WS46.00-Z-9999CZ
FG 46/91/14/32/ Set B MODEL 107, 123, 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 172 /, 197, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 245, 251, 414, 451, 461, 463 Further use FG 91/Set B WS91.00-N-3000B Use: Screwdriver bit T30 (TORX system) 1/4" hexagon, 70 mm long.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: STEERING - WS46.00-Z-9999CZ > MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P- 0007B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P- 0006Z 126 589 00 10 00 Screwdriver bit FG 46/91/14/32/ Set B WS46.00-P- 0033B 220 589 04 99 00 New passenger car wiring harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P- 0006B 452 589 00 23 00 Steering column catch FG 46/Set B WS46.00-P- 0084B 454 589 00 33 00 Puller FG 46/Set B WS46.00-P- 0087B Fig 1: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
tensioning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2106 · Applies to: 450, 451, 452, 454
retractor units 01A 1 Set steering and turn signal switch to center position If the steering and turn signal switch are not in the center position for removal/ installation of the steering wheel (2), the fanfare horns and airbag clock spring contact (A45) and the turn signal canceling cam may be damaged. Calibration of the steering angle sensor in the fanfare horns and airbag clock spring contact (A45) remains impossible.
2 Disconnect battery ground line
AR54.10- P- 0003MCC 3 Remove lower steering column trim (1)
AR68.30- P- 2000MCC 4 Detach clock spring contact and airbag connector (A45x1)
5 Undo bolt (3) from below on the steering wheel (2) The steering wheel (2) may only be rotated using the tightened bolt (3), to avoid damaging the fanfare horns and airbag clock spring contact (A45). The bolt (3) remains on the steering wheel (2).
*BA46.10- P-1001- 02D 6 Remove steering wheel (2) The steering wheel (2) may only be rotated using the tightened bolt (3), to avoid damaging the fanfare horns and airbag clock spring contact (A45). When removing the steering wheel (2) from the steering column, the fanfare horns and airbag clock spring contact (A45) is blocked against any inadvertent turning. Installation: Mount steering wheel (2) so that the locking pins (arrows A) line up with the fixtures (arrows B) of the fanfare horns and airbag clock spring contact (A45). Ensure that the front wheels are in the straight-ahead position before installing the steering wheel (2).
7 Remove clock spring contact Only when replacing the steering wheel (2).
- not for USA AR46.10- P- 0200MCC
- for USA only AR46.10- P- 0200MCU 8 Install in the
reverse order¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2107 · Applies to: 450, 451, 452, 454
STEERING WHEEL Number Designation Model 451.3/4 BA46.10-P-1001-02D Bolts, steering wheel to steering shaft Nm 27 TESTING & REPAIR > REMOVE/INSTALL STEERING WHEEL SPOKE COVERS - AR46.10- P-0105MCC > MODEL 451.3 /4 Shown on the steering wheel with code (I75) Leather sport steering wheel with steering wheel rocker switch system Remove/install
1 Remove steering wheel (2)
AR46.10- P- 0100MCC 2 Remove bolts (1) For vehicles without code (I75) Leather sport steering wheel with steering wheel rocker switch system the bolts (1) are screwed on immediately at the rear covering (3).
Remove the steering Fig 1: Identifying Steering Wheel Spoke Covers Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2109 · Applies to: 450, 451, 452, 454
1 Remove airbag unit from steering wheel (1)
2 Detach electrical connector (6) at fanfare horns and airbag clock spring contact The electrical connector (arrow C) of the driver airbag unit must not be disconnected, otherwise the fanfare horns and airbag clock spring contact has to be renewed. 3 Release the catch on the plug (5) and detach the plug (5) and the ground line (4) from the steering wheel (1) After disconnecting the plug (5) from the steering wheel (1), the wiring harness (3) gas to be replaced.For vehicles as of 31.8.10, the connector (5) must not be detached from the steering wheel (1). The new steering wheel (1) is delivered with the corresponding wiring harness and a connector (5) already fitted. 4 Route plug for steering wheel rocker switch system (2) through the opening on the steering wheel (1) For vehicles with code (I75) Leather sport steering wheel with steering wheel rocker switch system 5 Release wiring harness (3) from holders (arrows A) on steering wheel (1) For vehicles with code (I75) Leather sport steering wheel with steering wheel rocker switch system 6 Release and remove wiring Observe installation position Fig 1: Identifying Steering Wheel Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
harne¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2110 · Applies to: 450, 451, 452, 454
(3) from holder (arrows B) on steering wheel (1) of wiring harne (3) Installation: Renew wiring harness (3). 7 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL CLOCK SPRING CONTACT - AR46.10-P- 0200MCU > MODEL 451.3 /4 Shown on the steering wheel with code (I75) Leather sport steering wheel with steering wheel rocker switch system Remove/install
1 Remove airbag unit from steering wheel (1)
AR91.60- P- 0660MCU 2 Detach electrical connector (3) at fanfare horns and airbag clock spring contact (A45) The electrical connector (2) of the driver airbag unit must not be detached at the fanfare horns and airbag clock spring contact (A45) as otherwise the fanfare horns and airbag clock spring contact (A45) will have to be replaced.The wiring harness with the electrical connector (3) must not be detached from the steering wheel (1), as otherwise the steering wheel (1) will have to be replaced.
3 Release latches (arrows) of fanfare horns and airbag clock spring contact (A45) by applying suitable screwdriver to steering wheel (1)
Remove fanfare Fig 1: Identifying Clock Spring Contact Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2112 · Applies to: 450, 451, 452, 454
22.8.07 Bolt, steering coupling to rack- and-pinion steering *BA46.10-P-1001-01F
Remove/install
Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A 1 Remove bottom paneling for instrument panel on driver side Installation: Before installing the steering wheel ensure that the rack-and-pinion steering (1) is in the center position (front wheels straightahead). AR68.10- P- 1501MCU 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 2 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
3 Loosen nut (3) on steering coupling (2) Turn the front wheels until the nut (3) is accessible.
4 Move the rack- and-pinion steering (1) into the center position (front wheels
Fig 3: Identifying Jacket Tube Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
traightahead)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2113 · Applies to: 450, 451, 452, 454
5 Unscrew nut (3) on the steering coupling (2), remove bolt (4) and slide steering coupling (2) upwards off the rack-and- pinion steering (1) Replace nut (3) and bolt (4).Only the bolt (4) and nut (3) approved for model 451 may be used. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. When the nut (3) is released, the cam-shaped bolt (4) rotates approx. half a revolution at the same time. However, the bolt (4) does not have to be counterheld. Check the steering coupling (2) for ease of movement and replace if necessary. Installation: Turn the jacket tube (8) relative to the rack-and-pinion steering (1) until the steering coupling (2) can be assembled.
*BA46.10- P-1001- 01F 6 Lower vehicle with lifting platform
7 Remove bolts (5) on SAM control unit (N10/10)
8 Loosen locking device (arrow A) in the rear area of the SAM control unit (N10/10) and place SAM control unit (N10/10) to one side with electrical lines connected
9 Unscrew bolts (9) and remove top bearing cap (7) Replace bolts (9). Installation: The top bearing (10) must close flush with the cutouts (arrows C) of the crossmember under the dashboard (14).The bolts (9) are self-tapping, therefore a thread must not be precut.In each case tighten bolts (9) in steps of one revolution.
*BA46.10- P-1002- 01F 10 Unscrew bolts (13) and remove bottom bearing cap (6) Install new bolts (13). Installation: The bottom bearing (11) must be flush with the bottom area (arrow B) of the crossmember below the dashboard (14) otherwise the specified installation position of the jacket tube (8) will not be reached. The bolts (13) are self-tapping; therefore a thread must not be precut.In each case tighten bolts (13) in steps of one revolution.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2115 · Applies to: 450, 451, 452, 454
1 Remove steering wheel (1)
AR46.10- P- 0100MCC 2 Remove bolts (2)
3 Remove the steering wheel gear shifter PLUS (S112s1) or the steering wheel gear shifter MINUS (S112s2) until the electrical connector (3) is accessible
4 Detach electrical connector (3) and remove steering wheel gear shifter PLUS (S112s1) or the steering wheel gear shifter MINUS (S112s2)
5 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL RACK-AND-PINION STEERING - AR46.20-P- 0600MCB > MODEL 451.3 /4 with CODE (V26) Power steering, EPS (FFO) MODIFICATION NOTES 3.9.08 "Detach/attach wheels" added in accordance with new repair method Operation step 9, 24 Fig 1: Identifying Rack-And-Pinion Steering Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
"Remove/install rubber mounts¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2116 · Applies to: 450, 451, 452, 454
to replace rack-and-pinion steering bolts" added Operation step 16, 18 4.11.08 Wheel alignment check with recording of vehicle level, added Step 37 Removing
Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A Evaluating steering rack when repairing accident vehicles
AH46.20- P-9409- 01SM 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 using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
2 Remove front bulkhead The front bulkhead is attached with two nuts.
3 Loosen nut (3) on steering coupling (2) until it can be turned by hand Do not unscrew the nut (3) completely otherwise the bolt (4) may fall out and the steering coupling (2) become separated. The consequence of this is that with the front wheels in the straight ahead position the fanfare horns and airbag clock spring contact may be damaged. Turn the front wheels onto lock until the nut (3) is accessible.
4 Lower vehicle with vehicle lift
5 Place the front wheels in the straight-ahead position and block the teering wheel using the holding device Hold the steering wheel firmly otherwise the fanfare horns and airbag clock spring contact may be damaged.
Fig 2 6 Raise vehicle with vehicle lift
Unscrew nut (3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2117 · Applies to: 450, 451, 452, 454
7 Unscrew nut (3) on the steering coupling (2), remove bolt (4) and slide steering coupling (2) upwards off the rack-and-pinion steering (1) Only use the bolt (4) and nut (3) approved for model 451. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. When the nut (3) is loosened, the cam- haped bolt (4) rotate with it appro half a revolution However, the bolt (4) does not have to be counterheld.Check the steering coupling (2) for ease of movement and replace if necessary.
8 Disconnect connector of power steering torque sensor (B23x1)
9 Disconnect power steering connector (M19x1)
10 Ground; disconnect interference suppression of power steering pump (W30/2)
11 Remove front wheels * for USA only AR40.10- P- 1100MCU except USA AR40.10- P- 1100MCC 12 Unscrew nut (6) on the left and right tie rod end (5) and pry off left and right tie rod end (5) using puller and unhook Press out tie rod ends (5) carefully in order to avoid damage to the rubber boots.
Fig 3 13 Support front axle carrier (7) using transmission jack and removal fixture Transmission jack Fig 4 14 Remove bolts (8) on front axle carrier (7)
Lower the front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2118 · Applies to: 450, 451, 452, 454
15 Lower the front axle carrier (7) carefully until the bolts (9) are accessible Do not pull the front axle carrier (7) downwards otherwise the axle components may be damaged.
16 Remove bolts (9) The left bolt (9) at the power steering motor can only be removed together with the rubber mount of the rack- and-pinion steering (1).
17 Remove rack- and-pinion steering (1)
18 Remove rubber mount for attaching rack- and-pinion steering (1) and remove bolts (9)
AR46.20- P-0600- 02SM Checking
19 Check the rubber mount for attaching the rack-and-pinion steering (1) for damage and replace if necessary
Install
20 Insert bolts (9) and install rubber mount for attaching rack-and-pinion steering (1) Replace bolts (9). AR46.20- P-0600- 02SM Lubricant paste *BR00.45- Z-1002- 06A 21 Mount rack-and- pinion steering (1) on the front axle carrier (7)
22 Lift the front axle carrier (7) using transmission jack and removal fixture up to the bolting-on points Transmission jack Fig 4 23 Tighten bolts (9) *BA46.20- P-1001- 01G
Insert and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2119 · Applies to: 450, 451, 452, 454
24 Insert and tighten bolts (8) Screw in bolts (8) and remove transmission jack with removal fixture. Slide front axle carrier (7) forwards completely and align centrally in this position, then tighten bolts (8).
*BA33.10- P-1001- 01D 25 Engage left and right tie rod end (5) in the steering knuckle and tighten nuts (6) Check the rubber boots; replace the tie rod end (5) if necessary. Replace self-locking nut (6).
*BA46.40- P-1001- 01F 26 Mount front wheels * for USA only AR40.10- P- 1100MCU except USA AR40.10- P- 1100MCC 27 Contact connector of power steering torque sensor (B23x1)
28 Contact power steering connector (M19x1)
29 Ground; contact interference suppressor of power steering pump (W30/2)
30 Mount steering coupling (2) on the rack-and- pinion steering (1), insert bolt (4) and screw on nut (3) Replace nut (3) and bolt (4). Only use the bolt (4) and nut (3) approved for model 451. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. Ensure that the front wheels are in the straight-ahead position.The nut (3) of steering coupling (2) will be tightened later.
31 Lower vehicle with vehicle lift
32 Remove retainer from steering wheel Fig 2 33 Raise vehicle with vehicle lift
Tighten nut (3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2120 · Applies to: 450, 451, 452, 454
34 Tighten nut (3) on steering coupling (2) Turn the front wheels onto lock until the nut (3) is accessible.
*BA46.10- P-1001- 01F 35 Install front bulkhead
36 Install underfloor paneling Rechargeable drill / screwdriver
37 Perform wheel alignment check When replacing the rack-and-pinion steering (1). Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20- P- 0200MCC with recording the vehicle level AR40.20- P- 0200MCE FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491 BA33.10-P-1001-01D Bolt, front-axle carrier to body Nm 100 STEERING SHAFT Number Designation Model 451.3/4 BA46.10-P-1001-01F Bolt, steering coupling to rack-and-pinion steering Nm 20 STEERING GEAR Number Designation Model 451.3/4 BA46.20-P-1001- 01G Bolt, rack-and-pinion steering to front axle carrier Stage 1 Nm 70 Stage 2 ∠° - TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001-01F Self-locking nut, tie rod to steering knuckle Nm 34
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2121 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1002- 06A Lubricating paste, rubber parts 2.5 kg, DB supply specification 6867.00 A 000 989 01 60 TESTING & REPAIR > REMOVE/INSTALL RACK-AND-PINION STEERING - AR46.20-P- Fig 2: Identifying Holding Device (129 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
0600MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2122 · Applies to: 450, 451, 452, 454
MODEL 451.3 /4 except CODE (V26) Power steering, EPS (FFO) Fig 1: Identifying Rack-And-Pinion Steering Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2123 · Applies to: 450, 451, 452, 454
Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A Evaluating steering rack when repairing accident vehicles
AH46.20- P-9409- 01SM 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 using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
2 Remove front bulkhead The front bulkhead is attached with two nuts.
Loosen nut (3) Do not unscrew the nut (3) completely otherwise the bolt (4) may fall out and the steering coupling (2) become Fig 2: Identifying Rack-And-Pinion Steering Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
on teering¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2124 · Applies to: 450, 451, 452, 454
3 on teering coupling (2) until it can be turned by hand eparated The con equence of thi i that with the front wheels in the straight ahead position the fanfare horns and airbag clock spring contact may be damaged. Turn the front wheels onto lock until the nut (3) is accessible.
4 Lower vehicle with vehicle lift
5 Place the front wheels in the straight-ahead position and block the steering wheel using the holding device Hold the steering wheel firmly otherwise the fanfare horns and airbag clock spring contact may be damaged.
Holding device Figure 6 Raise vehicle with vehicle lift
7 Unscrew nut (3) on the steering coupling (2), remove bolt (4) and slide steering coupling (2) upwards off the rack-and-pinion steering (1) Only use the bolt (4) and nut (3) approved for model 451. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. When the nut (3) is loosened, the cam- shaped bolt (4) rotates with it approx. half a revolution. However, the bolt (4) does not have to be counterheld.Check the steering coupling (2) for ease of movement and replace if necessary.
8 Remove front wheels * for USA only AR40.10- P- 1100MCU * not for USA AR40.10- P- 1100MCC 9 Unscrew nut (5) on left and right tie rod end (6), pry off left and right and tie rod end (6) with puller and unhook Press out tie rod ends (6) carefully in order to avoid damage to the rubber boots.
Puller Figure 10 Loosen refrigerant lines (14) from bracket (13) in the area of the battery recess and unscrew bracket (13) On vehicles with code (I01) Air conditioning Plus
Un crew nut¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2125 · Applies to: 450, 451, 452, 454
11 Un crew nut (7) and remove retaining clamps (8) from stabilizer bar (10) The retaining clamps (8) are 2-piece.
12 Pull stabilizer bar (10) forwards and fold away downwards
13 Remove bolts (11)
14 Turn rack-and- pinion steering (1) forwards and guide out over the left wheel well
Checking
15 Check rubber mounts for attaching the rack-and-pinion steering (1) for damage Check rubber mounts on the rack-and-pinion steering (1) and replace if necessary.See: ↓
Remove/install rubber mount of rack-and-pinion mounting AR46.20- P-0600- 02SM Lubricant paste *BR00.45- Z-1002- 06A Install
16 Mount the rack- and-pinion teering (1) over the left wheel well on the front axle carrier (12)
17 Tighten bolts (11) *BA46.20- P-1001- 01G 18 Fold stabilizer bar (10) upwards and position
19 Insert retaining clamps (8) at a right angle to the stabilizer bar Check rubber mount (9) and replace if necessary. The opening of the rubber mounts (9) must point in the direction of travel.
(10) and tighten¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2126 · Applies to: 450, 451, 452, 454
nuts (7) *BA32 20 P-1003- 02I 20 Position bracket (13) of refrigerant lines (14) on the underbody, tighten and clip refrigerant lines (14) into bracket (13) On vehicles with code (I01) Air conditioning Plus
21 Engage left and right tie rod end (6) in the steering knuckle and tighten nuts (5) Replace self-locking nut (5). Check the rubber boots; replace the tie rod end (6) if necessary.
*BA46.40- P-1001- 01F 22 Mount front wheels * for USA only AR40.10- P- 1100MCU * not for USA AR40.10- P- 1100MCC 23 Mount steering coupling (2) on the rack-and- pinion steering (1), insert bolt (4) and crew on nut (3) Replace nut (3) and bolt (4). Only use the bolt (4) and nut (3) approved for model 451. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. Ensure that the front wheel are in the traight ahead po ition The nut (3) of steering coupling (2) will be tightened later.
24 Lower vehicle with vehicle lift
25 Remove retainer from steering wheel Holding device Figure 26 Raise vehicle with vehicle lift
27 Tighten nut (3) on steering coupling (2) Turn the front wheels onto lock until the nut (3) is accessible.
*BA46.10- P-1001- 01F 28 Install front bulkhead
29 Install underfloor Rechargeable drill / screwdriver
paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2127 · Applies to: 450, 451, 452, 454
30 Perform wheel alignment check When replacing the rack-and-pinion steering (1). Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20- P- 0200MCC with recording the vehicle level AR40.20- P- 0200MCE FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1003-02I Nut, stabilizer bar to retaining clamp Nm 95 STEERING SHAFT Number Designation Model 451.3/4 BA46.10-P-1001-01F Bolt, steering coupling to rack-and-pinion steering Nm 20 STEERING GEAR Number Designation Model 451.3/4 BA46.20-P-1001- 01G Bolt, rack-and-pinion steering to front axle carrier Stage 1 Nm 70 Stage 2 ∠° - TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001-01F Self-locking nut, tie rod to steering knuckle Nm 34
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2128 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1002- 06A Lubricating paste, rubber parts 2.5 kg, DB supply specification 6867.00 A 000 989 01 60 TESTING & REPAIR > REMOVE/INSTALL POWER STEERING CONTROL UNIT - AR46.35- P-1000MCU > MODEL 451.3 /4 with CODE (V26) Power steering, EPS (FFO) Fig 3: Identifying Holding Device (129 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2130 · Applies to: 450, 451, 452, 454
30.7.07 Remove front bulkhead, added Step 2
22.8.07 Bolt, steering coupling to rack-and-pinion steering
*BA46.10-P-1001- 01F Fig 1: Identifying Power Steering Electric Motor Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Power Steering Electric Motor Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Wheel alignment check with recording of vehicle level,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2131 · Applies to: 450, 451, 452, 454
4.11.08 Wheel alignment check with recording of vehicle level, added Step 18
Remove/install
Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A 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 using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
2 Remove front bulkhead The front bulkhead is attached with two nuts.
3 Loosen nut (3) on steering coupling (2) Do not unscrew the nut (3) completely otherwise the bolt (4) may fall out and the steering coupling (2) become separated. The consequence of this is that with the front wheels in the straight ahead position the fanfare horns and airbag clock spring contact may be damaged. Turn the front wheels until the nut (3) is accessible.
*BA46.10- P-1001- 01F 4 Lower vehicle with vehicle lift
5 Place the front wheels in the straight-ahead position and block the steering wheel using the holding device Fasten the steering wheel otherwise the fanfare horns and airbag clock spring contact can be damaged.
Figure 6 Raise vehicle with vehicle lift
7 Unscrew nut (3) on the steering coupling (2), remove bolt (4) and slide steering coupling Replace nut (3) and bolt (4). Only the bolt (4) and nut (3) approved for model 451 may be used. Bolts and nuts of other models with the same dimensions have different properties due to other surface coatings and may impair the strength of the bolted connection. When the nut (3) is loosened, the cam-shaped bolt (4) rotates with it
(2) upwards off¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2132 · Applies to: 450, 451, 452, 454
the rack-and- pinion steering (1) approx. half a revolution. However, the bolt (4) does not have to be counterheld. Installation: Check steering coupling (2) for ease of movement, replace if necessary. 8 Disconnect connector of power steering torque sensor (B23x1)
9 Disconnect power steering connector (M19/1)
10 Ground; disconnect interference suppression of power steering pump (W30/2)
11 Support front axle carrier (5) with transmission jack and removal fixture Transmission jack Figure 12 Remove bolts (6) on front axle carrier (5) Installation: Screw in bolts (6) and remove transmission jack with removal fixture.Slide front axle carrier (5) forwards completely and align centrally in this position, then tighten bolts (6).
*BA33.10- P-1001- 01D 13 Lower the front axle carrier (5) carefully using transmission jack until the power steering motor (M19) is accessible
14 Remove cable ties (10) and place electrical line (11) to one side Observe routing of electrical line (11). Installation: Replace cable ties (10).
15 Remove bolts (12) on power steering motor (M19) Observe installation position of contact lug (13).
*BA46.20- P-1005- 01G
Remove power¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2133 · Applies to: 450, 451, 452, 454
16 Remove power steering motor (M19) from rack- and-pinion steering (1) Ensure that no dirt reaches the power steering motor (M19) and the rack-and-pinion steering (1). Check seal ring (14) for condition and seat. Installation: To facilitate assembly of the power steering motor (M19) grease the seal ring (14) lightly.
Syntheso GLK 1 grease *BR00.45- Z-1059- 06A 17 Install in the reverse order
18 Perform wheel alignment check Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20- P- 0200MCC with recording the vehicle level AR40.20- P- 0200MCE FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491 BA33.10-P-1001-01D Bolt, front-axle carrier to body Nm 100 STEERING SHAFT Number Designation Model 451.3/4 BA46.10-P-1001-01F Bolt, steering coupling to rack-and-pinion steering Nm 20 STEERING GEAR Number Designation Model 451.3/4 BA46.20-P-1005-01G Bolt, electric motor to rack-and-pinion steering Nm 25 Fig 3: Identifying Holding Device (129 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
off of the lifting platform.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2135 · Applies to: 450, 451, 452, 454
manufacturer. 1 Raise vehicle with vehicle lift
2 Counterhold left or right tie rod (2) and loosen nut (3) Mark installation position of tie rod end (1) on tie rod (2) or count the threads when unscrewing the tie rod end (1).
*BA46.40- P-1002- 01F 3 Unscrew nut (4) and pry tie rod end (1) off steering knuckle (5) using puller and unhook Pry off tie rod end (1) carefully in order to avoid damage to the rubber boot. Installation: Check rubber boot; replace tie rod end (1) if necessary.
Figure *BA46.40- P-1001- 01F 4 Unscrew tie rod end (1) from the tie rod (2) Counterhold tie rod (2). Installation: Check tie rod end (1) for play, replace if necessary.
5 Install in the reverse order
6 Perform wheel alignment check Depending on the workshop equipment select between the measurement variant with recording the vehicle level or without recording the vehicle level.
without recording the vehicle level AR40.20- P- 0200MCC with recording the vehicle level AR40.20- P- 0200MCE TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001-01F Self-locking nut, tie rod to steering knuckle Nm 34 BA46.40-P-1002-01F Lock nut to tie rod Nm 50
Loosen clamp (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2137 · Applies to: 450, 451, 452, 454 · AR: AS46.00-Z-9999ZZ, AZ46.10-P-1005MCC
3 Loosen clamp (2) and click-model clamp (3) on boot (1) and remove (2) and on the click-model clamp (3) must point downwards otherwise the coolant hose may be damaged.
Fig 2 Fig 3 4 Remove boot (1) from the tie rod Installation: Pay attention to correct seat of bellows (1).
5 Install in the reverse order
SAFETY PRECAUTIONS > SAFETY INFORMATION: STEERING - AS46.00-Z-9999ZZ > MODEL all Danger of injury to eyes caused by steering oil emerging at high pressure. Danger of poisoning caused by swallowing steering oil MODEL 372, 397, 405, 436, 437, 461, 463, 613, 667, 668, 670, 671, 684... AS46.00- Z-0001- 01A RETROFITTING & CONVERSION > INSTALL STEERING WHEEL WITH PADDLE SHIFT - AZ46.10-P-1005MCC > Fig 2: Identifying Pliers (450 589 06 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Pliers (450 589 07 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2138 · Applies to: 450, 451, 452, 454
Remove
1 Disconnect battery ground line
AR54.10- P- 0003MCC 2 Remove steering column cover
AR68.30- P- 2000MCC 3 Disconnect clock spring contact and airbag connector
Check
4 Check whether lines to pin 8 and 9 are present The lines to pin 8 and 9 are marked with the letters "SAL [steering wheel gearshift]".Refer to: ↓
Location and assignment of line and plug connectors, cockpit
-
not for USA GF00.19- P-1000- 03MCC
-
for USA only If lines to pin 8 and 9 are present, the steering wheel with shift paddles can be fitted directly.If the lines to pin 8 and 9 are not present, then they should be routed corresponding to the wiring diagram from the clock spring contact and airbag connector to the instrument cluster.Refer to: ↓ GF00.19- P-1000- 03MCU Wiring diagram large instrument (instrument cluster)
-
not for USAModel 451.### ## up to 013644 PE54.30- P- 2001MCC
-
not for USAModel 451.### /###(except 451.334/380/480) ## as of 013645 PE54.30- P- 2001MCD
-
not for USAModel 451.334/380/480 PE54.30- P- 2001MCE
-
for USA only PE54.30- P- 2001MCU Remove
AR46.10-
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2139 · Applies to: 450, 451, 452, 454
5 Remove steering wheel
P- 0100MCC Install
6 Install steering wheel with steering wheel rocker switch system
AR46.10- P- 0100MCC 7 Activate steering wheel rocker switch system using STAR DIAGNOSIS The software can only be programmed after enable by a transaction number.The order form for enable is available from the Market Performance Center.To activate the steering wheel rocker switch system follow the instructions in STAR DIAGNOSIS.
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC 8 Conduct function test of steering wheel rocker switch system
9 Add special equipment to the vehicle data card and to the online vehicle data card Code (I75) Leather sport steering wheel with steering wheel rocker switch system to be added.
TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: STEERING - BA46.00-Z- 9999CZ > MODEL all Steering gear MODEL 454.0 BA46.20-P-1000-01H Steering gear MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA46.20-P-1000-01G Steering shaft MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA46.10-P-1000-01F Steering wheel MODEL 450.3 /4 BA46.10-P-1000-02E Steering wheel MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA46.10-P-1000-02D Steering wheel, jacket tube, steering shaft MODEL 454.0 BA46.10-P-1000-05A
Tie rod¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2140 · Applies to: 450, 451, 452, 454
MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA46.40-P-1000-01F Tie rod MODEL 454.0 BA46.40-P-1000-01I TORQUE SPECIFICATIONS > STEERING SHAFT - BA46.10-P-1000-01F > Model 450, 451, 452 MODIFICATION NOTES 13.12.06 Bolt, steering coupling to rack- and-pinion steering Model 451.3/4 22.8.07 Bolt, steering coupling to rack- and-pinion steering Model 451.3/4 STEERING SHAFT Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA46.10-P- 1001-01F Bolt, steering coupling to rack-and- pinion steering Nm 27 20 27 BA46.10-P- 1002-01F Bolt to upper bearing shell Nm 25 25 25 BA46.10-P- 1003-01F Bolt to lower bearing shell Nm 25 25 25 TORQUE SPECIFICATIONS > STEERING WHEEL - BA46.10-P-1000-02D > Model 450, 451, 452 MODIFICATION NOTES 12.12.06 Bolts, steering wheel to steering shaft Model 451.3/4 STEERING WHEEL Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA46.10-P-1001- 02D Bolts, steering wheel to steering shaft Nm 30 27 30 TORQUE SPECIFICATIONS > STEERING GEAR - BA46.20-P-1000-01G > Model 450, 451, 452 MODIFICATION NOTES 11.2.08 Value modified: Bolt, rack-and- pinion steering to front axle carrier, Stage 1 Model 451.3/4
Value modified: Bolt, rack-and-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2141 · Applies to: 450, 451, 452, 454
pinion steering to front axle carrier, Stage 2 Model 451.3/4 STEERING GEAR Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA46.20-P- 1001-01G Bolt, rack-and-pinion steering to front axle carrier Stage 1 Nm 46 70 46 Stage 2 ∠° - - - BA46.20-P- 1002-01G Bolt, steering damper to rack-and-pinion steering Nm 15 - - BA46.20-P- 1003-01G Bolt, steering damper to driver Nm 15 - - BA46.20-P- 1004-01G Union nut to rack-and-pinion steering Nm 45 - - BA46.20-P- 1005-01G Bolt, electric motor to rack-and-pinion steering Nm 16 25 16 TORQUE SPECIFICATIONS > TIE ROD - BA46.40-P-1000-01F > Model 450, 451, 452 TIE ROD Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA46.40-P- 1001-01F Self-locking nut, tie rod to steering knuckle Nm 40 34 40 BA46.40-P- 1002-01F Lock nut to tie rod Nm 50 50 50 BASIC KNOWLEDGE > ELECTRIC STEERING, LOCATION OF COMPONENTS - GF46.35-P- 0002-01MCU >
General¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2143 · Applies to: 450, 451, 452, 454
The electric steering is based on a conventional rack and pinion steering gear which is assisted by the power steering motor. The steering power assistance takes place steplessly and speed-dependent. Functions Power steering assistance Steering reset assistance "active center feeling" function Function requirements Circuit 15 On Engine speed > 500 rpm No overvoltage or undervoltage The steering assist control unit requires the following information to calculate the steering power assistance: Steering torque from torque sensor Vehicle speed via CAN from ESP control unit Steering angle and steering speed via CAN from steering angle sensor Engine speed via CAN from motor electronics control unit Steering power assistance By turning the steering wheel a torque on the control rod is produced by which is recorded by the torque sensor and passed on to the power steering control unit. By means of the steering torque determined, the steering angle and vehicle speed the assistance torque is established by the steering assist control unit and the power steering motor actuated accordingly. This assists the driver's steering torque at the drive pinion of the rack-and-pinion steering via a worm gear. The direction of rotation of the power steering motor depends on the direction of motion of the steering wheel. The steering power assistance is at a maximum at low speeds and when the vehicle is stationary and decreases as the vehicle speed increases. Once the engine is switched off and the vehicle stops the steering power assistance is deactivated in steps after approx. 3 s. Steering reset assistance The steering reset is introduced due to the shaft kinematics (after-run). As a result the power steering motor is excited passively and operates as a generator. On the basis of this signal the power steering control unit detects the assistance requirement and assists the return force by the corresponding energizing of the power steering motor. "active center feeling" function When the steering wheel center position is detected and in the absence of steering movements, the power steering motor is energized by the power steering control unit so that an adequate torque is produced in order to hold the steering in the center position. As a result the driver has an improved "feel" for the center position of the steering.
R12/14¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2149 · Applies to: 450, 451, 452, 454
Driver airbag ignition squib 2 16A R12/14 Driver airbag ignition squib 2 42A S112s1 Steering wheel gear shifter PLUS 11A S112s1 Steering wheel gear shifter PLUS 38A S112s2 Steering wheel gear shifter MINUS 8A S112s2 Steering wheel gear shifter MINUS 34A S112s3 Fanfare horn system button 4A S112s3 Fanfare horn system button 22A S112s4 Left cruise control switch 27A S112s5 Right cruise control switch 30A U1012 Valid up to 30/08/2010 1A U1013 Valid as of 31/08/2010 19A U1014 Valid for steering wheel shifting 7A U1014 Valid for steering wheel shifting 33A U4 Valid for cruise control 25A U4 Valid for cruise control 27H W110 Ground on steering wheel 3D W110 Ground on steering wheel 21D W110 Ground on steering wheel 32B W9 Ground (left front, at lamp unit) 4J W9 Ground (left front, at lamp unit) 21J Z81 Circuit 58d connector sleeve 34H
Fig 1: Steering Wheel Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2150 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Steering Wheel Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2151 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
P-1001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2153 · Applies to: 450, 451, 452, 454
27MC Abbreviations for wiring diagrams
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 plug 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 PE07.00- P- 1100MCU
Engine 132Further wiring diagrams PE07.00- P- 1100MCU PE08.00- P- 1100MCC
Engine 780.009Further wiring diagrams PE08.00- P- 1100MCC PE26.00- P- 1100MCU
Transmission 717 (except model 451.391 /491)Further wiring diagrams PE26.00- P- 1100MCU PE27.00- P- 1100MCC
Model 451.391 / 491Further wiring diagrams PE27.00- P- 1100MCC PE42.00- P- 1100MCU
Further wiring diagrams PE42.00- P- 1100MCU PE43.00- P- 1100MCC
Model 451.391 / 491Further wiring diagrams PE43.00- P- 1100MCC PE46.00- P- 1100MCU
Further wiring diagrams PE46.00- P- 1100MCU PE54.00- P- 1100MCU
Further wiring diagrams PE54.00- P- 1100MCU PE72.00- P- 1100MCU
Further wiring diagrams PE72.00- P- 1100MCU PE80.00- P- 1100MCU
Further wiring diagrams PE80.00- P- 1100MCU PE82.00- PE82.00-
1100MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2154 · Applies to: 450, 451, 452, 454
P- 1100MCU
Further wiring diagrams P- 1100MCU PE83.00- P- 1100MCU
Further wiring diagrams PE83.00- P- 1100MCU PE91.00- P- 1100MCU
Further wiring diagrams PE91.00- P- 1100MCU Document number: pe42.45-p-2000-97mcu Document title: Wiring diagram of Electronic Stability Program (ESP) Code: Designation: Position: A1 Instrument cluster 13L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20L L6/1 Left front wheel speed sensor 26L L6/1x1 Wheel speed sensor connector
L6/2 Right front wheel speed sensor 28L L6/2x1 Wheel speed sensor connector
L6/3 Left rear wheel speed sensor 29L L6/3x1 Wheel speed sensor connector
L6/4 Right rear wheel speed sensor 31L L6/4x1 Wheel speed sensor connector
N10/10 SAM control unit 4L N10/10f11 Fuse 11 2L N10/10f18 Fuse 18 5L N10/10f34 Fuse 34 3L N10/10f38 Fuse 38 7L N47-5 ESP control module 28A N47-5 ESP control module 12A N47-5 ESP control module 20A N47-5 ESP control module 4A N49 Steering angle sensor 17L S11 Brake fluid indicator switch 23L S12 Parking brake indicator switch 25L S9/1 Stop lamp switch (4-pin) 9L W10 Ground (battery) 11G
Ground (battery)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2155 · Applies to: 450, 451, 452, 454
W10 Ground (battery) 7E W14 Left floor interior compartment ground 22G W43 Ground (outside left fire wall) 24G W7 Ground (right wheelhousing in trunk) 25G W9 Ground (at left headlamp unit) 16G Z3/17 Circuit 15 (fused) connector sleeve 18G Z3/17 Circuit 15 (fused) connector sleeve 5G Z37/2 CAN engine bus (low) connector sleeve 14G Z37/2 CAN engine bus (low) connector sleeve 16E Z37/3 CAN engine bus (high) connector sleeve 12G Z37/3 CAN engine bus (high) connector sleeve 17E Z37/41 CAN databus (high) connector sleeve 12E Z37/41 CAN databus (high) connector sleeve 19E Z37/42 CAN bus (low) connector sleeve 14E Z37/42 CAN bus (low) connector sleeve 21E Z40 Stop lamp signal connector sleeve 9G Fig 1: Electric Stability Program Wiring Diagram (1 Of 2)
OV00.01-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2158 · Applies to: 450, 451, 452, 454 · AR: WS46.00-Z-9999CZ
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 SPECIAL TOOLS > 126 589 00 10 00 SCREWDRIVER BIT - WS46.00-P-0033B > FG 46/91/14/32/ Set B MODEL 107, 123, 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 172 /, 197, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 245, 251, 414, 451, 461, 463
Further use FG 91/Set B WS91.00-N-3000B Use: Screwdriver bit T30 (TORX system) 1/4" hexagon, 70 mm long.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: STEERING - WS46.00-Z-9999CZ > MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P-0007B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/47/82/83/Set B WS00.00-P-0006Z Fig 1: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Screwdriver bit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2159 · Applies to: 450, 451, 452, 454
126 589 00 10 00 Screwdriver bit FG 46/91/14/32/ Set B WS46.00-P-0033B 220 589 04 99 00 New passenger car wiring harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P-0006B 452 589 00 23 00 Steering column catch FG 46/Set B WS46.00-P-0084B 454 589 00 33 00 Puller FG 46/Set B WS46.00-P-0087B
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2163 · Applies to: 450, 451, 452, 454
Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension Use only approved tensioning devices; shield off hazard area if necessary.Inspect special tools for damage and proper operation (visual inspection).Wear protective gloves. AS00.00-Z- 0001-01A Notes on self- locking nuts and bolts
AH00.00-N- 0001-01A Daimler AG has not specifically called for the springs (1) to be changed in pairs, but it is advisable
1 Remove left or right front suspension strut
AR32.25-P- 1017MCU 2 Clamp assembly tool set (2) in vise Pay attention to firm seating of assembly tool set (2) in vise.
*450589089900 3 Insert suspension strut with spring (1) into the assembly tool set (2) and slightly pretighten The windings of the spring (1) must be gripped reliably in order to prevent the assembly tool set (2) from slipping off.
4 Tension spring (1) Do not use an impact wrench when clamping.Clamp spring (1) far enough until the spring cup (3) is exposed Installation: Ensure correct seating of spring (1) in guide (8).
5 Unscrew nut (4) Do not rotate the piston rod, as otherwise the shock absorber (7) may be damaged. Counterhold the piston rod of the shock absorber (7) using a Torx bit (size T45) and a shank length of 100 mm.If the nut (4) sticks, push back the boot, fasten the holding device (9) on the shock absorber's piston rod (7) and counterhold using open end wrench (10).
450589010100 450589089900 451589006300 BA32.25-P-
1001-04D¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2164 · Applies to: 450, 451, 452, 454
6 Remove rubber mount (5) with thrust bearing (6) Installation: Check that the thrust bearing (6) is in good condition and is not worn; replace if necessary.
7 Remove spring cup (3) and pull shock absorber (7) out of spring (1)
8 Release spring (1) Do not use an impact wrench/driver when releasing it. Installation: Do not scratch spring (1), paint damage should be repaired.
Preservation agent *BR00.45-Z- 1003-05A 9 Install in the reverse order
SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1001- 04D Self-locking nut, spring plate to piston rod Nm 60 Fig 2: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2166 · Applies to: 450, 451, 452, 454
DaimlerChrysler has not specifically called for the rear springs (1) to be changed in pairs, but it is advisable
1 Release left or right rear axle shaft, outboard
AR35.30- P- 0620MCU 2 Lower axle tube (2) using major assembly lifting table or transmission jack until the rear springs (1) can be removed from their mountings on the axle tube (2) and on the frame-type integral support (3) If both rear springs (1) are removed at the same time, the major assemblies lifting table should be used to support the axle tube (5).Major assembly lifting table, transmission jackhttp://gotis.aftersales.mercedes- benz.com
3 Remove rear spring (1) Pay attention to the installation position of the rear spring (1). Clean the top and bottom rubber mount of rear spring (1) and replace if necessary.
4 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL FRONT SHOCK ABSORBER - AR32.25-P- 0105MCU > MODEL 451.3/4 Fig 1: Identifying Rear Spring, Axle Tube And Frame-Type Integral Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2167 · Applies to: 450, 451, 452, 454
11.4.08 Special tool for releasing nut on piston rod, added Step 5
Remove/install
Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension Use only approved tensioning devices; shield off hazard area if necessary.Inspect special tools for damage and proper operation (visual inspection).Wear protective gloves. AS00.00-Z- 0001-01A Notes on self- locking nuts and bolts
AH00.00-N- 0001-01A Daimler AG has not specifically called for the springs (1) to be
Fig 1: Identifying Front Shock Absorber Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
changed in pair ,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2168 · Applies to: 450, 451, 452, 454
but it is advisable 1 Remove left or right front suspension strut
AR32.25-P- 1017MCU 2 Clamp assembly tool set (2) in vise Pay attention to firm seating of assembly tool set (2) in vise.
*450589089900 3 Insert suspension strut with spring (4) into the assembly tool set (2) and slightly pretighten The windings of the spring (4) must be gripped reliably in order to prevent the assembly tool set (2) from slipping off.
*450589089900 4 Tension spring (4) Do not use an impact wrench.Clamp spring (4) far enough until the spring cup (5) is exposed Installation: Pay attention to the correct seat of the spring (4) on the end stop (9) of the damper (1).Paint damage on the spring (4) should be rectified.
450589089900 Preservation agent BR00.45-Z- 1003-05A 5 Remove nut (7) Do not turn at the piston rod of the damper (1) otherwise the damper (1) may be damaged. Counterhold the piston rod of the shock absorber (1) using a Torx bit (size T45) and a shank length of 100 mm.If the nut (7) is seized, slide back the boot (3) and attach holding device (10) to the piston rod of the damper (1) and counterhold with open end wrench (11).
450589010100 450589089900 451589006300 BA32.25-P- 1001-04D 6 Remove rubber mount (6) with thrust bearing (8) Installation: Check that the thrust bearing (8) is in good condition and is not worn; replace if necessary.
7 Remove spring cup (5) and pull shock absorber (1) out of spring (4)
In tall in the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2169 · Applies to: 450, 451, 452, 454
8 In tall in the reverse order
SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1001- 04D Self-locking nut, spring plate to piston rod Nm 60 Fig 2: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Assembly Tool Set (450 589 08 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Holding Device (451 589 00 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2170 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1003-05A Cavity preservation, solvent-free (1 l container) A 000 986 72 70 05 TESTING & REPAIR > REMOVE/INSTALL REAR SHOCK ABSORBER - AR32.25-P- 0110MCU > MODEL 451.3/4 MODIFICATION NOTES 26.10.07 Bolt, shock absorber to rear axle *BA32.25-P-1001-03N Remove/install
DaimlerChrysler has not specifically called for the shock absorbers (1) to be changed in pairs, but it is advisable
1 Remove the fender liner in the left or right rear fender
AR88.10-P- 1400MCU Support axle tube (2) with transmission jack The major assemblies lifting table should be used to support the axle tube (2) when removing both shock absorbers (1).
Fig 1: Identifying Rear Shock Absorber Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
or major¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2171 · Applies to: 450, 451, 452, 454
2 or major assemblies lifting table Transmission jack, major assembly lifting tablehttp://gotis.aftersales.mercedes-benz.com *450589026200 3 Counterhold piston rod (3) using suitable tool and unscrew nut (4) Replace self-locking nut (4).
*BA32.25-P- 1002-03N 4 Remove shim (5) and rubber mount (6) from shock absorber (1) Installation: Clean rubber mount (6) and check for signs of damage, replace if necessary.
5 Carefully lower axle tube (2) far enough until the shock absorber (1) is completely relieved Do not lower the axle tube (2) too far, as otherwise the rear springs (7) may drop out of their mountings and be damaged. Ensure that the inner ball joint of the rear axle shaft is not pulled apart as it may be destroyed as a result. Installation: Make sure that the rear springs (7) are correctly seated in their mountings.
6 Remove expansion clip on cover (8) and remove cover (8)
7 Undo bolt (9) and remove shock absorber (1) *BA32.25-P- 1001-03N 8 Install in the reverse order
REAR AXLE SHOCK ABSORBER Number Designation Model 451.3/4 BA32.25-P-1001- 03N Bolt, shock absorber to rear axle Nm 70 BA32.25-P-1002- 03N Nut, shock absorber to frame-type integral support Nm 20
TESTING & REPAIR > REMOVE/INSTALL THE SUSPENSION STRUT - AR32.25-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2172 · Applies to: 450, 451, 452, 454
1017MCU > MODEL 451.3/4 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Suspension Strut 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. 2173 · Applies to: 450, 451, 452, 454
Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension Use only approved tensioning devices; shield off hazard area if necessary.Inspect special tools for damage and proper operation (visual inspection). Wear protective gloves. AS00.00-Z- 0001-01A Notes on self- locking nuts and bolts
AH00.00-N- 0001-01A Daimler AG has not specifically called for the suspension struts (1) to be changed in pairs, but it is advisable
1 Remove front CBS
AR88.00-P- 1010MCC 2 Remove left and right lamp unit
AR82.10-P- 4730MCU 3 Remove brake caliper on front axle and hang up to one side with connected brake hose
AR42.10-P- 0070MCU 4 Unscrew screw (2) and pull the left front RPM sensor (L6/1) or
Fig 2: Identifying Suspension Strut Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
right front RPM¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2174 · Applies to: 450, 451, 452, 454
sensor (L6/2) out of the upright (3) 5 Using a suitable tool unclip the bracket (4) on the suspension strut (1) and place the left front RPM sensor (L6/1) or right front RPM sensor (L6/2) to one side
6 Unscrew nut (5) and unhook link rod (6) from suspension strut (1). Counterhold threaded stud of link rod (6).
Screwdriver bit 126589001000 Tool assortment for stabilizer assembly 450589001700 *BA32.20-P- 1004-02I 7 Unscrew nut (7) and release tie rod end (8) from steering knuckle (3) using puller and remove Carefully press out tie rod end (8) to prevent damaging rubber boot. Installation: Check rubber boot, replace tie rod end (8), if necessary.
Puller 450589013300 BA46.40-P- 1001-01F 8 Unscrew nut (9) and using puller release flange ball joint (10) from upright (3) Press out flange ball joint (10) carefully in order to avoid damage to the rubber boot. Counterhold the flange ball joint's threaded pin (10) using a Torx wrench (size T40). Installation: Check rubber boot, replace flange ball joint (10), if necessary.
Puller 454589003300 BA33.25-P- 1001-01D 9 Undo nut (11) and remove bolt (12) from steering knuckle (3) *BA32.25-P- 1003-04D 10 Mount clamping device (13) onto steering knuckle (3), insert retaining pin (14) into the bolt bore in the steering knuckle (3) and Tighten the expansion bolt (15) until resistance is felt, do not overtighten, as otherwise the clamping device (13) or the steering knuckle (3) may be damaged. Installation: Push steering knuckle (3) all the way upwards to the end stop.
spread the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2175 · Applies to: 450, 451, 452, 454
steering knuckle (3) using the expansion bolt (15) Tensioning device *451589003100 11 Detach steering knuckle (3) from suspension strut (1) Push transverse control arm on front axle down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged.
12 Lower vehicle with vehicle lift
13 Unscrew nut (16) and remove suspension strut (1) Secure the suspension strut (1) to prevent it from falling, otherwise it could be damaged.Do not turn at the piston rod of the suspension strut (1), otherwise the suspension strut (1) could be damaged. Push transverse control arm on front axle down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged. Counterhold the piston rod of the suspension strut (1) using a Torx bit (size T45) and a shank length of 100 mm.If the nut (16) has seized, push back the boot, attach the holding device (17) to the piston rod of the suspension strut (1) and counterhold using the open end wrench (18).
Open end wrench 450589010100 Assembly tool set 450589089900 Holding device 451589006300 BA32.25-P- 1002-04D 14 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1004- 02I Nut, link rod to suspension strut Nm 58 SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1002- 04D Nut, suspension strut at rebound buffer Nm 45 BA32.25-P-1003- 04D Bolt, fastening shackle of suspension strut at swiveling bearing Stage 1 Nm 30 Stage 2 ∠° 180
AXLE HOUSING, STEERING KNUCKLE¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2176 · Applies to: 450, 451, 452, 454
Number Designation Model 451.3/4 BA33.25-P-1001- 01D Nut, flange ball joint to swivel bearing Nm 50 TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001- 01F Self-locking nut, tie rod to steering knuckle Nm 34 Fig 3: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Open End Wrench (450 589 01 01 00)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2177 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 7: Identifying Assembly Tool Set (450 589 08 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2179 · Applies to: 450, 451, 452, 454
Notes on self- locking nuts and bolts
AH00.00-N- 0001-01A 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 using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdrivergotis://G_58.0_01.1
2 Unscrew nuts (2) on link rods (3) Counterhold threaded studs of link rods (3). Position the vehicle on its wheels. Only tighten nuts (4) of the clamps (5) when the vehicle is unladen (approx. 75 kg weight on the driver seat and full tank or approx. 20 kg weight in the front passenger area).
Screwdriver bit 126589001000 Tool assortment for stabilizer assembly 450589001700 BA32.20-P- 1001-02I BA32.20-P- 1003-02I Fig 1: Identifying Front Stabilizer Bar Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unhook link rods¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2180 · Applies to: 450, 451, 452, 454
3 Unhook link rods (3) from stabilizer bar (1)
4 Unscrew nuts (4), remove clamps (5) and remove the rubber mounts underneath (6) from the stabilizer bar (1) The clamps (5) are 2-piece ones. Installation: Check rubber bushing (6) and replace if necessary.The opening of the rubber mounts (6) must point in the direction of travel. Insert the clamps (5) at a right angle to the stabilizer bar (1). The nuts (4) of clamps (5) are tightened later.
5 Remove stabilizer (1) Remove stabilizer (1) carefully, otherwise the radiator may be damaged.
6 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1001- 02I Self-locking nut, link rod to stabilizer bar Nm 58 BA32.20-P-1003- 02I Nut, stabilizer bar to retaining clamp Nm 95 Fig 2: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL FRONT STABILIZER BAR LINK ROD - AR32.35-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2181 · Applies to: 450, 451, 452, 454
P-3328MCC > MODEL 451.3/4 MODIFICATION NOTES 11.4.08 Special tool for releasing nut on link rod, added Step 2
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 Raise vehicle with vehicle lift
Fig 3: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Link Rod And Nuts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unscrew nuts (2, 3) on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2182 · Applies to: 450, 451, 452, 454
2 Unscrew nuts (2, 3) on left or right link rod (1) Replace the self-locking nuts (2, 3). To make access easier, turn the steering at the wheel.Counterhold threaded stud of link rod (1).
126589001000 450589001700 BA32.20-P- 1001-02I BA32.20-P- 1004-02I 3 Remove link rod (1)
4 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1001- 02I Self-locking nut, link rod to stabilizer bar Nm 58 BA32.20-P-1004- 02I Nut, link rod to suspension strut Nm 58 Fig 2: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SAFETY PRECAUTIONS > SAFETY INFORMATION: SUSPENSION - AS32.00-Z-9999ZZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2183 · Applies to: 450, 451, 452, 454 · AR: AS32.00-Z-9999ZZ
MODEL all Risk of death from lowering vehicle when working between wheels and body. Risk of injury from pinching or crushing when working on the air suspension. MODEL all AS32.22-Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: SUSPENSION - BA32.00- Z-9999CZ > MODEL all Front axle steel springs MODEL 454.0 BA32.20-P-1000-01K Front axle torsion bar MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA32.20-P-1000-02I Rear axle shock absorber MODEL 451.3/4 BA32.25-P-1000-03N Rear axle shock absorber MODEL 454.0 BA32.25-P-1000-03H Rear axle shock absorber MODEL 450.3 /4, 452.334 /432 /434 BA32.25-P-1000-03F Rear axle torsion bar MODEL 450.3 /4 BA32.20-P-1000-04H Spring struts MODEL 454.0 BA32.25-P-1000-04I Spring struts MODEL 450.3 /4 BA32.25-P-1000-04F Spring struts MODEL 450.3 /4 BA32.25-P-1000-04E Spring struts MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA32.25-P-1000-04D TORQUE SPECIFICATIONS > FRONT AXLE TORSION BAR - BA32.20-P-1000-02I > Model 450, 454, 452 Fig 3: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2184 · Applies to: 450, 451, 452, 454
8.4.09 Value modified: Nut, stabilizer bar to retaining clamp Model 451.3/4 FRONT AXLE TORSION BAR Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA32.20-P-1001- 02I Self-locking nut, link rod to stabilizer bar Nm 46 58 46 BA32.20-P-1002- 02I Nut, connecting rod to wishbone Nm 46 - 46 BA32.20-P-1003- 02I Nut, stabilizer bar to retaining clamp Nm 85 95 85 BA32.20-P-1004- 02I Nut, link rod to suspension strut Nm - 58 - TORQUE SPECIFICATIONS > REAR AXLE SHOCK ABSORBER - BA32.25-P-1000-03N > Model 451.3/4 22.3.07 Bolt, shock absorber to rear axle 26.10.07 Bolt, shock absorber to rear axle REAR AXLE SHOCK ABSORBER Number Designation Model 451.3/4 BA32.25-P-1001- 03N Bolt, shock absorber to rear axle Nm 70 BA32.25-P-1002- 03N Nut, shock absorber to frame-type integral support Nm 20 TORQUE SPECIFICATIONS > SPRING STRUTS - BA32.25-P-1000-04D > Model 450, 451, 452 MODIFICATION NOTES 11.2.08 Value changed: Bolt for mounting bracket on suspension strut to swivel bearing Model 451.3/4 SUSPENSION STRUTS Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA32.25-P- 1001-04D Self-locking nut, spring plate to piston rod Nm 60 60 60 BA32.25-P- Nut, suspension strut at rebound buffer Nm 45 45 45
1002-04D¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2185 · Applies to: 450, 451, 452, 454
BA32.25-P- 1003-04D Bolt, fastening shackle of suspension strut at swiveling bearing Stage 1 Nm 46 30 46 Stage 2 ∠° - 180 - SPECIAL TOOLS > 450 589 08 99 00 ASSEMBLY TOOL KIT - WS32.00-P-0065B > FG 32/Set B MODEL 450, 451, 452, 454 Use: Assembly tool kit for working on the McPherson suspension strut. NOTE: Assembly tool for McPherson strut smartno.: 001 0480 V001 0000 00 SPECIAL TOOLS > 451 589 00 31 00 TENSIONING DEVICE - WS32.00-P-0090B > FG 32/Set B MODEL 451 Use: Clamping device for spreading damper clamps on steering knuckle. Fig 1: Identifying Assembly Tool Kit (450 589 08 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 00 63 00 HOLDING FIXTURE - WS32.00-P-0091B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2186 · Applies to: 450, 451, 452, 454
FG 32/Set B MODEL 450, 451, 452 Use: Retaining device for holding the piston rod on the suspension strut. SPECIAL TOOLS > 450 589 01 01 00 OPEN END WRENCH - WS32.00-P-0094B > FG 32/Set B MODEL 450, 451, 452 Further use FG 33/Set B WS33.00-P-0144B Use: Fig 1: Identifying Tensioning Device (451 589 00 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Holding Fixture (451 589 00 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Open end wrench for counterholding the piston rod at the suspension strut.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2187 · Applies to: 450, 451, 452, 454 · AR: WS32.00-Z-9999CZ
NOTE: Only in combination with 451 589 00 63 00 holding device. SPECIAL TOOLS > SPECIAL TOOLS: SMART: SUSPENSION - WS32.00-Z-9999CZ > MODEL all 126 589 00 10 00 Screwdriver bit FG 46/91/14/32/ Set B WS46.00-P-0033B 450 589 01 01 00 Open end wrench FG 32/Set B WS32.00-P-0094B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 450 589 08 99 00 Assembly tool kit FG 32/Set B WS32.00-P-0065B 451 589 00 31 00 Tensioning device FG 32/Set B WS32.00-P-0090B 451 589 00 63 00 Holding fixture FG 32/Set B WS32.00-P-0091B 454 589 01 99 00 Set of socket wrench bits FG 32/Set B WS32.00-P-0074B Fig 1: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > INSTALL BRABUS SPORT SUSPENSION - AN32.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2188 · Applies to: 450, 451, 452, 454
0002MCC > MODEL 451.3 /4 (except 451.391 /491) Removing
1 Remove left and right front spring The dampers and front springs are no longer required for the installation.
- not for USA AR32.20- P- 0200MCC
-
for USA only AR32.20- P- 0200MCU 2 Remove left and right damper at the rear The dampers are no longer required for the installation.
-
not for USA AR32.25- P- 0110MCC
- for USA only AR32.25- P- 0110MCU Lower the major assembly lifting platform Fig 1: Identifying Rear Spring, Axle Tube And Frame-Type Integral Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2191 · Applies to: 450, 451, 452, 454
11.4.08 Special tool for releasing nut on piston rod, added Step 5
Remove/install
Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension Use only approved tensioning devices; shield off hazard area if necessary.Inspect special tools for damage and proper operation (visual inspection).Wear protective gloves. AS00.00- Z-0001- 01A Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A Daimler AG has not specifically called for the springs (1) to be
Fig 1: Identifying Front Spring Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
changed in pair ,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2192 · Applies to: 450, 451, 452, 454
but it is advisable 1 Remove left or right front suspension strut
AR32.25- P- 1017MCU 2 Clamp assembly tool set (2) in vise Pay attention to firm seating of assembly tool set (2) in vise.
Fig 3 3 Insert suspension strut with spring (1) into the assembly tool set (2) and slightly pretighten The windings of the spring (1) must be gripped reliably in order to prevent the assembly tool set (2) from slipping off.
4 Tension spring (1) Do not use an impact wrench when clamping.Clamp spring (1) far enough until the spring cup (3) is exposed Installation: Ensure correct seating of spring (1) in guide (8).
5 Unscrew nut (4) Do not rotate the piston rod, as otherwise the shock absorber (7) may be damaged. Counterhold the piston rod of the shock absorber (7) using a Torx bit (size T45) and a shank length of 100 mm.If the nut (4) sticks, push back the boot, fasten the holding device (9) on the shock absorber's piston rod (7) and counterhold using open end wrench (10).
Fig 2 Fig 3 Fig 4 *BA32.25- P-1001- 04D 6 Remove rubber mount (5) with thrust bearing (6) Installation: Check that the thrust bearing (6) is in good condition and is not worn; replace if necessary.
7 Remove spring cup (3) and pull shock absorber (7) out of spring (1)
8 Release spring (1) Do not use an impact wrench/driver when releasing it. Installation: Do not scratch spring (1), paint damage should be repaired.
Preservation agent *BR00.45- Z-1003- 05A
In tall in the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2193 · Applies to: 450, 451, 452, 454
9 In tall in the reverse order
SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1001-04D Self-locking nut, spring plate to piston rod Nm 60 Fig 2: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Assembly Tool Set (450 589 08 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Holding Device (451 589 00 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. 2195 · Applies to: 450, 451, 452, 454
4 Install in the reverse order
TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT SHOCK ABSORBER - AR32.25- P-0105MCU > MODEL 451.3 /4 MODIFICATION NOTES 11.4.08 Special tool for releasing nut on piston rod, added Step 5
Remove/install
Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension Use only approved tensioning devices; shield off hazard area if necessary.Inspect special tools for damage and proper operation (visual inspection).Wear protective gloves. AS00.00- Z-0001- 01A Notes on self- AH00.00- Fig 1: Identifying Front Shock Absorber Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
locking nuts and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2196 · Applies to: 450, 451, 452, 454
bolts
N-0001- 01A Daimler AG has not specifically called for the springs (1) to be changed in pairs, but it is advisable
1 Remove left or right front suspension strut
AR32.25- P- 1017MCU 2 Clamp assembly tool set (2) in vise Pay attention to firm seating of assembly tool set (2) in vise.
Figure 3 Insert suspension strut with spring (4) into the assembly tool set (2) and slightly pretighten The windings of the spring (4) must be gripped reliably in order to prevent the assembly tool set (2) from slipping off.
Figure 4 Tension spring (4) Do not use an impact wrench.Clamp spring (4) far enough until the spring cup (5) is exposed Installation: Pay attention to the correct seat of the spring (4) on the end stop (9) of the damper (1).Paint damage on the spring (4) should be rectified.
Figure Preservation agent *BR00.45- Z-1003- 05A 5 Remove nut (7) Do not turn at the piston rod of the damper (1) otherwise the damper (1) may be damaged. Counterhold the piston rod of the shock absorber (1) using a Torx bit (size T45) and a shank length of 100 mm.If the nut (7) is seized, slide back the boot (3) and attach holding device (10) to the piston rod of the damper (1) and counterhold with open end wrench (11).
Figure Figure Figure *BA32.25- P-1001- 04D 6 Remove rubber mount (6) with thrust bearing (8) Installation: Check that the thrust bearing (8) is in good condition and is not worn; replace if necessary.
Remove spring¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2197 · Applies to: 450, 451, 452, 454
7 Remove spring cup (5) and pull shock absorber (1) out of spring (4)
8 Install in the reverse order
SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1001-04D Self-locking nut, spring plate to piston rod Nm 60 Fig 2: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Assembly Tool Set (450 589 08 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2198 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1003-05A Cavity preservation, solvent-free (1 l container) A 000 986 72 70 05 TESTING & REPAIR INDEX > REMOVE/INSTALL REAR SHOCK ABSORBER - AR32.25-P- 0110MCU > MODEL 451.3 /4 MODIFICATION NOTES 26.10.07 Bolt, shock absorber to rear axle *BA32.25-P-1001-03N
Remove/install
DaimlerChrysler has Fig 4: Identifying Holding Device (451 589 00 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Rear Shock Absorber Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
not specifically¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2199 · Applies to: 450, 451, 452, 454
called for the shock absorbers (1) to be changed in pairs, but it is advisable
1 Remove the fender liner in the left or right rear fender
AR88.10- P- 1400MCU 2 Support axle tube (2) with transmission jack or major assemblies lifting table The major assemblies lifting table should be used to support the axle tube (2) when removing both shock absorbers (1).
Transmission jack, major assembly lifting table Fig 2 3 Counterhold piston rod (3) using suitable tool and unscrew nut (4) Replace self-locking nut (4).
*BA32.25- P-1002- 03N 4 Remove shim (5) and rubber mount (6) from shock absorber (1) Installation: Clean rubber mount (6) and check for signs of damage, replace if necessary.
5 Carefully lower axle tube (2) far enough until the shock absorber (1) is completely relieved Do not lower the axle tube (2) too far, as otherwise the rear springs (7) may drop out of their mountings and be damaged. Ensure that the inner ball joint of the rear axle shaft is not pulled apart as it may be destroyed as a result. Installation: Make sure that the rear springs (7) are correctly seated in their mountings.
6 Remove expansion clip on cover (8) and remove cover (8)
7 Undo bolt (9) and remove shock absorber (1) *BA32.25- P-1001- 03N 8 Install in the reverse order
REAR AXLE SHOCK ABSORBER Number Designation Model 451.3/4 BA32.25-P-1001-03N Bolt, shock absorber to rear axle Nm 70 BA32.25-P-1002-03N Nut, shock absorber to frame-type integral support Nm 20
TESTING & REPAIR INDEX > REMOVE/INSTALL THE SUSPENSION STRUT - AR32.25-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2200 · Applies to: 450, 451, 452, 454
1017MCU > MODEL 451.3 /4 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Suspension Strut 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. 2201 · Applies to: 450, 451, 452, 454
Risk of injury caused by pinching or crushing when working on springs or spring bodies that are under tension Use only approved tensioning devices; shield off hazard area if necessary.Inspect special tools for damage and proper operation (visual inspection). Wear protective gloves. AS00.00- Z-0001- 01A Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A Daimler AG has not specifically called for the suspension struts (1) to be changed in pairs, but it is advisable
1 Remove front CBS
AR88.00- P- 1010MCC 2 Remove left and right lamp unit
AR82.10- P- 4730MCU 3 Remove brake caliper on front axle and hang up to one side with connected brake hose
AR42.10- P- 0070MCU Unscrew screw (2) and pull the Fig 2: Identifying Suspension Strut Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
left front rpm¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2202 · Applies to: 450, 451, 452, 454
4 left front rpm sensor (L6/1) or right front rpm sensor (L6/2) out of the upright (3)
5 Using a suitable tool unclip the bracket (4) on the suspension strut (1) and place the left front rpm sensor (L6/1) or right front rpm sensor (L6/2) to one side
6 Unscrew nut (5) and unhook link rod (6) from suspension strut (1). Counterhold threaded stud of link rod (6).
Screwdriver bit Fig 3 Tool assortment for stabilizer assembly Fig 4 *BA32.20- P-1004- 02I 7 Unscrew nut (7) and release tie rod end (8) from steering knuckle (3) using puller and remove Carefully press out tie rod end (8) to prevent damaging rubber boot. Installation: Check rubber boot, replace tie rod end (8), if necessary.
Puller Fig 6 *BA46.40- P-1001- 01F 8 Unscrew nut (9) and using puller release flange ball joint (10) from upright (3) Press out flange ball joint (10) carefully in order to avoid damage to the rubber boot. Counterhold the flange ball joint's threaded pin (10) using a Torx wrench (size T40). Installation: Check rubber boot, replace flange ball joint (10), if necessary.
Puller Fig 10 BA33.25- P-1001- 01D 9 Undo nut (11) and remove bolt (12) from steering knuckle (3) BA32.25- P-1003- 04D Mount clamping device (13) onto steering knuckle Tighten the expansion bolt (15) until resistance is felt, do not overtighten, as otherwise the clamping device (13) or the steering knuckle (3) may be damaged.
(3), in ert¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2203 · Applies to: 450, 451, 452, 454
10 (3), in ert retaining pin (14) into the bolt bore in the steering knuckle (3) and pread the steering knuckle (3) using the expansion bolt (15) Installation: Pu h teering knuckle (3) all the way upwards to the end stop. Tensioning device Fig 8 11 Detach steering knuckle (3) from suspension strut (1) Push transverse control arm on front axle down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged.
12 Lower vehicle with vehicle lift
13 Unscrew nut (16) and remove suspension strut (1) Secure the suspension strut (1) to prevent it from falling, otherwise it could be damaged.Do not turn at the piston rod of the suspension strut (1), otherwise the suspension strut (1) could be damaged. Push transverse control arm on front axle down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged. Counterhold the piston rod of the suspension strut (1) using a Torx bit (size T45) and a shank length of 100 mm.If the nut (16) has seized, push back the boot, attach the holding device (17) to the piston rod of the suspension strut (1) and counterhold using the open end wrench (18).
Open end wrench Figure Assembly tool set Figure Holding device Figure *BA32.25- P-1002- 04D 14 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1004-02I Nut, link rod to suspension strut Nm 58 SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1002- 04D Nut, suspension strut at rebound buffer Nm 45
BA32.25-P-1003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2204 · Applies to: 450, 451, 452, 454
04D Bolt, fastening shackle of suspension strut at swiveling bearing Stage 1 Nm 30 Stage 2 ∠° 180 AXLE HOUSING, STEERING KNUCKLE Number Designation Model 451.3/4 BA33.25-P-1001-01D Nut, flange ball joint to swivel bearing Nm 50 TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001-01F Self-locking nut, tie rod to steering knuckle Nm 34 Fig 3: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Open End Wrench (450 589 01 01 00)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2205 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 7: Identifying Assembly Tool Set (450 589 08 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT STABILIZER BAR - AR32.35-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2206 · Applies to: 450, 451, 452, 454
2050MCU > MODEL 451.3 /4 Fig 8: Identifying Tensioning Device (451 589 00 31 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. Fig 10: Identifying Puller (454 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2207 · Applies to: 450, 451, 452, 454
Notes on self-locking nuts and bolts
AH00.00- N-0001- 01A 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 using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
2 Unscrew nuts (2) on link rods (3) Counterhold threaded studs of link rods (3). Position the vehicle on its wheels. Only tighten nuts (4) of the clamps (5) when the vehicle is unladen (approx. 75 kg weight on the driver seat and full tank or approx. 20 kg weight in the front passenger area).
Screwdriver bit Figure Tool assortment for stabilizer assembly Figure BA32.20- P 1001 02I BA32.20- Fig 1: Identifying Front Stabilizer Bar Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
P 1003¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2208 · Applies to: 450, 451, 452, 454
02I 3 Unhook link rods (3) from stabilizer bar (1)
4 Unscrew nuts (4), remove clamps (5) and remove the rubber mounts underneath (6) from the stabilizer bar (1) The clamps (5) are 2-piece ones. Installation: Check rubber bushing (6) and replace if necessary.The opening of the rubber mounts (6) must point in the direction of travel. Insert the clamps (5) at a right angle to the stabilizer bar (1). The nuts (4) of clamps (5) are tightened later.
5 Remove stabilizer (1) Remove stabilizer (1) carefully, otherwise the radiator may be damaged.
6 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1001-02I Self-locking nut, link rod to stabilizer bar Nm 58 BA32.20-P-1003-02I Nut, stabilizer bar to retaining clamp Nm 95 Fig 2: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 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. 2210 · Applies to: 450, 451, 452, 454 · AR: AS32.00-Z-9999ZZ, BA31.00-Z-9999CZ
4 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1001-02I Self-locking nut, link rod to stabilizer bar Nm 58 BA32.20-P-1004-02I Nut, link rod to suspension strut Nm 58 SAFETY PRECAUTIONS > SAFETY INFORMATION: SUSPENSION - AS32.00-Z-9999ZZ > MODEL all Risk of death from lowering vehicle when working between wheels and body. Risk of injury from pinching or crushing when working on the air suspension. MODEL all TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: FRAME, TRAILER OPERATION - BA31.00-Z-9999CZ > Fig 2: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2211 · Applies to: 450, 451, 452, 454
Trailer coupling mechanism MODEL 454.0 TORQUE SPECIFICATIONS > FRONT AXLE TORSION BAR - BA32.20-P-1000-02I > Model 450, 454, 452 MODIFICATION NOTES 8.4.09 Value modified: Nut, stabilizer bar to retaining clamp Model 451.3/4 FRONT AXLE TORSION BAR Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA32.20-P- 1001-02I Self-locking nut, link rod to stabilizer bar Nm 46 58 46 BA32.20-P- 1002-02I Nut, connecting rod to wishbone Nm 46 - 46 BA32.20-P- 1003-02I Nut, stabilizer bar to retaining clamp Nm 85 95 85 BA32.20-P- 1004-02I Nut, link rod to suspension strut Nm - 58 - TORQUE SPECIFICATIONS > SPRING STRUTS - BA32.25-P-1000-04D > Model 450, 451, 452 MODIFICATION NOTES 11.2.08 Value changed: Bolt for mounting bracket on suspension strut to swivel bearing Model 451.3/4 SUSPENSION STRUTS Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA32.25-P- 1001-04D Self-locking nut, spring plate to piston rod Nm 60 60 60 BA32.25-P- 1002-04D Nut, suspension strut at rebound buffer Nm 45 45 45 BA32.25-P- 1003-04D Bolt, fastening shackle of suspension strut at swiveling bearing Stage 1 Nm 46 30 46 Stage 2 ∠° - 180 -
SPECIAL TOOLS > 450 589 08 99 00 ASSEMBLY TOOL KIT - WS32.00-P-0065B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2212 · Applies to: 450, 451, 452, 454
FG 32/Set B MODEL 450, 451, 452, 454 Use: Assembly tool kit for working on the McPherson suspension strut. NOTE: Assembly tool for McPherson strut smartno.: 001 0480 V001 0000 00 SPECIAL TOOLS > 451 589 00 31 00 TENSIONING DEVICE - WS32.00-P-0090B > FG 32/Set B MODEL 451 Use: Clamping device for spreading damper clamps on steering knuckle. Fig 1: Identifying Assembly Tool Kit (450 589 08 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 00 63 00 HOLDING FIXTURE - WS32.00-P-0091B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2213 · Applies to: 450, 451, 452, 454
FG 32/Set B MODEL 450, 451, 452 Use: Retaining device for holding the piston rod on the suspension strut. SPECIAL TOOLS > 450 589 01 01 00 OPEN END WRENCH - WS32.00-P-0094B > FG 32/Set B MODEL 450, 451, 452
Further use FG 33/Set B WS33.00-P-0144B Use: Fig 1: Identifying Tensioning Device (451 589 00 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Holding Fixture (451 589 00 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Open end wrench for counterholding the piston rod at the suspension strut.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2214 · Applies to: 450, 451, 452, 454 · AR: WS32.00-Z-9999CZ
NOTE: Only in combination with 451 589 00 63 00 holding device. SPECIAL TOOLS > SPECIAL TOOLS: SMART: SUSPENSION - WS32.00-Z-9999CZ > MODEL all 126 589 00 10 00 Screwdriver bit FG 46/91/14/32/ Set B WS46.00-P-0033B 450 589 01 01 00 Open end wrench FG 32/Set B WS32.00-P-0094B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 450 589 08 99 00 Assembly tool kit FG 32/Set B WS32.00-P-0065B 451 589 00 31 00 Tensioning device FG 32/Set B WS32.00-P-0090B 451 589 00 63 00 Holding fixture FG 32/Set B WS32.00-P-0091B 454 589 01 99 00 Set of socket wrench bits FG 32/Set B WS32.00-P-0074B Fig 1: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
DESCRIPTION & OPERATION >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2215 · Applies to: 450, 451, 452, 454
NOTE: The TPM system must be restarted for each change in tire inflation pressure, when replacing a wheel or a wheel sensor, as well as when replacing the TPM [RDK] control unit. See RESET PROCEDURES . DESCRIPTION & OPERATION > TIRE PRESSURE MONITOR (TPM) SYSTEM > NOTE: The TPM system may also be referred to as RDK. The Tire Pressure Monitor monitors the air pressure in the individual tires using sensors installed on each wheel. A previously stored tire pressure is used as a comparative value. In the event of a relevant pressure loss the driver is warned via the tire pressure monitor warning lamp. The tire pressure measuring range extends from p = 0 and 5.5 bar. A warning is issued when a relevant loss of pressure has been detected in at least one of the tires. The driver receives the feedback over the tire pressure monitor warning lamp. The warning is issued without any position data. DESCRIPTION & OPERATION > TIRE PRESSURE MONITOR WARNING LIGHT > The tire pressure monitoring system will illuminate a low pressure telltale when one of more of the tires is significantly underinflated. The TPMS malfunction indicator is combined with the low tire pressure telltale. When the system detects a malfunction, the telltale will flash for approximately 1 minute and then remain continuously illuminated. This sequence will continue upon subsequent vehicle start-ups as long as the malfunction exists. When the malfunction indicator is illuminated, the system may not be able to detect or signal low tire pressure as intended. TPMS malfunctions may occur for a variety of reasons, including the installation of incompatible replacement of alternate tires or wheels on the vehicle that prevent the TPMS from functioning properly. Always check the TPMS malfunction telltale after replacing one or more tires or wheels on the vehicle to ensure that the replacement or alternate tires and wheels allow the TPMS to continue to function properly. NOTE: If a condition causing the TPMS to malfunction develops, it may take up to 10 minutes for the system to signal a malfunction using the TPMS telltale flashing and illumination sequence. The telltale extinguishes after a few minutes driving if the malfunction has been connected.
RESET PROCEDURES >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2216 · Applies to: 450, 451, 452, 454
NOTE: A manual restart must be carried out for each change in tire inflation pressure, when replacing a wheel or a wheel sensor, as well as when replacing the TPM [RDK] control unit. If the multifunction display shows a tire pressure warning message, immediately check air pressure of all tires and adjust to the specified pressure. Drive vehicle for 10 minutes to ensure malfunction has been corrected. RESET PROCEDURES > TIRE PRESSURE MONITOR SYSTEM RESTART > The TPMS button in the cockpit switch panel is used to reactivate the TPM system. When the TPMS button is pressed the current tire pressure, as long as it is within permissible limits, is stored in the internal memory of the TPM [RDK] control unit and used as a reference pressure. 1. Adjust the tire inflation pressure recommended for the vehicle operating condition using the tire and loading information placard on the driver's B-pillar. NOTE: The tire pressure should only be adjusted on cold tires. 3. Press the TPMS Restart button. See Fig 1. 4. Observe the combination low tire pressure/TPMS malfunction telltale in the instrument cluster. The light should flash for approximately 5 seconds and then go out. 5. Drive the vehicle a few minutes to allow the system to verify that the current tire inflation pressures are within the system's specified range. Afterwards the current tire inflation pressures are accepted as reference pressures and then monitored.
DISMOUNTING/MOUNTING PROCEDURES >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2217 · Applies to: 450, 451, 452, 454
CAUTION: The tire should be dismounted from the wheel using the tire changer manufacturer's instructions. Use the following information to avoid damage during the dismounting/mounting procedures. NOTE: The TPM system must be restarted for each change in tire inflation pressure, when replacing a wheel or a wheel sensor, as well as when replacing the TPM [RDK] control unit. See RESET PROCEDURES . DISMOUNTING/MOUNTING PROCEDURES > REMOVAL > 1. Raise vehicle on a suitable support. Remove tire/wheel assembly from vehicle. Place on tire changing machine. 2. Detach jammed balance weight with assembly tool (M-B# 124589176300). 3. Remove bonded balance weight with tool. Do not use a hard, pointed or sharp-edged removal object. 4. Remove valve cap. Remove valve element from valve. Fig 1: TPMS Restart Button Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Position the press-off blade of the tire mounting device on the tire bead flank opposite the valve.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2218 · Applies to: 450, 451, 452, 454
Press inner and outer bead flank over safety bead seats and into drop center of disk wheel. NOTE: Do not position the bead breaker shovel on the inside or outside of the tire in the area of the valve, otherwise the tire pressure sensor will be damaged. 7. Fasten disk wheel on tire mounting device. Apply mounting paste to disk wheel flange and tire beads. 8. Position the disk wheel so that the valve is 4.0 in. (10 cm) behind the assembly head, viewed in the direction of rotation (arrow) of the disk wheel. Align mounting head close to disk wheel. 9. Use assembly lever to lever the tire beads over the mounting lug of the mounting head and detach the tire from the disk wheel. 10. Remove collar nut from valve body. See Fig 1. 11. Remove the tire pressure sensor along with valve body from wheel. 12. Remove seal and support ring from the valve body. 13. Clean the tire pressure sensor and the valve bore. NOTE: If reusing the tire pressure sensor, clean and inspect the tire pressure for visible damages. If damages are detected replace the tire pressure sensor.
DISMOUNTING/MOUNTING PROCEDURES > INSTALLATION >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2219 · Applies to: 450, 451, 452, 454
- Remove the identification label from the tire pressure sensor. Place in owner's maintenance booklet, if available.
- Replace the valve element and valve body.
- Mount support ring and seal on the valve body. See Figure. Make certain angled edge of support ring is installed toward sensor. Fig 1: Tire Pressure Sensor Expanded View Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Assemble the tire pressure sensor and valve body, ensure the tire pressure sensor fits loosely in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2220 · Applies to: 450, 451, 452, 454
the valve body. Then insert the assembly in the wheel hole. 5. Tighten the valve nut on the valve body, while pressing the tire pressure sensor towards the wheel hole. 6. Apply mounting paste to disk wheel flanges and tire beads of new tire. Position disk wheel on the tire mounting device with valve opposite (180° from) the mounting head. 7. Place new tire at an angle on disk wheel and align mounting head close to disk wheel. 8. Pull tire over shoulder onto disk wheel with tire mounting device. 9. Align the match points of the tire and disk wheel relative to one another 10. Remove disc wheel with tire from tire mounting device and remove valve element from valve. 11. Inflate tires to maximum of 43.5 psi (3 bar) to seat beads on the disk wheel. NOTE: If beads fail to seat properly, deflate, apply mounting paste to the tire beads and repeat process. 13. Turn valve element into valve and adjust tire inflation pressure to correct pressure. 14. Balance and reinstall wheel on vehicle. 15. Reset TPM system. See RESET PROCEDURES . TORQUE SPECIFICATIONS > TORQUE SPECIFICATIONS Component Ft. Lbs. (N.m) Wheel Nut 80 (110) INCH Lbs. (N.m) Tire Pressure Sensor Valve Nut 53 (6)
GENERAL INFORMATION > TIREFIT TIRE SEALANT - AH40.10-P-0001-01MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2221 · Applies to: 450, 451, 452, 454
Model 451.3/4 NOTE: TIREFIT tire sealant has a shelf life of 3 to 4 years depending on the version, measured from the date of manufacture marked on the container. After this period has elapsed or the expiration date specified on the container is exceeded the TIREFIT tire sealant should be replaced. Use: TIREFIT tire sealer can be used to seal minor perforations, especially as encountered on the tire's tread, to allow repairs at the location where the tire problem occurs. The tire can then continue in limited use until it can be replaced. The customer is obliged, after using TIREFIT tire sealant to locate the next smart service center immediately in order to replace the damaged tire. Tires which have been treated with TIREFIT tire sealant must not be repaired. They must always be replaced with new tires of the same make and manufacture. To avoid strong odors from the TIREFIT tire sealer, take the tire outside to bleed the air from it. Regulations for disposal Dispose of used and expired TIREFIT tire sealer by emptying it into the special container for used painting materials (refer to Service Products Manual Volume 2, Chapter U, Group 00 (22), Topic 2.3). Fire hazard! No fire, naked flames or smoking. Avoid producing sparks. Avoid inhaling vapors. Fig 1: View Of TIREFIT Tire Sealant Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > INFORMATION ON TIRES/RIMS - AH40.10-P-9411-01A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2222 · Applies to: 450, 451, 452, 454
Tires For service conversions, the tire/disk wheel specifications and dimensions should be compared with the entries in the registration papers. Damaged and defective tires must always be replaced. The repair methods employed in the tire trade are not approved by Mercedes - Benz. Small nicks (< 0.8 mm) on the side wall of the tire do not usually pose a cause for concern, and continued use of such tires is approved. Only use tires listed in the valid Service Information bulletins and repair instructions. Replace tire valve, general. When mounting tires, the tires and rims must be carefully matched in order to guarantee the concentricity of the wheel. Identification of matching points: on tires by means of a colored dot on the outboard side of the tire on a steel rim, by color dot or punch mark on the outboard side of wheel on light alloy wheel, in general on the valve hole. Model 140: in addition color dot or countersink in rim base. If a single tire is replaced, always mount the new tire on the front axle. This does not apply to vehicles with different tires of varying specifications on the front and rear wheels. Always provide all disk wheels with tires of the same construction, same make and same design. If the maximum permissible speed of an M+S tire is lower than the maximum speed of the vehicle, an appropriate warning sticker must be affixed within the driver's field of view. Tires approved for higher speeds may be used. Run in new tires for approx. 100 km at moderate speed. Handed tires must be installed according to the arrow on the side wall of the tire. Tires are subject to an aging process with negative effects on the properties of the tire. In order to ensure optimum effectiveness in winter, M&S tires should not be used for longer than 3 years. Tire pressure (For specified values, see the tire pressure chart inside the fuel filler flap; on Vaneo model 414, see the B- pillar in the passenger side) Too low tire pressure increases the rolling resistance and increases the flexing energy of the tire. This causes the critical temperature limit to be exceeded (carcass detachment) and destroys the tire. In the event of a pressure loss establish cause and if necessary establish cause and if necessary replace tire, tire valve or disk wheel. Cleaning The use of high-pressure spray wands projecting a concentrated round-pattern stream to clean the wheels can lead to tire damage. Such damage occurs especially on the tire side walls. When using flat jet nozzles, observe the following instructions:
Maintain a distance of at least 300 mm¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2223 · Applies to: 450, 451, 452, 454
Do not direct the water jet at a single point on the surface of the tire for any length of time Bearing system Before putting into storage, clean tires thoroughly and check for damage and adequate tread depth. Mark the position and running direction of the tires with chalk. Do not store tires outdoors. The effects of sunlight, heat, moving air and ozone cause the rubber to lose its elasticity and strength, it ages faster and cracks. Storage areas should be dry, cool and dark. Avoid drafts by keeping doors and windows closed as much as possible. Do not bring tire into contact with gasoline, oil or greases as these dissolve rubber. Disposal Collection, storage and disposal should be performed in accordance with the legal requirements and the company's own regulations. Rims For safety reasons, damaged or deformed rims must not be repaired. When changing wheels, e.g. light alloy wheels for steel rims, ensure that the wheel bolts required for the spare wheel are enclosed in a clearly visible position. Since December 1994 all models 124 and 202 receive a spare wheel with a steel rim. Vehicles with light alloy rims fitted at the plant have corresponding wheel bolts enclosed. Strengthened steel rims are identified by a sticker on the wheel disk. On steel rims and light alloy disk wheels in general the wheel bolts should be tightened to the specified torque using a torque wrench. Retightening of the wheel bolts after approx. 100 to 500 km is not required. The seat for the tire bead must display no corrosion pits. Only use disk wheels of the same design approved by Mercedes - Benz. Before inserting a new tire valve clean the contact surfaces on the disk wheel. To support the tire valve wheel covers must be fitted to steel rims. Vehicles with tire pressure monitor Before replacing a tire, check the manufacture date of the wheel sensor. Wheel sensors, which are older than 5 or 7 years, must be replaced. Use STAR DIAGNOSIS to read out the actual values for the tire pressure monitoring system. Check the remaining life of the wheel sensor battery, replace the wheel sensor if necessary. GENERAL INFORMATION > INFORMATION ON TIRES / RIMS - AH40.10-P-9411-01MCU > Model 451.3/4 Replace valve, general. When mounting tires, the tires and rims must be carefully matched in order to guarantee the concentricity of the wheel.
Identification of matching points:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2224 · Applies to: 450, 451, 452, 454
on tires by means of a colored dot on the outboard side of the tire on sheet steel disk wheel, by color dot or punch mark on the outboard side of wheel on light alloy disk wheel, generally at valve hole Always provide all disk wheels with tires of the same construction, same make and same design. Tires approved for higher speeds may be used. Handed tires must be installed according to the arrow on the side wall of the tire. Tires are subject to an aging process with negative effects on the properties of the tire. In order to ensure optimum effectiveness in winter, M&S tires should not be used for longer than 3 years. Tires For service conversions, the tire/disk wheel specifications and dimensions should be compared with the entries in the registration papers. Damaged and defective tires must always be replaced. The repair methods employed in the tire trade are not approved by DaimlerChrysler. Small nicks (< 0.8 mm) on the side wall of the tire do not usually pose a cause for concern, and continued use of such tires is approved. Only use tires listed in the valid Service Information bulletins and repair instructions. Tire pressure (specified values, see tire pressure chart in door cutout on driver-side.) Too low tire pressure increases the rolling resistance and increases the flexing energy of the tire. This causes the critical temperature limit to be exceeded (carcass detachment) and destroys the tire. Respond to loss of tire pressure by determining the source and replacing the tire as indicated. Cleaning Using a spray wand with high-pressure nozzles to clean the wheel can lead to tire damage. Such damage occurs especially on the tire side walls. When using flat jet nozzles, observe the following instructions: Maintain a distance of at least 300 mm Do not direct the water jet at a single point on the surface of the tire for any length of time Bearing system Before putting into storage, clean tires thoroughly and check for damage and adequate tread depth. Mark the position and running direction of the tires with chalk. Do not store tires outdoors. The effects of sunlight, heat, moving air and ozone cause the rubber to lose its elasticity and strength, it ages faster and cracks. Storage areas should be dry, cool and dark. Avoid drafts by keeping doors and windows closed as much as possible. Do not allow tires to come into contact with gasoline, oil or greases as these can dissolve the rubber. Disposal Collection, storage and disposal should be performed in accordance with the legal requirements and the company's own regulations.
Rims¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2225 · Applies to: 450, 451, 452, 454 · AR: AN40.10-P-0002MCU
For safety reasons, damaged or deformed rims must not be repaired. When changing wheels, e.g. from light-alloy to steel rims, ensure that the necessary wheel bolts for the spare tire are provided in an easily visible location. Only use approved DaimlerChrysler rims of the same version. Reinforced steel rims are identified by a sticker on the wheel disc. The wheel bolts on steel and light-alloy rims should always be tightened to the specified tightening torque using a torque wrench. Retightening the wheel bolts after approx. 60 to 300 miles is not required. The seat for the tire bead must display no corrosion pits. Vehicles with tire pressure monitor Before replacing a tire, check the manufacture date of the wheel sensor. Wheel sensors, which are more than 10 years old, must be replaced. Use STAR DIAGNOSIS to read out the actual values for the tire pressure monitoring system. Check the remaining life of the wheel sensor battery, replace the wheel sensor if necessary. RETROFITTING & CONVERSION > RETROFIT BRABUS LIGHT ALLOY WHEELS - AN40.10-P-0002MCU > MODEL 451.3/4 (except 451.391 /491) with CODE (I01) Air conditioning Plus with CODE (V26) Power steering, EPS (FFO) Dimensions: Fig 1: Identifying Brabus Top Part Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2226 · Applies to: 450, 451, 452, 454 · AR: AN49.10-P-1003MCU, AN88.20-P-0001MCU
1 Remove wheels
AR40.10-P- 1100MCU Install
Retrofitting BRABUS (3) light alloy wheels is only permitted when the BRABUS parts listed in the following have been installed
2 Retrofit BRABUS muffler
AN49.10-P-1003MCU 3 Retrofit BRABUS rear apron
AN88.20-P-0001MCU 4 Retrofit BRABUS front spoiler
AN88.50-P- 0004MCC 5 Install side skirts, Brabus
AN88.80-P- 0010MCC 6 Install Brabus sport suspension
AN32.20-P- 0002MCC 7 Mount tire on BRABUS rim The valve, sleeve, sealing ring and nut are available in a repair kit and should always be replaced. AR40.10-P- 1030MCU 8 Install BRABUS light alloy wheels (3)
AR40.10-P- 1100MCU Fig 2: Identifying Brabus Light Alloy Wheels Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Mark the cut edge (arrow A)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2227 · Applies to: 450, 451, 452, 454
9 Mark the cut edge (arrow A) corresponding to dimensions (a and b) on BRABUS top part (1) Starting from the fir t attachment point (arrow B) dimension (a) is measured on the BRABUS top part (1) to the rear.Round off the cut edge (arrow A) lightly in the area of the corners.
10 Cut out the cutout along the cut edge (arrow A) Cut out the cutout carefully as the BRABUS top part (1) must be replaced in the event of damage.Window glazing device, FSC 1.6 gotis://K_67.0_01.0
11 Deburr cut edge (arrow A) with abrasive paper Do not grind off primer on the BRABUS top part (1) otherwise the BRABUS top part (1) must be replaced.
12 Position the BRABUS top part (1) on the CBS rear end (2) and align
13 Transfer the cutout (arrow A) made in the BRABUS top part (1) to the CBS rear end (2)
14 Remove BRABUS top part (1) from the CBS rear end (2)
15 Cut out the cutout along the marking (arrow C) on the CBS rear end (2) Do not damage fender liner (4) otherwise this must be replaced.Window glazing device, FSC 1.6 gotis://K_67.0_01.0
16 Install BRABUS top parts (1) on CBS rear end (2)
AN88.10-P- 0006MCC 17 Attach information label on BRABUS tire pressure to the right B-pillar
PARTS ORDERING NOTES Part no. Designation Quantity DG 58 (see EPC) Information label on BRABUS tire pressure 1 DG 98 (see EPC) Rear fender flares 1 DG 40 (see EPC) BRABUS disk wheel 4 MAINTENANCE > CHECK TIRES FOR DAMAGE AND CRACK FORMATIONS - AP40.10-P- 4051MCC > MODEL 451.3/4
Information on tires / rims¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2230 · Applies to: 450, 451, 452, 454
AH40.10-P-9411-01MCU 1 Obtain tire inflation pressure from the table
AP40.15-P-4060- 01MCU 2 Unscrew dust caps from the valves
3 Check and correct tire inflation pressure. Check and correct tire inflation pressure only when tires are cold.
4 Screw dust caps onto the valves
5 Press TPM switch (S6/1s9) in the
Fig 1: Identifying Correct Tire Inflation Pressure Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Cockpit Switch Group And TPM [RDK] Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unscrew valve protective¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2233 · Applies to: 450, 451, 452, 454
1 Unscrew valve protective cap (3) from valve (1) and unscrew valve element from the valve (1)
2 Remove wheel balance weights
3 Position bead breaker shovel of tire mounting device on the tire bead
4 Pry off the tire on the inside and outside over the safety hump of the disc wheel.
5 Clamp disc wheel on the tire mounting device
6 Align mounting head at a small distance (X, Y) to the disk wheel and fix in position
7 Position disk wheel so that valve (1) is approx. 10 cm in front of mounting head looking in the direction of rotation
8 Using an assembly lever, lever the tire bead over the assembly lug of the tire mounting device and pull off tire
9 Checking condition of rim If damaged, replace disk wheel.
10 Unscrew nut (2) on valve (1) and remove wheel sensor (A69/1, A69/2, A69/3, A69/4) downwards
11 Remove seal ring (4) and sleeve (5) and pull valve (1) out of the wheel sensor (A69/1, A69/2, A69/3, A69/4)
Attaching
12 Position valve (1) on wheel sensor (A69/1, A69/2, A69/3, A69/4) and slide sleeve (5) as well as seal ring (4) onto the valve (1) Installation: The marking (arrow A) on the sleeve (5) must be opposite the marking (arrow B) on the wheel sensor (A69/1, A69/2, A69/3, A69/4) The valve (1), sleeve (5), seal ring (4) and nut (2) are available in a
repair kit and should always¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2234 · Applies to: 450, 451, 452, 454
be replaced. 13 Position wheel sensor (A69/1, A69/2, A69/3, A69/4) with valve (1) on the disk wheel and tighten nut (2) *BA40.10-P-1002-01E 14 Coat inner and outer rim flange as well as both tire beads using tire assembly paste. Align mounting head of the tire mounting device at a small distance (X, Y) to the disk wheel Only use tire mounting paste for mounting tires.
15 Position the disk wheel so that the valve (1), viewed in the direction of rotation, is located approx. 180° degrees in front of the mounting head
16 Put the tire on the disk wheel at an angle and pull on over the rim flange Ensure that the tire does not exert any pressure on the wheel sensor (A69/1, A69/2, A69/3, A69/4) during pulling on as the latter can be damaged as a result. Observe the running direction on tires with specified running direction.Put as little stress as possible on bead area.
17 Align match points of the tire and disk wheel with each other, remove disk wheel with tire from tire mounting device
18 Pump up tire without valve element to a maximum of 3 bar The tire must slide evenly over the safety hump of the disk wheel, if necessary coat the tire bead with tire assembly paste again.
19 Screw the valve element into the valve (1) and correct tire inflation pressure to the specified value In order to prevent electrochemical corrosion, only special nickel-plated valve elements may be used may be used in the aluminum valves of wheel sensors (A69/1, A69/2, A69/3, A69/4).Uncoated brass inserts (standard
Dimensions:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2236 · Applies to: 450, 451, 452, 454
Drain
Risk of poisoning caused by swallowing the TIREFIT emulsion. Risk of injury caused by skin contact and eye contact with the TIREFIT emulsion. Risk of fire caused by ignition of the TIREFIT emulsion Do not swallow or come into contact with the TIREFIT tire sealant, which is an emulsion of rubber and terpene phenolic resin. No open fire or open light sources. AS40.10-Z-0001- 01A TIREFIT tire sealant
AH40.10-P-0001- 01MCC 1 Remove wheel
AR40.10-P- 1100MCU 2 Position the wheel upright with the valve (4)downwards for 10 minutes In order to permit the tire sealant (3) to drain away the wheel must be higher by the dimension (a) than the tire sealant reservoir (1).
3 Unscrew the valve element (4) from the valve and allow the pressure to slowly escape
Fig 1: Draining TIREFIT Sealant Out Of Tires Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
from the tire¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2237 · Applies to: 450, 451, 452, 454
4 Unscrew the nut on the valve (4) and press the valve (4) back in the inside of the wheel
5 Attach drain hose (2) to a genuine tire sealant container (1) and insert drain hose (2) through the valve bore of the disk wheel If an empty, genuine tire sealant container (1) is available. The drain hose (2) should be 400 mm long. 90 % of the tire sealant (3) can be removed using this method.
6 Extract tire sealant (3) by compressing and slowly releasing the tire sealant container (1) from the tire If an empty, genuine tire sealant container (1) is available.
7 Use a twist drill bit (dia. approximately 10 mm) to bore through the tire tread and allow the tire sealant (3) to drain into a suitable container If an empty, genuine tire sealant container (1) is not available.
*450589017000
Cordless drill/driverhttp://gotis.aftersales.mercedes- benz.com
8 Replace tires Wipe remaining tire sealant (3) off the disk wheel using a damp cloth. AR40.10-P- 1030MCU 9 Place new TIREFIT tire sealant container (1) in the vehicle
Detach wheel cover¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2239 · Applies to: 450, 451, 452, 454
3 Detach wheel cover Only on vehicles with steel wheels.
4 Unscrew wheel bolts and remove wheels In order to prevent damage, an impact wrench must not be used on light alloy rims. If the adapter for loosening the wheel antitheft locks is not available the set of master keys should be used.
BA40.10-P- 1001-01E 450589050900 *451589010900 5 Check wheel contact surfaces for dirt and corrosion Clean corroded surfaces with a wire brush or an emery cloth.
6 Install in the reverse order
7 Correct the tire inflation pressure in all wheels In the event of tire pressure loss: Determine cause and replace tires if necessary.
8 Press the TPM switch (S6/1s9) in the cockpit switch group (S6/1) and as a result recalibrate the tire pressure monitoring system
WHEELS Number Designation Model 451.3/4 BA40.10-P-1001- 01E Wheel bolt Nm 110 Fig 2: Identifying Wrench Socket (450 589 05 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Read out fault memory, erase and program in comfort¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2241 · Applies to: 450, 451, 452, 454
5 Read out fault memory, erase and program in comfort pressures using STAR DIAGNOSIS
Connect STAR DIAGNOSIS and read out fault memory
AD00.00-P- 2000- 04MCC 6 Press the TPM switch in the cockpit switch group and as a result recalibrate the tire pressure monitoring system
TESTING & REPAIR > ADJUST DRIVELINE ANGLE - AR40.20-P-0200-14MCC > TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 BE40.20-P-1001- 21A Driveline angle ∠° +0° 0' (0° 24') REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1002- 01F Bolt, axle tube to frame-type integral support Nm 160 TRAILING ARMS, WISHBONES Number Designation Model 451.3/4 BA35.15-P-1001- 02C Bolt, bar-type link to axle tube Nm 90 1. Loosen bolts (2) on bar link (4). 2. Loosen nut (1) on axle tube (3). 3. Adjust driveline angle by shifting the axle tube (3) to the left or to the right. 4. Tighten nut (1) on axle tube (3). 5. Tighten bolts (2) on bar link (4).
BE40.20-P-1002-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2244 · Applies to: 450, 451, 452, 454
06C Caster with 0° wheel toe +7° 50' (0° 30') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 BE40.20-P-1001- 07B Front axle overall toe-in ∠° +0° 36' (0° 10') TEST VALUES FOR TOE-OUT ON TURNS Number Designation Model 451.3/4 BE40.20-P-1001- 08C Toe-out on turns with the inside wheel steered through 20° ∠° -1° 36' (0° 30') INSPECTION AND SETTING DATA OF REAR AXLE CAMBER Number Designation Model 450, 451, 452 BE40.20-P-1001- 09U Rear axle camber ∠° -2° 00' (0° 30') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 451.3/4 BE40.20-P-1001- 10F Total rear axle toe ∠° +0° 00' (0° 18') TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 BE40.20-P-1001- 21A Driveline angle ∠° +0° 0' (0° 24') TIE ROD Number Designation Model 451.3/4 BA46.40-P-1002- 01F Lock nut to tie rod Nm 50
Total rear axle toe¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2249 · Applies to: 450, 451, 452, 454
BE40.20-P-1001- 10F Driveline angle BE40.20-P-1001- 21A 7 Install underfloor paneling
8 Use STAR DIAGNOSIS to calibrate steering angle sensor
Connect up STAR DIAGNOSIS and read out fault memory
AD00.00-P-2000- 04MCC INSPECTION AND SETTING DATA OF FRONT AXLE CAMBER/CASTER Number Designation Model 451.3/4 BE40.20-P-1001- 06C Camber with 0° wheel toe +0° 18' (0° 42') Max. difference left to right 0° 30' BE40.20-P-1002- 06C Caster with 0° wheel toe +7° 50' (0° 30') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 BE40.20-P-1001- 07B Front axle overall toe-in ∠° +0° 36' (0° 10') CHECK VALUES FOR TOE-OUT ANGLE Number Designation Model 451.3/4 BE40.20-P-1001- 08C Toe-out angle with inside wheel steered ∠° through 20° -1° 36' (0° 30') INSPECTION AND SETTING DATA OF REAR AXLE CAMBER Number Designation Model 450, 451, 452 BE40.20-P-1001- 09U Rear axle camber ∠° -2° 00' (0° 30') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 451.3/4 BE40.20-P-1001- 10F Total rear axle toe ∠° +0° 00' (0° 18') TEST VALUES FOR DRIVELINE ANGLE
calibrate teering angle en or¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2252 · Applies to: 450, 451, 452, 454
Connect up STAR DIAGNOSIS and read out fault memory
AD00.00-P-2000- 04MCC INSPECTION AND SETTING DATA OF FRONT AXLE CAMBER/CASTER Number Designation Model 451.3/4 BE40.20-P-1001- 06C Camber with 0° wheel toe +0° 18' (0° 42') Max. difference left to right 0° 30' BE40.20-P-1002- 06C Caster with 0° wheel toe +7° 50' (0° 30') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 BE40.20-P-1001- 07B Front axle overall toe-in ∠° +0° 36' (0° 10') CHECK VALUES FOR TOE-OUT ANGLE Number Designation Model 451.3/4 BE40.20-P-1001- 08C Toe-out angle with inside wheel steered through 20° ∠° -1° 36' (0° 30') INSPECTION AND SETTING DATA OF REAR AXLE CAMBER Number Designation Model 450, 451, 452 BE40.20-P-1001- 09U Rear axle camber ∠° -2° 00' (0° 30') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 451.3/4 BE40.20-P-1001- 10F Total rear axle toe ∠° +0° 00' (0° 18') TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 BE40.20-P-1001- 21A Driveline angle ∠° +0° 0' (0° 24') FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491
Shown on measuring point 2 (left front)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2254 · Applies to: 450, 451, 452, 454
Shown on measurement point 1 (right front) Fig 1: Identifying Inclinometer Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Positioning Measuring Sensor - Measuring Point 2 (Left Front) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Positioning Measuring Sensor - Measuring Point 1 (Right Front) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on measuring point 3 (left rear)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2255 · Applies to: 450, 451, 452, 454
Checking
The values determined with the inclinometer (1) are not used to evaluate the vehicle level, but rather to evaluate the corresponding camber, caster and toe values
1 Carry out preconditions and tests for vehicle level measurement
AR40.00-P-0202A 2 Clean measuring points This prevents any measuring errors.
3 Position measuring sensor (2), with measuring sensor connecting cable (3) facing towards vehicle center, on the recesses on the left front transverse control arm (6) (arrows) and read off vehicle level on inclinometer (1) and then save the measured values It is possible that the measuring sensor (2) may not be correctly seated in the recesses on the left front transverse control arm (6) (arrows) relative to the left front transverse control arm (6), and this could result in a positioning error.If the display on the inclinometer (1) shows "Y-position error for sensor position?", then the measuring sensor (2) on the rear measuring points must be tilted slightly towards the arrow (arrow A).
Vehicle level - front axle *BE40.20-P-1001- 02Q 4 Position measuring sensor (2), with measuring sensor connecting cable (3) facing It is possible that the measuring sensor (2) may not be correctly seated in the
Fig 4: Positioning Measuring Sensor - Measuring Point 3 (Left Rear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
towards vehicle center, on the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2256 · Applies to: 450, 451, 452, 454
recesses on the right front transverse control arm (5) (arrows) and read off vehicle level on inclinometer (1) and then save the measured values recesses on the right front transverse control arm (5) (arrows) relative to the right front transverse control arm (5), and this could result in a positioning error.If the display on the inclinometer (1) shows "Y-position error for sensor position?", then the measuring sensor (2) on the rear measuring points must be tilted slightly towards the arrow (arrow A). Vehicle level - front axle *BE40.20-P-1001- 02Q 5 Position measuring sensor (2), with measuring sensor connecting cable (3) facing towards vehicle center, on the left drive shaft (7) and read off vehicle level on inclinometer (1) and then save the measured value It is possible that the measuring sensor (2) on the lay-on point of the left drive shaft (7) may not be seated in the correct position, which could result in a positioning error.If the display on the inclinometer (1) shows "Y- position error for sensor position?", then the measuring sensor (2) on the lay-on point of the left drive shaft (7) should be turned or tilted slightly.
Vehicle level - rear axle BE40.20-P-1001- 03Q 6 Check the maximum permissible difference in front axle vehicle level between the left and right side of the vehicle Permissible difference in vehicle level between right and left side of vehicle BE40.20-P-1002- 02Q CHECK VALUES FOR VEHICLE LEVEL AT FRONT AXLE Number Designation Model 451 with engine 660, model 451.332/432 with engine 132 Model 451 with engine 132 except model 451.332/432 BE40.20-P- 1001-02Q Vehicle level - front axle ∠° 1.2 (±3) +2.4 (±3) BE40.20-P- 1002-02Q Permissible difference in vehicle level between right and left side of vehicle ∠° ±1,5 ±1,5 CHECK VALUES FOR REAR AXLE VEHICLE LEVEL CONTROL
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2257 · Applies to: 450, 451, 452, 454
Designation Model 451 with engine 132.910 except USA Model 451 with engine 132.910 USA BE40.20-P-1001- 03Q Vehicle level - rear axle ∠° 1.7 (±2.6) 1.4 (±2.6) CHECK VALUES FOR REAR AXLE VEHICLE LEVEL CONTROL Number Designation Model 451.333/433 with engine 132.930 Model 451 with engine 660, model 451.332/432 with engine 132.930 BE40.20-P-1001- 03Q Vehicle level - rear axle ∠° -0.3 (±2.6) 2.2 (±2.6) TESTING & REPAIR > CHECK CAMBER, ASSIGN TABULAR VALUE - AR40.20-P-0322- 02MCC > The camber on the front axle is measured at toe 0° and it is dependent on the vehicle level. Different vehicle levels make it therefore necessary to determine the camber specified value based on a camber table as follows: Determine level of front axle using electronic level gauge. The level value is displayed by the electronic level gauge in decimal degrees only (Romess value). The tolerance is 0° 30' Maximum camber difference between left and right is 0° 30'. Example: Level of front axle: 2° (value on level measuring device) Camber specified value: 0° 25' (determined from camber table) Level of front axle (Romess value) Camber Front axle (°) (∠) 6.0 1° 06' 5.0 0° 56' 4.0 0° 46' 3.0 0° 36' 2.0 0° 25' 1.0 0° 17' 0 0° 10' -1,0 0° 01'
TESTING & REPAIR > CHECK CASTER AND ASSIGN TO TABULAR VALUE - AR40.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2258 · Applies to: 450, 451, 452, 454
-2,0 -0° 05' TESTING & REPAIR > CHECK CASTER AND ASSIGN TO TABULAR VALUE - AR40.20-P- 0322-03MCC > The caster is measured between a 20° wheel angle to the right and a 20° wheel angle to the left, and varies according to the vehicle level. Different vehicle levels therefore make it necessary to determine the specified caster value based on a caster table as follows: Determine level of front axle and level of rear axle using the electronic inclinometer. The level value is displayed by the electronic level gauge in decimal degrees only (Romess value). The tolerance is 0° 30' Maximum caster difference between left and right is 0° 30'. Example: Level at front axle (VA): 3° (value on level measuring device) Level at rear axle (HA): 1° (value on level measuring device) Specified caster value: 8° 15' (determined from the caster table)
6 8° 55' 8° 52' 8° 48' 8° 43' 8° 37' 8° 31' 8° 23' 8° 15' 8° 05'
5 8° 50' 8° 47' 8° 43' 8° 37' 8° 31' 8° 23' 8° 14' 8° 08' 7° 55'
4 8° 46' 8° 43' 8° 37' 8° 31' 8° 23' 8° 14' 8° 04' 7° 55' 7° 44'
3 8° 41' 8° 37' 8° 31' 8° 24' 8° 15' 8° 05' 7° 55' 7° 45' 7° 35' Front axle 2 8° 35' 8° 31' 8° 23' 8° 14' 8° 04' 7° 53' 7° 43' 7° 34' 7° 24'
1 8° 30' 8° 24' 8° 16' 8° 05' 7° 55' 7° 44' 7° 34' 7° 25' 7° 16'
0 8° 23' 8° 17' 8° 07' 7° 56' 7° 46' 7° 35' 7° 25' 7° 17' 7° 10'
-1,0 8° 15' 8° 07' 7° 56' 7° 46' 7° 35' 7° 25' 7° 16' 7° 10' 7° 04'
-2,0 8° 07' 7° 58' 7° 47' 7° 37' 7° 26' 7° 17' 7° 10' 7° 05' 6° 59' Romess value (°) -3,0 -2,0 -1,0 0 1 2 3 4 5
Romess value
RA
TESTING & REPAIR > ADJUSTING CAMBER AND CASTER - AR40.20-P-0322-06MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2259 · Applies to: 450, 451, 452, 454
INSPECTION AND SETTING DATA OF FRONT AXLE CAMBER/CASTER Number Designation Model 451.3/4 BE40.20-P-1001- 06C Camber with 0° wheel toe +0° 18' (0° 42') Max. difference left to right 0° 30' BE40.20-P-1002- 06C Caster with 0° wheel toe +7° 50' (0° 30') FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491 BA33.10-P-1001- 01D Bolt, front-axle carrier to body Nm 100 1. Loosen bolts (2) of front axle (1). 2. Loosen nuts (4) on bolts (3). 3. Adjust camber and caster by moving the front axle. The camber is adjusted by moving the front axle (1) to the right or left. The caster is adjusted by moving the front axle (1) to the front or rear. 4. Tighten nuts (4) on bolts (3). 5. Tighten bolts (2) on front axle (1).
TESTING & REPAIR > CHECK TOE AND ASSIGN TO TABULAR VALUE - AR40.20-P-0322-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2260 · Applies to: 450, 451, 452, 454
11MCC > The total toe of the front and rear axle is dependent on the vehicle level. Different vehicle levels make it therefore necessary to determine the total toe specified value based on a total toe table as follows: Determine level of front axle or rear axle using the electronic inclinometer. The level value is displayed by the electronic level gauge in decimal degrees only (Romess value). Front axle The total toe tolerance is ±0° 18' The individual toe tolerance is ±0°' 09' Rear axle The total toe tolerance is ±0° 20' The individual toe tolerance is ±0°' 15' Maximum difference of individual toe-in between left and right is 0° 30'. Fig 1: Identifying Bolts Of Front Axle And Nuts On Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Example:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2261 · Applies to: 450, 451, 452, 454
Level of front axle: 3.0° (value read on inclinometer) Total toe value: 0° 48' (determined from the total toe table). Level of front axle (Romess value) Front axle overall toe-in Rear axle level (Romess value) Total rear axle toe (°) (∠°) (°) (∠°) 6.0 1° 10' - - 5.0 1° 03' 5.0 -0° 31' 4.0 0° 55' 4.0 -0° 18' 3.0 0° 48' 3.0 -0° 10' 2.0 0° 41' 2.0 0° 00' 1.0 0° 34' 1.0 0° 08' 0 0° 26' 0 0° 16' -1,0 0° 19' -1,0 0° 22' -2,0 0° 11' -2,0 0° 28' - - -3,0 0° 32' TESTING & REPAIR > ADJUST FRONT AXLE TOE - AR40.20-P-0323-02MCC > FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 BE40.20-P-1001- 07B Front axle overall toe-in ∠° +0° 36' (0° 10') TIE ROD Number Designation Model 451.3/4 BA46.40-P-1002- 01F Lock nut to tie rod Nm 50
1. Loosen clamps (3) of boots (4) on tie rods (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2262 · Applies to: 450, 451, 452, 454
- Loosen nuts (2).
- Rotate the tie rods (1) to adjust the toe-in. Check that the boots (4) are not twisted after adjusting the toe.
- Tighten nuts (2).
- Fasten clamps (3) of boots (4) on tie rods (1). Fig 1: Identifying Open-Ended Socket Wrench (450 589 01 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Clamps Of Boots On Tie Rods And Nuts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SAFETY PRECAUTIONS > SAFETY INFORMATION: WHEELS, CHASSIS ALIGNMENT¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2264 · Applies to: 450, 451, 452, 454 · AR: AS40.00-Z-9999ZZ
CHECK - AS40.00-Z-9999ZZ > MODEL all Risk of poisoning caused by swallowing the TIREFIT emulsion. Risk of injury caused by skin contact and eye contact with the TIREFIT emulsion. Risk of fire caused by ignition of the TIREFIT emulsion MODEL all AS40.10-Z-0001- 01A SAFETY PRECAUTIONS > RISK OF POISONING CAUSED BY SWALLOWING THE TIREFIT EMULSION. RISK OF INJURY CAUSED BY SKIN CONTACT AND EYE CONTACT WITH THE TIREFIT EMULSION. RISK OF FIRE CAUSED BY IGNITION OF THE TIREFIT EMULSION - AS40.10-Z-0001-01A > Do not swallow or come into contact with the TIREFIT tire sealant, which is an emulsion of rubber and terpene phenolic resin. No open fire or open light sources. Potential risks Risk of poisoning caused by swallowing the emulsion of rubber and terpene phenolic resin. Risk of injury caused by skin contact and eye contact. Especially sensitive individuals may experience allergic reactions following repeated contact. Risk of fire caused by ignition of the emulsion due to open fire and open light sources. Fig 1: Identifying Gauge (450 589 00 23 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Safety precautions/instructions¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2265 · Applies to: 450, 451, 452, 454
When using TIREFIT, ensure that smoking is prohibited and that there is no open fire in the vicinity. When working with artificial light sources, ensure that no open light sources used, in order to avoid ignition of the emulsion. Use only the compressor supplied with the TIREFIT kit. Avoid eye or skin contact with any TIREFIT emulsion that may escape. Highly sensitive (allergic) individuals should wear protective clothing, such as work gloves. Immediately change any clothing contaminated by TIREFIT. Avoid ingesting the TIREFIT emulsion, always wash hands after working with the TIREFIT emulsion. First aid measures If TIREFIT is swallowed, thoroughly rinse out mouth immediately and drink generous amounts of water. Do not induce vomiting! Consult a physician immediately. In the event of skin or eye contact, rinse area with plenty of water. Monitor development and consult physician immediately if allergic reactions occur. RETROFITTING & CONVERSION > RETROFIT SMART LIGHT ALLOY WHEELS - AZ40.10- P-0004MCC > MODEL 451.3/4 5-spoke light alloy wheels, 16 inch (Design 4) Wheels, front axle tire size: 5.5J x 16 ET33.5; 175/50 Wheels, rear axle tire size: 7J x 16 ET38.5; 215/40 Fig 1: Caution For TIREFIT Kit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6-spoke light alloy wheels, 15 inch (Design 3) up to 30.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2266 · Applies to: 450, 451, 452, 454
(Code (R74) 6-spoke light alloy wheels 175/55 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 175/55 Wheels, rear axle tire size: 6.5J x 15 ET34.5; 195/50 6-spoke light alloy wheels, 15 inch (Design 7) as of 31.8.10 (Code (R22) 6-spoke light alloy wheels 175/55 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 175/55 Wheels, rear axle tire size: 6.5J x 15 ET34.5; 195/50 Fig 1: View Of 5-Spoke Light Alloy Wheels, 16 Inch (Design 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: View Of 6-Spoke Light Alloy Wheels, 15 Inch (Design 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6-spoke light alloy wheels, 15 inch (Design 6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2267 · Applies to: 450, 451, 452, 454
(Code (R67) 6-spoke light alloy wheels 175/55 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 175/55 Wheels, rear axle tire size: 6.5J x 15 ET34.5; 195/50 6-spoke light alloy wheels, 15 inch, chrome look (Design 6) (Code (R67) 6-spoke light alloy wheels 175/55 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 175/55 Wheels, rear axle tire size: 6.5J x 15 ET34,5; 195/50 Fig 3: View Of 6-Spoke Light Alloy Wheels, 15 Inch (Design 7) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: View Of 6-Spoke Light Alloy Wheels, 15 Inch (Design 6) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6-spoke light alloy wheels, 15 inch (Design 9) as of 31.8.10 with code (494) USA version¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2268 · Applies to: 450, 451, 452, 454
(Code (R23) 6-spoke light alloy wheels 165/60 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 165/60 Wheels, rear axle tire size: 6.5J x 15 ET34.5; 195/50 9-spoke light alloy wheels, 15 inch (Design 5) up to 30.8.10 (Code (R73) 9-spoke light alloy wheels 155/60 & 175/55 R15) Wheels, front axle tire size: 4.5J x 15 ET23.5; 155/60 Wheels, rear axle tire size: 5.5J x 15 ET22; 175/55 Fig 5: View Of 6-Spoke Light Alloy Wheels, 15 Inch, Chrome Look (Design 6) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: View Of 6-Spoke Light Alloy Wheels, 15 Inch (Design 9) With Code (494) USA Version Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
12-spoke light alloy wheels, 15 inch (Design 8) as of 31.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2269 · Applies to: 450, 451, 452, 454
(Code (R24) 12-spoke light alloy wheels 155/60 & 175/55 R15) Wheels, front axle tire size: 4.5J x 15 ET23.5; 155/60 Wheels, rear axle tire size: 5.5J x 15 ET22; 175/55 12-spoke light alloy wheels, 15 inch (Design 1) (Code (R72) 12-spoke light alloy wheels 155/60 & 175/55 R15) Wheels, front axle tire size: 4.5J x 15 ET23; 155/60 Wheels, rear axle tire size: 5.5J x 15 ET22; 175/55 Fig 7: View Of 9-Spoke Light Alloy Wheels, 15 Inch (Design 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: View Of 12-Spoke Light Alloy Wheels, 15 Inch (Design 8) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Rear axle camber¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2272 · Applies to: 450, 451, 452, 454
BE40.20-P-1000-09U Rear axle toe-in MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 BE40.20-P-1000-10F Test values for distance and comparative measurement TYPE 450, 451, 452 BE40.30-P-1000-10A Toe-out on turns MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 BE40.20-P-1000-08C Vehicle level - front axle MODEL 451.3/4 BE40.20-P-1000- 02Q Vehicle level - rear axle MODEL 451.3/4 BE40.20-P-1000- 03Q TEST & ADJUSTMENT VALUES > VEHICLE LEVEL - FRONT AXLE - BE40.20-P-1000-02Q
Model 451.3/4 CHECK VALUES FOR VEHICLE LEVEL AT FRONT AXLE Number Designation Model 451 with engine 660, model 451.332/432 with engine 132 Model 451 with engine 132 except model 451.332/432 BE40.20-P- 1001-02Q Vehicle level - front axle ∠° 1.2 (±3) +2.4 (±3) BE40.20-P- 1002-02Q Permissible difference in vehicle level between right and left side of vehicle ∠° ±1,5 ±1,5 TEST & ADJUSTMENT VALUES > VEHICLE LEVEL - REAR AXLE - BE40.20-P-1000-03Q > Model 451.3/4 CHECK VALUES FOR REAR AXLE VEHICLE LEVEL CONTROL Number Designation Model 451 with engine 132.910 except USA Model 451 with engine 132.910 USA BE40.20-P-1001- 03Q Vehicle level - rear axle ∠° 1.7 (± 2.6) 1.4 (±2.6) CHECK VALUES FOR REAR AXLE VEHICLE LEVEL CONTROL Number Designation Model 451.333/433 with engine 132.930 Model 451 with engine 660, model 451.332/432 with engine 132.930 BE40.20-P-1001- Vehicle level - rear axle ∠° -0.3 (±2.6) 2.2 (±2.6)
TEST & ADJUSTMENT VALUES > FRONT AXLE CAMBER/CASTER - BE40.20-P-1000-06C¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2273 · Applies to: 450, 451, 452, 454
03Q TEST & ADJUSTMENT VALUES > FRONT AXLE CAMBER/CASTER - BE40.20-P-1000-06C
Model 450, 451, 452 MODIFICATION NOTES 8.7.03 Value changed from 0° 14' (±0° 30') to -0° 14' (±0° 30') Value changed in line 1001 for model 452.3/4 Inspection and setting data of front axle camber/caster Number Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 from 15.11.1999 to 7.1.2001 Model 450.3/4 as of 8.1.2001 up to 2.1.2003 BE40.20-P- 1001-06C Camber with 0° wheel toe +0° 15' (±0° 30') +0° 30' (±0° 30') +0° 09' (±0° 30')
Max. difference left to right 0° 30' 0° 30' 0° 30' BE40.20-P- 1002-06C Caster with 0° wheel toe +7° 00' (±1° 00') +7° 00' (±1° 00') +7° 00' (±1° 00') BE40.20-P- 1003-06C Steering axis inclination Left +14° 35' (±0° 20') +14° 35' (±0° 20') +14° 35' (±0° 20')
Right +14° 35' (±0° 20') +14° 35' (±0° 20') +14° 35' (±0° 20') Inspection and setting data of front axle camber/caster Number Designation Model 450.3/4 as of 3.1.2003 Model 451.3/4 BE40.20-P-1001- 06C Camber with 0° wheel toe +0° 18' (±0° 30') +0° 18' (±0° 42')
Max. difference left to right 0° 30' 0° 30' BE40.20-P-1002- 06C Caster with 0° wheel toe +7° 00' (±1° 00') +7° 50' (±0° 30') BE40.20-P-1003- 06C Steering axis inclination Left +14° 35' (±0° 20') +16° 00' (±0° 30')
Right +14° 35' (±0° 20') +16° 00' (±0° 30') Inspection and setting data of front axle camber/caster
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2274 · Applies to: 450, 451, 452, 454
Designation Model 452.3/4 except 452.337/437 Model 452.337/437 BE40.20-P- 1001-06C Camber with 0° wheel toe -0° 14' (±0° 30') -0° 44' (±0° 30')
Max. difference left to right 0° 30' 0° 30' BE40.20-P- 1002-06C Caster with 0° wheel toe +4° 00' (±0° 30') +3° 30' (±0° 30') BE40.20-P- 1003-06C Steering axis inclination Left +14° 12' (±0° 20') +14° 12' (±0° 20')
Right +14° 12' (±0° 20') +14° 12' (±0° 20') TEST & ADJUSTMENT VALUES > FRONT AXLE TOE - BE40.20-P-1000-07B > Model 450, 451, 452, 454 MODIFICATION NOTES 14.4.05 Front axle overall toe-in FRONT AXLE TOE CHECK VALUES Number Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 7.1.2001 Model 450.3/4 as of 8.1.2001 up to 2.1.2003 Model 450.3/4 as of 3.1.2003 BE40.20- P-1001- 07B Front axle overall toe- in ∠° +0° 24' (±0° 10') +0° 22' (± 0° 10') +0° 28' (± 0° 10') +0° 26' (± 0° 10') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 Model 452.3/4 except 452.337/437 Model 452.337/437 Model 454.0 BE40.20-P- 1001-07B Front axle overall toe-in ∠° +0° 36' (± 0° 10') +0° 16' (± 0° 10') +0° 20' (±0° 10') +0° 0' (± 0° 12') TEST & ADJUSTMENT VALUES > TOE-OUT ON TURNS - BE40.20-P-1000-08C > Model 450, 451, 452, 454 MODIFICATION NOTES 30.9.08 Value changed: Toe-out angle with inner wheel steered through 20° Model 451.3/4
TEST VALUES FOR TOE-OUT ON TURNS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2275 · Applies to: 450, 451, 452, 454
Number Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 7.1.2001 Model 450.3/4 as of 8.1.2001 BE40.20-P- 1001-08C Toe-out on turns with the inside wheel steered through 20° ∠° -2° 06' (±0° 20') -2° 06' (±0° 20') -2° 06' (± 0° 20') TEST VALUES FOR TOE-OUT ON TURNS Number Designation Model 451.3/4 Model 452.3/4 Model 454.0 BE40.20-P-1001- 08C Toe-out on turns with the inside wheel steered through 20° ∠° -1° 36' (±0° 30') -2° 06' (±0° 20') -1° 08' (±0° 30') TEST & ADJUSTMENT VALUES > REAR AXLE CAMBER - BE40.20-P-1000-09U > Model 450, 451, 452, 454 Inspection and setting data of rear axle camber Number Designation Model 450, 451, 452 BE40.20-P-1001-09U Rear axle camber ∠° -2° 00' (±0° 30') Inspection and setting data of rear axle camber Number Designation Model 454.0 BE40.20-P-1001-09U Rear axle camber ∠° -1° 00' (±0° 45') TEST & ADJUSTMENT VALUES > REAR AXLE TOE-IN - BE40.20-P-1000-10F > Model 450, 451, 452, 454 INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 02.01.2003 Model 450.3/4 as of 03.01.2003 BE40.20-P- 1001-10F Total rear axle toe ∠° +0° 20' (± 0° 10') +0° 10' (± 0° 10') +0° 10' (± 0° 12') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 451.3/4 Model 452.3/4 except 452.337/437 Model 452.337/437
BE40.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2276 · Applies to: 450, 451, 452, 454
1001-10F Total rear axle toe ∠° +0° 00' (±0° 18') +0° 06' (± 0° 12') +0° 30' (±0° 12') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 454.0 BE40.20-P-1001- 10F Total rear axle toe ∠° +0° 21' (± 0° 21') TEST & ADJUSTMENT VALUES > DRIVELINE ANGLE - BE40.20-P-1000-21A > Model 450, 451, 452, 454 TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 7.1.2001 Model 450.3/4 as of 8.1.2001 BE40.20-P- 1001-21A Driveline angle ∠° +0° 0' (±0° 30') +0° 0' (±0° 30') +0° 0' (± 0° 30') TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 Model 452.3/4 Model 454.0 BE40.20-P-1001- 21A Driveline angle ∠° +0° 0' (±0° 24') +0° 0' (±0° 30') +0° 0' (±0° 15') TEST & ADJUSTMENT VALUES > TEST VALUES FOR DISTANCE AND COMPARATIVE MEASUREMENT - BE40.30-P-1000-10A > Model 450, 451, 452 TEST VALUES FOR DISTANCE AND COMPARATIVE MEASUREMENT Number Designation Model 450 Model 451 Model 452 BE40.30-P- 1001-10A Dim. V1 mm 735 (2) - 71 (±2) V2 mm 394 (±2) - 105,3 (±2) V3 mm 850 (±2) - 105,3 (±2) V4 mm 694 (±2) - 109,5 (±2) V5 mm 873 (±2) - 109,5 (±2) V6 mm 683 (±2) - 164,4 (±2) V7 mm 1446 (±2) - 164,4 (±2) V8 mm 1327 (±2) - 64,5 (±2)
Tire designation¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2278 · Applies to: 450, 451, 452, 454
GF40.10-P-1020-01A
Rim designation GF40.10-P-1010-01A
Tire pressures GF40.10-P-1020-02MCU Information on tires / rims AH40.10-P-9411-01A TIREFIT tire sealant AH40.10-P-0001-01MCC BASIC KNOWLEDGE > ALL-SEASON TIRES, DISK WHEEL OVERVIEW - GF40.10-P- 1004MCU > MODEL 451.3/4 Vehicle/engine Disk wheel ETmm Tires Axle Snow chains 451.331 / 132.910 (52 kW) 4.5 J x 15 H2 23,5 155/60 R 15 1 - 5.5J x 15 H2 22 175/55 R 15 2 - 451.331 / 132.910 (52 kW) 5 J x 15 H2 34 175/55 R 15 1 - 6.5J x 15 H2 34,5 195/50 R 15 2 - 451.431 / 132.910 (52 kW) 4.5 J x 15 H2 23,5 155/60 R 15 1 - 5.5J x 15 H2 22 175/55 R 15 2 - 451.431 / 132.910 (52 kW) 5 J x 15 H2 34 175/55 R 15 1 - 6.5J x 15 H2 34,5 195/50 R 15 2 - BASIC KNOWLEDGE > RIM DESIGNATION - GF40.10-P-1010-01A > Example: 6 J X 15 H2 ET 44 Internal rim width in inches Code letter for height and contour of rim flange Code for one-piece drop center rim Rim diameter in inches Rim profile at outside and inside with hump shoulder ET = wheel offset (distance from rim center to wheel contact surface in mm) ET wheel offset (distance from rim center to wheel contact surface, measured in mm)
Sheet-steel disk wheel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2279 · Applies to: 450, 451, 452, 454
Light alloy rim Fig 1: Example Of Rim Designation Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Wheel Offset, Hump, Internal Rim Width And Rim Diameter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > TIRE DESIGNATION - GF40.10-P-1020-01A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2280 · Applies to: 450, 451, 452, 454
Fig 3: Identifying Sheet-Steel Disk Wheel Designation And Part Number Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Light Alloy Rim Wheel Designation And Part Number Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
For the designation of tires as per ECE directive, with the exception of ZR tires (see example 2), the speed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2281 · Applies to: 450, 451, 452, 454
symbol for the permissible maximum speed is specified after the tire size. Fig 1: Tire Designation Chart (Example 1) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Tire Designation Chart (Example 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Other important identifications¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2282 · Applies to: 450, 451, 452, 454
The four-digit code or production code as per the DOT letter sequence and numerical sequence specifies the manufacture date, e.g. 0907 = 9th week in the year 2007 (number 1 and 2 = production week, number 3 and 4 = the last digits of the year of manufacture). M + S = slush and snow tires (winter tires) All other designations are USA identification specifications. The speed symbol "W" has been added to the usual speed symbols "Q/R/S/T/H/V/VR/ZR". This symbol identifies tires that have been approved for speeds up to a maximum speed of 270 km/h. When installing new tires, these tires can be used as a replacement for "VR" and "ZR" tires. An entry in the registration papers is not necessary. Fig 3: Tire Designation Chart (Example 3 - Commercial Vehicle) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Tire Manufacturer With Tire Designation, Radial Tires Designation, Tubeless Tires Designation, And Date Of Manufacture Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The speed symbol "Y" has also been added. This symbol identifies tires that have been approved for speeds¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2283 · Applies to: 450, 451, 452, 454
up to a maximum speed of over 270 km/h. BASIC KNOWLEDGE > TIRE PRESSURES - GF40.10-P-1020-02MCU > Vehicle Tire pressure label Tires Tire pressure (in psi) Comfort air pressure Tire pressure (in psi) Comfort air pressure Tire pressure (in psi) up to V max. Tire pressure (in psi) up to V max. Partial load Front axle Partial load RA Full load Front axle Full load RA Partial load Front axle Partial load RA Full load Front axle Full load RA 451.3/4 - 155/60 R 15 74 T 29,0 - 29,0 - 29,0 - 29,0 - 175/55 R 15 77 T - 36,2 - 36,2 - 36,2 - 36,2 451.3/4 - 175/55 R 15 74 T 29,0 - 29,0 - 29,0 - 29,0 - 195/50 R 15 77 T - 36,2 - 36,2 - 36,2 - 36,2 BASIC KNOWLEDGE > TIRE PRESSURE MONITOR (TPM [RDK]) LOCATION OF COMPONENTS - GF40.15-P-0001-06MCU >
Function requirements¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2285 · Applies to: 450, 451, 452, 454
Circuit 15 On Tire pressure monitor system functional General information The tire pressure monitor assists the driver when checking the tire inflation pressure and thus serves active safety. The Tire pressure monitor monitors the air pressure in the individual tires. A previously stored tire pressure is used as a comparative value. In the event of a relevant pressure loss the driver is warned via the tire pressure monitor warning lamp. The tire pressure measuring range extends from p = 0 and 5.5 bar. The tire pressure monitor is made up of the following component functions: Tire pressure sensing Warning display Manual restart Tire pressure sensing The TPM [RDK] control unit is permanently operational. Each time the CAN wakes-up the TPM [RDK] control unit performs a re-initialization. While driving, the TPM [RDK] system continuously monitors the tire pressure of all rotating wheels (with circuit 15 Off for a further t = 19 min). With new wheels or a parking time in excess of t > 19 min, the individual wheel detection and axle assignment must be completed first via the TPM wheel sensors. The TPM wheel sensors transmit data telegrams every t = 60 s while driving. Fig 1: Tire Pressure Monitor Function CAN Communication Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Left front TPM [RDK] wheel sensor (A69/1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2288 · Applies to: 450, 451, 452, 454
Right front TPM [RDK] wheel sensor (A69/2) Left rear tire pressure monitor sensor (A69/3) Rear right tire pressure control wheel sensor (A69/4) The data telegrams contain the pressure, tire pressure temperature, individual serial number and status information (manufacturer, direction of rotation, operating mode etc.). If a pressure loss is detected, the tire pressure monitor warning lamp (A1e66) in the instrument cluster (A1) is actuated by the TPM [RDK] control unit. The TPM [RDK] control unit constantly monitors all input signals and output signals for faults. Detected faults that are relevant to function are entered into the fault memory. Discrete inputs Circuit 30 Circuit 31 CAN signals The TPM [RDK] control unit is connected to the Control Area Network (databus/CAN Bus) (CAN) for data exchange. BASIC KNOWLEDGE > WHEEL SENSOR, COMPONENT DESCRIPTION - GF40.15-P- 5126MCU > MODEL 451.3/4 Location The wheel sensors are fastened securely inside the respective rim. Fig 1: Locating Wheel Sensors Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Code:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2290 · Applies to: 450, 451, 452, 454
Designation: Position: A1 Instrument cluster 12L A69/1 Left front TPM [RDK] wheel sensor 15L A69/2 Right front TPM [RDK] wheel sensor 17L A69/3 Left rear TPM [RDK] wheel sensor 19L A69/4 Right rear TPM [RDK] wheel sensor 20L N10/10 SAM control unit 3L N10/10f12 Fuse 12 4L N10/10f19 Fuse 19 2L N88 TPM control module 4A N88 TPM control module 11A S6/1 Cockpit switch group 8L S6/1s9 TPM [RDK] switch 8L W10 Ground (battery) 3E W10 Ground (battery) 9E Z3/24 Circuit 15 (fused) connector sleeve, function 1E Z37/2 CAN engine bus (low) connector sleeve 11E Z37/3 CAN engine bus (high) connector sleeve 13E Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 4E Z81 Circuit 58d connector sleeve 10E
Fig 1: Tire Pressure Monitor Control System - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2291 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Socket wrench bit for loosening and securing wheel bolts on aluminum rims.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2294 · Applies to: 450, 451, 452, 454
NOTE: WAF 15 socket for wheel bolts, long version Smart no. 0007106. SPECIAL TOOLS > 230 589 00 99 01 PLUG-IN REVERSIBLE RATCHET - WS40.00-P-0061- 01B > FG40/Set B FG 00/Set A/B/C/K MODEL 230.467 /474 /475 /476 MODEL 164, 203, 209, 211, 219 with ENGINE 642 MODEL 221 with ENGINE 642 MODEL 251 with ENGINE 642 MODEL 463 with ENGINE 642 MODEL 450, 451, 452, 454 MODIFICATION NOTES 15.4.08 Replacement for: 452 589 00 16 00 plug-in reversible ratchet WS00.00-P-0241A Use: Plug in reversible ratchet 9 x 12 mm for hexagon bit blades 5/16" (8 mm). NOTE: Fig 1: Identifying Socket Wrench Bit (450 589 05 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Smart-no..: 001 5802 V000 0000 00Separate part for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2295 · Applies to: 450, 451, 452, 454
230 589 00 99 00.
SPECIAL TOOLS > 451 589 01 09 00 SET OF MASTER KEYS - WS40.00-P-3007A > FG 40/Set A MODEL 451 Use: Set of master keys for opening anti-theft wheel locks when code key is not available. This master key makes it possible to reorder for end-user customers who have lost their security key as it can be used to determine the code number. NOTE: Reordering info from Tel: +49 2232 943 170 or www.adl-sa.com Fig 1: Identifying Plug-In Reversible Ratchet (230 589 00 99 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: WHEELS, CHASSIS ALIGNMENT CHECK -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2296 · Applies to: 450, 451, 452, 454 · AR: WS40.00-Z-9999CZ
WS40.00-Z-9999CZ > MODEL all 129 589 01 21 00 Retainer device FG 40/01/Set B WS40.00-P-0025B 230 589 00 99 01 Plug-in reversible ratchet FG40/Set B FG 00/Set A/B/C/K WS40.00-P-0061-01B 450 589 05 09 00 Socket wrench bit FG 40/Set A WS40.00-P-0060A 451 589 01 09 00 Set of master keys FG 40/Set A WS40.00-P-3007A 454 589 08 09 00 Socket wrench bit FG 40/Set B WS40.00-P-0062B Fig 1: Identifying Set Of Master Keys (451 589 01 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > TIREFIT TIRE SEALANT - AH40.10-P-0001-01MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2297 · Applies to: 450, 451, 452, 454
Model 451.3/4 NOTE: TIREFIT tire sealant has a shelf life of 3 to 4 years depending on the version, measured from the date of manufacture marked on the container. After this period has elapsed or the expiration date specified on the container is exceeded the TIREFIT tire sealant should be replaced. Use: TIREFIT tire sealer can be used to seal minor perforations, especially as encountered on the tire's tread, to allow repairs at the location where the tire problem occurs. The tire can then continue in limited use until it can be replaced. The customer is obliged, after using TIREFIT tire sealant to locate the next smart service center immediately in order to replace the damaged tire. Tires which have been treated with TIREFIT tire sealant must not be repaired. They must always be replaced with new tires of the same make and manufacture. To avoid strong odors from the TIREFIT tire sealer, take the tire outside to bleed the air from it. Regulations for disposal Dispose of used and expired TIREFIT tire sealer by emptying it into the special container for used painting materials (refer to Service Products Manual Volume 2, Chapter U, Group 00 (22), Topic 2.3). Fire hazard! No fire, naked flames or smoking. Avoid producing sparks. Avoid inhaling vapors. Fig 1: Identifying Tirefit Tire Sealant Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > INFORMATION ON TIRES / RIMS - AH40.10-P-9411-01A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2298 · Applies to: 450, 451, 452, 454
Tires For service conversions, the tire/disk wheel specifications and dimensions should be compared with the entries in the registration papers. Damaged and defective tires must always be replaced. The repair methods employed in the tire trade are not approved by Mercedes-Benz. Small nicks (< 0.8 mm) on the side wall of the tire do not usually pose a cause for concern, and continued use of such tires is approved. Clean the disk wheels in the bead seat area before mounting the tires. Replace tire valve, general. If the tires have a matching point, then, when mounting the tires, a specific assignment of tires and disk wheel (matching) is necessary to ensure smooth wheel operation. Identification of matching points: on tires by means of a colored dot on the outboard side of the tire on a steel rim, by color dot or punch mark on the outboard side of wheel on light alloy wheel, in general on the valve hole. Model 140: in addition color dot or countersink in rim base. If a single tire is replaced, always mount the new tire on the front axle. This does not apply to vehicles with different tires of varying specifications on the front and rear wheels. Always provide all disk wheels with tires of the same construction, same make and same design. If the maximum permissible speed of an M+S tire is lower than the maximum speed of the vehicle, an appropriate warning sticker must be affixed within the driver's field of view. Tires approved for higher speeds may be used. Run in new tires for approx. 100 km at moderate speed. Handed tires must be installed according to the arrow on the side wall of the tire. Tires are subject to an aging process with negative effects on the properties of the tire. In order to ensure optimum effectiveness in winter, M&S tires should not be used for longer than 4 years. Tire pressure (For specified values, see the tire pressure chart inside the fuel filler flap; on Vaneo model 414, see the B- pillar in the passenger side) Too low tire pressure increases the rolling resistance and increases the flexing energy of the tire. This causes the critical temperature limit to be exceeded (carcass detachment) and destroys the tire. In the event of a pressure loss establish cause and if necessary establish cause and if necessary replace tire, tire valve or disk wheel. Cleaning The use of high-pressure spray wands projecting a concentrated round-pattern stream to clean the wheels can lead to tire damage. Such damage occurs especially on the tire side walls. When using flat jet nozzles,
observe the following instructions:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2299 · Applies to: 450, 451, 452, 454
Maintain a distance of at least 300 mm Do not direct the water jet at a single point on the surface of the tire for any length of time Bearing system Before putting into storage, clean tires thoroughly and check for damage and adequate tread depth. Mark the position and running direction of the tires with chalk. Do not store tires outdoors. The effects of sunlight, heat, moving air and ozone cause the rubber to lose its elasticity and strength, it ages faster and cracks. Storage areas should be dry, cool and dark. Avoid drafts by keeping doors and windows closed as much as possible. Do not bring tire into contact with gasoline, oil or greases as these dissolve rubber. Disposal Collection, storage and disposal should be performed in accordance with the legal requirements and the company's own regulations. Rims For safety reasons, damaged or deformed rims must not be repaired. When changing wheels, e.g. light alloy wheels for steel rims, ensure that the wheel bolts required for the spare wheel are enclosed in a clearly visible position. Since December 1994 all models 124 and 202 receive a spare wheel with a steel rim. Vehicles with light alloy rims fitted at the plant have corresponding wheel bolts enclosed. Only use disk wheels of the same design approved by Mercedes-Benz. Strengthened steel rims are identified by a sticker on the wheel disk. On steel rims and light alloy disk wheels in general the wheel bolts should be tightened to the specified torque using a torque wrench. Retightening of the wheel bolts after approx. 100 to 500 km is not required. The seat for the tire bead must display no corrosion pits. Before inserting a new tire valve clean the contact surfaces on the disk wheel. To support the tire valve wheel covers must be fitted to steel rims. Vehicles with tire pressure monitor Before replacing a tire, check the manufacture date of the wheel sensor. Wheel sensors, which are older than 5 or 7 years, must be replaced. Use STAR DIAGNOSIS to read out the actual values for the tire pressure monitoring system. Check the remaining life of the wheel sensor battery, replace the wheel sensor if necessary. GENERAL INFORMATION > INFORMATION ON TIRES / RIMS - AH40.10-P-9411-01MCU > Model 451.3/4 Replace valve, general. When mounting tires, the tires and rims must be carefully matched in order to guarantee the concentricity of the wheel.
Identification of matching points:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2300 · Applies to: 450, 451, 452, 454
on tires by means of a colored dot on the outboard side of the tire on sheet steel disk wheel, by color dot or punch mark on the outboard side of wheel on light alloy disk wheel, generally at valve hole Always provide all disk wheels with tires of the same construction, same make and same design. Tires approved for higher speeds may be used. Handed tires must be installed according to the arrow on the side wall of the tire. Tires are subject to an aging process with negative effects on the properties of the tire. In order to ensure optimum effectiveness in winter, M&S tires should not be used for longer than 3 years. Tires For service conversions, the tire/disk wheel specifications and dimensions should be compared with the entries in the registration papers. Damaged and defective tires must always be replaced. The repair methods employed in the tire trade are not approved by DaimlerChrysler. Small nicks (< 0.8 mm) on the side wall of the tire do not usually pose a cause for concern, and continued use of such tires is approved. Only use tires listed in the valid Service Information bulletins and repair instructions. Tire pressure (specified values, see tire pressure chart in door cutout on driver-side.) Too low tire pressure increases the rolling resistance and increases the flexing energy of the tire. This causes the critical temperature limit to be exceeded (carcass detachment) and destroys the tire. Respond to loss of tire pressure by determining the source and replacing the tire as indicated. Cleaning Using a spray wand with high-pressure nozzles to clean the wheel can lead to tire damage. Such damage occurs especially on the tire side walls. When using flat jet nozzles, observe the following instructions: Maintain a distance of at least 300 mm Do not direct the water jet at a single point on the surface of the tire for any length of time Bearing system Before putting into storage, clean tires thoroughly and check for damage and adequate tread depth. Mark the position and running direction of the tires with chalk. Do not store tires outdoors. The effects of sunlight, heat, moving air and ozone cause the rubber to lose its elasticity and strength, it ages faster and cracks. Storage areas should be dry, cool and dark. Avoid drafts by keeping doors and windows closed as much as possible. Do not allow tires to come into contact with gasoline, oil or greases as these can dissolve the rubber. Disposal Collection, storage and disposal should be performed in accordance with the legal requirements and the company's own regulations.
Rims¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2301 · Applies to: 450, 451, 452, 454 · AR: AN40.10-P-0002MCU
For safety reasons, damaged or deformed rims must not be repaired. When changing wheels, e.g. from light-alloy to steel rims, ensure that the necessary wheel bolts for the spare tire are provided in an easily visible location. Only use approved DaimlerChrysler rims of the same version. Reinforced steel rims are identified by a sticker on the wheel disc. The wheel bolts on steel and light-alloy rims should always be tightened to the specified tightening torque using a torque wrench. Retightening the wheel bolts after approx. 60 to 300 miles is not required. The seat for the tire bead must display no corrosion pits. Vehicles with tire pressure monitor Before replacing a tire, check the manufacture date of the wheel sensor. Wheel sensors, which are more than 10 years old, must be replaced. Use STAR DIAGNOSIS to read out the actual values for the tire pressure monitoring system. Check the remaining life of the wheel sensor battery, replace the wheel sensor if necessary. RETROFITTING & CONVERSION > RETROFIT BRABUS LIGHT ALLOY WHEELS - AN40.10-P-0002MCU > MODEL 451.3 /4 (except 451.391 /491) with CODE (I01) Air conditioning Plus with CODE (V26) Power steering, EPS (FFO) Dimensions: Fig 1: Identifying Brabus Top Part Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
the TIREFIT emulsion.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2305 · Applies to: 450, 451, 452, 454
Risk of injury caused by skin contact and eye contact with the TIREFIT emulsion. Risk of fire caused by ignition of the TIREFIT emulsion the TIREFIT tire sealant, which is an emulsion of rubber and terpene phenolic resin. No open fire or open light sources. 1 Fold back the floor mat on the passenger's side (1) When foldinTest values for driveline anglemaged by breaking or cracking.
2 Remove the TIREFIT tire sealer The TIREFIT tire sealant is located behind the compressor.
Checking
3 Check expiration date (2) on the bottle. Replace the TIREFIT tire sealant when the expiry date (2) is reached
TIREFIT tire sealant
AH40.10-P-0001- 01MCC Install
4 Insert TIREFIT tire sealant
5 Position floor covering on passenger-side (1)
MAINTENANCE > TIRE INFLATION PRESSURE TABLE - AP40.15-P-4060-01MCU > Tire inflation pressure in bar with tires cold
Wheel/tire size Front axle Rear axle 155/60 R 15 2.0
175/55 R 15
2.5 For each 18°F tire air temperature change the tire inflation pressure changes by approx. 0.1 bar. This is to be observed when checking the tire inflation pressure in workshop areas, especially in winter, when after a prolonged workshop visit the tire air temperature has reached room temperature. Example: Room air temperature = 36°F Ambient air temperature = 0°F
Information on tire/rims¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2310 · Applies to: 450, 451, 452, 454
AH40.10-P-9411- 01MCU 1 Obtain tire inflation pressure from the table
AP40.15-P-4060- 01MCU 2 Unscrew dust caps from the valves
3 Check and correct tire inflation pressure. Check and correct tire inflation pressure only when tires are cold.
4 Screw dust caps onto
Fig 1: Identifying Tire Inflation Pressure Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Cockpit Switch Group And TPM (RDK) Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Detaching¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2313 · Applies to: 450, 451, 452, 454
Information on tires / rims
AH40.10-P-9411- 01MCU 1 Unscrew valve protective cap (3) from valve (1) and unscrew valve element from the valve (1)
2 Remove wheel balance weights
3 Position bead breaker shovel of tire mounting device on the tire bead
4 Pry off the tire on the inside and outside over the safety hump of the disc wheel.
5 Clamp disc wheel on the tire mounting device
Fig 1: Replacing Tires Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Align mounting head at¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2314 · Applies to: 450, 451, 452, 454
6 Align mounting head at a small distance (X, Y) to the disk wheel and fix in position
7 Position disk wheel so that valve (1) is approx. 10 cm in front of mounting head looking in the direction of rotation
8 Using an assembly lever, lever the tire bead over the assembly lug of the tire mounting device and pull off tire
9 Checking condition of rim If damaged, replace disk wheel.
10 Unscrew nut (2) on valve (1) and remove wheel sensor (A69/1, A69/2, A69/3, A69/4) downwards
11 Remove seal ring (4) and sleeve (5) and pull valve (1) out of the wheel sensor (A69/1, A69/2, A69/3, A69/4)
Attaching
12 Position valve (1) on wheel sensor (A69/1, A69/2, A69/3, A69/4) and slide sleeve (5) as well as seal ring (4) onto the valve (1) Installation: The marking (arrow A) on the sleeve (5) must be opposite the marking (arrow B) on the wheel sensor (A69/1, A69/2, A69/3, A69/4).The valve (1), sleeve (5), seal ring (4) and nut (2) are available in a repair kit and should always be replaced.
13 Position wheel sensor (A69/1, A69/2, A69/3, A69/4) with valve (1) on the disk wheel and tighten nut (2) *BA40.10-P-1002-01E 14 Coat inner and outer rim flange as well as both tire beads using Only use tire mounting paste for mounting tires.
tire a¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2315 · Applies to: 450, 451, 452, 454
embly pa te Align mounting head of the tire mounting device at a small distance (X, Y) to the disk wheel 15 Position the disk wheel so that the valve (1), viewed in the direction of rotation, is located approx. 180° degrees in front of the mounting head
16 Put the tire on the disk wheel at an angle and pull on over the rim flange Ensure that the tire does not exert any pressure on the wheel sensor (A69/1, A69/2, A69/3, A69/4) during pulling on as the latter can be damaged as a result. Observe the running direction on tires with specified running direction.Put as little stress as possible on bead area.
17 Align match points of the tire and disk wheel with each other, remove disk wheel with tire from tire mounting device
18 Pump up tire without valve element to a maximum of 3 bar The tire must slide evenly over the safety hump of the disk wheel, if necessary coat the tire bead with tire assembly paste again.
19 Screw the valve element into the valve (1) and correct tire inflation pressure to the specified value In order to prevent electrochemical corrosion, only special nickel-plated valve elements may be used may be used in the aluminum valves of wheel sensors (A69/1, A69/2, A69/3, A69/4).Uncoated brass inserts (standard valve elements) lead to severe corrosion
front axle carrier, axle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2317 · Applies to: 450, 451, 452, 454
tube, rear-axle frame- type integral support, engine or transmission. 3 Detach wheel cover Only on vehicles with steel wheels.
4 Unscrew wheel bolts and remove wheels In order to prevent damage, an impact wrench must not be used on light alloy rims. If the adapter for loosening the wheel antitheft locks is not available the set of master keys should be used.
*BA40.10-P-1001- 01E Fig 2 Fig 3 5 Check wheel contact surfaces for dirt and corrosion Clean corroded surfaces with a wire brush or an emery cloth.
6 Install in the reverse order
7 Correct the tire inflation pressure in all wheels In the event of tire pressure loss: Determine cause and replace tires if necessary.
8 Press the TPM switch (S6/1s9) in the cockpit switch group (S6/1) and as a result recalibrate the tire pressure monitoring system
WHEELS Number Designation Model 451.3/4 BA40.10-P-1001-01E Wheel bolt Nm 110
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2319 · Applies to: 450, 451, 452, 454
1 Adjust driver seat to the rear
2 Unscrew nuts (1) and remove TPM [RDK] control unit (N88) until the electrical connector (2) is accessible Replace self- locking nuts (1).
3 Disconnect electrical connector (2) on TPM [RDK] control unit (N88) and remove TPM [RDK] control unit (N88)
4 Install in the reverse order
5 Read out fault memory, erase and program in comfort pressures using STAR DIAGNOSIS
Connect STAR DIAGNOSIS and read out fault memory
AD00.00-P-2000- 04MCC 6 Press the TPM switch in the cockpit switch group and as a result recalibrate the tire pressure monitoring system
Fig 1: Identifying TPM (RDK) Control Unit, Electrical Connector And Nut Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > ADJUST DRIVELINE ANGLE - AR40.20-P-0200-14MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2320 · Applies to: 450, 451, 452, 454
TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 BE40.20-P-1001-21A Driveline angle ∠° +0° 0' (0° 24') REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1002-01F Bolt, axle tube to frame-type integral support Nm 160 TRAILING ARMS, WISHBONES Number Designation Model 451.3/4 BA35.15-P-1001-02C Bolt, bar-type link to axle tube Nm 90 1. Loosen bolts (2) on bar link (4). 2. Loosen nut (1) on axle tube (3). 3. Adjust driveline angle by shifting the axle tube (3) to the left or to the right. 4. Tighten nut (1) on axle tube (3). 5. Tighten bolts (2) on bar link (4).
by mea uring device¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2322 · Applies to: 450, 451, 452, 454
manufacturer.Perform measurements on unladen vehicle with tank 90% full. Camber BE40.20-P-1001- 06C Caster BE40.20-P-1002- 06C Front axle overall toe-in BE40.20-P-1001- 07B Toe-out on turns with the inside wheel steered through 20° BE40.20-P-1001- 08C Rear axle camber BE40.20-P-1001- 09U Total rear axle toe BE40.20-P-1001- 10F Driveline angle *BE40.20-P-1001- 21A 3 Adjust front axle toe
AR40.20-P-0323- 02MCC Front axle overall toe-in BE40.20-P-1001- 07B BA46.40-P-1002- 01F Fig 1 4 Perform final measurement Camber BE40.20-P-1001- 06C Caster BE40.20-P-1002- 06C Front axle overall toe-in BE40.20-P-1001- 07B Toe-out on turns with the inside wheel steered through 20° BE40.20-P-1001- 08C Rear axle camber BE40.20-P-1001- 09U Total rear axle toe BE40.20-P-1001- 10F Driveline angle If, after adjusting the front axle toe, other values are still outside the tolerance *BE40.20-P-1001- 21A
range or the steering¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2323 · Applies to: 450, 451, 452, 454
wheel is not on straight:Refer to: ↓ Perform advanced wheel alignment AR40.20-P- 0250MCC 5 Use STAR DIAGNOSIS to calibrate steering angle sensor
Connect up STAR DIAGNOSIS and read out fault memory
AD00.00-P-2000- 04MCC INSPECTION AND SETTING DATA OF FRONT AXLE CAMBER/CASTER Number Designation Model 451.3/4 BE40.20-P-1001-06C Camber with 0° wheel toe +0° 18' (0° 42') Max. difference left to right 0° 30' BE40.20-P-1002-06C Caster with 0° wheel toe +7° 50' (0° 30') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 BE40.20-P-1001-07B Front axle overall toe- in ∠° +0° 36' (0° 10') TEST VALUES FOR TOE-OUT ON TURNS Number Designation Model 451.3/4 BE40.20-P-1001-08C Toe-out on turns with the inside wheel steered through 20° ∠° -1° 36' (0° 30') INSPECTION AND SETTING DATA OF REAR AXLE CAMBER Number Designation Model 450, 451, 452 BE40.20-P-1001-09U Rear axle camber ∠° -2° 00' (0° 30') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 451.3/4 BE40.20-P-1001-10F Total rear axle toe ∠° +0° 00' (0° 18') TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 BE40.20-P-1001-21A Driveline angle ∠° +0° 0' (0° 24')
Rear axle camber¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2325 · Applies to: 450, 451, 452, 454
BE40.20-P-1001- 09U Total rear axle toe BE40.20-P-1001- 10F Driveline angle *BE40.20-P-1001- 21A 3 Record vehicle level at front and rear axles using electronic inclinometer
AR40.20-P- 0303MCC 4 Determine toe of front axle from the table
AR40.20-P-0322- 11MCC 5 Adjust front axle toe
AR40.20-P-0323- 02MCC Front axle overall toe-in BE40.20-P-1001- 07B BA46.40-P-1002- 01F Figure 6 Perform final measurement Camber BE40.20-P-1001- 06C Caster BE40.20-P-1002- 06C Front axle overall toe-in BE40.20-P-1001- 07B Toe-out on turns with the inside wheel steered through 20° BE40.20-P-1001- 08C Rear axle camber BE40.20-P-1001- 09U Total rear axle toe BE40.20-P-1001- 10F Driveline angle If, after adjusting the front axle toe, other values are still outside the tolerance range or the steering wheel is not on straight:Refer to: ↓ *BE40.20-P-1001- 21A Perform advanced wheel alignment AR40.20-P- 0250MCE 7 Use STAR DIAGNOSIS to calibrate steering angle sensor
Connect up STAR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2326 · Applies to: 450, 451, 452, 454
DIAGNOSIS and read out fault memory
AD00.00-P-2000- 04MCC INSPECTION AND SETTING DATA OF FRONT AXLE CAMBER/CASTER Number Designation Model 451.3/4 BE40.20-P-1001-06C Camber with 0° wheel toe +0° 18' (0° 42') Max. difference left to right 0° 30' BE40.20-P-1002-06C Caster with 0° wheel toe +7° 50' (0° 30') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 BE40.20-P-1001-07B Front axle overall toe- in ∠° +0° 36' (0° 10') TEST VALUES FOR TOE-OUT ON TURNS Number Designation Model 451.3/4 BE40.20-P-1001-08C Toe-out on turns with the inside wheel steered through 20° ∠° -1° 36' (0° 30') INSPECTION AND SETTING DATA OF REAR AXLE CAMBER Number Designation Model 450, 451, 452 BE40.20-P-1001-09U Rear axle camber ∠° -2° 00' (0° 30') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 451.3/4 BE40.20-P-1001-10F Total rear axle toe ∠° +0° 00' (0° 18') TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 BE40.20-P-1001-21A Driveline angle ∠° +0° 0' (0° 24') TIE ROD Number Designation Model 451.3/4 BA46.40-P-1002-01F Lock nut to tie rod Nm 50
*BA35 15 P 1001¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2328 · Applies to: 450, 451, 452, 454
02C 5 Adjust front axle toe
AR40.20-P-0323- 02MCC Front axle overall toe- in BE40.20-P-1001- 07B BA46.40-P-1002- 01F Figure 6 Perform final measurement Camber BE40.20-P-1001- 06C Caster BE40.20-P-1002- 06C Front axle overall toe- in BE40.20-P-1001- 07B Toe-out angle with inside wheel steered through 20° BE40.20-P-1001- 08C Rear axle camber BE40.20-P-1001- 09U Total rear axle toe BE40.20-P-1001- 10F Driveline angle *BE40.20-P-1001- 21A 7 Install underfloor paneling
8 Use STAR DIAGNOSIS to calibrate steering angle sensor
Connect up STAR DIAGNOSIS and read out fault memory
AD00.00-P-2000- 04MCC INSPECTION AND SETTING DATA OF FRONT AXLE CAMBER/CASTER Number Designation Model 451.3/4 BE40.20-P-1001-06C Camber with 0° wheel toe +0° 18' (0° 42') Max. difference left to right 0° 30' BE40.20-P-1002-06C Caster with 0° wheel toe +7° 50' (0° 30') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4
BE40.20-P-1001-07B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2329 · Applies to: 450, 451, 452, 454
Front axle overall toe- in ∠° +0° 36' (0° 10') CHECK VALUES FOR TOE-OUT ANGLE Number Designation Model 451.3/4 BE40.20-P-1001-08C Toe-out angle with inside wheel steered ∠° through 20° -1° 36' (0° 30') INSPECTION AND SETTING DATA OF REAR AXLE CAMBER Number Designation Model 450, 451, 452 BE40.20-P-1001-09U Rear axle camber ∠° -2° 00' (0° 30') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 451.3/4 BE40.20-P-1001-10F Total rear axle toe ∠° +0° 00' (0° 18') TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 BE40.20-P-1001-21A Driveline angle ∠° +0° 0' (0° 24') FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491 BA33.10-P-1001-01D Bolt, front-axle carrier to body Nm 100 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1002-01F Bolt, axle tube to frame-type integral support Nm 160 TRAILING ARMS, WISHBONES Number Designation Model 451.3/4 BA35.15-P-1001-02C Bolt, bar-type link to axle tube Nm 90 TIE ROD Number Designation Model 451.3/4
*BA35.15-P-1001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2331 · Applies to: 450, 451, 452, 454
01F *BA35.15-P-1001- 02C 7 Determine toe of front axle from the table
AR40.20-P-0322- 11MCC 8 Adjust front axle toe
AR40.20-P-0323- 02MCC Front axle overall toe- in BE40.20-P-1001- 07B BA46.40-P-1002- 01F Figure 9 Perform final measurement Camber BE40.20-P-1001- 06C Caster BE40.20-P-1002- 06C Front axle overall toe- in BE40.20-P-1001- 07B Toe-out angle with inside wheel steered through 20° BE40.20-P-1001- 08C Rear axle camber BE40.20-P-1001- 09U Total rear axle toe BE40.20-P-1001- 10F Driveline angle *BE40.20-P-1001- 21A 10 Install underfloor paneling
11 Use STAR DIAGNOSIS to calibrate steering angle sensor
Connect up STAR DIAGNOSIS and read out fault memory
AD00.00-P-2000- 04MCC INSPECTION AND SETTING DATA OF FRONT AXLE CAMBER/CASTER Number Designation Model 451.3/4 BE40.20-P-1001-06C Camber with 0° wheel toe +0° 18' (0° 42') Max. difference left to right 0° 30'
BE40.20-P-1002-06C¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2332 · Applies to: 450, 451, 452, 454
Caster with 0° wheel toe +7° 50' (0° 30') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 BE40.20-P-1001-07B Front axle overall toe- in ∠° +0° 36' (0° 10') CHECK VALUES FOR TOE-OUT ANGLE Number Designation Model 451.3/4 BE40.20-P-1001-08C Toe-out angle with inside wheel steered through 20° ∠° -1° 36' (0° 30') INSPECTION AND SETTING DATA OF REAR AXLE CAMBER Number Designation Model 450, 451, 452 BE40.20-P-1001-09U Rear axle camber ∠° -2° 00' (0° 30') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 451.3/4 BE40.20-P-1001-10F Total rear axle toe ∠° +0° 00' (0° 18') TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 BE40.20-P-1001-21A Driveline angle ∠° +0° 0' (0° 24') FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491 BA33.10-P-1001-01D Bolt, front-axle carrier to body Nm 100 REAR AXLE CARRIER Number Designation Model 451.3/4 BA35.10-P-1002-01F Bolt, axle tube to frame-type integral support Nm 160 TRAILING ARMS, WISHBONES Number Designation Model 451.3/4 BA35.15-P-1001-02C Bolt, bar-type link to Nm 90
Shown on measurement point 1 (right front)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2334 · Applies to: 450, 451, 452, 454
Shown on measuring point 3 (left rear) Fig 2: Positioning Measuring Sensor - Shown On Measuring Point 2 (Left Front) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Positioning Measuring Sensor - Shown On Measuring Point 1 (Right Front) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Positioning Measuring Sensor - Shown On Measuring Point 3 (Left Rear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Checking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2335 · Applies to: 450, 451, 452, 454
The values determined with the inclinometer (1) are not used to evaluate the vehicle level, but rather to evaluate the corresponding camber, caster and toe values
1 Carry out preconditions and tests for vehicle level measurement
AR40.00-P-0202A 2 Clean measuring points This prevents any measuring errors.
3 Position measuring sensor (2), with measuring sensor connecting cable (3) facing towards vehicle center, on the recesses on the left front transverse control arm (6) (arrows) and read off vehicle level on inclinometer (1) and then save the measured values It is possible that the measuring sensor (2) may not be correctly seated in the recesses on the left front transverse control arm (6) (arrows) relative to the left front transverse control arm (6), and this could result in a positioning error.If the display on the inclinometer (1) shows "Y-position error for sensor position?", then the measuring sensor (2) on the rear measuring points must be tilted slightly towards the arrow (arrow A).
Vehicle level - front axle *BE40.20-P-1001- 02Q 4 Position measuring sensor (2), with measuring sensor connecting cable (3) facing towards vehicle center, on the recesses on the right front transverse control arm (5) (arrows) and read off vehicle level on inclinometer (1) and then save the measured values It is possible that the measuring sensor (2) may not be correctly seated in the recesses on the right front transverse control arm (5) (arrows) relative to the right front transverse control arm (5), and this could result in a positioning error.If the display on the inclinometer (1) shows "Y-position error
for sensor position?",¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2336 · Applies to: 450, 451, 452, 454
then the measuring sensor (2) on the rear measuring points must be tilted slightly towards the arrow (arrow A). Vehicle level - front axle *BE40.20-P-1001- 02Q 5 Position measuring sensor (2), with measuring sensor connecting cable (3) facing towards vehicle center, on the left drive shaft (7) and read off vehicle level on inclinometer (1) and then save the measured value It is possible that the measuring sensor (2) on the lay-on point of the left drive shaft (7) may not be seated in the correct position, which could result in a positioning error.If the display on the inclinometer (1) shows "Y-position error for sensor position?", then the measuring sensor (2) on the lay-on point of the left drive shaft (7) should be turned or tilted slightly.
Vehicle level - rear axle BE40.20-P-1001- 03Q 6 Check the maximum permissible difference in front axle vehicle level between the left and right side of the vehicle Permissible difference in vehicle level between right and left side of vehicle BE40.20-P-1002- 02Q CHECK VALUES FOR VEHICLE LEVEL AT FRONT AXLE Number Designation Model 451 with engine 660, model 451.332/432 with engine 132 Model 451 with engine 132 except model 451.332/432 BE40.20-P- 1001-02Q Vehicle level - front axle ∠° 1.2 (±3) +2.4 (±3) BE40.20-P- 1002-02Q Permissible difference in vehicle level between right and left side of vehicle ∠° ±1,5 ±1,5 CHECK VALUES FOR REAR AXLE VEHICLE LEVEL CONTROL
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2337 · Applies to: 450, 451, 452, 454
Designation Model 451 with engine 132.910 except USA Model 451 with engine 132.910 USA BE40.20-P-1001- 03Q Vehicle level - rear axle ∠° 1.7 (±2.6) 1.4 (±2.6) CHECK VALUES FOR REAR AXLE VEHICLE LEVEL CONTROL Number Designation Model 451.333/433 with engine 132.930 Model 451 with engine 660, model 451.332/432 with engine 132.930 BE40.20-P-1001- 03Q Vehicle level - rear axle ∠° -0.3 (±2.6) 2.2 (±2.6) TESTING & REPAIR INDEX > CHECK CAMBER, ASSIGN TABULAR VALUE - AR40.20-P- 0322-02MCC > The camber on the front axle is measured at toe 0° and it is dependent on the vehicle level. Different vehicle levels make it therefore necessary to determine the camber specified value based on a camber table as follows: Determine level of front axle using electronic level gauge. The level value is displayed by the electronic level gauge in decimal degrees only (Romess value). The tolerance is 0° 30' Maximum camber difference between left and right is 0° 30'. Example: Level of front axle: 2° (value on level measuring device) Camber specified value: 0° 25' (determined from camber table) Level of front axle (Romess value) Camber Front axle (°) (∠) 6.0 1° 06' 5.0 0° 56' 4.0 0° 46' 3.0 0° 36' 2.0 0° 25' 1.0 0° 17' 0 0° 10' -1,0 0° 01'
TESTING & REPAIR INDEX > CHECK CASTER AND ASSIGN TO TABULAR VALUE -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2338 · Applies to: 450, 451, 452, 454
-2,0 -0° 05' TESTING & REPAIR INDEX > CHECK CASTER AND ASSIGN TO TABULAR VALUE - AR40.20-P-0322-03MCC > The caster is measured between a 20° wheel angle to the right and a 20° wheel angle to the left, and varies according to the vehicle level. Different vehicle levels therefore make it necessary to determine the specified caster value based on a caster table as follows: Determine level of front axle and level of rear axle using the electronic inclinometer. The level value is displayed by the electronic level gauge in decimal degrees only (Romess value). The tolerance is 0° 30' Maximum caster difference between left and right is 0° 30'. Example: Level at front axle (VA): 3° (value on level measuring device) Level at rear axle (HA): 1° (value on level measuring device) Specified caster value: 8° 15' (determined from the caster table)
6 8° 55' 8° 52' 8° 48' 8° 43' 8° 37' 8° 31' 8° 23' 8° 15' 8° 05'
5 8° 50' 8° 47' 8° 43' 8° 37' 8° 31' 8° 23' 8° 14' 8° 08' 7° 55'
4 8° 46' 8° 43' 8° 37' 8° 31' 8° 23' 8° 14' 8° 04' 7° 55' 7° 44'
3 8° 41' 8° 37' 8° 31' 8° 24' 8° 15' 8° 05' 7° 55' 7° 45' 7° 35' Front axle 2 8° 35' 8° 31' 8° 23' 8° 14' 8° 04' 7° 53' 7° 43' 7° 34' 7° 24'
1 8° 30' 8° 24' 8° 16' 8° 05' 7° 55' 7° 44' 7° 34' 7° 25' 7° 16'
0 8° 23' 8° 17' 8° 07' 7° 56' 7° 46' 7° 35' 7° 25' 7° 17' 7° 10'
-1,0 8° 15' 8° 07' 7° 56' 7° 46' 7° 35' 7° 25' 7° 16' 7° 10' 7° 04'
-2,0 8° 07' 7° 58' 7° 47' 7° 37' 7° 26' 7° 17' 7° 10' 7° 05' 6° 59' Romess value (°) -3,0 -2,0 -1,0 0 1 2 3 4 5
Romess value
RA
TESTING & REPAIR INDEX > ADJUSTING CAMBER AND CASTER - AR40.20-P-0322-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2339 · Applies to: 450, 451, 452, 454
06MCC > INSPECTION AND SETTING DATA OF FRONT AXLE CAMBER/CASTER Number Designation Model 451.3/4 BE40.20-P-1001-06C Camber with 0° wheel toe +0° 18' (0° 42') Max. difference left to right 0° 30' BE40.20-P-1002-06C Caster with 0° wheel toe +7° 50' (0° 30') FRONT AXLE CARRIER Number Designation Model 451.3/4 except 451.391/491 BA33.10-P-1001-01D Bolt, front-axle carrier to body Nm 100 1. Loosen bolts (2) of front axle (1). 2. Loosen nuts (4) on bolts (3). 3. Adjust camber and caster by moving the front axle. The camber is adjusted by moving the front axle (1) to the right or left. The caster is adjusted by moving the front axle (1) to the front or rear. 4. Tighten nuts (4) on bolts (3). 5. Tighten bolts (2) on front axle (1).
TESTING & REPAIR INDEX > CHECK TOE AND ASSIGN TO TABULAR VALUE - AR40.20-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2340 · Applies to: 450, 451, 452, 454
P-0322-11MCC > The total toe of the front and rear axle is dependent on the vehicle level. Different vehicle levels make it therefore necessary to determine the total toe specified value based on a total toe table as follows: Determine level of front axle or rear axle using the electronic inclinometer. The level value is displayed by the electronic level gauge in decimal degrees only (Romess value). Front axle The total toe tolerance is ±0° 18' The individual toe tolerance is ±0°' 09' Rear axle The total toe tolerance is ±0° 20' The individual toe tolerance is ±0°' 15' Maximum difference of individual toe-in between left and right is 0° 30'. Fig 1: Identifying Bolts Of Front Axle And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Example:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2341 · Applies to: 450, 451, 452, 454
Level of front axle: 3.0° (value read on inclinometer) Total toe value: 0° 48' (determined from the total toe table). Level of front axle (Romess value) Front axle overall toe-in Rear axle level (Romess value) Total rear axle toe (°) (∠°) (°) (∠°) 6.0 1° 10' - - 5.0 1° 03' 5.0 -0° 31' 4.0 0° 55' 4.0 -0° 18' 3.0 0° 48' 3.0 -0° 10' 2.0 0° 41' 2.0 0° 00' 1.0 0° 34' 1.0 0° 08' 0 0° 26' 0 0° 16' -1,0 0° 19' -1,0 0° 22' -2,0 0° 11' -2,0 0° 28' - - -3,0 0° 32' TESTING & REPAIR INDEX > ADJUST FRONT AXLE TOE - AR40.20-P-0323-02MCC > FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 BE40.20-P-1001-07B Front axle overall toe- in ∠° +0° 36' (0° 10') TIE ROD Number Designation Model 451.3/4 BA46.40-P-1002-01F Lock nut to tie rod Nm 50
1. Loosen clamps (3) of boots (4) on tie rods (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2342 · Applies to: 450, 451, 452, 454
- Loosen nuts (2).
- Rotate the tie rods (1) to adjust the toe-in. Check that the boots (4) are not twisted after adjusting the toe.
- Tighten nuts (2).
- Fasten clamps (3) of boots (4) on tie rods (1). Fig 1: Identifying Open-Ended Socket Wrench (450 589 01 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Clamps Of Boots On Tie Rods And Nuts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
lists as follow.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2344 · Applies to: 450, 451, 452, 454
Checking
Chassis accident initial measurement
1 Perform initial measurement Without recording the vehicle levelWith recording the vehicle level AR40.20-P- 0200MCC AR40.20-P- 0200MCE
Body accident initial measurement
2 Carrying out distance and comparative measurement Comparative measurement of body and bolt-on points using gauge. Gauge Fig 1
In the event of accident damage, which requires repair work to be performed on a straightening bench
3 Body measurement and repair using approved straightening bench Perform the body measurement in accordance with the assembly instructions.Straightening benchStraightening tool set (Celette)Straightening tool set (Car Bench)Accessories for straightening systems (Celette)Accessories for straightening system (Car Bench)
TESTING & REPAIR INDEX > DRAINING TIREFIT SEALANT OUT OF TIRES - AR40.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2345 · Applies to: 450, 451, 452, 454
1080MCU >
Drain
Risk of poisoning caused by swallowing the TIREFIT emulsion. Risk of injury caused by skin contact and eye contact with TIREFIT emulsion. Risk of fire caused ignition of the TIREFIT emulsion. Do not swallow or come into contact with TIREFIT tire sealant, which is an emulsion of rubber and terpene phenolic resin. No open fire or open light sources. AS40.10-Z-0001-01A TIREFIT tire sealant
AH40.10-P-0001- 01MCC Fig 1: Identifying Gauge (450589002300) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Draining TIREFIT Sealant Out Of Tires Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SAFETY PRECAUTIONS > SAFETY INFORMATION: WHEELS, CHASSIS ALIGNMENT¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2347 · Applies to: 450, 451, 452, 454 · AR: AS40.00-Z-9999ZZ
CHECK - AS40.00-Z-9999ZZ > MODEL all Risk of poisoning caused by swallowing the TIREFIT emulsion. Risk of injury caused by skin contact and eye contact with the TIREFIT emulsion. Risk of fire caused by ignition of the TIREFIT emulsion MODEL all AS40.10-Z-0001-01A SAFETY PRECAUTIONS > RISK OF POISONING CAUSED BY SWALLOWING THE TIREFIT EMULSION. RISK OF INJURY CAUSED BY SKIN CONTACT AND EYE CONTACT WITH THE TIREFIT EMULSION. RISK OF FIRE CAUSED BY IGNITION OF THE TIREFIT EMULSION - AS40.10-Z-0001-01A > Do not swallow or come into contact with the TIREFIT tire sealant, which is an emulsion of rubber and terpene phenolic resin. No open fire or open light sources. Potential risks Risk of poisoning caused by swallowing the emulsion of rubber and terpene phenolic resin. Risk of injury caused by skin contact and eye contact. Especially sensitive individuals may experience allergic reactions following repeated contact. Risk of fire caused by ignition of the emulsion due to open fire and open light sources. Fig 2: Identifying Twist Drill Bit Set (450589017000) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Safety precautions/instructions¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2348 · Applies to: 450, 451, 452, 454
When using TIREFIT, ensure that smoking is prohibited and that there is no open fire in the vicinity. When working with artificial light sources, ensure that no open light sources used, in order to avoid ignition of the emulsion. Used only the compressor supplied with the TIREFIT kit. Avoid eye or skin contact with any TIREFIT emulsion that may escape. Highly sensitive (allergic) individuals should wear protective clothing, such as work gloves. Immediately change any clothing contaminated by TIREFIT. Avoid ingesting the TIREFIT emulsion, always wash hands after working with the TIREFIT emulsion. First aid measures If TIREFIT is swallowed, thoroughly rinse out mouth immediately and drink generous amounts of water. Do not induce vomiting! Consult a physician immediately. In the event of skin or eye contact, rinse area with plenty of water. Monitor development and consult physician immediately if allergic reactions occur. RETROFITTING & CONVERSION > RETROFIT SMART LIGHT ALLOY WHEELS - AZ40.10- P-0004MCC > MODEL 451.3 /4 5-spoke light alloy wheels, 16 inch (Design 4) Wheels, front axle tire size: 5.5J x 16 ET33.5; 175/50 Wheels, rear axle tire size: 7J x 16 ET38.5; 215/40 Fig 1: Caution For Tirefit Kit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6-spoke light alloy wheels, 15 inch (Design 3) up to 30.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2349 · Applies to: 450, 451, 452, 454
(Code (R74) 6-spoke light alloy wheels 175/55 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 175/55 Wheels, rear axle tire size: 6.5J x 15 ET34.5; 195/50 6-spoke light alloy wheels, 15 inch (Design 7) as of 31.8.10 (Code (R22) 6-spoke light alloy wheels 175/55 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 175/55 Wheels, rear axle tire size: 6.5J x 15 ET34.5; 195/50 Fig 1: Identifying 5-Spoke Light Alloy Wheels, 16 Inch (Design 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying 6-Spoke Light Alloy Wheels, 15 Inch (Design 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6-spoke light alloy wheels, 15 inch (Design 6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2350 · Applies to: 450, 451, 452, 454
(Code (R67) 6-spoke light alloy wheels 175/55 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 175/55 Wheels, rear axle tire size: 6.5J x 15 ET34.5; 195/50 6-spoke light alloy wheels, 15 inch, chrome look (Design 6) (Code (R67) 6-spoke light alloy wheels 175/55 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 175/55 Wheels, rear axle tire size: 6.5J x 15 ET34,5; 195/50 Fig 3: Identifying 6-Spoke Light Alloy Wheels, 15 Inch (Design 7) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying 6-Spoke Light Alloy Wheels, 15 Inch (Design 6) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6-spoke light alloy wheels, 15 inch (Design 9) as of 31.8.10 with code (494) USA version¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2351 · Applies to: 450, 451, 452, 454
(Code (R23) 6-spoke light alloy wheels 165/60 & 195/50 R15) Wheels, front axle tire size: 5J x 15 ET34; 165/60 Wheels, rear axle tire size: 6.5J x 15 ET34.5; 195/50 9-spoke light alloy wheels, 15 inch (Design 5) up to 30.8.10 (Code (R73) 9-spoke light alloy wheels 155/60 & 175/55 R15) Wheels, front axle tire size: 4.5J x 15 ET23.5; 155/60 Wheels, rear axle tire size: 5.5J x 15 ET22; 175/55 Fig 5: Identifying 6-Spoke Light Alloy Wheels, 15 Inch, Chrome Look (Design 6) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying 6-Spoke Light Alloy Wheels, 15 Inch (Design 9) With Code (494) USA Version Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
12-spoke light alloy wheels, 15 inch (Design 8) as of 31.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2352 · Applies to: 450, 451, 452, 454
(Code (R24) 12-spoke light alloy wheels 155/60 & 175/55 R15) Wheels, front axle tire size: 4.5J x 15 ET23.5; 155/60 Wheels, rear axle tire size: 5.5J x 15 ET22; 175/55 12-spoke light alloy wheels, 15 inch (Design 1) (Code (R72) 12-spoke light alloy wheels 155/60 & 175/55 R15) Wheels, front axle tire size: 4.5J x 15 ET23; 155/60 Wheels, rear axle tire size: 5.5J x 15 ET22; 175/55 Fig 7: Identifying 9-Spoke Light Alloy Wheels, 15 Inch (Design 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Identifying 12-Spoke Light Alloy Wheels, 15 Inch (Design 8) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Toe-out on turns¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2355 · Applies to: 450, 451, 452, 454
MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 BE40.20-P-1000-08C Vehicle level - front axle MODEL 451.3 /4 BE40.20-P-1000-02Q Vehicle level - rear axle MODEL 451.3 /4 BE40.20-P-1000-03Q TEST & ADJUSTMENT VALUES > VEHICLE LEVEL - FRONT AXLE - BE40.20-P-1000-02Q
Model 451.3/4 CHECK VALUES FOR VEHICLE LEVEL AT FRONT AXLE Number Designation Model 451 with engine 660, model 451.332/432 with engine 132 Model 451 with engine 132 except model 451.332/432 BE40.20-P- 1001-02Q Vehicle level - front axle ∠° 1.2 (±3) +2.4 (±3) BE40.20-P- 1002-02Q Permissible difference in vehicle level between right and left side of vehicle ∠° ±1,5 ±1,5 TEST & ADJUSTMENT VALUES > VEHICLE LEVEL - REAR AXLE - BE40.20-P-1000-03Q > Model 451.3/4 CHECK VALUES FOR REAR AXLE VEHICLE LEVEL CONTROL Number Designation Model 451 with engine 132.910 except USA Model 451 with engine 132.910 USA BE40.20-P-1001- 03Q Vehicle level - rear axle ∠° 1.7 (± 2.6) 1.4 (±2.6) CHECK VALUES FOR REAR AXLE VEHICLE LEVEL CONTROL Number Designation Model 451.333/433 with engine 132.930 Model 451 with engine 660, model 451.332/432 with engine 132.930 BE40.20-P-1001- 03Q Vehicle level - rear axle ∠° -0.3 (±2.6) 2.2 (±2.6) TEST & ADJUSTMENT VALUES > DRIVELINE ANGLE - BE40.20-P-1000-21A > Model 450, 451, 452, 454 TEST VALUES FOR DRIVELINE ANGLE
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2356 · Applies to: 450, 451, 452, 454
Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 7.1.2001 Model 450.3/4 as of 8.1.2001 BE40.20-P- 1001-21A Driveline angle ∠° +0° 0' (±0° 30') +0° 0' (± 0° 30') +0° 0' (± 0° 30') TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 Model 452.3/4 Model 454.0 BE40.20-P- 1001-21A Driveline angle ∠° +0° 0' (±0° 24') +0° 0' (± 0° 30') +0° 0' (± 0° 15') TEST & ADJUSTMENT VALUES > FRONT AXLE TOE - BE40.20-P-1000-07B > Model 450, 451, 452, 454 MODIFICATION NOTES 14.4.05 Front axle overall toe-in FRONT AXLE TOE CHECK VALUES Number Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 7.1.2001 Model 450.3/4 as of 8.1.2001 up to 2.1.2003 Model 450.3/4 as of 3.1.2003 BE40.20-P- 1001-07B Front axle overall toe- in ∠° +0° 24' (±0° 10') +0° 22' (±0° 10') +0° 28' (±0° 10') +0° 26' (±0° 10') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 Model 452.3/4 except 452.337/437 Model 452.337/437 Model 454.0 BE40.20-P- 1001-07B Front axle overall toe- in ∠° +0° 36' (±0° 10') +0° 16' (±0° 10') +0° 20' (±0° 10') +0° 0' (±0° 12') TEST & ADJUSTMENT VALUES > TOE-OUT ON TURNS - BE40.20-P-1000-08C > Model 450, 451, 452, 454 MODIFICATION NOTES 30.9.08 Value changed: Toe-out angle with inner wheel steered through 20° Model 451.3/4 TEST VALUES FOR TOE-OUT ON TURNS
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2357 · Applies to: 450, 451, 452, 454
Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 7.1.2001 Model 450.3/4 as of 8.1.2001 BE40.20-P- 1001-08C Toe-out on turns with the inside wheel steered through 20° ∠° -2° 06' (±0° 20') -2° 06' (±0° 20') -2° 06' (± 0° 20') TEST VALUES FOR TOE-OUT ON TURNS Number Designation Model 451.3/4 Model 452.3/4 Model 454.0 BE40.20-P- 1001-08C Toe-out on turns with the inside wheel steered through 20° ∠° -1° 36' (±0° 30') -2° 06' (±0° 20') -1° 08' (±0° 30') TEST & ADJUSTMENT VALUES > FRONT AXLE TOE - BE40.20-P-1000-07B > Model 450, 451, 452, 454 MODIFICATION NOTES 14.4.05 Front axle overall toe- in
FRONT AXLE TOE CHECK VALUES Number Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 7.1.2001 Model 450.3/4 as of 8.1.2001 up to 2.1.2003 Model 450.3/4 as of 3.1.2003 BE40.20-P- 1001-07B Front axle overall toe- in ∠° +0° 24' (±0° 10') +0° 22' (± 0° 10') +0° 28' (± 0° 10') +0° 26' (± 0° 10') FRONT AXLE TOE CHECK VALUES Number Designation Model 451.3/4 Model 452.3/4 except 452.337/437 Model 452.337/437 Model 454.0 BE40.20-P- 1001-07B Front axle overall toe- in ∠° +0° 36' (± 0° 10') +0° 16' (± 0° 10') +0° 20' (±0° 10') +0° 0' (± 0° 12') TEST & ADJUSTMENT VALUES > REAR AXLE TOE-IN - BE40.20-P-1000-10F > Model 450, 451, 452, 454
INSPECTION VALUES FOR TOE-IN AT REAR AXLE¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2358 · Applies to: 450, 451, 452, 454
Number Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 02.01.2003 Model 450.3/4 as of 03.01.2003 BE40.20-P- 1001-10F Total rear axle toe ∠° +0° 20' (± 0° 10') +0° 10' (± 0° 10') +0° 10' (± 0° 12') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 451.3/4 Model 452.3/4 except 452.337/437 Model 452.337/437 BE40.20-P- 1001-10F Total rear axle toe ∠° +0° 00' (±0° 18') +0° 06' (± 0° 12') +0° 30' (±0° 12') INSPECTION VALUES FOR TOE-IN AT REAR AXLE Number Designation Model 454.0 BE40.20-P-1001-10F Total rear axle toe ∠° +0° 21' (± 0° 21') TEST & ADJUSTMENT VALUES > DRIVELINE ANGLE - BE40.20-P-1000-21A > Model 450, 451, 452, 454 TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 450.3/4 up to 14.11.1999 Model 450.3/4 as of 15.11.1999 up to 7.1.2001 Model 450.3/4 as of 8.1.2001 BE40.20-P- 1001-21A Driveline angle ∠° +0° 0' (±0° 30') +0° 0' (±0° 30') +0° 0' (± 0° 30') TEST VALUES FOR DRIVELINE ANGLE Number Designation Model 451.3/4 Model 452.3/4 Model 454.0 BE40.20-P- 1001-21A Driveline angle ∠° +0° 0' (±0° 24') +0° 0' (±0° 30') +0° 0' (±0° 15') TEST & ADJUSTMENT VALUES > TEST VALUES FOR DISTANCE AND COMPARATIVE MEASUREMENT - BE40.30-P-1000-10A > Model 450, 451, 452 TEST VALUES FOR DISTANCE AND COMPARATIVE MEASUREMENT Number Designation Model 450 Model 451 Model 452 BE40.30-P- Dim. V1 mm 735 (2) - 71 (±2)
1001-10A¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2359 · Applies to: 450, 451, 452, 454
V2 mm 394 (±2) - 105,3 (±2) V3 mm 850 (±2) - 105,3 (±2) V4 mm 694 (±2) - 109,5 (±2) V5 mm 873 (±2) - 109,5 (±2) V6 mm 683 (±2) - 164,4 (±2) V7 mm 1446 (±2) - 164,4 (±2) V8 mm 1327 (±2) - 64,5 (±2) V9 mm 1286 - 64,5 (±2) V10 mm 650 (±1) 650 (±2) 87,9 (±2) V11 mm 1812 - - V12 mm 1353 - - V13 mm 653 (±1) - - V14 mm 800 (±1) - - V15 mm 890 (±1) 890 (±2) - V16 mm 1512 (±2) - - V17 mm 1512 (±2) 1512 (±2) - V18 mm 2125 (±2) 2125 (±2) - V19 mm 2125 (±2) 2125 (±2) - V20 mm - 890 (±2) - V21 mm - 800 (±2) - V22 mm - 805 (±2) - V23 mm - 705 (±2) - V24 mm - 1486 (±2) - V25 mm - 1452 (±2) - V26 mm - 738 (±2) - V27 mm - 738 (±2) - See picture in - - AR40.30-P- 0402-03R R TEST & ADJUSTMENT VALUES > FRONT AXLE CAMBER/CAST - BE40.20-P-1000-06C > Model 450, 451, 452 Modification notes 8.7.03 Value changed from 0° 14' (+/-0° 30') Value changed in line 1001 for model 452.3/4
4.5 J x 15 H2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2361 · Applies to: 450, 451, 452, 454
451.331 / 132.910 (52 kW) 4.5 J x 15 H2 23,5 155/60 R 15 1 - 5.5J x 15 H2 22 175/55 R 15 2 - 451.331 / 132.910 (52 kW) 5 J x 15 H2 34 175/55 R 15 1 - 6.5J x 15 H2 34,5 195/50 R 15 2 - 451.431 / 132.910 (52 kW) 4.5 J x 15 H2 23,5 155/60 R 15 1 - 5.5J x 15 H2 22 175/55 R 15 2 - 451.431 / 132.910 (52 kW) 5 J x 15 H2 34 175/55 R 15 1 - 6.5J x 15 H2 34,5 195/50 R 15 2 - BASIC KNOWLEDGE > RIM DESIGNATION - GF40.10-P-1010-01A > Example: 6 J X 15 H2 ET 44 Internal rim width in inches Code letter for height and contour of rim flange Code for one-piece drop center rim Rim diameter in inches Rim profile at outside and inside with hump shoulder ET = wheel offset (distance from rim center to wheel contact surface in mm) ET wheel offset (distance from rim center to wheel contact surface, measured in mm)
Sheet-steel disk wheel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2362 · Applies to: 450, 451, 452, 454
Light alloy rim Fig 1: Example Of Rim Designation Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Wheel Offset, Hump, Internal Rim Width And Rim Diameter Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > ALL-SEASON TIRES, DISK WHEEL OVERVIEW - GF40.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2363 · Applies to: 450, 451, 452, 454
1004MCU > MODEL 451.3 /4 Vehicle/engine Disk wheel ETmm Tires Axle Snow chains 451.331 / 132.910 (52 kW) 4.5 J x 15 H2 23,5 155/60 R 15 1 - 5.5J x 15 H2 22 175/55 R 15 2 - 451.331 / 132.910 (52 kW) 5 J x 15 H2 34 175/55 R 15 1 - 6.5J x 15 H2 34,5 195/50 R 15 2 - 451.431 / 132.910 (52 kW) 4.5 J x 15 H2 23,5 155/60 R 15 1 - 5.5J x 15 H2 22 175/55 R 15 2 - 451.431 / 132.910 (52 kW) 5 J x 15 H2 34 175/55 R 15 1 - 6.5J x 15 H2 34,5 195/50 R 15 2 - BASIC KNOWLEDGE > TIRE PRESSURES - GF40.10-P-1020-02MCU > Fig 3: Identifying Sheet-Steel Disk Wheel Designation And Part Number Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Light Alloy Rim Wheel Designation And Part Number Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2364 · Applies to: 450, 451, 452, 454
Tire pressure label Tires Tire pressure (in psi) Comfort air pressure Tire pressure (in psi) Comfort air pressure Tire pressure (in psi) up to V max. Tire pressure (in psi) up to V max. Partial load Front axle Partial load RA Full load Front axle Full load RA Partial load Front axle Partial load RA Full load Front axle Full load RA 451.3/4 - 155/60 R 15 74 T 29,0 - 29,0 - 29,0 - 29,0 - 175/55 R 15 77 T - 36,2 - 36,2 - 36,2 - 36,2 451.3/4 - 175/55 R 15 74 T 29,0 - 29,0 - 29,0 - 29,0 - 195/50 R 15 77 T - 36,2 - 36,2 - 36,2 - 36,2 BASIC KNOWLEDGE > TIRE PRESSURE MONITOR (TPM [RDK]) LOCATION OF COMPONENTS - GF40.15-P-0001-06MCU > BASIC KNOWLEDGE > TIRE PRESSURE MONITOR (TPM [RDK]) BLOCK DIAGRAM - Fig 1: Tire Pressure Monitor (RDK) Components Location Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Circuit 15 On¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2366 · Applies to: 450, 451, 452, 454
Tire pressure monitor system functional General information The tire pressure monitor assists the driver when checking the tire inflation pressure and thus serves active safety. The Tire pressure monitor monitors the air pressure in the individual tires. A previously stored tire pressure is used as a comparative value. In the event of a relevant pressure loss the driver is warned via the tire pressure monitor warning lamp. The tire pressure measuring range extends from p = 0 and 5.5 bar. The tire pressure monitor is made up of the following component functions: Tire pressure sensing Warning display Manual restart Tire pressure sensing The TPM [RDK] control unit is permanently operational. Each time the CAN wakes-up the TPM [RDK] control unit performs a re-initialization. While driving, the TPM [RDK] system continuously monitors the tire pressure of all rotating wheels (with circuit 15 Off for a further t = 19 min). With new wheels or a parking time in excess of t > 19 min, the individual wheel detection and axle assignment must be completed first via the TPM wheel sensors. The TPM wheel sensors transmit data telegrams every t = 60 s while driving. These data telegrams contain the pressure, tire pressure temperature, individual serial number and status information (manufacturer, direction of rotation, operating mode etc.). The data are conveyed via two-way radio to the TPM [RDK] control unit. In addition the TPM [RDK] control unit takes into account the outside temperature and the vehicle speed for the tire pressure determination. These data are provided via CAN from the instrument cluster. Warning indicator A warning is issued when a relevant loss of pressure has been detected in at least one of the tires. The driver receives the feedback over the tire pressure monitor warning lamp. The warning is issued without any position data. Manual restart The tire pressure monitor button in the cockpit switch panel can be used to reactivate the tire pressure to be monitored. When the tire pressure monitor button is pressed the tire pressure at that time, as long as it is in the permissible limits, is stored in the internal memory of the TPM [RDK] control unit and used as a reference pressure. A manual restart is displayed by the tire pressure monitor warning lamp flashing 3 times. The warning lamp request is sent over CAN from the TPM [RDK] control unit. A manual restart must be carried out for each change in tire inflation pressure, when replacing a wheel or a wheel sensor as well as when replacing the TPM [RDK] control unit.
Tire pressure monitor (TPM [RDK]) location
GF40.15-P-0001- 06MCU
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2368 · Applies to: 450, 451, 452, 454
The TPM [RDK] control unit is located in the footwell on the driver-side. Task The TPM [RDK] control unit realizes the following functions: Tire pressure temperature compensation Warning for pressure loss Status monitoring The TPM [RDK] control unit receives data telegrams via two-way radio from the following sensors: Left front TPM [RDK] wheel sensor (A69/1) Right front TPM [RDK] wheel sensor (A69/2) Left rear tire pressure monitor sensor (A69/3) Rear right tire pressure control wheel sensor (A69/4) The data telegrams contain the pressure, tire pressure temperature, individual serial number and status information (manufacturer, direction of rotation, operating mode etc.). If a pressure loss is detected, the tire pressure monitor warning lamp (A1e66) in the instrument cluster (A1) is actuated by the TPM [RDK] control unit. The TPM [RDK] control unit constantly monitors all input signals and output signals for faults. Detected faults that are relevant to function are entered into the fault memory. Fig 1: Identifying TPM (RDK) Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Discrete inputs¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2369 · Applies to: 450, 451, 452, 454
Circuit 30 Circuit 31 CAN signals The TPM [RDK] control unit is connected to the Control Area Network (databus/CAN Bus) (CAN) for data exchange. BASIC KNOWLEDGE > WHEEL SENSOR, COMPONENT DESCRIPTION - GF40.15-P- 5126MCU > MODEL 451.3 /4 Location The wheel sensors are fastened securely inside the respective rim. Task The primary task of the TPM wheel sensors is to measure the pressure/temperature. The measuring range extends from p = 0 and 5.5 bar. While driving the tire pressure sensors transmit six data messages every t = 60 s. Absolute pressure, tire pressure temperature, wheel identifier and status information (manufacturer, direction of turning, operating mode) are transmitted in these data messages. The TPM [RDK] control unit (N88) receives the data telegrams and assigns (after a learning phase) the wheel identifier to the wheels fitted to the vehicle. As long as the TPM [RDK] control unit does not recognize the vehicle's own wheel identifier during initial commissioning, no fault message is displayed. After replacing a tire pressure sensor in each case the new tire pressure sensor is taught in and monitored with a new wheel identifier after driving for approx. t = 10 min. Design Each TPM wheel sensor is connected to the filling valve via a mounting bolt and forms an assembly unit with Fig 1: Identifying Left/Right Front And Rear Tpm (RDK) Wheel Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
N10/10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2371 · Applies to: 450, 451, 452, 454
SAM control unit 3L N10/10f12 Fuse 12 4L N10/10f19 Fuse 19 2L N88 TPM control module 4A N88 TPM control module 11A S6/1 Cockpit switch group 8L S6/1s9 TPM [RDK] switch 8L W10 Ground (battery) 3E W10 Ground (battery) 9E Z3/24 Circuit 15 (fused) connector sleeve, function 1E Z37/2 CAN engine bus (low) connector sleeve 11E Z37/3 CAN engine bus (high) connector sleeve 13E Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 4E Z81 Circuit 58d connector sleeve 10E
Fig 1: Tire Pressure Monitor Control Unit - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2372 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > LEGEND OF WIRING DIAGRAM FOR TIRE PRESSURE MONITOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2373 · Applies to: 450, 451, 452, 454
CONTROL UNIT - PE40.15-P-2101-60MCU > Model 451 Code: Designation: Position: A1 Instrument cluster 12L Fig 2: Tire Pressure Monitor Control Unit - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Ground (battery)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2376 · Applies to: 450, 451, 452, 454
W10 Ground (battery) 3E W10 Ground (battery) 8E Z3/24 Circuit 15 (fused) connector sleeve, function 1E Z37/2 CAN engine bus (low) connector sleeve 11E Z37/3 CAN engine bus (high) connector sleeve 12E Z45 ATA [EDW] sensor circuit 30 voltage supply connector sleeve 4E Z81 Circuit 58d connector sleeve 10E SPECIAL TOOLS > 129 589 01 21 00 RETAINER DEVICE - WS40.00-P-0025B > FG 40/01/Set B MODEL 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 172, 197, 199, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245.20 /23, 251, 414, 450, 451, 452, 460, 461, 463, 636, 638, 639, 906 Part 129 589 01 21 25 Clamping nut (complete) FG 40/Set B Use: Retainer for steering wheel in straight-ahead position.
Fig 1: Tire Pressure Monitor Control Unit Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 05 09 00 SOCKET WRENCH BIT - WS40.00-P-0060A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2377 · Applies to: 450, 451, 452, 454
FG 40/Set A MODEL 450, 451, 452 Use: Socket wrench bit for loosening and securing wheel bolts on aluminum rims. NOTE: WAF 15 socket for wheel bolts, long version Smart no. 0007106. SPECIAL TOOLS > 230 589 00 99 01 PLUG-IN REVERSIBLE RATCHET - WS40.00-P-0061- 01B > FG40/Set B Fig 1: Identifying Retainer Device (129 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Socket Wrench Bit (450 589 05 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 00/Set A/B/C/K¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2378 · Applies to: 450, 451, 452, 454
MODEL 230.467 /474 /475 /476 MODEL 164, 203, 209, 211, 219 with ENGINE 642 MODEL 221 with ENGINE 642 MODEL 251 with ENGINE 642 MODEL 463 with ENGINE 642 MODEL 450, 451, 452, 454 MODIFICATION NOTES 15.4.08 Replacement for: 452 589 00 16 00 plug-in reversible ratchet WS00.00-P-0241A Use: Plug in reversible ratchet 9 x 12 mm for hexagon bit blades 5/16" (8 mm). NOTE: Smart-no..: 001 5802 V000 0000 00Separate part for 230 589 00 99 00.
SPECIAL TOOLS > 451 589 01 09 00 SET OF MASTER KEYS - WS40.00-P-3007A > FG 40/Set A MODEL 451 Use: Set of master keys for opening anti-theft wheel locks when code key is not available. This master key makes it possible to reorder for end-user customers who have lost their security key as it can be used to determine Fig 1: Identifying Plug-In Reversible Ratchet (230 589 00 99 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
the code number.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2379 · Applies to: 450, 451, 452, 454 · AR: WS40.00-Z-9999CZ
NOTE: Reordering info from Tel: +49 2232 943 170 or www.adl-sa.com SPECIAL TOOLS > SPECIAL TOOLS: SMART: WHEELS, CHASSIS ALIGNMENT CHECK - WS40.00-Z-9999CZ > MODEL all 129 589 01 21 00 Retainer device FG 40/01/Set B WS40.00-P-0025B 230 589 00 99 01 Plug-in reversible ratchet FG40/Set B FG 00/Set A/B/C/K WS40.00-P-0061-01B 450 589 05 09 00 Socket wrench bit FG 40/Set A WS40.00-P-0060A 451 589 01 09 00 Set of master keys FG 40/Set A WS40.00-P-3007A 454 589 08 09 00 Socket wrench bit FG 40/Set B WS40.00-P-0062B Fig 1: Identifying Set Of Master Keys (451 589 01 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2381 · Applies to: 450, 451, 452, 454
Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities No parts of the body or limbs should be within the operating range of the mechanism when moving components. AS00.00-Z-0009-01A 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 2 Pull out pins (2) using suitable pliers from the expansion clip (1), remove expansion clip (1) and cover (3)
Checking
3 Turn engine at the center bolt (6) of the crankshaft in the direction of engine rotation and check poly-V belt (5) and poly-V belt of refrigerant compressor (4) for wear and damage The poly-V belt of refrigerant compressor (4) is only fitted to vehicles with code (I01) Air conditioning Plus.Apply chalk marking as a starting point on the poly-V belt (5) and on the poly-V belt of the refrigerant compressor
Fig 2: Identifying Poly-V Belt Damage Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
components.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2386 · Applies to: 450, 451, 452, 454
Risk of death caused by vehicle slipping or toppling off 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 2 Remove expansion clips (1) and remove cover (2)
3 Detention clamping device (5) using a wrench and secure using a suitable locking pin (6) The locking pin (6) should have a diameter of about 4 mm.
*451589001000 4 Remove poly-V belt (4)
Install
5 Fit on poly-V belt (4) Check poly-V belt (4) before installing for wear and damage.
6 Detention clamping device (5) using a wrench and remove locking pin (6) *451589001000 7 Position cover (2), insert expansion clip (1) and fix in place with a pin
8 Lower vehicle
TESTING & REPAIR > REMOVE/INSTALL POLY-V BELT TENSIONING DEVICE - AR13.25- P-3200MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 3: Identifying Wrench SW 12 (451 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2391 · Applies to: 450, 451, 452, 454
The clamping device is located seen in the direction of travel on the right side on the engine. Task The poly-V belt is automatically tensioned with the required force via the tensioning device. Function The poly-V belt is tensioned with the specified force via a spring integrated into the tensioning device. Transfer of the spring force on the V-belt takes place via the tensioner pulley mounted on the clamping device. SPECIAL TOOLS > 451 589 00 10 00 WRENCH SW 12 - WS13.00-P-0006B > FG 13/Set B ENGINE 132 Use: Wrench SW 12 for detensioning the belt tensioning pulley Fig 1: Identifying Tensioning Device, Poly-V-Belt And Tensioner Pulley Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 00 61 00 ASSEMBLY TOOL - WS13.00-P-0007B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2392 · Applies to: 450, 451, 452, 454
FG 13/Set B MODEL 451 Use: Assembly tool for disassembly and assembly of elastic permanent belt pulley. SPECIAL TOOLS > 450 589 00 21 00 GAUGE (V-BELT TENSION) - WS13.00-P-0010A > FG 13/Set A ENGINE 122, 132, 134, 135, 160, 639, 660 Use: Gauge (V-belt tension) for testing and adjusting the belt tension. Fig 1: Identifying Wrench SW 12 (451 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Assembly Tool (451 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
NOTE:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2393 · Applies to: 450, 451, 452, 454
Gauge for testing the V-belt tensionSmart No. 0005080 SPECIAL TOOLS > 451 589 00 09 00 SOCKET WRENCH - WS13.00-P-0013B > FG 13/Set B MODEL 451 Use: Socket wrench for disassembly and assembly of belt pulley on coolant pump. SPECIAL TOOLS > 000 589 28 01 00 OPEN WRENCH - WS13.00-P-0015B > FG 13/Set B Fig 1: Identifying Gauge (V-Belt Tension) (450 589 00 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Socket Wrench (451 589 00 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINES 132 in MODEL 451¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2394 · Applies to: 450, 451, 452, 454 · AR: WS13.00-Z-9999CZ
Use: SW 24 mm open end wrench, 3/8 inch square, to tension and slacken the poly-V belt for the E-machine and water pump. SPECIAL TOOLS > SPECIAL TOOLS: SMART: AIR COMPRESSOR, BELT DRIVES - WS13.00-Z-9999CZ > MODEL all 000 589 28 01 00 Open wrench FG 13/Set B WS13.00-P- 0015B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 001 589 76 21 00 Compression tester FG 01/13/Set A WS01.00-P-0004A 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 450 589 00 21 00 Gauge (V- belt tension) FG 13/Set A WS13.00-P- 0010A 451 589 00 09 00 Socket wrench FG 13/Set B WS13.00-P- 0013B 451 589 00 10 00 Wrench SW 12 FG 13/Set B WS13.00-P- 0006B 451 589 00 61 00 Assembly tool FG 13/Set B WS13.00-P- 0007B 451 589 01 61 00 Assembly FG 13/Set B WS13.00-P-0012B Fig 1: Identifying Open Wrench (000 589 28 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
tool¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2395 · Applies to: 450, 451, 452, 454
452 589 00 09 00 Set of Torx blades FG 13/Set A/B WS13.00-P-0005A 454 589 03 09 00 Torx wrench FG 13/Set B WS13.00-P-0011B
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2397 · Applies to: 450, 451, 452, 454
Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities No parts of the body or limbs should be within the operating range of the mechanism when moving components. AS00.00- Z-0009- 01A 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 2 Pull out pins (2) using suitable pliers from the expansion clip (1), remove expansion clip (1) and cover (3)
Checking
3 Turn engine at the center bolt (6) of the crankshaft in the direction of engine rotation and check poly- The poly-V belt of refrigerant compressor (4) is only fitted to vehicles with code (I01) Air conditioning Plus.Apply chalk marking as a starting point on the poly-V belt (5) and on the poly-V belt of the refrigerant compressor (4).If nece ary ↓Replace poly V belt (5) or poly V belt of refrigerant compressor (4) - subject to a separate repair order.
Fig 2: Identifying Poly-V Belt Damage Profiles Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2399 · Applies to: 450, 451, 452, 454
Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities No parts of the body or limbs should be within the operating range of the mechanism when moving components. AS00.00- Z-0009- 01A 1 Remove poly-V belt (1)
AR13.22- P- 1202MCU 2 Place one clamp for assembly tool (5) in the marked area (arrow A) on refrigerant compressor belt pulley Place one clamp for assembly tool (5), with the long strut upwards, on the belt pulley.
Fig 2 3 Turn engine at center bolt (3) through about 30° in direction of engine rotation until poly-V belt (2) lies on the first clamp for the assembly tool (5) Fig 2 4 Place a second clamp for assembly tool (5) in the marked area (arrow A) on refrigerant compressor belt pulley Place one clamp for assembly tool (5), with the long strut upwards, on the belt pulley.
Fig 2 5 Continue to turn engine at the center bolt (3) through a further 30° until poly-V belt (2) lies on the second clamp for the assembly tool (5) Fig 2 Fig 1: Identifying Poly-V Belt For Compressor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2401 · Applies to: 450, 451, 452, 454
Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities No parts of the body or limbs should be within the operating range of the mechanical components when moving components. AS00.00- Z-0009- 01A Risk of death caused by vehicle slipping or toppling off the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at AS00.00- Z-0010- Fig 1: Identifying Expansion Clip And Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Poly-V Belt, Tensioning Device And Locking Pin Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
vehicle lift support points specified by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2402 · Applies to: 450, 451, 452, 454
vehicle manufacturer. 01A 1 Raise vehicle with vehicle lift 2 Remove expansion clips (1) and remove cover (2)
3 Detention clamping device (5) using a wrench and secure using a suitable locking pin (6) The locking pin (6) should have a diameter of about 4 mm.
Fig 3 4 Remove poly-V belt (4)
Install
5 Fit on poly-V belt (4) Check poly-V belt (4) before installing for wear and damage.
6 Detention clamping device (5) using a wrench and remove locking pin (6) Fig 3 7 Position cover (2), insert expansion clip (1) and fix in place with a pin
8 Lower vehicle
TESTING & REPAIR > REMOVE/INSTALL POLY-V BELT TENSIONING DEVICE - AR13.25- P-3200MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 3: Identifying Wrench SW 12 (451 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2407 · Applies to: 450, 451, 452, 454
The clamping device is located seen in the direction of travel on the right side on the engine. Task The poly-V belt is automatically tensioned with the required force via the tensioning device. Function The poly-V belt is tensioned with the specified force via a spring integrated into the tensioning device. Transfer of the spring force on the V-belt takes place via the tensioner pulley mounted on the clamping device. SPECIAL TOOLS > 451 589 00 10 00 WRENCH SW 12 - WS13.00-P-0006B > FG 13/Set B ENGINE 132 Use: Wrench SW 12 for detensioning the belt tensioning pulley Fig 1: Identifying Tensioning Device, Poly-V-Belt And Tensioner Pulley Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 00 61 00 ASSEMBLY TOOL - WS13.00-P-0007B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2408 · Applies to: 450, 451, 452, 454
FG 13/Set B MODEL 451 Use: Assembly tool for disassembly and assembly of elastic permanent belt pulley. SPECIAL TOOLS > 450 589 00 21 00 GAUGE (V-BELT TENSION) - WS13.00-P-0010A > FG 13/Set A ENGINE 122, 132, 134, 135, 160, 639, 660 Use: Gauge (V-belt tension) for testing and adjusting the belt tension. Fig 1: Identifying Wrench SW 12 (451 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Assembly Tool (451 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
NOTE:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2409 · Applies to: 450, 451, 452, 454
Gauge for testing the V-belt tensionSmart No. 0005080 SPECIAL TOOLS > 451 589 00 09 00 SOCKET WRENCH - WS13.00-P-0013B > FG 13/Set B MODEL 451 Use: Socket wrench for disassembly and assembly of belt pulley on coolant pump. SPECIAL TOOLS > 000 589 28 01 00 OPEN WRENCH - WS13.00-P-0015B > FG 13/Set B Fig 1: Identifying Gauge (V-Belt Tension) (450 589 00 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Socket Wrench (451 589 00 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ENGINES 132 in MODEL 451¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2410 · Applies to: 450, 451, 452, 454 · AR: WS13.00-Z-9999CZ
Use: SW 24 mm open end wrench, 3/8 inch square, to tension and slacken the poly-V belt for the E-machine and water pump. SPECIAL TOOLS > SPECIAL TOOLS: SMART: AIR COMPRESSOR, BELT DRIVES - WS13.00-Z-9999CZ > MODEL all 000 589 28 01 00 Open wrench FG 13/Set B WS13.00-P-0015B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 001 589 76 21 00 Compression tester FG 01/13/Set A WS01.00-P-0004A 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 450 589 00 21 00 Gauge (V- belt tension) FG 13/Set A WS13.00-P-0010A 451 589 00 09 00 Socket wrench FG 13/Set B WS13.00-P-0013B 451 589 00 10 00 Wrench SW 12 FG 13/Set B WS13.00-P-0006B 451 589 00 61 00 Assembly tool FG 13/Set B WS13.00-P-0007B 451 589 01 61 00 Assembly FG 13/Set B WS13.00-P-0012B Fig 1: Identifying Open Wrench (000 589 28 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
tool¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2411 · Applies to: 450, 451, 452, 454
452 589 00 09 00 Set of Torx blades FG 13/Set A/B WS13.00-P-0005A 454 589 03 09 00 Torx wrench FG 13/Set B WS13.00-P-0011B
GENERAL INFORMATION > NOTES ON HANDLING REFRIGERANT R134A - AH83.30-N-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2412 · Applies to: 450, 451, 452, 454
0003-01A > Air conditioning with refrigerant R134a The refrigerant R134a is colorless and odorless. At normal temperatures it is neither toxic nor flammable, and will not explode in the air, no matter what its mixing ratio. The R134a refrigerant may only be used in air conditioning systems for which R134a has been specifically approved. The refrigerant R134a must not be mixed with other refrigerants (e.g. R12). The refrigerant R134a does not contain any chlorofluorocarbons (CFC). In contrast to other refrigerants (e.g. R12) it is not hazardous to the environment at normal temperatures. The refrigerant R134a does not damage the earth's ozone layer. Despite these benefits, refrigerant R134a may only be extracted by experts with suitable extraction, recycling and filling equipment that includes integral disposal and reprocessing capabilities. GENERAL INFORMATION > CONDUCT IF AIR CONDITIONING SYSTEM IS DAMAGED OR LEAKING - AH83.30-N-0004-01A > All models The air conditioning system should never be operated if it is damaged or when there is evidence of refrigerant loss. In the event that refrigerant is lost, lubrication can fail. This will lead to damage of the refrigerant compressor. Evacuate damaged and/or leaking air conditioning refrigerant circuits as quickly as possible using extraction, processing and recharging equipment with integral disposal and reprocessing capabilities. GENERAL INFORMATION > PROTECT AIR CONDITIONING CIRCUIT AND COMPONENTS FROM MOISTURE WHEN CARRYING OUT REPAIR WORK - AH83.30-N-0005-01A > All models with air conditioning Do not carry repair operations out on the air conditioning circuit in the open air during moist weather. Moisture in the refrigerant circuit reduces the system's refrigeration output and leads to damage to the components. Acidification in the circuit caused by moisture decomposes the drier element installed (e.g. fluid reservoir, filter drier or desiccant cartridge) and thus damages the entire system. After separating/unscrewing refrigerant lines, immediately seal off the connection openings so that they are airproof using suitable stop plugs (parts kit). The drier element must be replaced every time the refrigeration circuit is opened.
Remove bolt (2) and remove cover¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2423 · Applies to: 450, 451, 452, 454
3 Remove bolt (2) and remove cover (1)
4 Use rag (7) to protect battery and battery recess against escaping coolant
5 Release clamps (4) at coolant lines (3) and detach
6 Pull coolant lines (3) out of heater heat exchanger (5) Make sure that coolant does not run over the battery or into the battery recess, as this may damage the on- board electrical system, the battery or the body.
7 Pull heater heat exchanger (5) out of the heater/air conditioner housing and put down Make sure that coolant does not run over the battery or into the battery recess, as this may damage the on- board electrical system, the battery or the body.
Install
8 Insert heater heat exchanger (5) into the heater/air conditioner housing
9 Position coolant lines (3) on heater heat exchanger (5) and secure in place using clamps (4) Replace seals (6).
10 Top up with coolant and check cooling system in area of heater heat exchanger (5) and coolant lines (3) for signs of leaks
AR20.00-P- 1142MCU 11 Insert cover (1) into heater/air conditioner housing in the marked areas (arrows) and tighten bolt (2)
12 Remove rag (7)
13 Install foot support on passenger side
AR68.30-P- 1340MCC TESTING & REPAIR > REMOVE/INSTALL HEATER CONTROL CABLE - AR83.20-P- 1400MCU > MODEL 451.3/4 except CODE (I01) Air conditioning Plus
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2425 · Applies to: 450, 451, 452, 454
1.1 Remove center stowage compartment on center part of dashboard For vehicleswithout code (C50) smart radio 10 or without code (C57) smart radio 9 AR68.10- P- 1620MCC 1.2 Remove smart radio 9 or smart radio 10 For vehicleswith code (C50) smart radio 10 or with code (C57) smart radio 9 AR82.60- P- 7502MCC 2 Turn air distribution control lever (1) to footwell ventilation position
3 Move temperature control lever (2) to lowest position
4 Set fan speed control lever (4) to speed 2
5 Remove screws (3) on heater/air conditioning operating unit (N23)
6 Use a suitable screwdriver (10) to release bracket (arrow C) of flexible shaft (6) and detach flexible shaft (6) from guide wheel (11)
7 Press back catch hook (arrow B) and remove eyelet (8) from relay lever (9)
Fig 1: Identifying Heater/Ventilation Operating Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2428 · Applies to: 450, 451, 452, 454
1 Remove front CBS
AR88.00- P- 1010MCC Fig 2: Identifying Heater Housing Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Heater Housing Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Drain coolant¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2429 · Applies to: 450, 451, 452, 454
2 Drain coolant
AR20.00- P- 1142MCU 3 Release click clamps (1) on coolant hoses (2) and then remove
4 Remove crossmember below instrument panel
AR62.30- P- 1250MCU 5 Disconnect heater or AC connector (X85/10)
6 Place right front floor covering in area of heater housing (3) to one side
7 Unclip retaining clip (6) of electrical wiring harness (7) on heater housing (3)
8 Place left front floor covering in area of heater housing (3) to one side
9 Unscrew nuts (4) on heater housing (3)
10 Remove heater housing (3) from firewall and route to the rear until the coolant hoses (2) are accessible
11 Detach coolant hoses (2) Make sure that the interior is not contaminated by any escaping coolant, as contaminated parts will have to be cleaned or replaced. Note installation position of coolant hoses (2). Installation: Position click clamps (1) on coolant hoses (2), slide coolant hoses (2) onto connections on heater housing (3) and fasten click clamps (1) in place.Position openings of click clamps (1) such that they face upward or to the right and that they do not come into contact with the coolant hoses (2).
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2431 · Applies to: 450, 451, 452, 454
1.1 Remove center stowage compartment on center part of dashboard For vehicleswithout code (C50) smart radio 10 or without code (C57) smart radio 9 AR68.10- P- 1620MCC 1.2 Remove smart radio 9 or smart radio 10 For vehicleswith code (C50) smart radio 10 or with code (C57) smart radio 9 AR82.60- P- 7502MCC 2 Turn air distribution control lever (1) to footwell ventilation position
3 Set temperature control lever and fan stage control lever to center position
4 Remove screws (2) on heater/air conditioning operating unit (N23)
5 Use a suitable screwdriver (5) to release bracket (arrow) of flexible shaft (3) and detach flexible shaft (3) from guide wheel (4)
6 Detach electrical connector (6) from heater/ air conditioning operating unit (N23)
7 Release locks (8) and detach electrical connectors (7)
8 Remove heater/air conditioning operating unit (N23)
Fig 1: Identifying Air Conditioning Control And Operating Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2434 · Applies to: 450, 451, 452, 454
1 Disconnect electrical connector (1) 2 Release blower motor series resistor group (R14) by turning clockwise and remove 3 Install in the reverse order TESTING & REPAIR > PERFORM AIR CONDITIONING SYSTEM LEAK TEST - AR83.30-P- 1011MCU > MODEL 451.3/4 (except 451.391 /491) with CODE (I01) Air conditioning Plus Illustrated on model 451.4 Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out AS83.00-Z-0001-01A Fig 1: Identifying Blower Motor Series Resistor Group And Electrical Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Condensation Drain Hose Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2437 · Applies to: 450, 451, 452, 454
2.8.07 Refrigerant, filling capacity *BF83.30-P-1001-01C
Drain
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged.
AS83.00- Z-0001- 01A 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 For all operation steps, the operating instructions for the air Fig 1: Identifying Cap, Refrigerant Line, Air Conditioner Service Unit And Service Unit Connections Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
conditioning ervice unit (6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2438 · Applies to: 450, 451, 452, 454
must be followed
1 Remove maintenance flap
2 Unscrew plugs (1) on service valves of refrigerant lines (2, 3)
3 Connect air conditioning service unit connection (4) to service valve of refrigerant line (2) and air conditioning service unit connection (5) to service valve of refrigerant line (3) Air conditioning service unit (6) gotis://E_83_05.0
4 Extract refrigerant using air conditioning service unit (6) Note down suctioned off compressor oil quantity.
Evacuating
5 Replace dehydrator Only if refrigerant circuit has been opened. AR83.30- P- 6525MCC 6 Clean refrigerant and evacuate air conditioning system using air conditioning service unit (6)
Fill
7 Replace the quantity of compressor oil noted when evacuating the air conditioning system with new compressor oil and route back to the refrigerant circuit If the wrong quantity of compressor oil is refilled then the refrigerant compressor may be damaged.
8 Fill air conditioning system using air conditioning service unit (6) Capacity of refrigerant *BF83.30- P-1001- 01C 9 Disconnect air conditioning service unit connection (4) from service valve of refrigerant line (2) and air conditioning service unit connection (5) from service valve of refrigerant line (3)
10 Screw on plugs (1) onto service valves of refrigerant lines (2, 3)
Checking
11 Using air conditioning leak detector, inspect air conditioning for leaks at all points at which Air conditioner leak detector gotis://E_83_04.
the y tem wa opened¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2439 · Applies to: 450, 451, 452, 454
12 Install maintenance flap
AIR CONDITIONING SYSTEM Number Designation Model 451.3/4 except 451.391/491 Model 451.391/491 BF83.30-P- 1001-01C Refrigerants Filling capacity g 430 (+0/-20) 550 Specifications for Operating Fluids Sheet - - TESTING & REPAIR > REMOVE/INSTALL AIR CONDITIONER HOUSING - AR83.30-P- 5200MCU > MODEL 451.3/4 with CODE (I01) Air conditioning Plus Fig 1: Identifying Air Conditioner Housing Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2440 · Applies to: 450, 451, 452, 454
Fig 2: Identifying Air Conditioner Housing Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Air Conditioner Housing Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of explosion caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2441 · Applies to: 450, 451, 452, 454
welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 1 Remove front CBS
AR88.00- P- 1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC 3 Disconnect fully automatic air conditioning service station Air conditioner service unit gotis://E_83_05.0
4 Remove front module
AR62.30- P- 1575MCU 5 Drain coolant
AR20.00- P- 1142MCU 6 Unclip brake fluid reservoir (8) in the area marked (arrow) using a suitable screwdriver (7) and place to one side
7 Disconnect electrical connector (6) from refrigerant pressure sensor (B12)
8 Unscrew nut (2) *BA83.30- P-1004- 01L 9 Pull out refrigerant lines (3) at expansion valve (1) and remove Close off refrigerant lines (3) and expansion valve (1) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit.
seal rings of refrigerant lines (3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2442 · Applies to: 450, 451, 452, 454
Installation: Replace sealing rings at refrigerant lines (3) and coat with compressor fluid when inserting. 10 Loosen click clamps (5) on coolant hoses (4) and detach coolant hoses (4) Collect discharged coolant in a suitable container.
11 Remove crossmember below dashboard
AR62.30- P- 1250MCU 12 Disconnect heater or AC connector (X85/10)
13 Remove retaining clip at right front floor covering (22) and place right front floor covering (22) in area of air conditioner housing (13) to one side
14 Detach condensation water drain hose (23) from air conditioner housing (13) Installation: It must be ensured that the condensation water drain hose (23) is correctly aligned and engaged at the connection to the air conditioner housing (13).
15 Unclip retaining clip (20) of main wiring harness (21) at air conditioner housing (13)
16 Place left front floor covering (22) in area of air conditioner housing (13) to one side
17 Unscrew nuts (9) from air conditioner housing (13)
18 Remove air conditioner housing (13) from vehicle Ensure that the interior is not dirtied by discharged coolant, as dirty parts will have to be cleaned or replaced.
19 Disconnect electrical connector (19) from air recirculation flap actuator motor (M39) When replacing the air conditioner housing (13).
20 Release air recirculation unit (18) from air conditioner housing (13) by twisting and remove When replacing the air conditioner housing (13).
21 Disconnect electrical connector (14), remove bolts (15) and remove blend air flap actuator (M16/8) When replacing the air conditioner housing (13). Installation: Counterhold driver shaft on the opposite side on air conditioner housing (13).
22 Disconnect electrical connector (16) and pull evaporator temperature sensor (B10/6) out When replacing the air conditioner housing (13).
of air conditioner housing (13)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2443 · Applies to: 450, 451, 452, 454
23 Disconnect electrical connector (11), release lock (10) and loosen blower motor (M2) by turning counterclockwise and pull out of air conditioner housing (13) When replacing the air conditioner housing (13).
24 Disconnect electrical connector (12) and release blower motor series resistor group (R14) by twisting clockwise and remove When replacing the air conditioner housing (13).
25 Detach air conditioner housing wiring harness (17) from air conditioner housing (13) and remove When replacing the air conditioner housing (13).
26 Remove heat exchanger When replacing the air conditioner housing (13). AR83.20- P- 1100MCU 27 Remove combination filter When replacing the air conditioner housing (13). AP83.00- P- 8384MCC 28 Install in the reverse order
AIR CONDITIONING Number Designation Model 451.3/4 BA83.30-P-1004- 01L Nut, refrigerant lines to expansion valve Nm 4 TESTING & REPAIR > REMOVE/INSTALL REFRIGERANT PRESSURE SENSOR - AR83.30- P-5430MCC > MODEL 451.3/4 with CODE (I01) Air conditioning Plus
Remove/install
Fig 1: Identifying Refrigerant Pressure Sensor, Refrigerant Line And Electrical Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3/4 (except 451.391 /491) with CODE (I01) Air conditioning Plus¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2445 · Applies to: 450, 451, 452, 454
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 1 Remove front CBS
AR88.00- P- 1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC 3 Remove front module
AR62.30- P- 1575MCU 4 Unscrew nut (2) *BA83.30- P-1004- 01L Fig 1: Identifying Expansion Valve, Refrigerant Lines, Bolts And Nut Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Pull out refrigerant lines (3) at¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2446 · Applies to: 450, 451, 452, 454
5 Pull out refrigerant lines (3) at expansion valve (1) and remove seal rings of refrigerant lines (3) Close off refrigerant lines (3) and expansion valve (1) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (3) and coat with compressor fluid when inserting.
Compressor oils (specification 362.0) Sheet 362.0 BB00.40- P-0362- 00A 6 Remove bolts (4) *BA83.30- P-1003- 01L 7 Remove expansion valve (1) Close off openings at the evaporator connection lines using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace seal rings at evaporator connecting lines and coat with compressor fluid when inserting.
Compressor oils (specification 362.0) Sheet 362.0 BB00.40- P-0362- 00A 8 Remove filter dryer Always replace the filter drier after opening the refrigerant circuit AR83.30- P- 6525MCC 9 Install in the reverse order
AIR CONDITIONING Number Designation Model 451.3/4 BA83.30-P-1003- 01L Bolt, expansion valve to vaporizer tube Nm 6 BA83.30-P-1004- 01L Nut, refrigerant lines to expansion valve Nm 4 TESTING & REPAIR > REMOVE/INSTALL INTAKE MANIFOLD FILLING VALVE - AR83.30- P-5535MCC > MODEL 451.3/4 with CODE (I01) Air conditioning Plus
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2447 · Applies to: 450, 451, 452, 454
8.4.10 Special tool for removal/installation of service valve exchanged Operation step 3
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained. AS83.00-Z- 0001-01A 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 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P- 1760MCC 2 Disconnect air conditioner service unit from the service valve of the suction line (2) and the service valve of the pressure line (3) Air conditioner service unit gotis://E_83_05.
Fig 1: Identifying Valve Element, Suction Pipe And Pressure Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove valve element (1) on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2448 · Applies to: 450, 451, 452, 454
3 Remove valve element (1) on service valve of suction line (2) In model 451.391/491, the valve insert (1) must be removed using a commercially available valve wrench for Schrader valves (connection width 4.5 mm).In model 451 (except 451.391/491), the valve wrench must be used.
Valve wrench *203589031000 4 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL CONDENSER FILLING VALVE - AR83.30-P- 5536MCC > MODEL 451.3/4 with CODE (I01) Air conditioning Plus MODIFICATION NOTES Fig 2: Identifying Valve Wrench (203 589 03 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Valve Element, Suction Pipe And Pressure Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Special tool for removal/installation of service valve¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2449 · Applies to: 450, 451, 452, 454
8.4.10 Special tool for removal/installation of service valve exchanged Operation step 3
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained. AS83.00-Z- 0001-01A 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 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P- 1760MCC 2 Disconnect air conditioner service unit from the service valve of the suction line (2) and the service valve of the pressure line (3) Air conditioner service unit gotis://E_83_05.
3 Remove valve element (1) on service valve of pressure line (3) In model 451.391/491, the valve insert (1) must be removed using a commercially available valve wrench for Schrader valves (connection width 4.5 mm).In model 451 (except 451.391/491), the valve wrench must be used.
Valve wrench *203589031000 4 Install in the reverse order
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2451 · Applies to: 450, 451, 452, 454
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 refrigerant R134a
AH83.30- N-0003- 01A 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC 2 Disconnect fully automatic air conditioning service station Fully automatic air conditioning service station http://gotis.aftersales.mercedes-
Fig 2: Identifying Filter Drier, Front CBS, Screws, Cover And Circlip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2453 · Applies to: 450, 451, 452, 454
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 refrigerant R134a
AH83.30- N-0003- 01A 1 Remove front module
AR62.30- P- 1575MCU 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC 3 Unscrew nut (3) from condenser (1) and detach refrigerant lines (2) from condenser (1) Close off refrigerant lines (2) and condenser (1) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit.
Fig 1: Identifying Capacitor, Refrigerant Line, Nut And Catch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
refrigerant vapors. Risk of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2455 · Applies to: 450, 451, 452, 454
injury to skin and eyes caused by contact with liquid refrigerant. only in well ventilated areas. Carry out 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 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30-P- 1760MCC 2 Disconnect air conditioning service unit Air conditioner service unit gotis://E_83_05.0
3 Release rear drive module
AR01.00-P- 3050MCU 4 Remove bolt (1, 3) for refrigerant line to be removed (2, 4) and remove refrigerant line (2, 4) from refrigerant compressor (A9) Close off refrigerant lines (2, 4) and their connection to the refrigerant compressor (A9) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace seal ring at the detached refrigerant line (2, 4) and coat with compressor oil when inserting.
Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P- 0362-00A
*BA83.30-P- 1002-01L 5 Remove rubber retainer (5)
6 Unclip refrigerant lines (2, 4) from bracket (7) and remove bracket (7) On vehicles in which the bracket (7) is still installed. Installation: The bracket (7) may no longer be installed.
7 Open quick-release coupling (6) of refrigerant line to be removed (2, 4) *452589003300 8 Remove refrigerant line to be removed (2, 4) Installation: Note routing of refrigerant lines (8). They must have a minimum distance of 5 mm to the body, fuel tank or other components, as otherwise noises or damages may be
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2457 · Applies to: 450, 451, 452, 454
1.4.08 Repair method revised Operation steps 8 and 9
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning AS83.00-Z- 0001-01A Fig 1: Identifying Refrigerant Line Components Between Refrigerant Compressor And Evaporator Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Refrigerant Lines, Radiator Unit & Coolant Hose Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
injury to skin and eyes¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2458 · Applies to: 450, 451, 452, 454
caused by contact with liquid refrigerant. 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 1 Remove refrigerant line (16) between evaporator and condenser
AR83.30-P- 7812MCU 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 2 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver gotis://G_58.0_01.1
3 Remove front bulkhead (17) The front bulkhead is bolted with two nuts.
4 Drain coolant
AR20.00-P- 1142MCU 5 Remove diagonal struts On model 451.4 AR61.10-P- 5138MCU 6 Remove bolts (10) and remove carrier (9) On model 451.4
*BA61.25-P- 1003-01B 7 Remove bulkhead wall On model 451.4 AR61.25-P- 6600MCU 8 Unclip refrigerant lines (1, 2) from bracket (5) Installation: Note routing of refrigerant lines (1, 2). They must have a minimum distance of 5 mm to the body, fuel tank (8) or other components, as otherwise noises or damages may be caused by impacts or chafing.
9 Unclip refrigerant lines (1, 2) from bracket (18) and remove bracket (18) On vehicles in which the bracket (18) is still installed. Installation: The bracket (18) may no longer be installed.
Close off refrigerant line (1) and
Open quick-release¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2459 · Applies to: 450, 451, 452, 454
10 Open quick-release coupling (11) of refrigerant line (1) and remove seal ring of refrigerant line (1) refrigerant line of refrigerant compressor using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace the sealing ring at the refrigerant line (1) and coat with compressor fluid when inserting.
Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P- 0362-00A
452589003300 11 Support fuel tank (8) using transmission jack (15) and removal fixture Transmission jack gotis://H_00.10_01.0 450589026200 12 Remove bolts (7) *BA47.10-P- 1001-01F 13 Carefully lower fuel tank (8) as far as possible When lowering the fuel tank (8), ensure that the filler neck of the fuel tank (8) is not damaged, otherwise the fuel tank (8) must be replaced.
14 Unclip brake line (6) from brackets (3, 4)
15 Unclip wiring harness bracket (12) on refrigerant line (1)
16 Pull refrigerant line (1) out of expansion valve
17 Remove supports and swivel radiator unit (14) forward and to one side Aid of helper required.
*451589013100 18 Place coolant hose (13) to one side and lead out refrigerant line (1) towards front Aid of helper required.
19 Secure radiator unit (14) with supports *451589013100 20 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30-P- 6525MCC 21 Install in the reverse order
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13
UNDERBODY FRAME¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2460 · Applies to: 450, 451, 452, 454
Number Designation Model 451.4 except 451.491 BA61.25-P-1003-01B Bolt, console to underbody Nm 26 TESTING & REPAIR > REMOVE/INSTALL REFRIGERANT LINE BETWEEN EVAPORATOR Fig 3: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Mount (451 589 01 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Cutting Tool Set (452 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2463 · Applies to: 450, 451, 452, 454
1.4.08 Repair method revised Steps 9 and 10
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00-Z- 0001-01A 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 Fig 1: Identifying Refrigerant Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on handling R134a¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2464 · Applies to: 450, 451, 452, 454
refrigerant Air conditioning with refrigerant R134a AH83.30-N- 0003-01A 1 Remove refrigerant line (13) between evaporator and condenser
AR83.30-P- 7812MCU 2 Disconnect electrical connector from refrigerant pressure sensor (B12).
3 Remove supports and secure radiator unit (14) against falling down using suitable cable ties *451589013100 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 4 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver gotis://G_58.0_01.1
5 Remove front bulkhead (15) The front bulkhead (15) is bolted with two nuts.
6 Remove diagonal struts On model 451.4 AR61.10-P- 5138MCU 7 Remove bolts (10) and remove carrier (9) On model 451.4
*BA61.25-P- 1003-01B 8 Remove bulkhead wall On model 451.4 AR61.25-P- 6600MCU 9 Unclip refrigerant lines (1, 2) from bracket (5) Installation: Note routing of refrigerant lines (1, 2). They must have a minimum distance of 5 mm to the body, fuel tank (8) or other components, as otherwise noises or damages may be caused by impacts or chafing.
10 Unclip refrigerant lines (1, 2) from bracket (16) and remove bracket (16) On vehicles in which the bracket (16) is still installed. Installation: The bracket (16) may no longer be installed.
11 Open quick-release coupling (11) of refrigerant line (2) and remove seal ring of refrigerant line (2) Close off refrigerant line (2) and refrigerant line of refrigerant compressor using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit.
Installation: Replace the sealing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2465 · Applies to: 450, 451, 452, 454
ring at the refrigerant line (2) and coat with compressor fluid when inserting. Compressor oils (specification 362.0) Sheet 362.0 BB00.40-P- 0362-00A
452589003300 12 Support fuel tank (8) with a transmission jack and a removal fixture Transmission jack gotis://H_00.10_01.0 450589026200 13 Remove bolts (7) *BA47.10-P- 1001-01F 14 Carefully lower fuel tank (8) as far as possible When lowering the fuel tank (8), ensure that the filler neck of the fuel tank (8) is not damaged, otherwise the fuel tank (8) must be replaced.
15 Unclip brake line (6) from brackets (3, 4)
16 Unclip wiring harness bracket (12) on refrigerant line (1)
17 Lead out refrigerant line (2) between front axle carrier and body and remove Assistant needed to hold radiator unit (14).
18 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30-P- 6525MCC 19 Install in the reverse order
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 UNDERBODY FRAME Number Designation Model 451.4 except 451.491 BA61.25-P-1003-01B Bolt, console to underbody Nm 26
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2467 · Applies to: 450, 451, 452, 454
1 Move right seat toward rear 2 Disconnect electrical connector (2) at evaporator temperature sensor (B10/6) 3 Pull evaporator temperature sensor (B10/6) out of air conditioner housing (1) 4 Install in the reverse order TESTING & REPAIR > DETACH/ATTACH REFRIGERANT COMPRESSOR - AR83.55-P- 5300-04MCU > REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001- 01V Bolt, AC compressor to crankcase Nm 20 BA83.55-P-1002- 01V Bolt, AC compressor to oil pan Nm 20 1. Loosen bolt (1) of refrigerant compressor (A9) at cylinder crankcase above the right wheel well by half a thread. Attachment: Use suitable Torx wrench insert to tighten to the specified tightening torque. Fig 1: Identifying AC Housing, Electrical Connector And Evaporator Temperature Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Lift vehicle with lifting platform.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2468 · Applies to: 450, 451, 452, 454
- Loosen bolts (2) of refrigerant compressor (A9) at the oil pan (3). The bolts (2) remain on the refrigerant compressor (A9).
- Install in the reverse order. Fig 1: Locating Cylinder Crankcase Refrigerant Compressor And Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Locating Refrigerant Compressor Bolts At Oil Pan Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL REFRIGERANT COMPRESSOR - AR83.55-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2469 · Applies to: 450, 451, 452, 454
5300MCU > ENGINE 132.910 in MODEL 451.3/4 with CODE (I01) Air conditioning Plus
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 refrigerant R134a
AH83.30- N-0003- 01A 1 Discharge air conditioning Installation: Evacuate air conditioning AR83.30- P- Fig 1: Identifying Refrigerant Compressor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
system¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2470 · Applies to: 450, 451, 452, 454
and then fill. 1760MCC 2 Disconnect fully automatic air conditioning service station Fully automatic air conditioning service station http://gotis.aftersales.mercedes- benz.com
3 Release rear drive module
AR01.00- P- 3050MCU 4 Remove poly-V belt for refrigerant compressor (A9)
AR13.21- P- 1202MCU 5 Detach electrical connector (1) for refrigerant compressor (A9)
6 Remove bolts (2), place refrigerant lines (3) to one side and remove seal rings of refrigerant lines (3) Close off refrigerant lines (3) and refrigerant compressor (A9) using appropriate stop plugs, as otherwise any penetrating dirt and moisture damages components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (3) and coat with compressor fluid when inserting.
BA83.55- P-1003- 01V 7 Unscrew screws (4) from refrigerant compressor (A9) BA83.55- P-1001- 01V *BA83.55- P-1002- 01V 8 Remove refrigerant compressor (A9)
9 Remove filter dryer Always replace the filter drier after opening the refrigerant circuit AR83.30- P- 6525MCC 10 Install in the reverse order
REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001- 01V Bolt, AC compressor to crankcase Nm 20 BA83.55-P-1002- 01V Bolt, AC compressor to oil pan Nm 20 BA83.55-P-1003- Bolt, refrigerant line to refrigerant Nm 20
compressor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2471 · Applies to: 450, 451, 452, 454
01V compressor SAFETY PRECAUTIONS > RISK OF EXPLOSION. EXPLOSIONS MAY RESULT WHEN PERFORMING WELDING OR SOLDERING WORK ON A CLOSED AIR CONDITIONING SYSTEM. RISK OF POISONING CAUSED BY INHALING OVERHEATED REFRIGERANT VAPORS. RISK OF INJURY TO SKIN AND EYES CAUSED BY CONTACT WITH LIQUID REFRIGERANT. - AS83.00-Z-0001-01A > Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. Potential risks Risk of explosion When closed air conditioning systems (charged or empty) become heated, high pressures are produced that can ultimately cause the system to burst. For this reason, all welding and soldering operations on or near closed air conditioning systems are prohibited. High pressure levels can combine with refrigerant vapors to produce a mixture that is potentially explosive when exposed to atmospheric air. Risk of poisoning Refrigerant can decompose when overheated. The resulting substances are toxic and should never be inhaled. Risk of injury Refrigerant vapors are heavier than air; this means that escaping gases pose a risk of suffocation for anyone in a work pit beneath the vehicle. Contact with liquid refrigerant may cause chilblain-like damage to the skin (due to undercooling). Safety instructions/precautions All welding, brazing and soldering operations on sealed air conditioning systems and in their immediate vicinity are prohibited. Never smoke when working with refrigerant, never expose refrigerant to open flames. A piercing odor can indicate overheated refrigerant - never inhale these vapors. Leave closed rooms immediately and ventilate thoroughly. All refrigerant must be evacuated from the entire air conditioning system prior to doing any repair work on the air conditioning circuit or components. Because it poses a hazard to the atmosphere as well as to personal health and safety, discharging refrigerant directly into the air is prohibited. Suitable evacuation, treatment and charging devices equipped with integral disposal and treatment facilities must be used for evacuating refrigerant. Even after the system has been evacuated, residual pressure may still be present in the system when loosening couplings. Therefore, loosen the couplings carefully, so that the pressure can dissipate slowly. Avoid all contact with liquid refrigerant.
Always wear safety glasses and protective gloves when working with refrigerant.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2472 · Applies to: 450, 451, 452, 454
First aid measures In case of eye contact Immediately flush with plenty of running water and consult a physician. In case of skin contact Consult a physician immediately in case of frostbite. In case of inhalation of concentrated refrigerant, immediately take victim out into the fresh air and keep victim calm. If the victim's breathing is shallow, or the individual has stopped breathing altogether, tilt the head back and administer artificial resuscitation. Call a physician. In case of ingestion Consult a physician immediately. SAFETY PRECAUTIONS > SAFETY INFORMATION: CLIMATE CONTROL - AS83.00-Z- 9999ZZ > MODEL all Hazard from contact with parts conducting high voltages. MODEL all with CODE (H25) Eberspacher D 30 W with CODE (H26) Webasto DW 300 AS83.70-Z-0001- 01A Risk of death caused by contact with current conducting parts when repairing parts of the external power supply MODEL 639, 903... AS83.00-Z-0002- 01A Risk of explosion caused by fuel vapors igniting, risk of poisoning caused by inhaling combustible gases and risk of injury caused by burns during and after operation of heater unit MODEL all mit Zuheizer, Zusatzheizung oder Standheizung AS83.70-Z-0002- 01A Risk of explosion. Explosions may result when performing welding or soldering work on a closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. MODEL all AS83.00-Z-0001- 01A Risk of explosion. Explosions may result when performing welding or soldering work on a closed air MODEL 240 AS83.00-P-0001- 01H
conditioning system. Risk of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2473 · Applies to: 450, 451, 452, 454 · AR: BA83.00-Z-9999CZ
poisoning. Poisoning may result from inhaling overheated refrigerant vapors. Risk of injury. Contact with liquid refrigerant may result in injury to the skin and eyes. Risk of explosion from liquefied petroleum gas flowing out and from fuel vapors. Risk of poisoning from inhaling combustion gases. BODY 940, 972... AS83.70-Z-0004- 01A Risk of poisoning due to inhalation of heater exhaust gases MODELS 901, 902, 903, 904, 905 for underfloor heaters AS83.70-Z-0005- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: CLIMATE CONTROL - BA83.00-Z-9999CZ > MODEL all Air conditioning MODEL 451.3/4 BA83.30-P-1000-01L Air conditioning MODEL 454.0 BA83.30-P-1000-01F Air conditioning MODEL 450.3 /4, 452.3 /4 BA83.30-P-1000-01E Heater MODEL 452.3 /4 BA83.20-P-1000-01C Heater booster unit MODEL 451.39 /49 BA83.70-P-1000-02D Refrigerant compressor ENGINE 132.9, 780.009 BA83.55-P-1000-01V Refrigerant compressor ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BA83.55-P-1000-01L Refrigerant compressor ENGINE 160.910 /920 /921 /922 /923 BA83.55-P-1000-01J Refrigerant compressor ENGINE 660.940 /950 /951 BA83.55-P-1000-01I Stationary heater unit MODEL 451.3/4 with ENGINE 132.9 BA83.70-P-1000-01G Stationary heater unit MODEL 454 BA83.70-P-1000-01D TORQUE SPECIFICATIONS > REFRIGERANT COMPRESSOR - BA83.55-P-1000-01V > Engine 132, 780.009 REFRIGERANT COMPRESSOR Number Designation Engine 132.9 Engine 780.009 BA83.55-P-1001- 01V Bolt, refrigerant compressor to cylinder crankcase Nm 20 -
BA83.55-P-1002-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2474 · Applies to: 450, 451, 452, 454
01V Bolt, AC compressor to oil pan Nm 20 - BA83.55-P-1003- 01V Bolt, refrigerant line to refrigerant compressor Nm 20 - BA83.55-P-1004- 01V Screw/bolt, refrigerant compressor to engine M8 Nm - 20 M10 Nm - 40 BA83.55-P-1005- 01V Nut, refrigerant line to refrigerant compressor Nm - 20 BA83.55-P-1006- 01V Nut refrigerant line to expansion valve Nm - 11 BA83.55-P-1007- 01V Nut, high-voltage battery circuit heater bracket to body Nm - 11 BA83.55-P-1008- 01V Nut, high-voltage battery circuit heat exchanger bracket to body Nm - 11 BA83.55-P-1009- 01V Screw/bolt, refrigerant line holder to intake side/thrust side refrigerant line Nm - 11 TORQUE SPECIFICATIONS > STATIONARY HEATER UNIT - BA83.70-P-1000-01G > Model 451.3/4 with engine 132.9 HEATER UNIT OF STATIONARY HEATER Number Designation Model 451.3/4 with engine 132.9 BA83.70-P-1001- 01G Nut, tank remover to fuel pump with fuel level sensor Nm 5 CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: CLIMATE CONTROL - BF83.00- Z-9999CZ > MODEL all AC compressor MODEL 450.3 /4 BF83.55-P-1000- 01B Air conditioning MODEL 454.0 BF83.30-P-1000- 01D Air conditioning MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454 BF83.30-P-1000- 01C Refrigerant compressor ENGINE 639.939, 134.910 /911, 135.930 /950 in MODEL 454.0 BF83.55-P-1000- 01E CAPACITIES & SPECIFICATIONS > AIR CONDITIONING - BF83.30-P-1000-01C > Model 450, 451, 452, 454
Function requirements:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2476 · Applies to: 450, 451, 452, 454
Circuit 15 On The ventilation allows the following operating modes: Fresh air mode Air recirculation mode (with code (I01) Air conditioning Plus) The following components are actuated by the heater/AC operating unit: Blend air flap actuator (M16/8) (with code (I01) Air conditioning Plus) Air recirculation flap actuator motor (M39) (with code (I01) Air conditioning Plus) Fresh air mode The fresh air is drawn in through the air inlet in the front maintenance flap and passed on into the heater or air conditioner housing (with code (I01) Air conditioning Plus) via the pollen filter. Depending on the preselection via the air distribution rotary switch, the fresh air is passed on via the blend air flap into the vehicle interior through the air ducts and air outlets (arrows). On vehicles with code (I01) Air conditioning Plus, the blend air flap is actuated via the blend air flap actuator, which is actuated by the heater/AC operating unit depending on the following information: Specified temperature set on the temperature preselection slider switch Interior temperature Temperature on evaporator Coolant temperature On vehicles without code (I01) Air conditioning Plus, the blend air flap is adjusted mechanically by the temperature preselection slider switch in the heater/AC operating unit by means of a cable. Depending on the actuation of the blend air flap, it opens or closes the air passage through the heater heat exchanger. The blower switch (S98/1) integrated in the heater/air conditioning control unit can be used to regulate the air flow over the blower motor (M2). Air recirculation mode (with code (I01) Air conditioning Plus) By actuating the air recirculation switch (N23s3) on the heater/AC operating unit, the air recirculation flap actuator motor is actuated, which closes the air recirculation flap. As a result, supply of outside air is prevented; the air only circulates in the vehicle interior and unpleasant odors and harmful gases are kept out. The visual feedback of air recirculation mode takes place via the light-emitting diode integrated in the air recirculation switch. Blower, component description M2 GF83.10-P- 2050MCC Actuator motors, component description M16/8, M39For code (I01) Air conditioning Plus GF83.10-P- 2201MCC
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2480 · Applies to: 450, 451, 452, 454
The heater heat exchanger is located in the left of the front passenger footwell. Task The heater heat exchanger warms the air flow which is directed to the vehicle interior via the various air distribution vents. Design The heater heat exchanger consists of coiled pipes and slats in order to offer the largest surface possible for the heat output. Function Coolant heated by the engine flows through the heater heat exchanger. The inflow is regulated by the thermostat of the cooling-water circulation. The heat is dissipated via the coiled pipes and lamellae made of aluminum towards the outside to the air blowing by, which is heated up in the process and then routed into the vehicle interior. BASIC KNOWLEDGE > AUTOMATIC HEATER (HEAT) COMPONENT LOCATIONS - GF83.25-P-0001-02MCU > Fig 1: Locating Heating System Heat Exchanger Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2487 · Applies to: 450, 451, 452, 454
The automatic air conditioning is regulated via the heater/AC operating unit, which is networked with the vehicle electronics via CAN. This permits the best possible climate control while considering any climate- relevant events, as well as the adaptation of the engine management to the power absorption capacity of the refrigerant compressor. The following information is directly read in by the heater/AC operating unit: Evaporator temperature via evaporator temperature sensor Refrigerant pressure via refrigerant pressure sensor Interior temperature via the interior temperature sensor (N23b1) integrated in the heater/AC operating unit Position feedback by the blend air flap actuator The following information is transmitted to the heater/AC operating unit via CAN: Outside temperature via the instrument cluster Coolant temperature via the ME control unit The following components are directly actuated by the heater/ AC operating unit: Blend air flap actuator Air recirculation flap actuator motor Fig 1: Regulation Of Automatic Air Conditioning Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Function¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2489 · Applies to: 450, 451, 452, 454
The hot coolant coming from the refrigerant compressor is pressed upwards into the condenser. Coiled pipes and fins absorb this heat extremely rapidly and give it off into the outside air flowing through the condenser. This serves to cool the refrigerant. As the refrigerant cools, the refrigerant condenses and turns to a liquid. As it flows through the desiccant cartridge mounted directly onto the condenser, the refrigerant is cleaned of chemical and mechanical impurities. BASIC KNOWLEDGE > EVAPORATOR, COMPONENT DESCRIPTION - GF83.40-P- 2189MCC > MODEL 451.3/4 with CODE (I01) Air conditioning Plus Location The evaporator is installed in the bottom in the air conditioner housing. Task During cooling mode, the air flowing through the evaporator into the vehicle interior is cooled down, dried and cleaned. BASIC KNOWLEDGE > EXPANSION VALVE, COMPONENT DESCRIPTION - GF83.40-P- 2190MCC > MODEL 451.3/4 with CODE (I01) Air conditioning Plus Fig 1: Locating Evaporator Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The heater/AC operating unit is located in the center console.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2493 · Applies to: 450, 451, 452, 454
The heater/AC operating unit permits the following operations: Switching the air conditioning system on and off Interior temperature selection cold/warm Manual blower control Manual air distribution Recirculated air mode Defrost function Rear window heater The heater/AC operating unit takes over the following actuations: Via Controller Area Network (data bus/CAN bus) (CAN): Refrigerant compressor (A9) via the SAM control unit (N10/10) Blower motor (M2) via the SAM control unit Heated rear window (R1) via the SAM control unit Direct: Recirculated air flap actuator motor (M39) Blend air flap actuator (M16/8) The heater/AC operating unit reads in the following sensor signals: Direct: Interior temperature sensor (integrated in heater/AC operating unit) Evaporator temperature sensor (B10/6) Blend air flap actuator Via CAN: Outside temperature through the instrument cluster (A1) Coolant temperature through the ME control unit (N3/10) Design The heater/AC operating unit contains the following controls and displays: Air distribution rotary switch Temperature preselection slider switch Air conditioning switch
M16/8¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2498 · Applies to: 450, 451, 452, 454
Stellglied Mischluftklappe 26L M2 Geblasemotor 6L M39 Stellmotor Umluftklappe 30L N10/10 Steuergerat SAM 10L N10/10f20 Sicherung 20
N10/10f4 Sicherung 4 8L N23 Bediengerat Heizung / Klima 12A N23 Bediengerat Heizung / Klima 20A N23 Bediengerat Heizung / Klima 28A N23b1 Innentemperaturfuhler
N23s1 Schalter Heckscheibenheizung
N23s2 Schalter Klimaanlage
N23s3 Schalter Umluft
R14 Vorwiderstandsgruppe Geblasemotor 3L S98/1 Geblaseschalter 4A W10 Masse Batterie 14E W26 Masse Mitteltunnel 8H X26 Steckverbindung Innenraum-Motor 11H X85/10 Steckverbindung Heizung oder Klima 7E Z3/44 Endhulse Klemme 15 gesichert Kombi Radio 10E Z37/2 Endhulse CAN-Motor-Bus (low) 21E Z37/3 Endhulse CAN-Motor-Bus (high) 20E Z5/1 Endhulse Geblase/Lufter 1H Z5/1 Endhulse Geblase/Lufter 6H Z81 Endhulse Klemme 58d 18E
Fig 1: Air Conditioning - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2499 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Recirculated air flap actuator motor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2502 · Applies to: 450, 451, 452, 454
M39 Recirculated air flap actuator motor 8 H N10/10 SAM control unit 2 G N23 Heater/AC operating unit 10 H N3/10 ME-SFI [ME] control module 17 D R1 Heated rear window 3 B R14 Blower motor preresistor group 13 L S98/1 Blower switch 11 J X11/4 Data link connector 8 C Fig 1: Air Conditioning - Electrical Function Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 452, 451, 164, 251¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2504 · Applies to: 450, 451, 452, 454
Use: Separation of high-pressure/low-pressure A/C lines with connector dimensions 5/8" and 1/2". NOTE: smart no.: 001 5804 V000 0000 00 3/8" and 3/4" cutting tools have part number 164 589 03 33 00. SPECIAL TOOLS > 203 589 03 10 00 VALVE WRENCH - WS83.00-P-0060A > FG 83/Set A MODEL 164, 168, 169, 170, 171.4, 202, 203, 204, 207, 209, 211, 212, 216, 220, 221, 230, 240, 245, 251, 451, 454, 461, 463, 414 MODIFICATION NOTES 9.8.07 Replacement for 203 589 01 10 00 WS83.00-P-3023K
Replacement for 454 589 01 33 00 WS83.00-P-0056B Use: Valve wrench for assembling and disassembling the valve element at the high and low-pressure service valves.
Fig 1: Identifying Cutting Tool Set (452 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: CLIMATE CONTROL - WS83.00-Z-9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2505 · Applies to: 450, 451, 452, 454 · AR: WS83.00-Z-9999CZ
MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P-0007B 000 589 13 99 30 MCP 2.8 / Fl. blade 2.8 / JPT / SPT FG00/54/83/Set B WS00.19-P-0007- 30B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P-0111B 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 203 589 03 10 00 Valve wrench FG 83/Set A WS83.00-P-0060A 220 589 01 99 05 JPT crimping set FG 00/54/83/Set B WS00.19-P-0001- 05B 220 589 01 99 10 Crimp pliers FG 00/14/54/83/Set B WS00.19-P-0001- 09B 220 589 01 99 40 Wire stripper FG 00/54/83/Set B WS00.19-P-0001- 22B 220 589 01 99 41 Reflector FG 00/54/83/Set B WS00.19-P-0001- 23B 220 589 01 99 42 Adapter FG 00/54/83/Set B WS00.19-P-0001- 24B 220 589 01 99 50 Blade holder with clamping pliers FG00/14/54/83/Set B WS00.19-P-0001- 25B 220 589 01 99 54 MT 3 blade FG00/83/Set B WS00.19-P-0001- Fig 1: Identifying Valve Wrench (203 589 03 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
220 589 02 99 00 Wiring harness repair¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2506 · Applies to: 450, 451, 452, 454
29B 220 589 02 99 00 Wiring harness repair kit FG 00 FG 54/83/Set B WS00.19-P-0002B 220 589 04 99 00 New passenger car wiring harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P-0006B 450 589 00 07 00 Tank module tool FG 47/83/Set B WS47.00-P-0021B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 450 589 05 63 00 Remover FG 83/Set B WS83.00-P-0050B 450 589 06 63 00 Remover FG 83/Set B WS83.00-P-0051B 452 589 00 33 00 Cutting tool set FG 83/Set B WS83.00-P-0052B 452 589 02 99 00 Wiring harness repair kit FG 00/54/77/83/ Set B WS00.00-P-0243B 454 589 01 33 00 Turn out device FG 83/Set B WS83.00-P-0056B 454 589 07 09 00 Socket wrench bit FG 83/Set B WS83.00-P-0055B
GENERAL INFORMATION > NOTES ON HANDLING REFRIGERANT R134A - AH83.30-N-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2507 · Applies to: 450, 451, 452, 454
0003-01A > Air conditioning with refrigerant R134a The refrigerant R134a is colorless and odorless. At normal temperatures it is neither toxic nor flammable, and will not explode in the air, no matter what its mixing ratio. The R134a refrigerant may only be used in air conditioning systems for which R134a has been specifically approved. The refrigerant R134a must not be mixed with other refrigerants (e.g. R12). The refrigerant R134a does not contain any chlorofluorocarbons (CFC). In contrast to other refrigerants (e.g. R12) it is not hazardous to the environment at normal temperatures. The refrigerant R134a does not damage the earth's ozone layer. Despite these benefits, refrigerant R134a may only be extracted by experts with suitable extraction, recycling and filling equipment that includes integral disposal and reprocessing capabilities. GENERAL INFORMATION > PROCEDURE FOR A DAMAGED OR LEAKY AIR CONDITIONING SYSTEM - AH83.30-N-0004-01A > All models The air conditioning system should never be operated if it is damaged or when there is evidence of refrigerant loss. In the event that refrigerant is lost, lubrication can fail. This will lead to damage of the refrigerant compressor. Evacuate damaged and/or leaking air conditioning refrigerant circuits as quickly as possible using extraction, processing and recharging equipment with integral disposal and reprocessing capabilities. GENERAL INFORMATION > PROTECT AIR CONDITIONING CIRCUIT AND COMPONENTS FROM MOISTURE WHEN CARRYING OUT REPAIR WORK - AH83.30-N-0005-01A > All models with air conditioning Do not carry repair operations out on the air conditioning circuit in the open air during moist weather. Moisture in the refrigerant circuit reduces the system's refrigeration output and leads to damage to the components. Acidification in the circuit caused by moisture decomposes the drier element installed (e.g. fluid reservoir, filter drier or desiccant cartridge) and thus damages the entire system. After separating/unscrewing refrigerant lines, immediately seal off the connection openings so that they are airproof using suitable stop plugs (parts kit). The drier element must be replaced every time the refrigeration circuit is opened.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2517 · Applies to: 450, 451, 452, 454
1 Remove windshield washer fluid reservoir
AR82.35- P- 6000MCU 2 Release coolant hose (5) from bracket (arrow B) on fresh-air intake (1)
3 Unclip brake fluid reservoir (2) in the area marked (arrow A) using a suitable screwdriver (3) and place to one side
4 Unscrew nuts (4) on fresh-air intake (1)
Fig 1: Identifying Fresh-Air Intake, Brake Fluid Reservoir, Screwdriver, Nut And Coolant Hose Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Fresh-Air Intake And Gasket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
the battery or the body.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2519 · Applies to: 450, 451, 452, 454
7 Pull heater heat exchanger (5) out of the heater/air conditioner housing and put down Make sure that coolant does not run over the battery or into the battery recess, as this may damage the on-board electrical system, the battery or the body.
Install
8 Insert heater heat exchanger (5) into the heater/air conditioner housing
9 Position coolant lines (3) on heater heat exchanger (5) and secure in place using clamps (4) Replace seals (6).
10 Top up with coolant and check cooling system in area of heater heat exchanger (5) and coolant lines (3) for signs of leaks
AR20.00- P- 1142MCU 11 Insert cover (1) into heater/air conditioner housing in the marked areas (arrows) and tighten bolt (2)
12 Remove rag (7)
13 Install foot support on passenger side
AR68.30- P- 1340MCC TESTING & REPAIR > REMOVE/INSTALL HEATER CONTROL CABLE - AR83.20-P- 1400MCU > MODEL 451.3 /4 except CODE (I01) Air conditioning Plus Remove/install
Up to AR83.20- Fig 1: Identifying Heater Control Cable Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3 /4 except CODE (I01) Air conditioning Plus¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2523 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Heater Housing Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Heater Housing Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2524 · Applies to: 450, 451, 452, 454
1 Remove front CBS
AR88.00- P- 1010MCC 2 Drain coolant
AR20.00- P- 1142MCU 3 Release click clamps (1) on coolant hoses (2) and then remove
4 Remove crossmember below instrument panel
AR62.30- P- 1250MCU 5 Disconnect heater or AC connector (X85/10)
6 Place right front floor covering in area of heater housing (3) to one side
7 Unclip retaining clip (6) of electrical wiring harness (7) on heater housing (3)
Fig 3: Identifying Heater Housing Components (3 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Place left front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2525 · Applies to: 450, 451, 452, 454
8 Place left front floor covering in area of heater housing (3) to one side
9 Unscrew nuts (4) on heater housing (3)
10 Remove heater housing (3) from firewall and route to the rear until the coolant hoses (2) are accessible
11 Detach coolant hoses (2) Make sure that the interior is not contaminated by any escaping coolant, as contaminated parts will have to be cleaned or replaced. Note installation position of coolant hoses (2). Installation: Position click clamps (1) on coolant hoses (2), slide coolant hoses (2) onto connections on heater housing (3) and fasten click clamps (1) in place.Position openings of click clamps (1) such that they face upward or to the right and that they do not come into contact with the coolant hoses (2).
12 Remove heater housing (3) from vehicle Make sure that the interior is not contaminated by any escaping coolant, as contaminated parts will have to be cleaned or replaced.
13 Detach fresh air case (11) from the heater housing (3) by turning and remove When replacing the heater housing (3).
14 Detach electrical connector (9), release lock and detach blower motor (M2) by turning it counterclockwise and then remove from the heater housing (3) When replacing the heater housing (3).
15 Detach electrical connector (10) and relea e erie resistor group for blower motor (R14) by turning it clockwise and then remove from the heater housing (3) When replacing the heater housing (3).
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2530 · Applies to: 450, 451, 452, 454
1 Disconnect electrical connector (1) 2 Release blower motor series resistor group (R14) by turning clockwise and remove 3 Install in the reverse order TESTING & REPAIR > PERFORM AIR CONDITIONING SYSTEM LEAK TEST - AR83.30-P- 1011MCU > MODEL 451.3 /4 (except 451.391 /491) with CODE (I01) Air conditioning Plus Illustrated on model 451.4 Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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
AR88.00- Fig 1: Identifying Condensation Drain Hose Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove front CBS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2531 · Applies to: 450, 451, 452, 454
2 Remove front CBS
P 1010MCC 3 Remove rear CBS
AR88.20- P- 1900MCC 4 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
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
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 10 Inspect expansion valve with air conditioning leak detector If leaks are found, the expansion valve must be replaced.Refer to: ↓
Remove/install expansion valve AR83.30- P- 5520MCU 11 Inspect refrigerant compressor with air conditioning leak detector If leaks are found, the refrigerant compressor must be replaced.Refer to: ↓
Remove/install expansion valve ar83.30- P- 5300MCU Inspect condensation water drain If leaks are found, the evaporator must be replaced.Refer to: ↓
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2533 · Applies to: 450, 451, 452, 454
2.8.07 Refrigerant, filling capacity
*BF83.30-P-1001-01C
Drain
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged.
AS83.00- Z-0001- 01A 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 For all operation steps, the Fig 1: Identifying Cap, Refrigerant Line, Air Conditioner Service Unit And Service Unit Connection Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
operating in truction for the air¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2534 · Applies to: 450, 451, 452, 454
conditioning service unit (6) must be followed
1 Remove maintenance flap
2 Unscrew plugs (1) on service valves of refrigerant lines (2, 3)
3 Connect air conditioning service unit connection (4) to service valve of refrigerant line (2) and air conditioning service unit connection (5) to service valve of refrigerant line (3) Air conditioning service unit (6)
4 Extract refrigerant using air conditioning service unit (6) Note down suctioned off compressor oil quantity.
Evacuating
5 Replace dehydrator Only if refrigerant circuit has been opened. AR83.30- P- 6525MCC 6 Clean refrigerant and evacuate air conditioning system using air conditioning service unit (6)
Fill
7 Replace the quantity of compressor oil noted when evacuating the air conditioning system with new compressor oil and route back to the refrigerant circuit If the wrong quantity of compressor oil is refilled then the refrigerant compressor may be damaged.
8 Fill air conditioning system using air conditioning service unit (6) Capacity of refrigerant *BF83.30- P-1001- 01C 9 Disconnect air conditioning service unit connection (4) from service valve of refrigerant line (2) and air conditioning service unit connection (5) from service valve of refrigerant line (3)
Screw on plugs (1) onto service
valve of refrigerant line (2, 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2535 · Applies to: 450, 451, 452, 454
10 valve of refrigerant line (2, 3)
Checking
11 Using air conditioning leak detector, inspect air conditioning for leaks at all points at which the system was opened Air conditioner leak detector
12 Install maintenance flap
AIR CONDITIONING SYSTEM Number Designation Model 451.3/4 except 451.391/491 Model 451.391/491 BF83.30-P- 1001-01C Refrigerants Filling capacity g 430 (+0/-20) 550 Specifications for Operating Fluids Sheet - - TESTING & REPAIR > CHECK AIR CONDITIONING SYSTEM FOR LEAKAGE - AR83.30-P- 1761MCC > MODEL 450 with CODE (I01) Air conditioning Plus with CODE (I29) Air conditioning Plus (with combination filter and outside temperature indicator), smart & passion A/C drained MODEL 451 with CODE (I01) Air conditioning Plus A/C drained MODEL 452 with CODE (I01) Air conditioning Plus A/C drained MODEL 454 with CODE (I01) Air conditioning Plus with CODE (I77) Manual air conditioning A/C drained
Checking
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained. AS83.00- Z-0001- 01A Procedure for a damaged or leaky air conditioning system
AH83.30- N-0004- 01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30- N 0003 01A Connect air conditioning
ervice unit and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2536 · Applies to: 450, 451, 452, 454
1 ervice unit and evacuate air conditioning system Air conditioner service unit
2 Fill air conditioning system with nitrogen Fill system with a system pressure of 15 bar only when engine is cold. This system pressure must be maintained for at least 4 hours. Fill high and low-pressure side of air conditioning with nitrogen. Temperature changes during the pressure test can cause pressure surges, e.g. due to weather changes, transition from day to night, cooling down of engine compartment. Make sure the ambient conditions remain constant.Air conditioner pressure and leak tester (mobile)
3 Check A/C circuit for leaks using leak- detecting spray For pressure loss in the A/C.
Leak detection spray If a pressure loss is detected and leak in the A/C circuit is not locatable, check A/C for leaks using leak- detecting additive. See: ↓ *BR00.45- Z-1002- 03A Check air conditioning system for leakage (Fill A/C) AR83.30- P- 1761MCE 4 Drain nitrogen
5 Refill A/C Type 450 AR83.30- P-1760SM Type 451 AR83.30- P- 1760MCC Model 452 AR83.30- P-1760RR Type 454 AR83.30- P-1760FF REPAIR MATERIALS Number Designation Order number BR00.45- Z-1002- 03A Leak detection spray Christof Fischer GmbH, Augsburger Str. 289-293,70327 StuttgartGermanyTel. +49 711 30502-0Fax +49 711 30502- 10www.kaeltefischer.de TESTING & REPAIR > CHECK AIR CONDITIONING SYSTEM FOR LEAKAGE - AR83.30-P- 1761MCE > MODEL 450 with CODE (I01) Air conditioning Plus with CODE (I29) Air conditioning Plus (with combination filter and outside temperature indicator), smart & passion A/C filled MODEL 451 with CODE (I01) Air conditioning Plus A/C filled MODEL 452 with CODE (I01) Air conditioning Plus A/C filled
MODEL 454 with CODE (I01) Air conditioning Plus with CODE (I77) Manual air conditioning A/C¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2537 · Applies to: 450, 451, 452, 454
filled
Checking
Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00- Z-0005- 01A Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained. AS83.00- Z-0001- 01A Procedure for a damaged or leaky air conditioning system
AH83.30- N-0004- 01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30- N-0003- 01A 1 Check complete engine compartment using a UV lamp, remove any contrast agent by washing the engine UV leak detector kit for air conditioning systems
2 Check refrigerant circuit for leaks using leak-detector additive Carry out steps as per the operating instructions of the UV leak detection kit. Use only the approved MB leak detector additives. If it is proven that a different leak detector additive has been used, we will refuse to reimburse costs inside the warranty and goodwill term. Daimler AG reserves the right to perform reexaminations.UV leak detector kit for air conditioning systems
TESTING & REPAIR > REMOVE/INSTALL AIR CONDITIONER HOUSING - AR83.30-P- 5200MCU > MODEL 451.3 /4 with CODE (I01) Air conditioning Plus
Fig 1: Identifying Air Conditioner Housing Components (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2538 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Air Conditioner Housing Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2539 · Applies to: 450, 451, 452, 454
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 1 Remove front CBS
AR88.00- P- 1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC Disconnect fully automatic air Fig 3: Identifying Air Conditioner Housing Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
conditioning ervice tation¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2540 · Applies to: 450, 451, 452, 454
3 conditioning ervice tation Air conditioner ervice unit
4 Remove front module
AR62.30- P- 1575MCU 5 Drain coolant
AR20.00- P- 1142MCU 6 Unclip brake fluid reservoir (8) in the area marked (arrow) using a suitable screwdriver (7) and place to one side
7 Disconnect electrical connector (6) from refrigerant pressure sensor (B12)
8 Unscrew nut (2) *BA83.30- P-1004- 01L 9 Pull out refrigerant lines (3) at expansion valve (1) and remove seal rings of refrigerant lines (3) Close off refrigerant lines (3) and expansion valve (1) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (3) and coat with compressor fluid when inserting.
10 Loosen click clamps (5) on coolant hoses (4) and detach coolant hoses (4) Collect discharged coolant in a suitable container.
11 Remove crossmember below dashboard
AR62.30- P- 1250MCU 12 Disconnect heater or AC connector (X85/10)
13 Remove retaining clip at right front floor covering (22) and place right front floor covering (22) in area of air conditioner housing (13) to one side
14 Detach condensation water drain hose (23) from air conditioner housing (13) Installation: It must be ensured that the condensation water drain hose (23) is correctly aligned and engaged at the connection to the air conditioner housing (13).
15 Unclip retaining clip (20) of main wiring harness (21) at air conditioner housing (13)
Place left front floor covering¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2541 · Applies to: 450, 451, 452, 454
16 Place left front floor covering (22) in area of air conditioner housing (13) to one side
17 Unscrew nuts (9) from air conditioner housing (13)
18 Remove air conditioner housing (13) from vehicle Ensure that the interior is not dirtied by discharged coolant, as dirty parts will have to be cleaned or replaced.
19 Disconnect electrical connector (19) from air recirculation flap actuator motor (M39) When replacing the air conditioner housing (13).
20 Release air recirculation unit (18) from air conditioner housing (13) by twisting and remove When replacing the air conditioner housing (13).
21 Disconnect electrical connector (14), remove bolts (15) and remove blend air flap actuator (M16/8) When replacing the air conditioner housing (13). Installation: Counterhold driver shaft on the opposite side on air conditioner housing (13).
22 Disconnect electrical connector (16) and pull evaporator temperature sensor (B10/6) out of air conditioner housing (13) When replacing the air conditioner housing (13).
23 Disconnect electrical connector (11), release lock (10) and loosen blower motor (M2) by turning counterclockwise and pull out of air conditioner housing (13) When replacing the air conditioner housing (13).
24 Disconnect electrical connector (12) and release blower motor series resistor group (R14) by twisting clockwise and remove When replacing the air conditioner housing (13).
25 Detach air conditioner housing wiring harness (17) from air conditioner housing (13) and remove When replacing the air conditioner housing (13).
26 Remove heat exchanger When replacing the air conditioner housing (13). AR83.20- P- 1100MCU 27 Remove combination filter When replacing the air conditioner housing (13). AP83.00- P- 8384MCC 28 Install in the reverse order
AIR CONDITIONING Number Designation Model 451.3/4
BA83.30-P-1004-01L¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2542 · Applies to: 450, 451, 452, 454
Nut, refrigerant lines to expansion valve Nm 4 TESTING & REPAIR > REMOVE/INSTALL REFRIGERANT PRESSURE SENSOR - AR83.30- P-5430MCC > MODEL 451.3 /4 with CODE (I01) Air conditioning Plus
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 refrigerant R134a
AH83.30- N-0003- 01A 1 Remove front CBS
AR88.00- P- 1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC 3 Disconnect electrical connector (1) from refrigerant pressure sensor (B12)
Fig 1: Identifying Refrigerant Pressure Sensor, Refrigerant Line And Electrical Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Protect air conditioning circuit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2544 · Applies to: 450, 451, 452, 454
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 1 Remove front CBS
AR88.00- P- 1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC 3 Remove front module
AR62.30- P- 1575MCU 4 Unscrew nut (2) *BA83.30- P-1004- 01L 5 Pull out refrigerant lines (3) at expansion valve (1) and remove seal rings of refrigerant lines (3) Close off refrigerant lines (3) and expansion valve (1) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (3) and coat with compressor fluid when inserting.
Compressor oils (specification 362.0) Sheet 362.0 BB00.40- P-0362- 00A 6 Remove bolts (4) *BA83.30- P-1003- 01L 7 Remove expansion valve (1) Close off openings at the evaporator connection lines using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace seal rings at evaporator connecting lines and coat with compressor fluid when inserting.
Compressor oils (specification 362.0) Sheet 362.0 BB00.40- P-0362- 00A 8 Remove filter dryer Always replace the filter drier after opening the refrigerant circuit AR83.30- P- 6525MCC
Install in the reverse order¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2545 · Applies to: 450, 451, 452, 454
9 Install in the reverse order
AIR CONDITIONING Number Designation Model 451.3/4 BA83.30-P-1003-01L Bolt, expansion valve to vaporizer tube Nm 6 BA83.30-P-1004-01L Nut, refrigerant lines to expansion valve Nm 4 TESTING & REPAIR > REMOVE/INSTALL INTAKE MANIFOLD FILLING VALVE - AR83.30- P-5535MCC > MODEL 451.3 /4 with CODE (I01) Air conditioning Plus MODIFICATION NOTES 8.4.10 Special tool for removal/installation of service valve exchanged Operation step 3
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained. AS83.00- Z-0001- 01A Procedure for a damaged or leaky air conditioning system
AH83.30- N-0004- Fig 1: Identifying Valve Element, Suction Pipe And Pressure Line Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Protect air conditioning circuit and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2546 · Applies to: 450, 451, 452, 454
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 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC 2 Disconnect air conditioner service unit from the service valve of the suction line (2) and the service valve of the pressure line (3) Air conditioner service unit
3 Remove valve element (1) on service valve of suction line (2) In model 451.391/491, the valve insert (1) must be removed using a commercially available valve wrench for Schrader valves (connection width 4.5 mm).In model 451 (except 451.391/491), the valve wrench must be used.
Valve wrench Fig 2 4 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL CONDENSER FILLING VALVE - AR83.30-P- 5536MCC > MODEL 451.3 /4 with CODE (I01) Air conditioning Plus Fig 2: Identifying Valve Wrench (203 589 03 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2547 · Applies to: 450, 451, 452, 454
8.4.10 Special tool for removal/installation of service valve exchanged Operation step 3
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained. AS83.00- Z-0001- 01A 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 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC Disconnect air conditioner service unit from the service valve of the Fig 1: Identifying Condenser Filling Valve Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2549 · Applies to: 450, 451, 452, 454
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A Procedure for a damaged or leaky air conditioning system
AH83.30- N-0004- 01A 1 Close air recirculation flap
2 Switch off ignition, blower and air conditioning
3 Remove evaporator temperature sensor
AR83.30- P- 8085MCC 4 Remove combination filter
AP83.00- P- 8384MCC 5 Expose condensation drain (1) and place suitable collecting pan underneath
Fig 1: Identifying Condensation Drain, Spray Probe And Rotary Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fill disinfection cleaner into¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2550 · Applies to: 450, 451, 452, 454
6 Fill disinfection cleaner into disinfection cleaning equipment with connected spray probe (2) Use short spray probe (2).
7 Connect disinfection cleaning equipment to compressed air hose and adjust pressure up to 10 bar
Cleaning the evaporator
8 Insert spray probe (2) through opening of evaporator temperature sensor into evaporator housing
9 Cover opening of combination filter slot No disinfection cleaner must enter the interior.
10 Place thumb on plate on spray probe (2) This sets the spray direction of the spray probe (2).When spraying through the evaporator temperature sensor opening, the plate on the spray probe (2) must point towards the vehicle interior.
11 Actuate disinfection cleaning equipment and move back and forth with the spray probe (2) Spray using approx. 0.5 liters of disinfection cleaner. Allow disinfection cleaner to work in for at least 30 min.
12 Check whether disinfection cleaner escapes through the condensation drain (1), clean condensation drain (1) if necessary If disinfection cleaner is only dripping, check condensation drain (1) for contamination and clean.
13 Adjust rotary switch (3) of ventilation system as shown in picture A
14 Start engine, switch on air conditioning system, open all air vents and allow blower to run at highest setting for at least 10 min. Leave the doors on the vehicle open. The evaporator is flushed out. Only when these instructions are complied with exactly is the evaporator cleaned completely and the odor eliminated.Position rotary switch (3) after 5 min as shown in picture B.
15 Switch off ignition
Install
16 Remove collecting pan and install condensation drain (1)
17 Replace combination filter
AP83.00- P- 8384MCC
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2552 · Applies to: 450, 451, 452, 454
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 refrigerant R134a
AH83.30- N-0003- 01A 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC 2 Disconnect fully automatic air conditioning service station Fully automatic air conditioning service station
Fig 2: Identifying Filter Drier, Front CBS, Screws, Cover And Circlip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2555 · Applies to: 450, 451, 452, 454
31.3.08 Repair method revised Steps 6 and 8
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC Fig 1: Identifying Refrigerant Lines At Refrigerant Compressor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Disconnect air conditioning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2556 · Applies to: 450, 451, 452, 454
2 Disconnect air conditioning service unit Air conditioner service unit
3 Release rear drive module
AR01.00- P- 3050MCU 4 Remove bolt (1, 3) for refrigerant line to be removed (2, 4) and remove refrigerant line (2, 4) from refrigerant compressor (A9) Close off refrigerant lines (2, 4) and their connection to the refrigerant compressor (A9) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace seal ring at the detached refrigerant line (2, 4) and coat with compressor oil when inserting.
Compressor oils (specification 362.0) Sheet 362.0 BB00.40- P-0362- 00A
*BA83.30- P-1002- 01L 5 Remove rubber retainer (5)
6 Unclip refrigerant lines (2, 4) from bracket (7) and remove bracket (7) On vehicles in which the bracket (7) is still installed. Installation: The bracket (7) may no longer be installed.
7 Open quick-release coupling (6) of refrigerant line to be removed (2, 4) Fig 2 8 Remove refrigerant line to be removed (2, 4) Installation: Note routing of refrigerant lines (8). They must have a minimum distance of 5 mm to the body, fuel tank or other components, as otherwise noises or damages may be caused by impacts or chafing.
9 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30- P- 6525MCC 10 Install in the reverse order
AIR CONDITIONING Number Designation Model 451.3/4 BA83.30-P-1002-01L Bolt, refrigerant line to refrigerant compressor Nm 20
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2558 · Applies to: 450, 451, 452, 454
1.4.08 Repair method revised Operation steps 8 and 9
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 1 Remove refrigerant line (16) between evaporator and condenser
AR83.30- P- 7812MCU 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 Raise vehicle using the vehicle Fig 2: Identifying Refrigerant Line Between Refrigerant Compressor And Evaporator Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
lift and remove underfloor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2559 · Applies to: 450, 451, 452, 454
2 lift and remove underfloor paneling Rechargeable drill / screwdriver
3 Remove front bulkhead (17) The front bulkhead is bolted with two nuts.
4 Drain coolant
AR20.00- P- 1142MCU 5 Remove diagonal struts On model 451.4 AR61.10- P- 5138MCU 6 Remove bolts (10) and remove carrier (9) On model 451.4
*BA61.25- P-1003- 01B 7 Remove bulkhead wall On model 451.4 AR61.25- P- 6600MCU 8 Unclip refrigerant lines (1, 2) from bracket (5) Installation: Note routing of refrigerant lines (1, 2). They must have a minimum distance of 5 mm to the body, fuel tank (8) or other components, as otherwise noises or damages may be caused by impacts or chafing.
9 Unclip refrigerant lines (1, 2) from bracket (18) and remove bracket (18) On vehicles in which the bracket (18) is still installed. Installation: The bracket (18) may no longer be installed.
10 Open quick-release coupling (11) of refrigerant line (1) and remove seal ring of refrigerant line (1) Close off refrigerant line (1) and refrigerant line of refrigerant compressor using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace the sealing ring at the refrigerant line (1) and coat with compressor fluid when inserting.
Compressor oils (specification 362.0) Sheet 362.0 BB00.40- P-0362- 00A
Figure 11 Support fuel tank (8) using transmission jack (15) and removal fixture Transmission jack Fig 3 12 Remove bolts (7) *BA47.10- P-1001- 01F When lowering the fuel tank (8),
Carefully lower fuel tank (8) as¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2560 · Applies to: 450, 451, 452, 454
13 Carefully lower fuel tank (8) as far as possible ensure that the filler neck of the fuel tank (8) is not damaged, otherwise the fuel tank (8) must be replaced.
14 Unclip brake line (6) from brackets (3, 4)
15 Unclip wiring harness bracket (12) on refrigerant line (1)
16 Pull refrigerant line (1) out of expansion valve
17 Remove supports and swivel radiator unit (14) forward and to one side Aid of helper required.
Fig 4 18 Place coolant hose (13) to one side and lead out refrigerant line (1) towards front Aid of helper required.
19 Secure radiator unit (14) with supports Fig 4 20 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30- P- 6525MCC 21 Install in the reverse order
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 UNDERBODY FRAME Number Designation Model 451.4 except 451.491 BA61.25-P-1003-01B Bolt, console to underbody Nm 26 Fig 3: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of explosion caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2562 · Applies to: 450, 451, 452, 454
welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 1 Remove front CBS
AR88.00- P- 1010MCC 2 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC 3 Disconnect air conditioning service unit Air conditioner service unit
4 Remove front module
AR62.30- P- 1575MCU 5 Unscrew nut (6) *BA83.30- P-1004- 01L 6 Pull out refrigerant lines (4, 7) at expansion valve (5) and remove seal rings of refrigerant lines (4, 7) Close off refrigerant lines (4, 7) and expansion valve (5) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (4, 7) and coat with compressor oil when inserting.
Compressor oils (specification 362.0) Sheet 362.0 BB00.40- P-0362- 00A 7 Unscrew nut (3) from condenser (2), detach refrigerant lines (1, 4) from condenser (2) and Close off refrigerant lines (1, 4) and condenser (2) using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2564 · Applies to: 450, 451, 452, 454
1.4.08 Repair method revised Steps 9 and 10
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 Fig 1: Identifying Refrigerant Line Between Condenser And Refrigerant Compressor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on handling R134a¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2565 · Applies to: 450, 451, 452, 454
refrigerant Air conditioning with refrigerant R134a AH83.30- N-0003- 01A 1 Remove refrigerant line (13) between evaporator and condenser
AR83.30- P- 7812MCU 2 Disconnect electrical connector from refrigerant pressure sensor (B12).
3 Remove supports and secure radiator unit (14) against falling down using suitable cable ties Figure 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 4 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver
5 Remove front bulkhead (15) The front bulkhead (15) is bolted with two nuts.
6 Remove diagonal struts On model 451.4 AR61.10- P- 5138MCU 7 Remove bolts (10) and remove carrier (9) On model 451.4
*BA61.25- P-1003- 01B 8 Remove bulkhead wall On model 451.4 AR61.25- P- 6600MCU 9 Unclip refrigerant lines (1, 2) from bracket (5) Installation: Note routing of refrigerant lines (1, 2). They must have a minimum distance of 5 mm to the body, fuel tank (8) or other components, as otherwise noises or damages may be caused by impacts or chafing.
10 Unclip refrigerant lines (1, 2) from bracket (16) and remove bracket (16) On vehicles in which the bracket (16) is still installed. Installation: The bracket (16) may no longer be installed.
11 Open quick-release coupling (11) of refrigerant line (2) and remove seal ring of refrigerant Close off refrigerant line (2) and refrigerant line of refrigerant compressor using appropriate stop plugs, as otherwise penetrating dirt and moisture damage components that are connected to the refrigerant circuit. Installation:
line (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2566 · Applies to: 450, 451, 452, 454
Replace the sealing ring at the refrigerant line (2) and coat with compressor fluid when inserting. Compressor oils (specification 362.0) Sheet 362.0 BB00.40- P-0362- 00A
Figure 12 Support fuel tank (8) with a transmission jack and a removal fixture Transmission jack Figure 13 Remove bolts (7) *BA47.10- P-1001- 01F 14 Carefully lower fuel tank (8) as far as possible When lowering the fuel tank (8), ensure that the filler neck of the fuel tank (8) is not damaged, otherwise the fuel tank (8) must be replaced.
15 Unclip brake line (6) from brackets (3, 4)
16 Unclip wiring harness bracket (12) on refrigerant line (1)
17 Lead out refrigerant line (2) between front axle carrier and body and remove Assistant needed to hold radiator unit (14).
18 Remove filter dryer Installation: Always replace the filter drier after opening the refrigerant circuit. AR83.30- P- 6525MCC 19 Install in the reverse order
FUEL TANK Number Designation Model 451.3/4 BA47.10-P-1001-01F Bolt, fuel tank to body Nm 13 UNDERBODY FRAME Number Designation Model 451.4 except 451.491 BA61.25-P-1003-01B Bolt, console to underbody Nm 26
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2568 · Applies to: 450, 451, 452, 454
1 Move right seat toward rear 2 Disconnect electrical connector (2) at evaporator temperature sensor (B10/6) 3 Pull evaporator temperature sensor (B10/6) out of air conditioner housing (1) 4 Install in the reverse order TESTING & REPAIR > DETACH/ATTACH REFRIGERANT COMPRESSOR - AR83.55-P- 5300-04MCU > REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001-01V Bolt, AC compressor to crankcase Nm 20 BA83.55-P-1002-01V Bolt, AC compressor to oil pan Nm 20 1. Loosen bolt (1) of refrigerant compressor (A9) at cylinder crankcase above the right wheel well by half a thread. Attachment: Use suitable Torx wrench insert to tighten to the specified tightening torque. Fig 1: Identifying AC Housing, Electrical Connector And Evaporator Temperature Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Lift vehicle with lifting platform.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2569 · Applies to: 450, 451, 452, 454
- Loosen bolts (2) of refrigerant compressor (A9) at the oil pan (3). The bolts (2) remain on the refrigerant compressor (A9).
- Install in the reverse order. Fig 1: Identifying Cylinder Crankcase Refrigerant Compressor And Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Oil Pan Refrigerant Compressor And Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL REFRIGERANT COMPRESSOR - AR83.55-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2570 · Applies to: 450, 451, 452, 454
5300MCU > ENGINE 132.910 in MODEL 451.3 /4 with CODE (I01) Air conditioning Plus
Remove/install
Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. AS83.00- Z-0001- 01A 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 refrigerant R134a
AH83.30- N-0003- 01A 1 Discharge air conditioning system Installation: Evacuate air conditioning and then fill. AR83.30- P- 1760MCC Fig 1: Identifying Refrigerant Compressor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Disconnect fully automatic air¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2571 · Applies to: 450, 451, 452, 454
2 Disconnect fully automatic air conditioning service station Fully automatic air conditioning service station
3 Release rear drive module
AR01.00- P- 3050MCU 4 Remove poly-V belt for refrigerant compressor (A9)
AR13.21- P- 1202MCU 5 Detach electrical connector (1) for refrigerant compressor (A9)
6 Remove bolts (2), place refrigerant lines (3) to one side and remove seal rings of refrigerant lines (3) Close off refrigerant lines (3) and refrigerant compressor (A9) using appropriate stop plugs, as otherwise any penetrating dirt and moisture damages components that are connected to the refrigerant circuit. Installation: Replace sealing rings at refrigerant lines (3) and coat with compressor fluid when inserting.
BA83.55- P-1003- 01V 7 Unscrew screws (4) from refrigerant compressor (A9) BA83.55- P-1001- 01V *BA83.55- P-1002- 01V 8 Remove refrigerant compressor (A9)
9 Remove filter dryer Always replace the filter drier after opening the refrigerant circuit AR83.30- P- 6525MCC 10 Install in the reverse order
REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001-01V Bolt, AC compressor to crankcase Nm 20 BA83.55-P-1002-01V Bolt, AC compressor to oil pan Nm 20 BA83.55-P-1003-01V Bolt, refrigerant line to refrigerant compressor Nm 20 SAFETY PRECAUTIONS > RISK OF EXPLOSION. EXPLOSIONS MAY RESULT WHEN PERFORMING WELDING OR SOLDERING WORK ON A CLOSED AIR CONDITIONING SYSTEM. RISK OF POISONING CAUSED BY INHALING OVERHEATED REFRIGERANT
VAPORS. RISK OF INJURY TO SKIN AND EYES CAUSED BY CONTACT WITH LIQUID¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2572 · Applies to: 450, 451, 452, 454
REFRIGERANT. - AS83.00-Z-0001-01A > Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. Potential risks Risk of explosion When closed air conditioning systems (charged or empty) become heated, high pressures are produced that can ultimately cause the system to burst. For this reason, all welding and soldering operations on or near closed air conditioning systems are prohibited. High pressure levels can combine with refrigerant vapors to produce a mixture that is potentially explosive when exposed to atmospheric air. Risk of poisoning Refrigerant can decompose when overheated. The resulting substances are toxic and should never be inhaled. Risk of injury Refrigerant vapors are heavier than air; this means that escaping gases pose a risk of suffocation for anyone in a work pit beneath the vehicle. Contact with liquid refrigerant may cause chilblain-like damage to the skin (due to undercooling). Safety instructions/precautions All welding, brazing and soldering operations on sealed air conditioning systems and in their immediate vicinity are prohibited. Never smoke when working with refrigerant, never expose refrigerant to open flames. A piercing odor can indicate overheated refrigerant - never inhale these vapors. Leave closed rooms immediately and ventilate thoroughly. All refrigerant must be evacuated from the entire air conditioning system prior to doing any repair work on the air conditioning circuit or components. Because it poses a hazard to the atmosphere as well as to personal health and safety, discharging refrigerant directly into the air is prohibited. Suitable evacuation, treatment and charging devices equipped with integral disposal and treatment facilities must be used for evacuating refrigerant. Even after the system has been evacuated, residual pressure may still be present in the system when loosening couplings. Therefore, loosen the couplings carefully, so that the pressure can dissipate slowly. Avoid all contact with liquid refrigerant. Always wear safety glasses and protective gloves when working with refrigerant. First aid measures
In case of eye contact¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2573 · Applies to: 450, 451, 452, 454
Immediately flush with plenty of running water and consult a physician. In case of skin contact Consult a physician immediately in case of frostbite. In case of inhalation of concentrated refrigerant, immediately take victim out into the fresh air and keep victim calm. If the victim's breathing is shallow, or the individual has stopped breathing altogether, tilt the head back and administer artificial resuscitation. Call a physician. In case of ingestion Consult a physician immediately. SAFETY PRECAUTIONS > SAFETY INFORMATION: CLIMATE CONTROL - AS83.00-Z- 9999ZZ > MODEL all Hazard from contact with parts conducting high voltages. MODEL all with CODE (H25) Eberspacher D 30 W with CODE (H26) Webasto DW 300 AS83.70- Z-0001- 01A Risk of death caused by contact with current conducting parts when repairing parts of the external power supply MODEL 639, 903... AS83.00- Z-0002- 01A Risk of explosion caused by fuel vapors igniting, risk of poisoning caused by inhaling combustible gases and risk of injury caused by burns during and after operation of heater unit MODEL all mit Zuheizer, Zusatzheizung oder Standheizung AS83.70- Z-0002- 01A Risk of explosion. Explosions may result when performing welding or soldering work on a closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant. MODEL all AS83.00- Z-0001- 01A Risk of explosion. Explosions may result when performing welding or soldering work on a closed air conditioning system. Risk of poisoning. Poisoning may result from inhaling overheated refrigerant vapors. Risk of injury. Contact with liquid refrigerant may result in injury to the skin and eyes. MODEL 240 AS83.00- P-0001- 01H Risk of explosion from liquified petroleum gas flowing out and from fuel vapors. Risk of poisoning from inhaling combustion gases. BODY 940, 972... AS83.70- Z-0004- 01A
Risk of poisoning due to inhalation of heater exhaust¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2574 · Applies to: 450, 451, 452, 454 · AR: BA83.00-Z-9999CZ
gases MODELS 901, 902, 903, 904, 905 for underfloor heaters AS83.70- Z-0005- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: CLIMATE CONTROL - BA83.00-Z-9999CZ > MODEL all Air conditioning MODEL 451.3 /4 BA83.30-P-1000-01L Air conditioning MODEL 454.0 BA83.30-P-1000-01F Air conditioning MODEL 450.3 /4, 452.3 /4 BA83.30-P-1000-01E Heater MODEL 452.3 /4 BA83.20-P-1000-01C Heater booster unit MODEL 451.39 /49 BA83.70-P-1000-02D Refrigerant compressor ENGINE 132.9, 780.009 BA83.55-P-1000-01V Refrigerant compressor ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BA83.55-P-1000-01L Refrigerant compressor ENGINE 160.910 /920 /921 /922 /923 BA83.55-P-1000-01J Refrigerant compressor ENGINE 660.940 /950 /951 BA83.55-P-1000-01I Stationary heater unit MODEL 451.3 /4 with ENGINE 132.9 BA83.70-P-1000-01G Stationary heater unit MODEL 454 BA83.70-P-1000-01D TORQUE SPECIFICATIONS > AIR CONDITIONING - BA83.30-P-1000-01L > Model 451 AIR CONDITIONING Number Designation Model 451.3/4 BA83.30-P-1001-01L Refrigerant pressure sensor to AC line Nm 10 BA83.30-P-1002-01L Bolt, refrigerant line to refrigerant compressor Nm 20 BA83.30-P-1003-01L Bolt, expansion valve to vaporizer tube Nm 6 BA83.30-P-1004-01L Nut, refrigerant lines to expansion valve Nm 4 BA83.30-P-1005-01L Screw/bolt at refrigerant line separating point Nm 8 TORQUE SPECIFICATIONS > REFRIGERANT COMPRESSOR - BA83.55-P-1000-01V > Engine 132, 780.009 REFRIGERANT COMPRESSOR
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2575 · Applies to: 450, 451, 452, 454
Designation Engine 132.9 Engine 780.009 BA83.55-P- 1001-01V Bolt, refrigerant compressor to cylinder crankcase Nm 20 - BA83.55-P- 1002-01V Bolt, AC compressor to oil pan Nm 20 - BA83.55-P- 1003-01V Bolt, refrigerant line to refrigerant compressor Nm 20 - BA83.55-P- 1004-01V Screw/bolt, refrigerant compressor to engine M8 Nm - 20 M10 Nm - 40 BA83.55-P- 1005-01V Nut, refrigerant line to refrigerant compressor Nm - 20 BA83.55-P- 1006-01V Nut refrigerant line to expansion valve Nm - 11 BA83.55-P- 1007-01V Nut, high-voltage battery circuit heater bracket to body Nm - 11 BA83.55-P- 1008-01V Nut, high-voltage battery circuit heat exchanger bracket to body Nm - 11 BA83.55-P- 1009-01V Screw/bolt, refrigerant line holder to intake side/thrust side refrigerant line Nm - 11 TORQUE SPECIFICATIONS > STATIONARY HEATER UNIT - BA83.70-P-1000-01G > Model 451.3/4 with engine 132.9 HEATER UNIT OF STATIONARY HEATER Number Designation Model 451.3/4 with engine 132.9 BA83.70-P-1001- 01G Nut, tank remover to fuel pump with fuel level sensor Nm 5 CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: CLIMATE CONTROL - BF83.00- Z-9999CZ > MODEL all AC compressor MODEL 450.3 /4 BF83.55-P-1000-01B Air conditioning MODEL 454.0 BF83.30-P-1000-01D Air conditioning MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454 BF83.30-P-1000-01C Refrigerant compressor ENGINE 639.939, 134.910 /911, 135.930 /950 in MODEL 454.0 BF83.55-P-1000-01E
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2581 · Applies to: 450, 451, 452, 454
The heater heat exchanger is located in the left of the front passenger footwell. Task The heater heat exchanger warms the air flow which is directed to the vehicle interior via the various air distribution vents. Design The heater heat exchanger consists of coiled pipes and slats in order to offer the largest surface possible for the heat output. Function Coolant heated by the engine flows through the heater heat exchanger. The inflow is regulated by the thermostat of the cooling-water circulation. The heat is dissipated via the coiled pipes and lamellae made of aluminum towards the outside to the air blowing by, which is heated up in the process and then routed into the vehicle interior. BASIC KNOWLEDGE > AUTOMATIC HEATER (HEAT) COMPONENT LOCATIONS - GF83.25-P-0001-02MCU > Fig 1: Identifying Heating System Heat Exchanger Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
0001MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2585 · Applies to: 450, 451, 452, 454
MODEL 451.3 /4 with CODE (I01) Air conditioning Plus The automatic air conditioning has an electronically controlled cooling and heating system. It controls the temperature of the vehicle interior. Even at low outside temperatures, the air is first cooled down by the evaporator and dehumidified, it is then routed through the heat exchanger where it is heated up to the desired interior temperature. The following functions are implemented Ventilation Heating circuit Refrigerant circuit Safety shutoff Ventilation The ventilation system ventilates the interior of the vehicle. The air is drawn in by the blower motor (M2) and passes through the various air ducts to the air distribution flaps, which distribute it in the vehicle interior. Heating circuit The coolant is heated up by the engine. The heated coolant is subsequently guided through the heat exchanger, where the heat is emitted into the air in the interior. The coolant returns back to the coolant pump via the coolant return line. Refrigerant circuit The refrigerant compressor (A9) driven by the engine compresses the refrigerant vapor which is cooled down in the condenser. The refrigerant liquefies during cooling. The refrigerant flows into the evaporator via the expansion valve and is heated there indirectly by the warm air blowing by on the outside of the evaporator. The refrigerant compressor aspirates the refrigerant which has turned gaseous on account of the heat absorption and then compresses it yet again. Safety shutoff To prevent damages to the refrigerant compressor, the following automatically shutoffs are integrated: Hot gas shutoff (through integrated sensor in refrigerant compressor) High-pressure shutoff in the system (through refrigerant pressure sensor (B12)) Low-pressure shutoff in the event of missing refrigerant (through refrigerant pressure sensor) Overtemperature deactivation (coolant temperature above 115°C) Undertemperature shutoff
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2590 · Applies to: 450, 451, 452, 454
The condenser is located behind the radiator grille, immediately in front of the radiator. Task The compressed refrigerant is cooled in the condenser. This changes the state of the matter from gaseous to liquid. Function The hot coolant coming from the refrigerant compressor is pressed upwards into the condenser. Coiled pipes and fins absorb this heat extremely rapidly and give it off into the outside air flowing through the condenser. This serves to cool the refrigerant. As the refrigerant cools, the refrigerant condenses and turns to a liquid. As it flows through the desiccant cartridge mounted directly onto the condenser, the refrigerant is cleaned of chemical and mechanical impurities. BASIC KNOWLEDGE > EVAPORATOR, COMPONENT DESCRIPTION - GF83.40-P- 2189MCC > MODEL 451.3 /4 with CODE (I01) Air conditioning Plus Fig 1: Identifying Capacitor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2591 · Applies to: 450, 451, 452, 454
The evaporator is installed in the bottom in the air conditioner housing. Task During cooling mode, the air flowing through the evaporator into the vehicle interior is cooled down, dried and cleaned. BASIC KNOWLEDGE > EXPANSION VALVE, COMPONENT DESCRIPTION - GF83.40-P- 2190MCC > MODEL 451.3 /4 with CODE (I01) Air conditioning Plus Location The expansion valve is located in the front module, immediately behind the cooler. Task Fig 1: Identifying Evaporator Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Expansion Valve Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2593 · Applies to: 450, 451, 452, 454
The heater/AC operating unit is located in the center console. The heater/AC operating unit permits the following operations: Interior temperature selection cold/warm Manual blower control Manual air distribution Rear window heater Design The heater/AC operating unit contains the following controls and displays: Temperature preselection slider switch Air distribution rotary switch Blower switch Heated rear window switch Temperature preselection slider switch The intensity of air heating is selected via the slider switch. A cable is used to operate the blend air flap, which routes the air flow corresponding to the position of the slider switch over the heater heat exchanger or directly to the air outlet nozzles in the vehicle interior. Fig 1: Identifying Heater/Air Conditioning Operating Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Manual blower control¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2595 · Applies to: 450, 451, 452, 454
Manual air distribution Recirculated air mode Defrost function Rear window heater The heater/AC operating unit takes over the following actuations: Via Controller Area Network (data bus/CAN bus) (CAN): Refrigerant compressor (A9) via the SAM control unit (N10/10) Blower motor (M2) via the SAM control unit Heated rear window (R1) via the SAM control unit Direct: Recirculated air flap actuator motor (M39) Blend air flap actuator (M16/8) The heater/AC operating unit reads in the following sensor signals: Direct: Interior temperature sensor (integrated in heater/AC operating unit) Evaporator temperature sensor (B10/6) Blend air flap actuator Via CAN: Outside temperature through the instrument cluster (A1) Coolant temperature through the ME control unit (N3/10) Design The heater/AC operating unit contains the following controls and displays: Air distribution rotary switch Temperature preselection slider switch Air conditioning switch Air recirculation switch Blower switch Heated rear window switch Air distribution rotary switch
Communication control unit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2601 · Applies to: 450, 451, 452, 454
N4 Communication control unit 12A N4 Communication control unit 4A N4 Communication control unit 20A U16 Valid for Bluetooth
U3 Valid for PND (Personal Navigation Device) 10C U863 Valid for external audio source 7C X39/45 External audio source separation point 8L X9 Bluetooth microphone connector 21G Fig 1: Communications Interface (KOM) - Wiring Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1000MC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2603 · Applies to: 450, 451, 452, 454
Location and assignment of line and connectors
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 WIRING DIAGRAMS > LEGEND OF ELECTRICAL FUNCTION DIAGRAM FOR AIR CONDITIONING - PE83.30-P-2050-60MCU > MODEL 451 Code Designation Coordinates A1 Instrument cluster 21G A9 Refrigerant compressor 3L B10/6 Evaporator temperature sensor 12H B12 Refrigerant pressure sensor 12H B14 Outside temperature display temperature sensor 22E M2 Blower motor 9K M16/8 Blend air flap actuator 8G M39 Air recirculation flap actuator motor 8G N3/10 ME-SFI [ME] control unit 17D N10/10 SAM control unit 2G N23 Heater/AC operating unit 10G R1 Rear window defroster 3B R14 Blower motor series resistor group 13L S98/1 Blower switch 11J X11/4 Data link connector 8C Document number: pe83.30-p-2050-99mcu Document title: Electrical function diagram for air conditioning Code: Designation: Position: A1 Instrument cluster 21 G A9 AC compressor 3 L B10/6 Evaporator temperature sensor 12 H
Refrigerant pressure sensor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2604 · Applies to: 450, 451, 452, 454
B12 Refrigerant pressure sensor 12 H B14 Ambient temperature display temperature sensor 22 E M16/8 Blending air flap actuator 8 G M2 Blower motor 9 L M39 Recirculated air flap actuator motor 8 H N10/10 SAM control unit 2 G N23 Heater/AC operating unit 10 H N3/10 ME-SFI [ME] control module 17 D R1 Heated rear window 3 B R14 Blower motor preresistor group 13 L S98/1 Blower switch 11 J X11/4 Data link connector 8 C Fig 1: Air Conditioning Electrical Function Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
PE07.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2606 · Applies to: 450, 451, 452, 454
1100MCU
wiring diagrams PE07.00-P- 1100MCU PE54.00-P- 1100MCU
Further wiring diagrams PE54.00-P- 1100MCU PE83.00-P- 1100MCU
Further wiring diagrams PE83.00-P- 1100MCU SPECIAL TOOLS > 452 589 00 33 00 CUTTING TOOL SET - WS83.00-P-0052B > FG 83/Set B MODEL 452, 451, 164, 251 Use: Separation of high-pressure/low-pressure A/C lines with connector dimensions 5/8" and 1/2". NOTE: smart no.: 001 5804 V000 0000 00 3/8" and 3/4" cutting tools have part number 164 589 03 33 00. SPECIAL TOOLS > 203 589 03 10 00 VALVE WRENCH - WS83.00-P-0060A > FG 83/Set A MODEL 164, 168, 169, 170, 171.4, 202, 203, 204, 207, 209, 211, 212, 216, 220, 221, 230, 240, 245, 251, 451, 454, 461, 463, 414 MODIFICATION NOTES 9.8.07 Replacement for 203 589 01 10 00 WS83.00-P-3023K Fig 1: Identifying Cutting Tool Set (452 589 00 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Replacement for 454 589 01 33¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2607 · Applies to: 450, 451, 452, 454 · AR: WS83.00-Z-9999CZ
00 WS83.00-P-0056B Use: Valve wrench for assembling and disassembling the valve element at the high and low-pressure service valves.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: CLIMATE CONTROL - WS83.00-Z-9999CZ > MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P-0007B 000 589 13 99 30 MCP 2.8 / Fl. blade 2.8 / JPT / SPT FG00/54/83/Set B WS00.19-P-0007-30B 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P-0111B 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 203 589 03 10 00 Valve wrench FG 83/Set A WS83.00-P-0060A 220 589 01 99 05 JPT crimping set FG 00/54/83/Set B WS00.19-P-0001-05B 220 589 01 99 10 Crimp pliers FG 00/14/54/83/Set B WS00.19-P-0001-09B 220 589 01 99 40 Wire stripper FG 00/54/83/Set B WS00.19-P-0001-22B Fig 1: Identifying Valve Wrench (203 589 03 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
220 589 01 99 41 Reflector¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2608 · Applies to: 450, 451, 452, 454
FG 00/54/83/Set B WS00.19-P-0001-23B 220 589 01 99 42 Adapter FG 00/54/83/Set B WS00.19-P-0001-24B 220 589 01 99 50 Blade holder with clamping pliers FG00/14/54/83/Set B WS00.19-P-0001-25B 220 589 01 99 54 MT 3 blade FG00/83/Set B WS00.19-P-0001-29B 220 589 02 99 00 Wiring harness repair kit FG 00 FG 54/83/Set B WS00.19-P-0002B 220 589 04 99 00 New passenger car wiring harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P-0006B 450 589 00 07 00 Tank module tool FG 47/83/Set B WS47.00-P-0021B 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 450 589 05 63 00 Remover FG 83/Set B WS83.00-P-0050B 450 589 06 63 00 Remover FG 83/Set B WS83.00-P-0051B 452 589 00 33 00 Cutting tool set FG 83/Set B WS83.00-P-0052B 452 589 02 99 00 Wiring harness repair kit FG 00/54/77/83/ Set B WS00.00-P-0243B 454 589 01 33 00 Turn out device FG 83/Set B WS83.00-P-0056B 454 589 07 09 00 Socket wrench bit FG 83/Set B WS83.00-P-0055B
GENERAL INFORMATION > NOTES ON SPRAYABLE SEAM SEALING - AH97.10-P-0002-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2609 · Applies to: 450, 451, 452, 454
01FF > Model 450.3/4, 451.3/4, 452.3/4, 454.0 Applications With this material, when applied over large surfaces on areas such as the wheelhouses, longitudinal members (rocker panels) and vehicle floor systems, nearly optical characteristics of standard or plant seals can be achieved, thanks to the technical processing properties. When applying the material from the standard cartridge (300 ml), a special compressed air gun is required which allows different types of application for structured joints, surface coatings, stone-impact protection and sound deadening in combination with the associated plastic injection nozzles. Editing Wet-in-wet coating possible between 30 minutes and 8 hours after application without paint additives. Forced drying is necessary between 8 h and 72 h. Longer standing times should be avoided to exclude paint adhesion losses. Adhesion surfaces must be clean, dry and free of grease. Filler/filler primer should be sprayed on before application of sprayable seam sealant. Do not apply sprayable seam sealant to fresh (uncured) 1-component polyurethane material. Specific material advantages of "sprayable seam sealant": Does not contain any isocyanates, silicone, PVCs and no dangerous agent. The replaceable nozzle makes cleaning unnecessary. Visual repair of plant seals and underbody coating. Good stability UV resistant Material offers a number of application possibilities. The sprayable seam sealant and surface coating can be applied one after another with corresponding gun setting. It is necessary, however, to wait for the end of the skin formation period of about 15 min. for the sprayed seam Can be painted over well GENERAL INFORMATION > NOTES ON CAVITY PRESERVATION - AH97.20-P-0001-01FF > Model 450.3/4, 451.3/4, 452.3/4, 454.0
The corrosion prevention measures are completed with the cavity preservation performed at the factory.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2610 · Applies to: 450, 451, 452, 454
For this reason, it is not necessary to repeat this cavity preservation work. Cavity preservation work is to be performed on vehicles on which accident repairs have been performed to the sheet metal parts. Always perform cavity preservation twice in sequence after a flash-off time of 5 minutes. It is also necessary to preserve replacement bodies twice after painting. GENERAL INFORMATION > UNDERFLOOR PRESERVATION - AH97.20-P-2000-01FF > Model 450.3/4, 451.3/4, 452.3/4, 454.0 Repair damage to permanent underfloor protection as well as paint damage on sheet metal parts on body, e.g. wheelhouse edges and entry. After repair following an accident on sheet metal parts, preserve underbody in repaired area. Replacement body shells must have their underbodies preserved when the vehicle is fully assembled. Clean bottom of vehicle before apply preservation wax. Apply preservation wax only to dry underbody. Do not spray preservation wax onto brake linings, brake disks, brake hoses, exhaust line, mufflers and propeller shafts (cover up if possible) to prevent excessive cleaning and damage. GENERAL INFORMATION > INSTRUCTIONS FOR PROCESSING PERMANENT UNDERBODY PROTECTION - AH97.20-P-9409-01FF > Model 450, 451, 452, 454 The PVC permanent underfloor protection is applied to the frame floor as a standard feature. PVC is used as a standard material for sealing such as spot welds, etc. Combustion of PVC materials causes highly corrosive hydrochloric acid. The new permanent underfloor protection adheres poorly to combusted PVC material. For this reason, the new permanent underfloor protection applied is insufficient which could later lead to formation of corrosion. For this reason, remove underfloor protection and seam sealants from PVC before starting cutting, grinding, soldering and welding. For the same reasons, it is preferable to separate damaged body parts using "cold" separating methods. MAINTENANCE > PROCESSING INSTRUCTIONS FOR CAVITY PRESERVATION AGENT - AP97.20-P-0640-01SM > Cavity preservation at factory The cavity preservation with wax already performed at the factory completes the corrosion prevention measures. No repetition of this preservation work is necessary. Repair cavity preservation After accident repair spray cavities with wax in machined areas. Perform repair cavity preservation after welding, riveting and soldering operations.
1. Carefully clean affected body parts.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2614 · Applies to: 450, 451, 452, 454
All bare sheet metal parts must be completely clean and free of rust, oil and wax. 2. Uniformly apply zinc dust paint with brush or primer gun. Brush or primer gun http://gotis.aftersales.mercedes-benz.com Zinc dust pain serves to prevent corrosion on weld seams, overlapping sheet metal points and surfaces which are difficult to paint after assembly or are not to be painted at all. Do not use for painting outer surface. Maintain drying time before painting. TESTING & REPAIR > PROCESSING PERMANENT UNDERFLOOR PROTECTION AGENT FOR PAINTING - AR97.20-P-0500-03FF > Permanent underfloor protection (containing solvent) The underfloor protection is suited for processing underbodies as well as for transitions to underfloor protection applied at the factory. Not suited for sealing work (seam sealing). Blow through spray gun with solvent after use. Expose air hole on screw-in thread to prevent spray gun from sticking Underfloor protection (water-base dispersion), gray The permanent underfloor protection is a water-base dispersion which is suited for processing underbody, fender bottom sections as well as the outer surface. For processing on the outer surface (e.g. below CBS front end, longitudinal members at entrance), thin material with 5 % water to achieve better coverage. Not suited for transitions to the underfloor protection and seam sealing work (seam sealing) processed (insufficient adhesion and crack formation). After finishing work clean tools thoroughly with water to prevent sticking Before reuse moisten air flap with mineral oil so that spray fog does not dry on. 1. All areas to which permanent underfloor protection is to be applied must be thoroughly cleaned (steam cleaner). In particular, remove wax and oil residues as well as loose pieces of PVC thoroughly. Grind corroded points down to bare metal and prime. Electric plastic hot air blower and flat-spray nozzle with scraper http://gotis.aftersales.mercedes-benz.com A hot air blower and a flat-spray nozzle with integrated scraper or rotating wire brushes is suitable for removing PVC material. 2. Uniformly apply permanent underfloor protection Compressed air gun http://gotis.aftersales.mercedes-benz.com Do not spray underfloor protection on major assemblies, otherwise functions may be impaired. Maintain drying time before painting. TESTING & REPAIR > CAVITY PRESERVATION FOLLOWING REPAIR WORK - AR97.20-P-
1500FF >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2615 · Applies to: 450, 451, 452, 454
MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. AS97.00-Z-0001- 01A Notes on cavity preservation
AH97.20-P-0001- 01FF 1 Perform repair preservation Apply cavity preservation agent in marked areas only after completing sealing and paintwork, however, from inside in repair area.The processing temperature should not be less than 15°C. Perform cavity preservation twice in sequence with a drying time of 5 minutes in between. The spraying hose should be stiff and the nozzles should spray at angle to the front and rear. The cavities should be dry. Insert spray hoses as far as possible into cavities. Spray while inserting and pulling out slowly.
Processing instructions for cavity preservation agent
AP97.20-P-0640- 01SM
Cavity preservation gun see GOTIS: http://gotis.aftersales.mercedes- benz.com
2 Remove cavity sealant from drain holes
SAFETY PRECAUTIONS > RISK OF EXPLOSION AND POISONING CAUSED BY SOLVENT VAPORS AND GASSES. RISK OF INJURY TO SKIN AND EYES WHEN WORKING WITH ANTICORROSION AGENTS - AS97.00-Z-0001-01A > Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. Potential risks Risk of explosion The solvents contained in anticorrosion agents (such as underfloor protective coatings, cavity wax, engine compartment wax) are flammable, and may burst into flame if sprayed onto glowing hot components or open flames.
Risk of poisoning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2616 · Applies to: 450, 451, 452, 454
Inhaling spray and solvent vapors can lead to damage of the respiratory system and lungs. Symptoms of poisoning include headache, breathing difficulty, nausea and loss of consciousness. Underfloor protective coating materials further pose the following risks: Risk of damage to liver and kidneys. Central nervous system disorders, loss of consciousness. When these substances burn they produce toxic gases with a noxious odor; these gases are dangerous in high concentrations. Risk of injury If anticorrosion coatings come in contact with the eyes they can cause severe eye damage. In the event of frequent or prolonged contact with the skin, these substances can drain the skin of natural oils and lead to inflammation. Safety instructions/precautions Always remove all PVC undercoating and PVC seam sealer from the areas to be treated before performing any welding or soldering. This also applies for work such as cutting, sanding or similar work. When removing damaged bodywork sections use "cold" separating methods when possible. With these methods, smoke and toxic fumes are avoided. Do not expose containers to direct sunlight or to temperatures in excess of 50 °C. Always apply at the prescribed pressure. Never spray corrosion inhibitor into flames or onto hot objects; keep well away from sparks and all potential sources of ignition, and do not smoke. Take precautions to avoid sparks from electrostatic discharge. Avoid all contact with eyes and skin. Wear tight-fitting safety glasses and solvent-resistant gloves. Wear respiratory protection and apply only in well ventilated areas. If clothing becomes soaked or contaminated, remove and wash it immediately. Keep well away from food and drinks. Seal containers tightly and store them in a well-ventilated area. First aid measures In case of eye contact Flush thoroughly with water and consult a physician (eye doctor) immediately. In case of ingestion Give medicinal activated charcoal, do not induce vomiting, consult a physician immediately. In case of inhalation
Move victim to fresh air, have victim lie down and remain calm, avoid strenuous activity.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2617 · Applies to: 450, 451, 452, 454 · AR: AS97.00-Z-9999ZZ
In case of skin contact Immediately wash with soap and water, apply protective skin ointment. Fire protection measures Rescue, extinguishing and cleanup operations in areas contaminated by fumes should only be undertaken by individuals wearing respiratory protection. Do not inhale fumes from flames or explosions. Suitable extinguishing agents: Indirect water spray Foam Extinguishing powder Carbon dioxide Non-suitable extinguishing agents: Direct high-pressure water spray SAFETY PRECAUTIONS > SAFETY INFORMATION: BODY SEALING, CORROSION PROTECTION - AS97.00-Z-9999ZZ > MODEL all Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents MODEL 100, 107, 108, 109, 111, 112, 113, 114, 115, 116, 123, 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 197, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 219, 220, 221, 230, 240, 245, 251, 405, 414, 436, 437, 450, 451, 452, 454, 461, 463, 613, 636, 638, 639, 671, 690, 901, 902, 903, 904, 905, 906, 930, 932, 933, 934, 940, 942, 943, 944, 950, 952, 953, 954, 970, 972, 974, 975, 976... AS97.00-Z-0001- 01A
GENERAL INFORMATION > NOTES ON SPRAYABLE SEAM SEALING - AH97.10-P-0002-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2618 · Applies to: 450, 451, 452, 454
01FF > Model 450.3/4, 451.3/4, 452.3/4, 454.0 Applications With this material, when applied over large surfaces on areas such as the wheelhouses, longitudinal members (rocker panels) and vehicle floor systems, nearly optical characteristics of standard or plant seals can be achieved, thanks to the technical processing properties. When applying the material from the standard cartridge (300 ml), a special compressed air gun is required which allows different types of application for structured joints, surface coatings, stone-impact protection and sound deadening in combination with the associated plastic injection nozzles. Editing Wet-in-wet coating possible between 30 minutes and 8 hours after application without paint additives. Forced drying is necessary between 8 h and 72 h. Longer standing times should be avoided to exclude paint adhesion losses. Adhesion surfaces must be clean, dry and free of grease. Filler/filler primer should be sprayed on before application of sprayable seam sealant. Do not apply sprayable seam sealant to fresh (uncured) 1-component polyurethane material. Specific material advantages of "sprayable seam sealant": Does not contain any isocyanates, silicone, PVCs and no dangerous agent. The replaceable nozzle makes cleaning unnecessary. Visual repair of plant seals and underbody coating. Good stability UV resistant Material offers a number of application possibilities. The sprayable seam sealant and surface coating can be applied one after another with corresponding gun setting. It is necessary, however, to wait for the end of the skin formation period of about 15 min. for the sprayed seam Can be painted over well GENERAL INFORMATION > NOTES ON CAVITY PRESERVATION - AH97.20-P-0001-01FF > Model 450.3/4, 451.3/4, 452.3/4, 454.0
The corrosion prevention measures are completed with the cavity preservation performed at the factory.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2619 · Applies to: 450, 451, 452, 454
For this reason, it is not necessary to repeat this cavity preservation work. Cavity preservation work is to be performed on vehicles on which accident repairs have been performed to the sheet metal parts. Always perform cavity preservation twice in sequence after a flash-off time of 5 minutes. It is also necessary to preserve replacement bodies twice after painting. GENERAL INFORMATION > UNDERFLOOR PRESERVATION - AH97.20-P-2000-01FF > Model 450.3/4, 451.3/4, 452.3/4, 454.0 Repair damage to permanent underfloor protection as well as paint damage on sheet metal parts on body, e.g. wheelhouse edges and entry. After repair following an accident on sheet metal parts, preserve underbody in repaired area. Replacement body shells must have their underbodies preserved when the vehicle is fully assembled. Clean bottom of vehicle before apply preservation wax. Apply preservation wax only to dry underbody. Do not spray preservation wax onto brake linings, brake disks, brake hoses, exhaust line, mufflers and propeller shafts (cover up if possible) to prevent excessive cleaning and damage. GENERAL INFORMATION > INSTRUCTIONS FOR PROCESSING PERMANENT UNDERBODY PROTECTION - AH97.20-P-9409-01FF > Model 450, 451, 452, 454 The PVC permanent underfloor protection is applied to the frame floor as a standard feature. PVC is used as a standard material for sealing such as spot welds, etc. Combustion of PVC materials causes highly corrosive hydrochloric acid. The new permanent underfloor protection adheres poorly to combusted PVC material. For this reason, the new permanent underfloor protection applied is insufficient which could later lead to formation of corrosion. For this reason, remove underfloor protection and seam sealants from PVC before starting cutting, grinding, soldering and welding. For the same reasons, it is preferable to separate damaged body parts using "cold" separating methods. MAINTENANCE > PROCESSING INSTRUCTIONS FOR CAVITY PRESERVATION AGENT - AP97.20-P-0640-01SM > Cavity preservation at factory The cavity preservation with wax already performed at the factory completes the corrosion prevention measures. No repetition of this preservation work is necessary. Repair cavity preservation After accident repair spray cavities with wax in machined areas. Perform repair cavity preservation after welding, riveting and soldering operations.
detachable body components¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2623 · Applies to: 450, 451, 452, 454
P-4000- 04FF TESTING & REPAIR > PROCESSING ZINC DUST PAINT BEFORE PAINTING - AR97.20-P- 0500-01FF > 1. Carefully clean affected body parts. All bare sheet metal parts must be completely clean and free of rust, oil and wax. 2. Uniformly apply zinc dust paint with brush or primer gun. Brush or primer gun http://gotis.aftersales.mercedes-benz.com Zinc dust pain serves to prevent corrosion on weld seams, overlapping sheet metal points and surfaces which are difficult to paint after assembly or are not to be painted at all. Do not use for painting outer surface. Maintain drying time before painting. TESTING & REPAIR > PROCESSING PERMANENT UNDERFLOOR PROTECTION AGENT FOR PAINTING - AR97.20-P-0500-03FF > Permanent underfloor protection (containing solvent) The underfloor protection is suited for processing underbodies as well as for transitions to underfloor protection applied at the factory. Not suited for sealing work (seam sealing). Blow through spray gun with solvent after use. Expose air hole on screw-in thread to prevent spray gun from sticking Underfloor protection (water-base dispersion), gray The permanent underfloor protection is a water-base dispersion which is suited for processing underbody, fender bottom sections as well as the outer surface. For processing on the outer surface (e.g. below CBS front end, longitudinal members at entrance), thin material with 5 % water to achieve better coverage. Not suited for transitions to the underfloor protection and seam sealing work (seam sealing) processed (insufficient adhesion and crack formation). After finishing work clean tools thoroughly with water to prevent sticking Before reuse moisten air flap with mineral oil so that spray fog does not dry on. 1. All areas to which permanent underfloor protection is to be applied must be thoroughly cleaned (steam cleaner). In particular, remove wax and oil residues as well as loose pieces of PVC thoroughly. Grind corroded points down to bare metal and prime. Electric plastic hot air blower and flat-spray nozzle with scraper http://gotis.aftersales.mercedes-benz.com A hot air blower and a flat-spray nozzle with integrated scraper or rotating wire brushes is suitable for removing PVC material. 2. Uniformly apply permanent underfloor protection Compressed air gun
after completing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2625 · Applies to: 450, 451, 452, 454
sealing and paintwork, however, from inside in repair area.The processing temperature should not be less than 15°C. Perform cavity preservation twice in sequence with a drying time of 5 minutes in between. The spraying hose should be stiff and the nozzles should spray at angle to the front and rear. The cavities should be dry. Insert spray hoses as far as possible into cavities. Spray while inserting and pulling out slowly. Processing instructions for cavity preservation agent
AP97.20-P-0640- 01SM
Cavity preservation gun
2 Remove cavity sealant from drain holes
SAFETY PRECAUTIONS > RISK OF EXPLOSION AND POISONING CAUSED BY SOLVENT VAPORS AND GASSES. RISK OF INJURY TO SKIN AND EYES WHEN WORKING WITH ANTICORROSION AGENTS - AS97.00-Z-0001-01A > Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. Potential risks Risk of explosion The solvents contained in anticorrosion agents (such as underfloor protective coatings, cavity wax, engine compartment wax) are flammable, and may burst into flame if sprayed onto glowing hot components or open flames. Risk of poisoning Inhaling spray and solvent vapors can lead to damage of the respiratory system and lungs. Symptoms of poisoning include headache, breathing difficulty, nausea and loss of consciousness. Underfloor protective coating materials further pose the following risks: Risk of damage to liver and kidneys.
Central nervous system disorders, loss of consciousness.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2626 · Applies to: 450, 451, 452, 454
When these substances burn they produce toxic gases with a noxious odor; these gases are dangerous in high concentrations. Risk of injury If anticorrosion agents come in contact with the eyes they can cause severe eye damage. In the event of frequent or prolonged contact with the skin, these substances can lead to inflammation of the skin and to the removal of the skin's natural oils. Safety instructions/precautions Always remove all PVC undercoating and PVC seam sealer from the areas before performing any welding or soldering work. This also applies for work such as cutting, sanding or similar work. When removing damaged bodywork sections use "cold" separating methods when possible. With these methods, smoke and toxic fumes are avoided. Do not expose containers to direct sunlight or to temperatures in excess of 50 °C. Always maintain the prescribed application pressure. Never spray corrosion protection agents into flames or onto hot objects; keep well away from sparks and all potential sources of ignition, and do not smoke. Take precautions to avoid sparks from electrostatic discharge. Avoid all contact with eyes and skin. Wear tight-fitting safety glasses and solvent-resistant gloves. Work in well ventilated areas; wear respiratory protection. If clothing becomes soaked or contaminated, remove and wash it immediately. Keep well away from food and drinks. Seal containers tightly and store them in a well-ventilated area. First aid measures In case of eye contact Flush thoroughly with water and consult a physician (eye doctor) immediately. In case of ingestion Give medicinal activated charcoal; do not induce vomiting; consult a physician immediately. In case of inhalation Move victim to fresh air, have victim lie down and remain calm, avoid strenuous activity. In case of skin contact Immediately wash with soap and water, apply protective skin ointment. Fire protection measures
Rescue, extinguishing and cleanup operations in areas contaminated by fumes should only be undertaken by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2627 · Applies to: 450, 451, 452, 454 · AR: AS97.00-Z-9999ZZ
individuals wearing respiratory protection. Do not inhale fumes from flames or explosions. Suitable extinguishing agents: Indirect water spray Foam Extinguishing powder Carbon dioxide Non-suitable extinguishing agents: Direct high-pressure water spray SAFETY PRECAUTIONS > SAFETY INFORMATION: BODY SEALING, CORROSION PROTECTION - AS97.00-Z-9999ZZ > MODEL all Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents MODEL 100, 107, 108, 109, 111, 112, 113, 114, 115, 116, 123, 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 172, 197, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 251, 405, 414, 436, 437, 450, 451, 452, 454, 461, 463, 613, 636, 638, 639, 671, 690, 901, 902, 903, 904, 905, 906, 930, 932, 933, 934, 940, 942, 943, 944, 950, 952, 953, 954, 970, 972, 974, 975, 976... AS97.00- Z-0001- 01A
RETROFITTING & CONVERSION > RETROFIT BRABUS ATTACHMENT PARTS ON REAR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2628 · Applies to: 450, 451, 452, 454 · AR: AN88.10-P-0006MCC
FENDER - AN88.10-P-0006MCC > MODEL 451.3/4 (except 451.391 /491) Install 1 Clean contact surfaces on attachment parts (2) on rear CBS (1). 2 Position attachment parts (2) on rear CBS (1) and clip in catch hook (arrows). 3 Install retaining clamps (3). RETROFITTING & CONVERSION > RETROFIT BRABUS REAR APRON - AN88.20-P- 0001MCU > MODEL 451.3/4 with ENGINE 132.910 Fig 1: Locating Rear CBS, Attachment Part And Retaining Clips Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2629 · Applies to: 450, 451, 452, 454
Fig 1: Identifying BRABUS Rear Apron Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying BRABUS Rear Apron Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove rear apron¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2630 · Applies to: 450, 451, 452, 454
1 Remove rear apron
Remove/install rear apron AR88.30-P- 0502MCC Install
2 Retrofit BRABUS muffler The BRABUS rear apron (1) can only be installed in combination with the BRABUS muffler. AN49.10-P- 1003MCU 3 Hook left and right cover (5) into mounts (arrows) on BRABUS rear apron (1) and clip in.
4 Install expansion clip (4) on left and right covering (5).
5 Position heat shield (2) on BRABUS rear apron (1) and tighten with bolts (6). Cordless drill/driver http://gotis.aftersales.mercedes- benz.com
6 Hook bracket (3) of BRABUS rear apron (1) into CBS rear end (12). Hook BRABUS rear apron (1) into same mounts on rear CBS (12) as the removed rear apron.
7 Clip catch hook (8) on BRABUS rear apron (1) into CBS rear end (12)
8 Hook BRABUS rear apron (1) into brackets (9).
9 Install expansion clip (7) on left and right on BRABUS rear apron (1)
10 Tighten bolt (11) on left and right on BRABUS rear apron (1)
11 Clip in coverings (10) on left and right above bolts (11)
12 Add special equipment to the vehicle data card and to the online vehicle data card Code (E78) Enter smart BRABUS (DFO) rear skirt
RETROFITTING & CONVERSION > RETROFIT BRABUS FRONT SPOILER - AN88.50-P- 0004MCC > MODEL 451.3/4 (except 451.391 /491)
Clip covers (2) into BRABUS front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2632 · Applies to: 450, 451, 452, 454
3 Clip covers (2) into BRABUS front spoiler (1) Ensure that clips (3) are seated correctly.
4 Position BRABUS front spoiler (1) on CBS front end (4) and arrest brackets (arrows B)
5 Arrest brackets (arrows C) between BRABUS front spoiler (1) and lower front grille (5) with extraction hook The extraction hook is included in the assembly tool set.
*450589079900 6 Turn steering wheel to right, slightly push right fender liner to side and install expansion clips (7).
7 Turn steering wheel to left, slightly push left fender liner to side and install expansion clips (9).
8 Clip brackets (arrows A) between BRABUS front spoiler (1) and underfloor paneling (6).
9 Position covers (8) on CBS front (4) and clip in clips (10)
RETROFITTING & CONVERSION > INSTALL SIDE SKIRTS, BRABUS - AN88.80-P- 0010MCC > MODEL 451.3/4 (except 451.391 /491) Shown on right side of vehicle Fig 3: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on vehicle with code (V07) Front fog lamps (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2635 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Front CBS Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front CBS Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2636 · Applies to: 450, 451, 452, 454
1 Remove antenna rod
2 Remove additional turn signal lamps
AR82.25- P- 4726MCC 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 bolts (2) from front CBS (1).
7 Remove longitudinal member paneling (8).
AR88.80- P- 6000MCC 8 Remove expansion clip (9) in area of left and right door hinge.
9 Unscrew bolts (10) located behind left and right longitudinal member paneling (8) from front CBS (1).
Fig 3: Identifying Front CBS, Bolt And Catch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2641 · Applies to: 450, 451, 452, 454
1 Remove rear CBS
AR88.20- P- 1900MCC 2 Remove expansion clips (9) from rear apron (5).
3 Loosen catch hook (10) on rear apron (5).
4 Unclip bracket (6) on rear apron (5) from left rear fender (1), right rear fender (4) and rear center part (3) and remove rear apron (5).
5 Remove expansion clips (7) from left rear fender (1) and right rear fender (4).
6 Loosen catch hook (8) between left rear fender (1) and rear center section (3) and remove left rear fender (1).
7 Loosen catch hook (8) between right rear fender (4) and rear center section (3) and remove right rear fender (4).
8 Unclip covers (11) from rear center part (3) and remove. When replacing rear center part (3).
9 Remove heat shield (2) When replacing rear center section (3) on vehicle with engine 132.930. AR88.20- P- 1925MCC Fig 1: Identifying Rear Center Part Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying Brake Line And Retaining Clip¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2648 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front Fender Liner Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2649 · Applies to: 450, 451, 452, 454
11.4.08 Special tool for loosening nut on link rod and piston rod added Operation step 7, 11 Remove/install
Notes on self- locking nuts and bolts
AH00.00-N- 0001-01A 1 Remove front CBS
AR88.00-P- 1010MCC 2 Remove left and right lamp unit
AR82.10-P- 4730MCU 3 Remove front wheel
AR40.10-P- 1100MCU 4 Remove underfloor panels Rechargeable drill / screwdriver http://gotis.aftersales.mercedes-benz.com
5 Unclip brake line (2) from retaining clips (3). When removing fender liner (1) in right front fender.
6 Unscrew nut (4), loosen tie rod end (5) using puller from steering knuckle Carefully press out tie rod end (5) to prevent damaging rubber boot. Installation: Check rubber boot, replace tie rod end (5), if necessary.
*450589013300 Fig 3: Identifying Fender Liner And Expansion Clips Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(6) and unhook¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2650 · Applies to: 450, 451, 452, 454
*BA46 40 P 1001-01F 7 Unscrew nut (7) and unhook link rod (8) from suspension strut (9). Counterhold threaded stud of link rod (8).
126589001000 450589001700 *BA32.20-P- 1004-02I 8 Unhook line (10) from bracket (11) and unscrew bracket (11). Observe installation position of line (10) and bracket (11).
9 Remove retaining clip (12) from bracket (13) and remove brake hose (14) from bracket (13).
10 Support steering knuckle (6) with manual hydraulic floor jack Use suitable protective subsurface to prevent damaging steering knuckle (6) or transverse control arm.Manual hydraulic floor jack http://gotis.aftersales.mercedes-benz.com
11 Unscrew nut (15) from suspension strut (9). Secure suspension strut (9) against falling down, otherwise it can be damaged. Do not turn piston rod on suspension strut (9), otherwise the suspension strut (9) can be damaged. Hold piston rod on suspension strut (9) with torx bit, size T45 and shaft length 100 mm.If the nut (15) sticks, push back the boot, fasten the holding device (16) on the suspension strut's piston rod (9) and counterhold using open end wrench (17).
450589010100 450589089900 451589006300 BA32.25-P- 1002-04D 12 Carefully lower manual hydraulic floor jack and fold suspension strut (9) toward outside.
13 Remove expansion clips (18) from fender
liner (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2651 · Applies to: 450, 451, 452, 454
14 Remove fender liner (1)
15 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1004- 02I Nut, link rod to suspension strut Nm 58 SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1002- 04D Nut, suspension strut at rebound buffer Nm 45 TIE ROD Number Designation Model 451.3/4 BA46.40-P-1001- 01F Self-locking nut, tie rod to steering knuckle Nm 34 Fig 4: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 5: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 00)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2652 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 7: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL FENDER LINER IN REAR FENDER - AR88.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2653 · Applies to: 450, 451, 452, 454
1400MCU > MODEL 451.3/4 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.
Illustrated on model 451.330¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2655 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Cover, Electrical Connector, Left And Right Taillamp Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Bolts, Rear CBS, Rear-End Door, Left And Right Taillamp Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.330¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2656 · Applies to: 450, 451, 452, 454
Not on model 451.391/491 Fig 3: Identifying Bolts, Rear CBS, Rear-End Door, Fuel Filler Flap And Catch Hook Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Rear CBS, Fuel Filler Flap, Gasket, Latch, Electrical Connector And Fuel Filler Flap CL Motor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Model 451.391/491¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2657 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove left and right longitudinal member paneling
AR88.80-P- 6000MCC 2 Open liftgate (3)
Fig 5: Locating Rear CBS Mounting Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Rear CBS, Gasket, Electrical Connector, Charger Feed-In Socket Flap And Charge Socket Flap CL Motor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove covers (10) and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2658 · Applies to: 450, 451, 452, 454
3 Remove covers (10) and disconnect electrical connector (11) from left taillamp (E3) and right taillamp (E4)
4 Unscrew bolts (1) from rear CBS (2).
5 Unscrew mounting bolt (9). With code (E14) Basic carrier
6 Loosen catch hook (5) on left and right bottom on rear CBS (2).
7.1 Open fuel filler flap (4) and unscrew lock (7). Not on model 451.391/491
7.2 Open charger feed-in socket flap (12) On model 451.391/491
8 Carefully loosen rear CBS (2) in marked area (arrows) starting at bottom with assembly wedge.
Installation: Slide seal (6) over tank filler neck or charger feed- in socket (X58/23) and align. *110589035900 9.1 Slightly pull rear CBS (2) toward outside in area of fuel filler flap (4) and disconnect electrical connector (8) from fuel filler flap CL motor (M14/10) Not on model 451.391/491
9.2 Slightly pull CBS rear-end (2) toward outside in area of charger feed-in socket flap (12) and disconnect electrical connector (8) from charger feed-in socket motor (M14/11) On model 451.391/491
10 Close rear-end door (3).
11 Guide rear CBS (2) downward along rear-end door (3) on left. Carefully remove rear CBS (2), otherwise rear-end door (3) and rear CBS (2) can be damaged by scratching. Aid of helper required.
12 Guide rear CBS (2) downward along rear-end door (3) on right side and remove. Carefully remove rear CBS (2), otherwise rear-end door (3) and rear CBS (2) can be damaged by scratching. Aid of helper required.Lay rear CBS (2) down on suitable subsurface.
13 Loosen latch (7) on fuel filler flap (4) and close tank filler neck Not on model 451.391/491
14 Install in the reverse order
15 Check left taillamp (E3) and right taillamp (E4) for proper function
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2662 · Applies to: 450, 451, 452, 454
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
2 Unclip catch hook (7) from coverings (5) and remove coverings (5).
3 Unclip front spoiler (3) from underfloor paneling
4 Turn wheel to right and remove expansion clips (4).
5 Turn wheel to left and remove expansion clips (6).
6 Unclip catch hooks (arrows B) between lower front grille (2) and front spoiler (3). Installation: Pull lower front grille (2) to front spoiler (3) from rear with pulling hook and clip in. *450589079900 7 Unclip front spoiler (3) on catch hooks (arrows A) from both fenders (1) and Do not damage catch hooks (arrows A), otherwise front spoiler (3) must be
Fig 1: Identifying Front Spoiler Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
remove.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2663 · Applies to: 450, 451, 452, 454
replaced. 8 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL INTERIOR COMPARTMENT FLAP ABOVE ENGINE - AR88.40-P-1100-03MCC > 1.1 Open upper rear-end door and lower rear-end door. On model 451.3. 1.2 Open lower rear-end door, unlock left and right lock lever and fold rear soft top upward. On model 451.4. Rear soft top must be engaged correctly on both sides. 2 Remove load compartment cover (1). On vehicles with load compartment cover (1) installed. 3 Fold floor covering (2) toward front and hook bracket (4) into opening (arrow) in right trunk paneling laterally (3). Do not break or tear floor covering (2) when folding down. Fig 2: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Load Compartment Cover, Floor Covering, Hook Bracket And Right Trunk Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2666 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00-Z- 0001-01A 1 Mask CBS rear end in rear area of tank recess (1) with suitable adhesive tape (6).
2 Open fuel filler flap (3) and unscrew plug (2) on fuel filler fitting.
3 Loosen plug (2) on hinge lever (9) (arrow A) and lay down to side.
4 Unclip bracket (7) from tank recess (1) with snap-release tool (5). *452589016300 5 Close fuel filler flap (3) and remove tank recess (1) until electrical connector (8) on fuel filler flap CL motor (M14/10) is accessible.
6 Disconnect electrical connector (8) on fuel filler flap CL motor (M14/10)
Fig 1: Identifying Tank Recess Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
and remove tank recess (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2667 · Applies to: 450, 451, 452, 454
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 > 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.
Shown without code (V21) Electrically adjustable and heated outside mirror (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2668 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Outside Mirror Components - With Code (V21) Electrically Adjustable And Heated Outside Mirror Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2669 · Applies to: 450, 451, 452, 454
1 Lower crank window
2 Unscrew bolt (3) from mirror triangle cover (2).
3.1 Detach brackets (4) on mirror triangle cover (2) from door paneling and remove mirror triangle cover (2) On vehicles with code (V21) Electrically adjustable and heated outside mirror (FFO) On vehicles with code (C17) smart surround sound system, disconnect electrical connector on left tweeter and right tweeter before remove mirror triangle cover (2). 3.2 Detach brackets (4) on mirror triangle cover (2) from door paneling and lay mirror triangle cover (2) to side until catch (arrow B) is accessible. On vehicles without code (V21) Electrically adjustable and heated outside mirror (FFO) 4 Loosen catch (arrow B) on mirror adjustment lever (5) with suitable screwdriver and remove mirror triangle cover (2) toward front. On vehicles without code (V21) Electrically adjustable and heated outside mirror (FFO) 5 Unscrew bolts (6) from seal (7), lift seal (7) over manual outside mirror (1) or left electrically adjustable and heated outside mirror (M21/1) or
Fig 2: Identifying Outside Mirror Components - Without Code (V21) Electrically Adjustable And Heated Outside Mirror Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2672 · Applies to: 450, 451, 452, 454
1 Open door and loosen covering (3) in upper area with assembly wedge. *110589035900 2 Unclip trim (1) in upper area with suitable screwdriver (2) and remove until electrical connector (5) is accessible.
3 Disconnect electrical connector (4) from left power window switch (S21/1) and electrical connector (6) from right power window switch (S21/2) On vehicles with code (V43) Power window
4 Disconnect electrical connector (5) from outside mirror adjustment switch (S50) and remove trim (1).
5 Unclip outside mirror adjustment switch (S50) from trim (1) with suitable screwdriver and remove.
6 Install in the reverse order
Fig 1: Identifying Outside Mirror Adjustment Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL LONGITUDINAL MEMBER PANELING - AR88.80-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2673 · Applies to: 450, 451, 452, 454
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). 3 Carefully pull longitudinal member paneling (1) toward outside in front area and slide 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.
toward rear until bracket (arrow A) separates from guide (arrow C).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2674 · Applies to: 450, 451, 452, 454 · AR: AS88.00-Z-9999ZZ, AZ88.00-P-0002MCC
4 Carefully pull longitudinal member paneling (1) in front area toward outside, slide toward rear and remove. 5 Unscrew brackets (3) still located on the threaded studs (arrows B) on the longitudinal member (5). Install 6 Insert brackets (3) into guides on longitudinal member paneling (1). 7 Position bracket (arrow A) in guide (arrow C) and clip brackets (3) on longitudinal member paneling (1) into threaded studs (arrows B) on longitudinal member (5). 8 Clip catch hook (4) on longitudinal member paneling (1) into longitudinal member (5). 9 Install expansion clip (2) on longitudinal member paneling (1) at front and rear. SAFETY PRECAUTIONS > SAFETY INFORMATION: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - AS88.00-Z-9999ZZ > MODEL all Risk of injury caused by pinching and crushing when opening and closing engine hood MODEL 949 AS88.40-Z-0001- 01A Risk of injury caused by tearing of the cutting wire MODEL all AS88.00-Z-0001- 01A RETROFITTING & CONVERSION > RETROFIT CHROME PACKAGE - AZ88.00-P-0002MCC
MODEL 451.3/4 Fig 1: Identifying Chrome Front Grille, Chrome Mirror Caps And Adhesive Strips Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
P-0005-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2676 · Applies to: 450, 451, 452, 454
02MCU Retrofit mounts for basic carrier
Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well- ventilated rooms; wear respiratory protection. AS97.00- Z-0001- 01A Cavity preservation following repair work AR97.20- P- 1500FF BASIC CARRIER Number Designation Model 451.3/4 BA88.00-P-1002- 02A Bolt to basic carrier bracket Nm 8 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1033- 02B Loctite 243 A 613 989 09 71 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 1. Remove edge guard (1) of rear-end door at lower area on body (3). Remove loose seam seal on body (3) in area of edge guard (1). 2. Line up supports (2) at left and right with marks (arrow A) on body (3). Align right support (2) at left next to mark (arrow A). Align left support (2) at right next to mark (arrow A). Fig 1: Identifying Edge Guard, Supports, & Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Position one self-tapping bolt (4) included in the package contents each at the left and right on the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2677 · Applies to: 450, 451, 452, 454
support's elongated hole (2) and screw in using the hand drill up to the stop. Hand drill gotis://G_58.0_00.1 Screw in self-tapping bolts (4) at a speed of 1200 RPM, to ensure specified strength of bolted connection. Do not tighten bolts (4) yet. 4. Coat the mounting bolts (5) with thread locking compound and - together with washers - screw into the supports (2). 5. Insert basic carrier (6) with brackets (arrows B) into mounting bolts (5). 6. Screw basic carrier (6) to adapter pins using bolts (7) and washers. 7. Align mount carrier (9) in center and tighten bolts (8). Fig 2: Identifying Mounting Bolts, Supports, Basic Carrier, Bracket And Mount Carrier Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Tighten self-tapping screws (4) at supports' elongated holes (2) with specified tightening torque.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2678 · Applies to: 450, 451, 452, 454 · AR: AZ88.00-P-0005MCU
- Unscrew bolts (7) at adapter pins again and remove together with washers and basic carrier (6).
- Position remaining self-tapping bolts (4) of left and right supports (2), screw in to the stop using the hand drill and then tighten with specified tightening torque. Hand drill gotis://G_58.0_00.1 Screw in self-tapping bolts (4) at a speed of 1200 RPM, to ensure specified strength of bolted connection. If the specified tightening torque is not attained with a self-tapping bolt (4), replace this with a 5 mm steel rivet after completing the assembly work.
- Unscrew the two self-tapping bolts (4) at the left and right at the supports' elongated holes (2) again and spray threaded holes with cavity preservative. Combination pressure spray gun (corrosion protection) gotis://K_91-97_01.0 Cavity sealant must not come into contact with the threaded holes.
- Tighten self-tapping bolts (4) again at supports' elongated holes to specified tightening torque.
- Spray cavity preservation from outside to left and right mount (2). Combination pressure spray gun (corrosion protection) gotis://K_91-97_01.0 RETROFITTING & CONVERSION > RETROFIT BASE CARRIER - AZ88.00-P-0005MCU > MODEL 451.3/4 Fig 3: Identifying Self-Tapping Screws, Basic Carrier, Bolts And Supports Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Assemble basic carrier¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2679 · Applies to: 450, 451, 452, 454
1 Position mount carrier (2) on completely folded up basic carrier (1) and screw on finger-tight using bolts
Fig 1: Identifying Base Carrier Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Base Carrier Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(3) and washers (4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2680 · Applies to: 450, 451, 452, 454
Removing
2 Remove CBS rear end (14)
AR88.20-P- 1900MCC 3 Unclip and remove caps (15)
4 Loosen rear-end door (16).
AR72.20-P-3500- 02MCC Install
5 Tighten adapter pins (6) on vehicle crossmember (13) BA88.00-P-1001- 02A Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. AS97.00-Z-0001- 01A 6 Install mounts (9) of basic carrier (1) with bolts (10). AZ88.00-P-0005- 02MCU Hand drill gotis://G_58.0_00.1 Combination spray gun (corrosion protection) gotis://K_91-97_01. BA88.00-P-1002- 02A Loctite 243 BR00.45-Z-1033- 02B Teroson protective wax BR00.45-Z-1008- 05A 7 Install CBS rear end (14)
AR88.20-P- 1900MCC 8 Position rear-end door (16) and fasten Observe marking of hinge in relation to body. AR72.20-P-3500- 02MCC BA72.20-P-1002- 02F BA72.20-P-1003- 02F 9 Position basic carrier (1) at mounting bolts (7) and tighten to adapter pins (6) with bolts (11) as well as washers (12).
10 Place tool (5) in vehicle The tool (5) is intended for the customer, for removing and
installing basic carrier (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2681 · Applies to: 450, 451, 452, 454 · AR: AZ88.20-P-0002MCC
11 Add special equipment to the vehicle data card and to the online vehicle data card Add code (E14) Basic carrier.
12 Install bicycle carrier, ski carrier or snowboard carrier according to assembly instructions included in the scope of delivery. Only on customer request.
REAR-END DOOR 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 BASIC CARRIER Number Designation Model 451.3/4 BA88.00-P-1001- 02A Adapter pins to crossmember Nm 80 BA88.00-P-1002- 02A Bolt to basic carrier bracket Nm 8 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1033- 02B Loctite 243 A 613 989 09 71 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 RETROFITTING & CONVERSION > RETROFIT CHROME RINGS AROUND FRONT FOG LAMPS - AZ88.20-P-0002MCC > MODEL 451.3/4
Install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2682 · Applies to: 450, 451, 452, 454
1 Clean contact surfaces of chrome rings (1) on front CBS using cleaner (3) contained in scope of delivery.
2 Remove protective foils from adhesive strips (2), position chrome rings (1) and press on. Observe installation position of chrome rings (2). RETROFITTING & CONVERSION > RETROFIT FRONT MUD GUARDS - AZ88.30-P-0003- 03MCC > The work procedure is shown on the left side of the vehicle. 1. Clean assembly area of front dirt trap (1). 2. Position front dirt trap (1) on fender and side skirt. 3. Position clips (4) with pliers (3) and push onto front dirt trap (1). Ensure that the clamps (4) are seated correctly. 4. Press clips (4) into final position with hammer handle. Counterhold front dirt trap (1) by hand. Fig 1: Identifying Chrome Ring, Adhesive Strips And Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT REAR MUD GUARDS - AZ88.30-P-0003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2683 · Applies to: 450, 451, 452, 454
04MCC > The work procedure is shown on the left side of the vehicle. 1. Clean assembly area of rear dirt trap (2). 2. Position rear dirt trap (2) on fender and rear apron. 3. Position clips (4) with pliers (3) and push onto rear dirt trap (2). Ensure that the clamps (4) are seated correctly. 4. Press clips (4) into final position with hammer handle. Counterhold rear dirt trap (2) by hand. Fig 1: Positioning Clips Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT MUD FLAPS - AZ88.30-P-0003MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2684 · Applies to: 450, 451, 452, 454 · AR: AZ88.30-P-0003MCC
MODEL 451.3/4 (except 451.333 /433) except CODE (P71) BRABUS sport package Install
Fig 1: Positioning Rear Dirt Trap Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Front And Rear Mud Guards Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
protective foil (6) on adhesive¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2686 · Applies to: 450, 451, 452, 454
tape and bend 45° in direction of outer edge of diffuser (1) 4 Clean adhesive area of rear diffuser (1) on rear styling conversion kit (2) The bonding surface must be free of dust and grease.
Cleaner *BR00.45-Z-1025- 04A 5 Screw rear diffuser (1) on to rear styling conversion kit (2) with bolts (5) so that protective foil (6) on adhesive tape can still be pulled off
6 Remove protective foil (6) from adhesive tape on rear diffuser (1)
7 Tighten rear diffuser (1) to rear styling conversion kit (2) with bolts (5)
8 Press rear diffuser (1) to rear styling conversion kit (2) in area of adhesive tape.
9 Tighten heat shield (4) with bolts (5) to rear styling conversion kit (2) and rear diffuser (1)
Install
10 Install rear styling conversion kit (2) with rear diffuser (1) The rear styling conversion kit (2) with rear diffuser (1) replace the standard rear apron.Before installing paint primed rear diffuser (1) according to customer request. AR88.30-P- 0502MCC 11 Clip caps (3) into rear styling conversion kit (2) Before installing, paint primed rear styling conversion kit (2) with caps (3) according to customer request.
12 Place certification in the vehicle Only for Europe.
Rear apron, certification * Applies to Europe only OF64.20-P-1000-01A REPAIR MATERIALS Number Designation Order number BR00.45-Z-1025-04A Cleaner A 005 989 19 71
TORQUE SPECIFICATIONS > BASIC CARRIER - BA88.00-P-1000-02A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2687 · Applies to: 450, 451, 452, 454 · AR: BA88.00-Z-9999CZ
Model 451 MODIFICATION NOTES 8.4.09 Value modified: Bolt, lamp unit crossmember on basic carrier BASIC CARRIER Number Designation Model 451.3/4 BA88.00-P-1001- 02A Adapter bolts to crossmember Nm 80 BA88.00-P-1002- 02A Bolt on basic carrier bracket Nm 8 BA88.00-P-1003- 02A Bolt, lamp unit crossmember on basic carrier Nm 6 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - BA88.00-Z-9999CZ > MODEL all Basic carrier MODEL 451.3/4 BA88.00-P-1000-02A Engine hood MODEL 454.0 BA88.40-P-1000-01H Engine hood MODEL 452.3 /4 BA88.40-P-1000-01G Outside mirrors MODEL 450.3 /4, 452.3 /4 BA88.70-P-1000-01D Tailgate MODEL 452.3 BA88.50-P-1000-02A Trunk lid MODEL 452.4 BA88.50-P-1000-01C BASIC KNOWLEDGE > ELECTRICALLY ADJUSTABLE OUTSIDE MIRRORS, LOCATION OF COMPONENTS - GF88.79-P-0005-01MCC >
General information¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2689 · Applies to: 450, 451, 452, 454
The left and right outside mirrors can be adjusted electrically using the outside mirror adjustment switch. The adjustments are performed by the mirror adjustment motors. The outside mirror adjustment switch is actuated directly. Moreover, the outside mirrors are heated. Function requirements: Circuit 15 ON Functions Mirror lens adjustment Heating outside mirror Mirror lens adjustment The outside mirror to be adjusted is preselected by turning the outside mirror adjustment switch. The corresponding mirror adjustment motor and the mirror lens are adjusted horizontally by actuating the outside mirror adjustment switch forward and backward. The corresponding mirror adjustment motor and the mirror lens are adjusted vertically by actuating the outside mirror adjustment switch to left or right. It is not possible to adjust the outside mirror when the outside mirror adjustment switch is set to "0". Heating outside mirror The SAM control unit supplies power to the mirror heater when circuit 15 is On. Fig 1: Electrically Adjustable Outside Mirrors Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
description¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2692 · Applies to: 450, 451, 452, 454
4110MCC Table of contents for function description for electrically adjustable outside mirror
GF88.79-P- 0999MCC WIRING DIAGRAMS > WIRING DIAGRAM OF OUTSIDE MIRRORS - PE88.79-P-2000-97MCU
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
Fig 1: Outside Mirrors - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2693 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT BRABUS ATTACHMENT PARTS ON REAR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2696 · Applies to: 450, 451, 452, 454 · AR: AN88.10-P-0006MCC
FENDER - AN88.10-P-0006MCC > MODEL 451.3 /4 (except 451.391 /491) Install 1 Clean contact surfaces on attachment parts (2) on rear CBS (1). 2 Position attachment parts (2) on rear CBS (1) and clip in catch hook (arrows). 3 Install retaining clamps (3). RETROFITTING & CONVERSION > RETROFIT BRABUS REAR APRON - AN88.20-P- 0001MCU > MODEL 451.3 /4 with ENGINE 132.910 Fig 1: Identifying Rear CBS, Attachment Part And Retaining Clips Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying BRABUS Rear Apron, Heat Shield , Bracket, Expansion Clip, Cover And Bolts¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2697 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying BRABUS Rear Apron, Expansion Clip, Chatch Hook, Bracket, Covers, Screw And Rear CBS Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2698 · Applies to: 450, 451, 452, 454
1 Remove rear apron
Remove/install rear apron AR88.30- P- 0502MCC Install
2 Retrofit BRABUS muffler The BRABUS rear apron (1) can only be installed in combination with the BRABUS muffler. AN49.10- P- 1003MCU 3 Hook left and right cover (5) into mounts (arrows) on BRABUS rear apron (1) and clip in.
4 Install expansion clip (4) on left and right covering (5).
5 Position heat shield (2) on BRABUS rear apron (1) and tighten with bolts (6). Cordless drill/driver
6 Hook bracket (3) of BRABUS rear apron (1) into CBS rear end (12). Hook BRABUS rear apron (1) into same mounts on rear CBS (12) as the removed rear apron.
7 Clip catch hook (8) on BRABUS rear apron (1) into CBS rear end (12)
8 Hook BRABUS rear apron (1) into brackets (9).
9 Install expansion clip (7) on left and right on BRABUS rear apron (1)
10 Tighten bolt (11) on left and right on BRABUS rear apron (1)
11 Clip in coverings (10) on left and right above bolts (11)
12 Add special equipment to the vehicle data card and to the online vehicle data card Code (E78) Enter smart BRABUS (DFO) rear skirt
RETROFITTING & CONVERSION > RETROFIT BRABUS REAR SPOILER - AN88.50-P- 0003MCC > MODEL 451.3 (except 451.391)
Fig 1: Identifying Rear Spoiler And Drilling Template Area¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2699 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Spoiler, BRABUS Rear Spoiler And Adhesive Strips Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2700 · Applies to: 450, 451, 452, 454
1 Remove rear spoiler (1)
AR88.30- P- 0500MCC Install
2 Cut out drilling templates (2) included in delivery contents along marking and fix in place on rear spoiler (1) from inside with suitable adhesive tape as shown
3 Drill holes with diameter of 5 mm, corresponding to markings (arrows A) along drilling templates (2) on rear spoiler (1). Rechargeable drill / screwdriverWet and dry vacuum cleaner Fig 5 4 Remove drilling templates (2)
Fig 3: Identifying Rear Spoiler And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Rear Spoiler And BRABUS Rear Spoiler Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Clean gluing surfaces on BRABUS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2701 · Applies to: 450, 451, 452, 454
5 Clean gluing surfaces on BRABUS rear spoiler (3) and rear spoiler (1). The contact surfaces must be free of dust and grease, otherwise the adhesive force of the adhesive strips (4) starts to decrease.
6 Remove white protective foil from adhesive strips (4) and glue adhesive strips (4) to contact surfaces on BRABUS rear spoiler (3). The installation position for the outer adhesive strips (4) is dictated by their shape. Do not yet remove red protective foil.
7 Tighten BRABUS rear spoiler (3) to rear spoiler (1) with bolts (5) included in delivery contents.
8 Check installation position of BRABUS rear spoiler (3), if applicable slightly cut out drill holes. The drill holes should be greater than 7 mm, otherwise it is not possible to install the BRABUS rear spoiler (3) correctly.Rechargeable drill / screwdriverWet and dry vacuum cleaner
9 Unscrew bolts (5) and remove BRABUS rear spoiler (3).
10 Remove red protective foil from adhesive strips (4)
11 Align rear spoiler (1) at left side above BRABUS rear spoiler (3) and carefully tighten with two bolts (5). Aid of helper requiredEnsure that the rear spoiler (1) is not pressed down on the adhesive strips (4) on the BRABUS rear spoiler (3).Screw bolts (5) in two turns only.
12 Fix rear spoiler (1) in place in center area on BRABUS rear spoiler (3) with two bolts (5). Aid of helper required.Ensure that the rear spoiler (1) is not pressed down on the adhesive strips (4) on the BRABUS rear spoiler (3).Screw bolts (5) in two turns only.
13 Fix rear spoiler (1) at right rear on BRABUS rear spoiler (3) with two bolts (5) and tighten all bolts (5).
14 Install rear spoiler (1)
AR88.30- P- 0500MCC
RETROFITTING & CONVERSION > RETROFIT BRABUS FRONT SPOILER - AN88.50-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2702 · Applies to: 450, 451, 452, 454
0004MCC > MODEL 451.3 /4 (except 451.391 /491) Fig 5: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Module And Lip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2703 · Applies to: 450, 451, 452, 454
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
3 Clip covers (2) into BRABUS front spoiler (1) Ensure that clips (3) are seated correctly.
4 Position BRABUS front spoiler (1) on CBS front end (4) and arrest brackets (arrows B)
5 Arrest brackets (arrows C) between BRABUS front spoiler (1) and lower front grille (5) with extraction hook The extraction hook is included in the assembly tool set.
Fig 3 6 Turn steering wheel to right, slightly push right fender liner to side and install expansion clips (7).
Fig 2: Identifying Retrofit BRABUS Front Spoiler Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Turn teering wheel to left, lightly pu h left¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2704 · Applies to: 450, 451, 452, 454
7 Turn teering wheel to left, lightly pu h left fender liner to side and install expansion clips (9).
8 Clip brackets (arrows A) between BRABUS front spoiler (1) and underfloor paneling (6).
9 Position covers (8) on CBS front (4) and clip in clips (10)
RETROFITTING & CONVERSION > INSTALL SIDE SKIRTS, BRABUS - AN88.80-P- 0010MCC > MODEL 451.3 /4 (except 451.391 /491) Shown on right side of vehicle Fig 3: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on vehicle with code (V07) Front fog lamps (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2706 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Front CBS Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front CBS Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2707 · Applies to: 450, 451, 452, 454
1 Remove antenna rod
2 Remove additional turn signal lamps
AR82.25- P- 4726MCC 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 bolts (2) from front CBS (1).
7 Remove longitudinal member paneling (8).
AR88.80- P- 6000MCC 8 Remove expansion clip (9) in area of left and right door hinge.
9 Unscrew bolts (10) located behind left and right longitudinal member paneling (8) from front CBS (1).
Fig 3: Identifying Front CBS, Bolt And Catch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2710 · Applies to: 450, 451, 452, 454
1 Carefully loosen company sign (1) from rear-end door paneling with clip remover and remove. Carefully company sign (2) to prevent scratching rear-end door paneling.
Fig 2 Install
2 Clean rear-end door paneling in area of company sign (1). The rear-end door paneling 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. Measure dimension (b) on upper edge of rear- end door paneling.
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 rear-end door paneling.
6 Press on company sign (1) and remove front carrier foil.
7 Remove adhesive tapes
TESTING & REPAIR INDEX > 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 (452 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2712 · Applies to: 450, 451, 452, 454
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 INDEX > 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.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2713 · Applies to: 450, 451, 452, 454
1 Remove rear CBS
AR88.20- P- 1900MCC 2 Remove expansion clips (9) from rear apron (5).
3 Loosen catch hook (10) on rear apron (5).
4 Unclip bracket (6) on rear apron (5) from left rear fender (1), right rear fender (4) and rear center part (3) and remove rear apron (5).
5 Remove expansion clips (7) from left rear fender (1) and right rear fender (4).
6 Loosen catch hook (8) between left rear fender (1) and rear center section (3) and remove left rear fender (1).
7 Loosen catch hook (8) between right rear fender (4) and rear center section (3) and remove right rear fender (4).
8 Unclip covers (11) from rear center part (3) and remove. When replacing rear center part (3).
9 Remove heat shield (2) When replacing rear center section (3) on vehicle with engine 132.930. AR88.20- P- 1925MCC Fig 1: Identifying Rear Center Part Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install fender liner in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2716 · Applies to: 450, 451, 452, 454
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 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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2719 · Applies to: 450, 451, 452, 454
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).
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
Fig 1: Identifying Rear Fender Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2721 · Applies to: 450, 451, 452, 454
11.4.08 Special tool for loosening nut on link rod and piston rod added Operation step 7, 11
Fig 2: Identifying Fender Liner In Front Fender Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Fender Liner In Front Fender Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2722 · Applies to: 450, 451, 452, 454
Notes on self- locking nuts and bolts
AH00.00- N-0001- 01A 1 Remove front CBS
AR88.00- P- 1010MCC 2 Remove left and right lamp unit
AR82.10- P- 4730MCU 3 Remove front wheel
AR40.10- P- 1100MCU 4 Remove underfloor panels Rechargeable drill / screwdriver
5 Unclip brake line (2) from retaining clips (3). When removing fender liner (1) in right front fender.
6 Unscrew nut (4), loosen tie rod end (5) using puller from steering knuckle (6) and unhook. Carefully press out tie rod end (5) to prevent damaging rubber boot. Installation: Check rubber boot, replace tie rod end (5), if necessary.
Fig 7 *BA46.40- P-1001- 01F 7 Unscrew nut (7) and unhook link rod (8) from suspension strut (9). Counterhold threaded stud of link rod (8).
Fig 4 Fig 5 *BA32.20- P-1004- 02I 8 Unhook line (10) from bracket (11) and unscrew bracket (11). Observe installation position of line (10) and bracket (11).
9 Remove retaining clip (12) from bracket (13) and remove brake hose (14) from bracket (13).
Support steering¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2723 · Applies to: 450, 451, 452, 454
10 Support steering knuckle (6) with manual hydraulic floor jack Use suitable protective subsurface to prevent damaging steering knuckle (6) or transverse control arm.Manual hydraulic floor jack
11 Unscrew nut (15) from suspension strut (9). Secure suspension strut (9) against falling down, otherwise it can be damaged. Do not turn piston rod on suspension strut (9), otherwise the suspension strut (9) can be damaged. Hold piston rod on suspension strut (9) with torx bit, size T45 and shaft length 100 mm.If the nut (15) sticks, push back the boot, fasten the holding device (16) on the suspension strut's piston rod (9) and counterhold using open end wrench (17).
Fig 6 Fig 8 Fig 9 *BA32.25- P-1002- 04D 12 Carefully lower manual hydraulic floor jack and fold suspension strut (9) toward outside.
13 Remove expansion clips (18) from fender liner (1)
14 Remove fender liner (1)
15 Install in the reverse order
FRONT AXLE STABILIZER BAR Number Designation Model 451.3/4 BA32.20-P-1004-02I Nut, link rod to suspension strut Nm 58 SUSPENSION STRUTS Number Designation Model 451.3/4 BA32.25-P-1002-04D Nut, suspension strut at rebound buffer Nm 45 TIE ROD Number Designation Model 451.3/4
BA46.40-P-1001-01F¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2724 · Applies to: 450, 451, 452, 454
Self-locking nut, tie rod to steering knuckle Nm 34 Fig 4: Identifying Screwdriver Bit (126 589 00 10 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Tool Assortment For Stabilizer Assembly (450 589 00 17 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Open End Wrench (450 589 01 01 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Illustrated on model 451.330¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2727 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Cover, Electrical Connector, Left And Right Taillamp Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Bolts, Rear CBS, Rear-End Door, Left And Right Taillmap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.330¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2728 · Applies to: 450, 451, 452, 454
Not on model 451.391/491 Fig 3: Identifying Bolts, Rear Cbs, Rear-End Door, Fuel Filler Flap And Catch Hook Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Rear CBS, Fuel Filler Flap, Gasket, Latch, Electrical Connector And Fuel Filler Flap CL (ZV) Motor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Model 451.391/491¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2729 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove left and right longitudinal member paneling
AR88.80- P- 6000MCC 2 Open liftgate (3)
Fig 5: Identifying Mounting Bolts Of Rear CBS Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Rear CBS, Gasket, Electrical Connector, Charger Feed-In Socket Flap And Charge Socket Flap CL (ZV) Motor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove covers (10) and disconnect¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2730 · Applies to: 450, 451, 452, 454
3 Remove covers (10) and disconnect electrical connector (11) from left taillamp (E3) and right taillamp (E4)
4 Unscrew bolts (1) from rear CBS (2).
5 Unscrew mounting bolt (9). With code (E14) Basic carrier
6 Loosen catch hook (5) on left and right bottom on rear CBS (2).
7.1 Open fuel filler flap (4) and unscrew lock (7). Not on model 451.391/491
7.2 Open charger feed-in socket flap (12) On model 451.391/491
8 Carefully loosen rear CBS (2) in marked area (arrows) starting at bottom with assembly wedge.
Installation: Slide seal (6) over tank filler neck or charger feed-in socket (X58/23) and align. Fig 7 9.1 Slightly pull rear CBS (2) toward outside in area of fuel filler flap (4) and disconnect electrical connector (8) from fuel filler flap CL motor (M14/10) Not on model 451.391/491
9.2 Slightly pull CBS rear-end (2) toward outside in area of charger feed-in socket flap (12) and disconnect electrical connector (8) from charger feed-in socket motor (M14/11) On model 451.391/491
10 Close rear-end door (3).
11 Guide rear CBS (2) downward along rear-end door (3) on left. Carefully remove rear CBS (2), otherwise rear-end door (3) and rear CBS (2) can be damaged by scratching. Aid of helper required.
12 Guide rear CBS (2) downward along rear-end door (3) on right side and remove. Carefully remove rear CBS (2), otherwise rear-end door (3) and rear CBS (2) can be damaged by scratching. Aid of helper required.Lay rear CBS (2) down on suitable subsurface.
13 Loosen latch (7) on fuel filler flap (4) and close tank filler neck Not on model 451.391/491
14 Install in the reverse order
15 Check left taillamp (E3) and right taillamp (E4) for proper function
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2733 · Applies to: 450, 451, 452, 454
1 Remove center high-mounted stop lamp (E21)
AR82.10- P- 5375MCC 2 Remove rear-end door wiper arm (9)
AR82.30- P- 6910MCC 3 Unscrew bolt (8) on rear spoiler (7).
Fig 1: Identifying Rear Spoiler Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Spoiler Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2736 · Applies to: 450, 451, 452, 454
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 2 Unclip catch hook (7) from coverings (5) and remove coverings (5).
3 Unclip front spoiler (3) from underfloor paneling
4 Turn wheel to right and remove expansion clips (4).
5 Turn wheel to left and remove expansion clips (6).
6 Unclip catch hooks (arrows B) between lower front grille (2) and front spoiler (3). Installation: Pull lower front grille (2) to front spoiler (3) from rear with pulling hook and clip in.
Figure 7 Unclip front spoiler (3) on catch hooks (arrows A) from both fenders (1) and remove. Do not damage catch hooks (arrows A), otherwise front spoiler (3) must be replaced.
8 Install in the reverse order
Fig 1: Identifying Front Spoiler Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > REMOVE/INSTALL C-PILLER OUTER COVRE - AR88.30-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2737 · Applies to: 450, 451, 452, 454
1200MCC > MODEL 451.3 Remove/install
1 Open rear-end door upper section and remove bolts (3)
2 Mask off roof paneling in area of outer cover (1) with suitable textile adhesive tape
Fig 2: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Outer Covre, Rear CBS, Retaining Clip, Bracket And Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unclip retaining clip (4) on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2738 · Applies to: 450, 451, 452, 454
3 Unclip retaining clip (4) on outer cover (1) in marked area (arrow A) with snap- release tool Figure 4 Remove outer cover (1) upward Installation: Check retaining clip (4) on outer cover (1); replace if necessary.Ensure that bracket (5) is seated correctly in area (arrow B) on CBS rear end (2).
5 Install in the reverse order
TESTING & REPAIR INDEX > REMOVE/INSTALL INTERIOR COMPARTMENT FLAP ABOVE ENGINE - AR88.40-P-1100-03MCC > 1. Open upper rear-end door and lower rear-end door. On model 451.3. Open lower rear-end door, unlock left and right lock lever and fold rear soft top upward. On model 451.4. Rear soft top must be engaged correctly on both sides. Fig 2: Identifying Snap-Release Tool (452 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Load Compartment Cover, Floor Covering, Hook Bracket And Right Trunk Paneling Laterally Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Remove load compartment cover (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2739 · Applies to: 450, 451, 452, 454
On vehicles with load compartment cover (1) installed. 3. Fold floor covering (2) toward front and hook bracket (4) into opening (arrow) in right trunk paneling laterally (3). Do not break or tear floor covering (2) when folding down. 4. Release quick-release coupling (6). 5. Remove engine compartment cover (5) from vehicle. 6. Install in the reverse order. TESTING & REPAIR INDEX > 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: Identifying 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. 2741 · Applies to: 450, 451, 452, 454
Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A 1 Mask CBS rear end in rear area of tank recess (1) with suitable adhesive tape (6).
2 Open fuel filler flap (3) and unscrew plug (2) on fuel filler fitting.
3 Loosen plug (2) on hinge lever (9) (arrow A) and lay down to side.
4 Unclip bracket (7) from tank recess (1) with snap-release tool (5). Figure 5 Close fuel filler flap (3) and remove tank recess (1) until electrical connector (8) on fuel filler flap CL motor (M14/10) is accessible.
6 Disconnect electrical connector (8) on fuel filler flap CL motor (M14/10) and remove tank recess (1).
Fig 1: Identifying Tank Recess Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown without code (V21) Electrically adjustable and heated outside mirror (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2743 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Complete Outside Mirror Remove/Install Components - Shown With Code (V21) Electrically Adjustable And Heated Outside Mirror (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2744 · Applies to: 450, 451, 452, 454
1 Lower crank window
2 Unscrew bolt (3) from mirror triangle cover (2).
3.1 Detach brackets (4) on mirror triangle cover (2) from door paneling and remove mirror triangle cover (2) On vehicles with code (V21) Electrically adjustable and heated outside mirror (FFO) On vehicles with code (C17) smart surround sound system, disconnect electrical connector on left tweeter and right tweeter before remove mirror triangle cover (2). 3.2 Detach brackets (4) on mirror triangle cover (2) from door paneling and lay mirror triangle cover (2) to side until catch (arrow B) is accessible. On vehicles without code (V21) Electrically adjustable and heated outside mirror (FFO) 4 Loosen catch (arrow B) on mirror adjustment lever (5) with suitable screwdriver and remove mirror triangle cover (2) toward front. On vehicles without code (V21) Electrically adjustable and heated outside mirror (FFO) 5 Unscrew bolts (6) from seal (7), lift seal (7) over manual outside
Fig 2: Identifying Complete Outside Mirror Remove/Install Components - Shown Without Code (V21) Electrically Adjustable And Heated Outside Mirror (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2747 · Applies to: 450, 451, 452, 454
1 Open door and loosen covering (3) in upper area with assembly wedge. Figure 2 Unclip trim (1) in upper area with suitable screwdriver (2) and remove until electrical connector (5) is accessible.
3 Disconnect electrical connector (4) from left power window switch (S21/1) and electrical connector (6) from right power window switch (S21/2) On vehicles with code (V43) Power window
4 Disconnect electrical connector (5) from outside mirror adjustment switch (S50) and remove trim (1).
5 Unclip outside mirror adjustment switch (S50) from trim (1) with suitable screwdriver and remove.
6 Install in the reverse order
Fig 1: Identifying Outside Mirror Adjustment Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Carefully pull longitudinal member paneling (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2749 · Applies to: 450, 451, 452, 454 · AR: AS88.00-Z-9999ZZ, AZ88.00-P-0002MCC
3 Carefully pull longitudinal member paneling (1) toward outside in front area and slide toward rear until bracket (arrow A) separates from guide (arrow C). 4 Carefully pull longitudinal member paneling (1) in front area toward outside, slide toward rear and remove. 5 Unscrew brackets (3) still located on the threaded studs (arrows B) on the longitudinal member (5). Install 6 Insert brackets (3) into guides on longitudinal member paneling (1). 7 Position bracket (arrow A) in guide (arrow C) and clip brackets (3) on longitudinal member paneling (1) into threaded studs (arrows B) on longitudinal member (5). 8 Clip catch hook (4) on longitudinal member paneling (1) into longitudinal member (5). 9 Install expansion clip (2) on longitudinal member paneling (1) at front and rear. SAFETY PRECAUTIONS > SAFETY INFORMATION: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - AS88.00-Z-9999ZZ > MODEL all Risk of injury caused by pinching and crushing when opening and closing engine hood MODEL 949 AS88.40-Z- 0001-01A Risk of injury caused by tearing of the cutting wire MODEL all AS88.00-Z- 0001-01A RETROFITTING & CONVERSION > RETROFIT CHROME PACKAGE - AZ88.00-P-0002MCC
MODEL 451.3/4
Removal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2750 · Applies to: 450, 451, 452, 454
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).
Carefully cut adhesive tape (5) in marked area Carefully cut adhesive tape (5) to prevent Fig 1: Identifying Chrome Front Grille, Chrome Mirror Caps And Adhesive-Strips Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Trim Strip And Adhesive Tape Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(arrow) and remove trim strip (4).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2751 · Applies to: 450, 451, 452, 454
7 (arrow) and remove trim strip (4). 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- P-0005- 02MCU Retrofit mounts for basic carrier
Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well- ventilated rooms; wear respiratory protection. AS97.00- Z-0001- 01A Cavity preservation following repair work AR97.20- P- 1500FF BASIC CARRIER Number Designation Model 451.3/4 BA88.00-P-1002-02A Bolt to basic carrier bracket Nm 8 REPAIR MATERIALS Number Designation Order number BR00.45- Z-1033- 02B Loctite 243 A 613 989 09 71 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
1. Remove edge guard (1) of rear-end door at lower area on body (3).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2752 · Applies to: 450, 451, 452, 454
Remove loose seam seal on body (3) in area of edge guard (1). 2. Line up supports (2) at left and right with marks (arrow A) on body (3). Align right support (2) at left next to mark (arrow A). Align left support (2) at right next to mark (arrow A). 3. Position one self-tapping bolt (4) included in the package contents each at the left and right on the support's elongated hole (2) and screw in using the hand drill up to the stop. Hand drill Screw in self-tapping bolts (4) at a speed of 1200 rpm, to ensure specified strength of bolted connection. Do not tighten bolts (4) yet. 4. Coat the mounting bolts (5) with thread locking compound and - together with washers - screw into the supports (2). 5. Insert basic carrier (6) with brackets (arrows B) into mounting bolts (5). 6. Screw basic carrier (6) to adapter pins using bolts (7) and washers. 7. Align mount carrier (9) in center and tighten bolts (8). Fig 1: Identifying Edge Guard, Line Up Supports, Self-Tapping Bolt And Rear-End Door At Lower Area On Body Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Tighten self-tapping screws (4) at supports' elongated holes (2) with specified tightening torque.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2753 · Applies to: 450, 451, 452, 454
- Unscrew bolts (7) at adapter pins again and remove together with washers and basic carrier (6).
- Position remaining self-tapping bolts (4) of left and right supports (2), screw in to the stop using the Fig 2: Identifying Mounting Bolts, Supports, Basic Carrier, Bracket And Mount Carrier Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Self-Tapping Screws, Basic Carrier, Bolts, Left And Right Supports Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
hand drill and then tighten with specified tightening torque.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2754 · Applies to: 450, 451, 452, 454 · AR: AZ88.00-P-0005MCU
Hand drill Screw in self-tapping bolts (4) at a speed of 1200 rpm, to ensure specified strength of bolted connection. If the specified tightening torque is not attained with a self-tapping bolt (4), replace this with a 5 mm steel rivet after completing the assembly work. 11. Unscrew the two self-tapping bolts (4) at the left and right at the supports' elongated holes (2) again and spray threaded holes with cavity preservative. Combination pressure spray gun (corrosion protection) Cavity sealant must not come into contact with the threaded holes. 12. Tighten self-tapping bolts (4) again at supports' elongated holes to specified tightening torque. 13. Spray cavity preservation from outside to left and right mount (2). Combination pressure spray gun (corrosion protection) RETROFITTING & CONVERSION > RETROFIT BASE CARRIER - AZ88.00-P-0005MCU > MODEL 451.3 /4 Fig 1: Identifying Retrofit Base Carrier Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Assemble basic carrier¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2755 · Applies to: 450, 451, 452, 454
1 Position mount carrier (2) on completely folded up basic carrier (1) and screw on finger- tight using bolts (3) and washers (4)
Removing
2 Remove CBS rear end (14)
AR88.20- P- 1900MCC 3 Unclip and remove caps (15)
4 Loosen rear-end door (16).
AR72.20- P-3500- 02MCC Install
5 Tighten adapter pins (6) on vehicle crossmember (13) *BA88.00- P-1001- 02A Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated AS97.00- Z-0001- 01A Fig 2: Identifying Retrofit Base Carrier Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
rooms; wear respiratory protection.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2756 · Applies to: 450, 451, 452, 454
6 Install mounts (9) of basic carrier (1) with bolts (10). AZ88.00- P-0005- 02MCU Hand drillCombination spray gun (corrosion protection) BA88.00- P-1002- 02A Loctite 243 BR00.45- Z-1033- 02B Teroson protective wax *BR00.45- Z-1008- 05A 7 Install CBS rear end (14)
AR88.20- P- 1900MCC 8 Position rear-end door (16) and fasten Observe marking of hinge in relation to body. AR72.20- P-3500- 02MCC BA72.20- P-1002- 02F BA72.20- P-1003- 02F 9 Position basic carrier (1) at mounting bolts (7) and tighten to adapter pins (6) with bolts (11) as well as washers (12).
10 Place tool (5) in vehicle The tool (5) is intended for the customer, for removing and installing basic carrier (1).
11 Add special equipment to the vehicle data card and to the online vehicle data card Add code (E14) Basic carrier.
12 Install bicycle carrier, ski carrier or snowboard carrier according to assembly instructions included in the scope of delivery. Only on customer request.
REAR-END DOOR 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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2757 · Applies to: 450, 451, 452, 454 · AR: AZ88.20-P-0002MCC
02F Nut, lower rear-end door hinge to body Nm 43 43 BASIC CARRIER Number Designation Model 451.3/4 BA88.00-P-1001-02A Adapter pins to crossmember Nm 80 BA88.00-P-1002-02A Bolt to basic carrier bracket Nm 8 REPAIR MATERIALS Number Designation Order number BR00.45- Z-1033- 02B Loctite 243 A 613 989 09 71 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 RETROFITTING & CONVERSION > RETROFIT CHROME RINGS AROUND FRONT FOG LAMPS - AZ88.20-P-0002MCC > MODEL 451.3 /4 Install
1 Clean contact surfaces of chrome rings (1) on front CBS using cleaner (3) contained in scope of delivery.
2 Remove protective foils from adhesive strips (2), position chrome rings (1) and press on. Observe installation position of chrome rings (2). RETROFITTING & CONVERSION > RETROFIT FRONT MUD GUARDS - AZ88.30-P-0003- Fig 1: Identifying Chrome Ring, Achesive Strips And Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
03MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2758 · Applies to: 450, 451, 452, 454
The work procedure is shown on the left side of the vehicle. 1. Clean assembly area of front dirt trap (1). 2. Position front dirt trap (1) on fender and side skirt. 3. Position clips (4) with pliers (3) and push onto front dirt trap (1). Ensure that the clamps (4) are seated correctly. 4. Press clips (4) into final position with hammer handle. Counterhold front dirt trap (1) by hand. RETROFITTING & CONVERSION > RETROFIT REAR MUD GUARDS - AZ88.30-P-0003- 04MCC > The work procedure is shown on the left side of the vehicle. 1. Clean assembly area of rear dirt trap (2). 2. Position rear dirt trap (2) on fender and rear apron. 3. Position clips (4) with pliers (3) and push onto rear dirt trap (2). Ensure that the clamps (4) are seated correctly. 4. Press clips (4) into final position with hammer handle. Counterhold rear dirt trap (2) by hand. Fig 1: Identifying Front Dirt Trap And Clips With Pliers Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT MUD FLAPS - AZ88.30-P-0003MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2759 · Applies to: 450, 451, 452, 454 · AR: AZ88.30-P-0003MCC
MODEL 451.3 /4 (except 451.333 /433) except CODE (P71) BRABUS sport package Install
Fig 1: Identifying Rear Dirt Trap And Clips With Pliers Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front And Rear Mud Guards Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Slightly remove ends of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2761 · Applies to: 450, 451, 452, 454
3 Slightly remove ends of protective foil (6) on adhesive tape and bend 45° in direction of outer edge of diffuser (1)
4 Clean adhesive area of rear diffuser (1) on rear styling conversion kit (2) The bonding surface must be free of dust and grease.
Cleaner *BR00.45- Z-1025- 04A 5 Screw rear diffuser (1) on to rear styling conversion kit (2) with bolts (5) so that protective foil (6) on adhesive tape can still be pulled off
6 Remove protective foil (6) from adhesive tape on rear diffuser (1)
7 Tighten rear diffuser (1) to rear styling conversion kit (2) with bolts (5)
8 Press rear diffuser (1) to rear styling conversion kit (2) in area of adhesive tape.
9 Tighten heat shield (4) with bolts (5) to rear styling conversion kit (2) and rear diffuser (1)
Install
10 Install rear styling conversion kit (2) with rear diffuser (1) The rear styling conversion kit (2) with rear diffuser (1) replace the standard rear apron.Before installing paint primed rear diffuser (1) according to customer request. AR88.30- P- 0502MCC 11 Clip caps (3) into rear styling conversion kit (2) Before installing, paint primed rear styling conversion kit (2) with caps (3) according to customer request.
12 Place certification in the vehicle Only for Europe.
Rear apron, certification * Applies to Europe only OF64.20- P-1000- 01A REPAIR MATERIALS Number Designation Order number BR00.45-Z-1025-04A Cleaner A 005 989 19 71
TORQUE SPECIFICATIONS > BASIC CARRIER - BA88.00-P-1000-02A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2762 · Applies to: 450, 451, 452, 454 · AR: BA88.00-Z-9999CZ
Model 451 MODIFICATION NOTES 8.4.09 Value modified: Bolt, lamp unit crossmember on basic carrier BASIC CARRIER Number Designation Model 451.3/4 BA88.00-P-1001-02A Adapter bolts to crossmember Nm 80 BA88.00-P-1002-02A Bolt on basic carrier bracket Nm 8 BA88.00-P-1003-02A Bolt, lamp unit crossmember on basic carrier Nm 6 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - BA88.00-Z-9999CZ > MODEL all
Basic carrier MODEL 451.3 /4 BA88.00-P-1000-02A
Engine hood MODEL 454.0 BA88.40-P-1000-01H
Engine hood MODEL 452.3 /4 BA88.40-P-1000-01G
Outside mirrors MODEL 450.3 /4, 452.3 /4 BA88.70-P-1000-01D
Tailgate MODEL 452.3 BA88.50-P-1000-02A
Trunk lid MODEL 452.4 BA88.50-P-1000-01C BASIC KNOWLEDGE > ELECTRICALLY ADJUSTABLE OUTSIDE MIRRORS, LOCATION OF COMPONENTS - GF88.79-P-0005-01MCC >
General information¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2764 · Applies to: 450, 451, 452, 454
The left and right outside mirrors can be adjusted electrically using the outside mirror adjustment switch. The adjustments are performed by the mirror adjustment motors. The outside mirror adjustment switch is actuated directly. Moreover, the outside mirrors are heated. Function requirements: Circuit 15 ON Functions Mirror lens adjustment Heating outside mirror Mirror lens adjustment The outside mirror to be adjusted is preselected by turning the outside mirror adjustment switch. The corresponding mirror adjustment motor and the mirror lens are adjusted horizontally by actuating the outside mirror adjustment switch forward and backward. The corresponding mirror adjustment motor and the mirror lens are adjusted vertically by actuating the outside mirror adjustment switch to left or right. It is not possible to adjust the outside mirror when the outside mirror adjustment switch is set to "0". Heating outside mirror The SAM control unit supplies power to the mirror heater when circuit 15 is On. Fig 1: Electrically Adjustable Outside Mirrors Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Outside Mirror - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2768 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
PE91.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2770 · Applies to: 450, 451, 452, 454 · AR: WS88.00-Z-9999CZ
2050-60MCU Legend of electrical function diagram for airbag (AB), emergency tensioning retractor (ETR)
PE91.00-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- 3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)
GF00.19-P- 3000MCU PE07.00-P- 1100MCU
Further wiring diagrams PE07.00-P- 1100MCU PE42.00-P- 1100MCU
Further wiring diagrams PE42.00-P- 1100MCU PE54.00-P- 1100MCU
Further wiring diagrams PE54.00-P- 1100MCU SPECIAL TOOLS > SPECIAL TOOLS: SMART: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - WS88.00-Z-9999CZ > MODEL all 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P-0027K 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P-0012K
MAINTENANCE > LUBRICATE HINGES AND LOCKS OF DOORS AND FLAPS - AP72.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2771 · Applies to: 450, 451, 452, 454
7223MCC > MODEL 451.3/4 Shown on model 451.3 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 Lubricate door hinges (arrows C) on the left and right door (1) using a suitable spray lubricant
2 Lubricate hinges (arrows E) at the top of the rear-end door (2) using a suitable spray lubricant in case of MODEL 451.3
3 Lubricate hinges (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
Fig 1: Identifying Doors Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2774 · Applies to: 450, 451, 452, 454
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 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-
Fig 1: Identifying Front Door Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.4 with code (V43) Power window¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2779 · Applies to: 450, 451, 452, 454
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 1 Remove service flap
Remove left and right longitudinal member AR88.80- Fig 1: Identifying Door Shell Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Door Shell & Door Hinges Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
paneling.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2780 · Applies to: 450, 451, 452, 454
2 paneling.
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 CBS to side, unscrew bolts (1) on door hinge (9) from A-pillar and remove door body shell (7). Aid of helper 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 > REMOVE/INSTALL FRONT DOOR INNER ACTUATION - AR72.10-P-
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2783 · Applies to: 450, 451, 452, 454
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.
*450589033900
For cordless drill/driver, see GOTIS http://gotis.aftersales.mercedes- benz.com *450589003900 5 Unscrew bolts (1) on power window (3)
6 Open door, guide power window (3) out of door and remove.
7 Install in the reverse order
Fig 1: Identifying Front Door Power Window Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL CRANK WINDOW IN FRONT DOOR - AR72.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2784 · Applies to: 450, 451, 452, 454
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. 2785 · Applies to: 450, 451, 452, 454
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 Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2786 · Applies to: 450, 451, 452, 454
De ignation Model 451 3/4 BA72.10-P-1007- 01H Screw, side window to power window Nm 10 TESTING & REPAIR > 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
*BA72.10-P- 1006-01H
*452589012100 Installation: When installing, do not damage Fig 1: Identifying Crank Window, Roof Frame Strut Seal, Washer, Seal And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2791 · Applies to: 450, 451, 452, 454
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) or left door CL motor (M14/6)
Unscrew bolts (4) on left right door *BA72.10- Fig 1: Identifying Front Door Lock Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
CL motor (M14/5) or left door CL¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2792 · Applies to: 450, 451, 452, 454
5 CL motor (M14/5) or left door CL motor (M14/6) 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 > 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. 2793 · Applies to: 450, 451, 452, 454
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 (A) into lock cylinder (7).
6 Remove retaining spring (9).
Fig 1: Identifying Front Door Lock Cylinder Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2795 · Applies to: 450, 451, 452, 454
MODIFICATION NOTES Fig 2: Identifying Front Door Panel Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Front Door Panel Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
"Remove, install window" added¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2796 · Applies to: 450, 451, 452, 454
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 previously.
*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
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)
Disconnect electrical¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2797 · Applies to: 450, 451, 452, 454
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 *110589035900 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.
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
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2801 · Applies to: 450, 451, 452, 454
1 Remove license plate lamps
AR82.10- P- 5161MCC 2 Open bottom rear-end door and inner cover (2) on bottom rear-end door.
3 Unscrew bolts (3) on rear-end door at bottom. Rechargeable drill / screwdriver gotis://G 58.0 01.1
Carefully close bottom rear-end door When removing bottom rear-end Fig 1: Identifying Rear-End Door Paneling Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear-End Door Paneling Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2803 · Applies to: 450, 451, 452, 454
1 Remove rear-end door paneling
AR72.20- P- 1000MCC 2 Remove cover (1) on left and right rear-end door lock (2).
3 Unclip Bowden cable (3) from brackets (arrows A and B) on left and right rear- end door lock (2)
4 Disconnect electrical connector (4) of right rear-end door lock (2) When removing right rear-end door lock (2).
5 Open rear-end door and open inner cover (6) on rear-end door.
6 Unscrew bolt (7) of door check strap from left and right rear-end door lock (2) When removing both rear-end door locks (2), secure rear-end door against folding down. BA72.20- P-1002- 02F 7 Unscrew bolts (5) on left and right rear- end door lock (2) BA72.20- P-1004- 02F 8 Remove left and right rear-end door lock (2).
Fig 1: Identifying Rear-End Door Lock Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2805 · Applies to: 450, 451, 452, 454
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)http://gotis.aftersales.mercedes- benz.com
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 > LOOSEN REAR-END DOOR AND FASTEN. - AR72.20-P-3500- 02MCC > REAR-END DOOR Fig 1: Identifying Rear-End Door Bottom, Pin And Door Hinge For Tailgate Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2806 · Applies to: 450, 451, 452, 454
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 Releasing 1. Unclip stop plug from floor covering (2) and fold floor covering (2) over toward front. Do not break or tear floor covering (2) when folding down. 2. Remove adhesive tape (9) from rear-end door wiring harness (7) on left in trunk and expose rear- end door wiring harness (7). 3. Loosen retaining clip (8) on rear-end door wiring harness (7). 4. Press grommet (6) on rear-end door wiring harness (7) out of body. 5. Mark position of hinge on rear-end door (1) on body. 6. Hold rear-end door (1) and unscrew bolt (4) on left and right check strap on rear-end door (1). 7. Unscrew nuts (3) on left and right hinge of rear-end door (1). 8. Fold back floor covering (2) and lay down rear-end door (1) with rear-end door wiring harness (7) in trunk. Aid of helper required. Mounting Fig 1: Identifying Rear-End Door, Floor Covering, Retaining Clip And Wiring Harness Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Illustrated on model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2808 · Applies to: 450, 451, 452, 454
Remove/install
Remove door paneling from rear-end door AR72.20- Fig 1: Identifying Rear-End Door Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear-End Door Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1000MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2809 · Applies to: 450, 451, 452, 454
1 (1).
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 strap on rear- end door (1). The bolt (8) remains on the corresponding door check strap.
BA72.20- P-1002- 02F 8 Lift load compartment floor covering, unscrew nut (7) on left and right hinge on rear-end door (1) and remove rear-end door (1). BA72.20- P-1003- 02F 9 Remove rear-end door CL motor (M14/7) When replacing rear-end door (1). AR80.20- P- 4005MCC 10 Remove inner cover from rear-end door (1) When replacing rear-end door (1). AR72.20- P- 0001MCC 11 Remove door locks on rear-end door (1). When replacing rear-end door (1).
Door lock on upper rear-end door on model 451.3 AR72.20- P- 2550MCC
Door lock on lower rear-end door on model 451.3 AR72.20- P- 2550MCD
Model 451.4 AR72.20- P- 2550MCO 12 Unclip cable on rear-end door (1) and remove. When replacing rear-end door (1). On model 451.3 only one cable is installed on the rear-end door (1).
height as the rear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2811 · Applies to: 450, 451, 452, 454
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 locking eye (5) without canting.
*BA72.20-P-1001- 02F Install
10 Install left and right paneling in trunk
AR68.30-P- 4800MCC
Move left seat forward and fold¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2813 · Applies to: 450, 451, 452, 454
1 Move left seat forward and fold backrest forward
2 Mark positions (arrows A) on left and right holes in rear-end door (1) according to dimensions (a, b)
3 Drill holes with a diameter of 5 mm in rear-end door (1). Cordless drill/driver, wet/dry vacuum cleaner http://gotis.aftersales.mercedes- benz.com *450589017000 4 Guide screwdrivers (2) approx. 8.5 cm on left and right into holes.
5 Unlock rear-end door (1) by moving both screwdriver handles in direction of arrow. Both locks must be unlocked simultaneously.Both screwdrivers (2) must press the relay lever (3) to the center of the vehicle.
6 Open rear-end door (1) at bottom.
7 Deburr holes and cover with suitable expansion clips (4).
Fig 2: Opening Tailgate Using Emergency Unlocking Feature (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Close crank window¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2816 · Applies to: 450, 451, 452, 454 · AR: AS72.00-Z-9999ZZ
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
SAFETY PRECAUTIONS > SAFETY INFORMATION: DOORS - AS72.00-Z-9999ZZ > MODEL all Injury hazard! When working on folding door or folding door control body parts can be pinched or crushed MODEL 957 AS72.00-Z-0001- 01A Risk of injury caused by performing testing or repair work on door hinges with pyrotechnical actuator MODEL 197.3 AS72.10-Z-0001- 01A RETROFITTING & CONVERSION > RETROFIT OUTER DECORATIVE FOIL - AZ72.10-P- 0003MCC > MODEL 451.3/4
The bonding positions shown are¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2817 · Applies to: 450, 451, 452, 454
recommended by DaimlerChrysler, however, without obligation. Customer requests are, therefore, to be taken into consideration Bond decorative foil at room temperature and maintain temperature for 24 h. When solar radiation is high, bond decorative foil in shade only.If the decorative foil should be removed after a longer period of time, paint may be discolored
Clean
1 Clean surfaces to be bonded Surfaces must be free of dust, grease and silicon.
Attachment
2 Attach adhesive tape as reference edge to align decorative foil later
3 Cut decorative foil to desired size.
4 Remove protective foil from decorative foil
5 Spray detergent on surfaces to be bonded and adhesive side of decorative foil
Fig 1: View Of Outer Decorative Foil Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install decorative foil on vehicle, press¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2818 · Applies to: 450, 451, 452, 454
6 Install decorative foil on vehicle, press out air pockets and water with a plastic squeegee from center toward outside.
7 Cut decorative foil in area of joints and beads and work into contour; heat decorative foil with heat gun. Ensure that the hot air jet is not too hot to damage the decorative foil.
*450589016300 8 Remove upper carrier foil of decorative foil
9 Remove air pockets in decorative foil Punch air pockets at edge with pin and then smooth decorative foil by hand.
TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: DOORS - BA72.00-Z- 9999CZ > MODEL all Front door MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA72.10-P-1000-01H Front door MODEL 454.0 BA72.10-P-1000-01K Rear door MODEL 452.3 /4 BA72.20-P-1000-02H Rear door MODEL 454.0 BA72.12-P-1000-01G Rear-end door MODEL 451.3/4 BA72.20-P-1000-02F Rear-end door MODEL 454.0 BA72.20-P-1000-02G Rear-end door MODEL 450.3 /4 BA72.20-P-1000-02E TORQUE SPECIFICATIONS > FRONT DOOR - BA72.10-P-1000-01H > Model 450, 451, 452 FRONT DOOR Fig 2: Identifying Hot-Air Gun (450 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2819 · Applies to: 450, 451, 452, 454
Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA72.10-P-1001- 01H Screw for hinge on front door Nm 34 35 30 BA72.10-P-1002- 01H Screw for hinge on body Nm 40 40 35 BA72.10-P-1003- 01H Screw for striker eye on pillar Nm 23 32 23 BA72.10-P-1004- 01H Bolt, lock to front door Nm 23 16 8 BA72.10-P-1005- 01H Bolt, quarter window to upper door frame Nm 9,5 10 - BA72.10-P-1006- 01H Bolt, quarter window to lower door frame Nm 23 10 - BA72.10-P-1007- 01H Screw, side window to power window Nm - 10 - TORQUE SPECIFICATIONS > REAR-END DOOR - BA72.20-P-1000-02F > Model 451 MODIFICATION NOTES 11.6.07 Bolt for rear-end upper door hinge on body Model 451.3 TAILGATE Number Designation Model 451.3 Model 451.4 BA72.20-P-1001- 02F Bolt for rear-end door lower check strap on body Nm 32 32 BA72.20-P-1002- 02F Bolt for check strap on bottom rear-end door lock Nm 20 20 BA72.20-P-1003- 02F Nut for rear-end door lower hinge on body Nm 43 43 BA72.20-P-1004- 02F Bolt for outer door lock on bottom of rear-end door Nm 11 11 BA72.20-P-1005- 02F Bolt for rear-end upper door hinge on body Nm 12 - BA72.20-P-1006- 02F Screw for hinge on window Nm 12 - BA72.20-P-1007- 02F Ball head for pneumatic spring on body Nm 12 - BA72.20-P-1008- 02F Gas-operated spring ball head on upper rear- end door Nm 12 -
S21/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2825 · Applies to: 450, 451, 452, 454
Left power window switch 11 L S21/2 Right power window switch 14 L S21/2 Right power window switch 21 L W43 Ground (outside left fire wall) 12 C W43 Ground (outside left fire wall) 20 C W9 Ground (at left headlamp unit) 3 H X35/1 Left door separation point 9 E X35/2 Right door separation point 18 E Z51/6 Circuit 58d connector sleeve 9 H Z51/6 Circuit 58d connector sleeve 15 H Z6/35 Left door ground connector sleeve 12 H Z6/36 Right door ground connector sleeve 20 H Z81 Circuit 58d connector sleeve 7 H Z81 Circuit 58d connector sleeve 22 C Fig 1: Power Windows - Wiring Diagrams (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > LEGEND OF WIRING DIAGRAM FOR POWER WINDOWS - PE72.29-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2826 · Applies to: 450, 451, 452, 454
P-2001-60MCU > MODEL 451 Code Designation Coordinates A1 Instrument cluster 7L Fig 2: Power Windows - Wiring Diagrams (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
M10/3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2827 · Applies to: 450, 451, 452, 454
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 4A12A20A S21/1 Left power window switch 11L S21/2 Right power window switch 14L21L W9 Ground (left front, at lamp unit) 3G W43 Ground (outside left fire wall) 12C20C X35/1 Left door separation point 9E X35/2 Right door separation point 18E Z6/35 Left door ground connector sleeve 12G Z6/36 Right door ground connector sleeve 20G Z51/6 Circuit 58d connector sleeve 9G15G Z81 Circuit 58d connector sleeve 7G22C 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 X35/1 Left door separation point 10E
X35/2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2828 · Applies to: 450, 451, 452, 454
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 Z81 Circuit 58d connector sleeve 7H Fig 1: Power Window - Wiring Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
NOTE:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2831 · Applies to: 450, 451, 452, 454 · AR: WS72.00-Z-9999CZ
Only in combination with W450 589 00 39 00. SPECIAL TOOLS > SPECIAL TOOLS: SMART: DOORS - WS72.00-Z-9999CZ > MODEL all 000 589 86 63 00 Adapter FG 60/67/72/Set K WS60.00-P- 0085K 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P- 0274K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P- 0027K 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P- 0050B 450 589 00 39 00 Riveter FG 72/Set B WS72.00-P- 0029B 451 589 01 39 00 Nosepiece extended Group 72/Set B WS72.00-P- 0036B 452 589 00 14 00 Assembly sleeve FG 72/Set B WS72.00-P- 0027B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P- 0107K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P- 0012K 452 589 03 23 00 Window adaptation Group 72/set K WS72.00-P- 0034K 454 589 00 59 00 Assembly Group 72/Set C/K WS72.00-P- Fig 1: Identifying Nosepiece Extended (451 589 01 39 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MAINTENANCE > LUBRICATE HINGES AND LOCKS OF DOORS AND FLAPS - AP72.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2833 · Applies to: 450, 451, 452, 454
7223MCC > MODEL 451.3/ 4 Shown on model 451.3 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 Lubricate door hinges (arrows C) on the left and right door (1) using a suitable spray lubricant
2 Lubricate hinges (arrows E) at the top of the rear-end door (2) using a suitable spray lubricant in case of MODEL 451.3
Fig 1: Identifying Door, Rear-End Door Top And Bottom (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
*BA72.10-P-1006-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2851 · Applies to: 450, 451, 452, 454
01H
Figure 3 Remove window (3) upward. Installation: When installing, do not damage 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 INDEX > 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.
(A) into lock cylinder¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2858 · Applies to: 450, 451, 452, 454
(7). 6 Remove retaining spring (9).
7 Pull lock cylinder (7) out of stator (4). Before removing transmitter 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 INDEX > 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.
Shown on left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2859 · Applies to: 450, 451, 452, 454
MODIFICATION NOTES Fig 2: Identifying Front Door Panel Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Front Door Panel Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove cover (1) on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2870 · Applies to: 450, 451, 452, 454
2 Remove cover (1) on left and right door lock (2)
3 Unhook Bowden cable (7) from bracket (8) on left and right door lock (2) As of 31.8.10
4 Unhook hook (11) on left and right Bowden cable (7) from clip (10) As of 31.8.10
5 Disconnect left trunk lid microswitch connector (S15/4x1) or right trunk lid microswitch connector (S15/5x1) As of 31.8.10
6 Unclip left and right electrical line (12) from stay (arrow A) on lower rear-end door (13) As of 31.8.10
7 Open lower rear-end door (13) As of 31.8.10After unclipping left and right Bowden cable (7), actuate left and right release lever (9) to open lower rear-end door (13).
8 Open inner cover (6) on lower rear-end door (13)
9 Unscrew bolt (4) on door check strap on left and right door lock (2) When removing both door locks (2), secure lower rear-end door (13) against folding down.
10
BA72.20-P-1002-02F 11 Unscrew bolts (3) on left and right door lock (2) BA72.20-P-1004-02F 12 Remove left and right door lock (2)
13 Remove threaded plate (5) on left and right door lock (2) from stowage compartment
14 Install in the reverse order
the door paneling on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2876 · Applies to: 450, 451, 452, 454
the rear-end door should be flush with the contour of the CBS rear end.
*BA72.20-P-1001- 02F 3 Unscrew bolt (2) on left or right door check strap (1). The bolt (2) remains on the door check strap (1).
*BA72.20-P-1002- 02F 4 Install in the reverse order
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-1002- 02F Bolt, check strap to lower rear-end door lock Nm 20 20 TESTING & REPAIR INDEX > LOOSEN REAR-END DOOR AND FASTEN. - AR72.20-P- 3500-02MCC > REAR-END DOOR 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
Releasing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2877 · Applies to: 450, 451, 452, 454
- Unclip stop plug from floor covering (2) and fold floor covering (2) over toward front. Do not break or tear floor covering (2) when folding down.
- Remove adhesive tape (9) from rear-end door wiring harness (7) on left in trunk and expose rear- end door wiring harness (7).
- Loosen retaining clip (8) on rear-end door wiring harness (7).
- Press grommet (6) on rear-end door wiring harness (7) out of body.
- Mark position of hinge on rear-end door (1) on body.
- Hold rear-end door (1) and unscrew bolt (4) on left and right check strap on rear-end door (1).
- Unscrew nuts (3) on left and right hinge of rear-end door (1).
- Fold back floor covering (2) and lay down rear-end door (1) with rear-end door wiring harness (7) in trunk. Aid of helper required. Mounting
- Remove rear-end door (1) from trunk and fold floor covering (2) over toward front. Do not break or tear floor covering (2) when folding down. Aid of helper required.
- Position rear-end door (1) and tighten nut (3) on left and right hinge on rear-end door (1) with Fig 1: Identifying Rear-End Door And Fasten Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Checking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2886 · Applies to: 450, 451, 452, 454
1 Check dimensions gaps on rear-end door (4) The rear-end door (4) should be located at the same height as the roof paneling (6) in the marked areas (C arrows); furthermore, the gap dimensions (B arrows) should be the same in relation to the C-pillar outer covers (5) on both sides.
CBS rear end to top rear-end door *BE60.00-P-1006-01V
Outer cover to upper rear-end door *BE60.00-P-1007-01V
Bottom rear-end door to top rear-end door *BE60.00-P-1009-01V
Roof paneling to rear spoiler *BE60.00-P-1010-01V
Figure
Adjust
2 Open rear-end door (4) and loosen bolts (arrows A) as well as bolts (1, 2) at door hinges (3)
Fig 2: Adjusting Rear-End Door (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Close rear-end door¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2887 · Applies to: 450, 451, 452, 454
3 Close rear-end door (4) and check gap dimensions on rear- end door (4); adjust if necessary. The rear-end door (4) should be located at the same height as the roof paneling (6) in the marked areas (C arrows); furthermore, the gap dimensions (B arrows) should be the same in relation to the C-pillar outer covers (5) on both sides.
CBS rear end to top rear-end door *BE60.00-P-1006-01V
Outer cover to upper rear-end door *BE60.00-P-1007-01V
Bottom rear-end door to top rear-end door *BE60.00-P-1009-01V
Roof paneling to rear spoiler *BE60.00-P-1010-01V
Figure 4 Open rear-end door (4) and tighten bolts (arrows A) as well as bolts (1, 2) at door hinges (3) Ensure that the adjusted position of the rear-end door (4) does not change.
*BA72.20-P-1005-02F
*BA72.20-P-1006-02F 5 Close rear-end door (4).
CHECK VALUES FOR GAPS Number Designation Model 451.3 BE60.00-P- 1006-01V Gap dimension CBS rear end to B-pillar Dimension "AA" mm 1 (±1) CBS rear end to taillamp Dimension "AB" mm 1 (±1) CBS rear center part to fender Dimension "AC" mm 3 (±0.5) CBS rear end to bottom rear- end door Dimension "AD" mm 5 (±2) CBS rear end to top rear- end door Dimension "AE" mm 7 (±2.5)
CBS rear end¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2888 · Applies to: 450, 451, 452, 454
to cover Dimension "AF" mm -
See picture AR60.00-P- 0700-01MCC BE60.00-P- 1007-01V Gap dimension Outer cover to CBS rear end Dimension "AG" mm 6 (±2) Outer cover to B-pillar Dimension "AH" mm 4 (±1.5) Outer cover to roof paneling Dimension "AI" mm 5 (±1.5) Outer cover to upper rear- end door Dimension "AJ" mm 5 (±1.5)
See picture¶
BE60.00-P- 1009-01V Gap dimension Bottom rear- end door to top rear-end door Dimension "AO" mm 7 (±2.5)
See picture AR60.00-P- 0700-01MCC BE60.00-P- 1010-01V Gap dimension Roof paneling to rear spoiler Dimension "AP" mm 6 (±2) Roof paneling to windshield Dimension "AQ" mm 5.5 (±3.5) roof paneling (full roof) to side roof frame Dimension "AR" mm 6 (±1.5) roof paneling (panoramic roof) to side roof frame Dimension "AR" mm 5 (±1.5)
See picture AR60.00-P- 0700-01MCC 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
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2892 · Applies to: 450, 451, 452, 454
1 Open door and loosen covering (3) in upper area with assembly wedge. Figure 2 Unclip paneling (1) in upper area with suitable screwdriver (2) and remove until the electrical connectors (4, 6) are accessible.
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
Fig 1: Identifying Front Door Power Window Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Installation: Clip gas-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2896 · Applies to: 450, 451, 452, 454 · AR: AS72.00-Z-9999ZZ
operated strut (1) to ball head on rear-end door upper section (3) using retainer (2) clipped in. 2 Lift retainer (2) using suitable screwdriver and remove left or right gas-operated strut (1) from body (4) Do not remove retainer (2), otherwise pretension on retainer (2) can be lost. Installation: Clip gas- operated strut (1) to ball head on baody (4) using retainer (2) clipped in.
3 Install in the reverse order
SAFETY PRECAUTIONS > SAFETY INFORMATION: DOORS - AS72.00-Z-9999ZZ > MODEL all Injury hazard! When working on folding door or folding door control body parts can be pinched or crushed MODEL 957 Risk of injury caused by performing testing or repair work on door hinges with pyrotechnical actuator MODEL 197.3 RETROFITTING & CONVERSION > RETROFIT OUTER DECORATIVE FOIL - AZ72.10-P- 0003MCC > MODEL 451.3 /4
The bonding positions¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2897 · Applies to: 450, 451, 452, 454
shown are recommended by DaimlerChrysler, however, without obligation. Customer requests are, therefore, to be taken into consideration Bond decorative foil at room temperature and maintain temperature for 24 h. When solar radiation is high, bond decorative foil in shade only.If the decorative foil should be removed after a longer period of time, paint may be discolored
Clean
1 Clean surfaces to be bonded Surfaces must be free of dust, grease and silicon.
Attachment
2 Attach adhesive tape as reference edge to align decorative foil later
Fig 1: Identifying Outer Decorative Foil Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Cut decorative foil to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2898 · Applies to: 450, 451, 452, 454
3 Cut decorative foil to desired size.
4 Remove protective foil from decorative foil
5 Spray detergent on surfaces to be bonded and adhesive side of decorative foil
6 Install decorative foil on vehicle, press out air pockets and water with a plastic squeegee from center toward outside.
7 Cut decorative foil in area of joints and beads and work into contour; heat decorative foil with heat gun. Ensure that the hot air jet is not too hot to damage the decorative foil.
Fig 2 8 Remove upper carrier foil of decorative foil
9 Remove air pockets in decorative foil Punch air pockets at edge with pin and then smooth decorative foil by hand.
TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: DOORS - BA72.00-Z- 9999CZ > MODEL all Front door MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA72.10-P-1000-01H Fig 2: Identifying Hot-Air Gun (450 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Front door¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2899 · Applies to: 450, 451, 452, 454
MODEL 454.0 BA72.10-P-1000-01K Rear door MODEL 452.3 /4 BA72.20-P-1000-02H Rear door MODEL 454.0 BA72.12-P-1000-01G Rear-end door MODEL 451.3 /4 BA72.20-P-1000-02F Rear-end door MODEL 454.0 BA72.20-P-1000-02G Rear-end door MODEL 450.3 /4 BA72.20-P-1000-02E TORQUE SPECIFICATIONS > FRONT DOOR - BA72.10-P-1000-01H > Model 450, 451, 452 FRONT DOOR Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA72.10-P- 1001-01H Screw for hinge on front door Nm 34 35 30 BA72.10-P- 1002-01H Screw for hinge on body Nm 40 40 35 BA72.10-P- 1003-01H Screw for striker eye on pillar Nm 23 32 23 BA72.10-P- 1004-01H Bolt, lock to front door Nm 23 16 8 BA72.10-P- 1005-01H Bolt, quarter window to upper door frame Nm 9,5 10 - BA72.10-P- 1006-01H Bolt, quarter window to lower door frame Nm 23 10 - BA72.10-P- 1007-01H Screw, side window to power window Nm - 10 - TORQUE SPECIFICATIONS > REAR-END DOOR - BA72.20-P-1000-02F > Model 451 MODIFICATION NOTES 11.6.07 Bolt for rear-end upper door hinge on body Model 451.3 TAILGATE
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2900 · Applies to: 450, 451, 452, 454
Designation Model 451.3 Model 451.4 BA72.20-P-1001- 02F Bolt for rear-end door lower check strap on body Nm 32 32 BA72.20-P-1002- 02F Bolt for check strap on bottom rear-end door lock Nm 20 20 BA72.20-P-1003- 02F Nut for rear-end door lower hinge on body Nm 43 43 BA72.20-P-1004- 02F Bolt for outer door lock on bottom of rear-end door Nm 11 11 BA72.20-P-1005- 02F Bolt for rear-end upper door hinge on body Nm 12 - BA72.20-P-1006- 02F Screw for hinge on window Nm 12 - BA72.20-P-1007- 02F Ball head for pneumatic spring on body Nm 12 - BA72.20-P-1008- 02F Gas-operated spring ball head on upper rear-end door Nm 12 - BA72.20-P-1009- 02F Bolt for center door lock on bottom rear-end door Nm 11 - BASIC KNOWLEDGE > POWER WINDOWS (PW), LOCATION OF COMPONENTS - GF72.29-P-0003-01MCU >
Circuit 58d connector sleeve¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2907 · Applies to: 450, 451, 452, 454
Z81 Circuit 58d connector sleeve 7H Fig 1: Power Windows - Wiring Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
S21/2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2910 · Applies to: 450, 451, 452, 454
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 X35/1 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 Z81 Circuit 58d connector sleeve 7H
Fig 1: Power Windows - Wiring Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2911 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM FOR POWER WINDOWS - PE72.29-P-2001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2912 · Applies to: 450, 451, 452, 454
60MCU > MODEL 451 Code: Designation: Position: A1 Instrument cluster 7L M10/3 Left power window motor 17L M10/4 Right power window motor 19L Fig 2: Power Windows - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
N10/10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2913 · Applies to: 450, 451, 452, 454
SAM control unit 3L N10/10f3 Fuse 3 2L N57/2 Power window convenience feature control unit 20A S21/1 Left power window switch 11L S21/2 Right power window switch 21L W43 Ground (outside left fire wall) 20C W9 Ground (at left headlamp unit) 3H X35/1 Left door separation point 10E X35/2 Right door separation point 18E Z6/35 Left door ground connector sleeve 12G Z6/36 Right door ground connector sleeve 20G Z51/6 Circuit 58d connector sleeve 15H Z81 Circuit 58d connector sleeve 7H SPECIAL TOOLS > 450 589 00 39 00 RIVETER - WS72.00-P-0029B > FG 72/Set B MODEL 451, 454 Use: Riveter for riveting blind rivets on power windows NOTE: Electro-mechanical blind riveter tool smart no.: 000 5030 V001 0000 00
SPECIAL TOOLS > 451 589 01 39 00 NOSEPIECE EXTENDED - WS72.00-P-0036B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2914 · Applies to: 450, 451, 452, 454 · AR: WS72.00-Z-9999CZ
Group 72/Set B MODEL 451 Use: Nosepiece extended for installing rivet for power window NOTE: Only in combination with W450 589 00 39 00. SPECIAL TOOLS > SPECIAL TOOLS: SMART: DOORS - WS72.00-Z-9999CZ > MODEL all 000 589 86 63 00 Adapter FG 60/67/72/Set K WS60.00-P-0085K Fig 1: Identifying Riveter (450 589 00 39 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Nosepiece Extended (451 589 01 39 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
110 589 03 59 00 Mounting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2915 · Applies to: 450, 451, 452, 454
wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P-0027K 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 450 589 00 39 00 Riveter FG 72/Set B WS72.00-P-0029B 451 589 01 39 00 Nosepiece extended Group 72/Set B WS72.00-P-0036B 452 589 00 14 00 Assembly sleeve FG 72/Set B WS72.00-P-0027B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P-0012K 452 589 03 23 00 Window adaptation Group 72/set K WS72.00-P-0034K 454 589 00 59 00 Assembly device Group 72/Set C/K WS72.00-P-0028C
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2920 · Applies to: 450, 451, 452, 454
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)
5 Remove driver-side frontal acceleration sensor (B48/1) and passenger-side frontal acceleration sensor (B48/2) When replacing front CMS (1). AR91.60- P- 0750MCU 6 Install in the reverse order
TESTING & REPAIR > PREPARE BODY FOR WELDING IN WHEEL WELL - AR62.20-P- 1200-13MCC > Fig 1: Identifying Front CMS 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. 2921 · Applies to: 450, 451, 452, 454
- Grind connecting flange down to bare metal in cross-hatched area. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > INSTALL AND WELD IN WHEEL WELL - AR62.20-P-1200-17MCC > Shown on model 451.3
- Fit 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 with straightening tool and fix in place with vise grip pliers. Fig 1: Identifying Wheel Well Grinding Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Fitting Wheel Well Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Observe set-up plans.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2922 · Applies to: 450, 451, 452, 454
- Tack weld wheel well (1) (area A).
- Remove 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.
- Wheel well (1) (area A).
- Grind all weld joints down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR > PREPARE WHEEL WELL FOR INSTALLATION - AR62.20-P-1200- 19MCC >
- Grind wheel well (1) down to bar metal on cross-hatched area. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > REMOVE WHEEL WELL - AR62.20-P-1200-21MCC > Shown on model 451.3
- Expose spot welds on wheel well (1) and cut out (area A).
- Remove damaged wheel well (1).
- Remove drilling shavings with wet/dry vacuum cleaner. Fig 1: Identifying Wheel Well Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2924 · Applies to: 450, 451, 452, 454
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 Notes on replacing body parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers
Spot welder¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2925 · Applies to: 450, 451, 452, 454
Weld protection blanket http://gotis.aftersales.mercedes- benz.com 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 front wheel well locking lug
AR63.20-P- 0013MCC 9 Remove longitudinal member locking lug
AR62.20-P- 1267MCC 10 Remove 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
AR62.20-P- 1242MCC 13 Remove wheel well (1)
AR62.20-P-1200- 21MCC 14 Prepare connection points for wheel well (1) on body
AR62.20-P-1200- 13MCC
Zinc dust paint suitable for spot *BR00.45-Z-1001-
welding¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2926 · Applies to: 450, 451, 452, 454
07A 15 Prepare wheel well (1) for installation
AR62.20-P-1200- 19MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
16 Install wheel well (1)
AR62.20-P-1200- 17MCC 17 Install front longitudinal member
AR62.20-P- 1242MCC 18 Partially install longitudinal member inner shell on entrance
AR63.30-P- 1143MCC 19 Install console on bottom front longitudinal member
AR62.20-P- 1265MCC 20 Install longitudinal member locking lug
AR62.20-P- 1267MCC 21 Install front wheel well locking lug
AR63.20-P- 0013MCC 22 Partially install longitudinal member reinforcement
AR63.30-P- 0818MCC 23 Partially install side wall reinforcement
AR63.20-P- 0862MCC 24 Install lower A-pillar reinforcement On model 451.3 AR63.20-P- 1114MCC
On model 451.4 AR63.20-P- 1114MCO 25 Install lower outer A-pillar On model 451.4 AR63.20-P- 1102MCO 26 Partially install side wall paneling On model 451.3 AR63.10-P- 0115MCC
On model 451.4 AR63.10-P- 0115MCO 27 Install front diagonal strut console on longitudinal member On model 451.4 AR61.10-P- 5140MCO 28 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
29 Prime area to be repaired using primer filler
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2928 · Applies to: 450, 451, 452, 454
- Expose spot welds on suspension strut tower (1) and cut out (areas A, B, C and D).
- Remove damaged suspension strut tower (1).
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PREPARE MATING SURFACES ON VEHICLE FOR SUSPENSION STRUT TOWER - AR62.20-P-1232-02MCC > Fig 1: Identifying Suspension Strut Tower Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Suspension Strut Tower Grinding Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2929 · Applies to: 450, 451, 452, 454
- Grind connection flange down to bare metal in cross-hatched area. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > PREPARE SUSPENSION STRUT TOWER FOR INSTALLATION - AR62.20-P-1232-03MCC >
- Grind suspension strut tower (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. TESTING & REPAIR > INSTALL SUSPENSION STRUT TOWER - AR62.20-P-1232-04MCC > Fig 1: Identifying Suspension Strut Tower Grinding Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2931 · Applies to: 450, 451, 452, 454
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 Suspension Strut Tower Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on replacing body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2932 · Applies to: 450, 451, 452, 454
parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Weld protection blanket http://gotis.aftersales.mercedes- benz.com
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
AR63.30-P- 0818MCC
reinforcement¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2933 · Applies to: 450, 451, 452, 454
8 Remove front wheel well locking lug
AR63.20-P- 0013MCC 9 Remove longitudinal member locking lug
AR62.20-P- 1267MCC 10 Remove 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
AR62.20-P- 1242MCC 13 Remove wheel well
AR62.20-P- 1200MCC 14 Remove suspension strut tower (1).
AR62.20-P-1232- 01MCC 15 Prepare mating surfaces on vehicle for suspension strut tower (1).
AR62.20-P-1232- 02MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 16 Prepare suspension strut tower (1) for installation
AR62.20-P-1232- 03MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
17 Install suspension strut tower (1).
AR62.20-P-1232- 04MCC 18 Install wheel well
AR62.20-P- 1200MCC 19 Install front longitudinal member
AR62.20-P- 1242MCC 20 Partially install longitudinal member inner shell on entrance
AR63.30-P- 1143MCC 21 Install console on bottom front longitudinal member
AR62.20-P- 1265MCC 22 Install front longitudinal member locking lug.
AR62.20-P- 1267MCC 23 Install wheel well locking lug
AR63.20-P- 0013MCC
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2935 · Applies to: 450, 451, 452, 454
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 BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > REMOVE/INSTALL FRONT LONGITUDINAL MEMBER - AR62.20-P- 1242MCC > 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
Fig 1: Identifying Front Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of death caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2936 · Applies to: 450, 451, 452, 454
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 Pretreatment of bonding surfaces
AH60.00-P-0008- 01MCC 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 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.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2940 · Applies to: 450, 451, 452, 454
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 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 Bottom Longitudinal Member With Mounting Consoles (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Bottom Longitudinal Member With Mounting Consoles (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
welding. Risk of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2941 · Applies to: 450, 451, 452, 454
poisoning caused by inhaling welding fumes. 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 Notes on replacing body parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cartridge gun Drill (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Expose spot welds on console (1) and cut out (areas A and B)
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2944 · Applies to: 450, 451, 452, 454
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 2: Identifying Mounting Console And Upper Longitudinal Member With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on replacing body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2945 · Applies to: 450, 451, 452, 454
parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cartridge gun Drill (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Expose spot welds on console (1) and cut out (areas A and B)
4 Remove damaged console (1)
5 Grind mating surfaces on upper longitudinal member (2) down to bare metal in shaded areas
6 Drill holes for plug weldings in console (1) (area C)
7 Remove protective paint in welding area of new console (1) and grind connecting flange down to bare metal in shaded areas
Shown on model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2947 · Applies to: 450, 451, 452, 454
- Expose spot welds on longitudinal member locking lug (1) and cut out (areas A, B and C).
- Remove damaged longitudinal member locking lug (1). TESTING & REPAIR > PREPARE CONNECTIONS POINTS FOR LONGITUDINAL MEMBER LOCKING LUG ON BODY. - AR62.20-P-1267-02MCC > Shown on model 451.3
- Sand mating surfaces down to bare metal in the cross-hatched areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Longitudinal Member Locking Lug Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE LONGITUDINAL MEMBER LOCKING LUG FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2948 · Applies to: 450, 451, 452, 454
INSTALLATION - AR62.20-P-1267-03MCC > 1. Separate protrusion (arrows) from brake line bracket (2) and grind welding area down to bare metal. Fig 1: Identifying Longitudinal Member Mating Surface Sanding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Line Bracket Protrusion Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind welding area for brake line bracket (2) down to bare metal on longitudinal member locking lug¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2949 · Applies to: 450, 451, 452, 454
(1). 3. Position brake line bracket (2) on longitudinal member locking lug (1) and (area C). Transfer position from removed part. 4. Drill holes for plug welding on longitudinal member locking lug (1) (areas A and B). 5. Grind longitudinal member locking lug (1) down to bare metal in shaded areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > INSTALL LONGITUDINAL MEMBER LOCKING LUG AND WELD IN. - AR62.20-P-1267-04MCC > Shown on model 451.3 1. Fit longitudinal member locking lug (1) and fasten with vise grip pliers and C-clamps. 2. Longitudinal member locking lug (1) (areas C, D, E, F and G). 3. Longitudinal member locking lug (1) (areas A and B). 4. Grind all weld joints down flat if required. 5. Clean all other weld joints with wire brush Fig 2: Identifying Longitudinal Member Locking Lug And Brake Line Bracket Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2951 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Longitudinal Member End Section And Brake Line Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2952 · Applies to: 450, 451, 452, 454
body
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fire-proof tarp to prevent damage from flying sparks.
3 Remove longitudinal member locking lug (1)
AR62.20- P-1267- 01MCC 4 Prepare connection points on longitudinal member locking lug (1) on body.
AR62.20- P-1267- 02MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A
AR62.20- P-1267- 03MCC
Prepare longitudinal member locking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2953 · Applies to: 450, 451, 452, 454
5 Prepare longitudinal member locking lug (1) for installation Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
6 Install longitudinal member locking lug (1) and weld in
AR62.20- P-1267- 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 GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49-
899268-0Fax +49-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2954 · Applies to: 450, 451, 452, 454
899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > PREPARE CONNECTING POINTS FOR FRONT AXLE CARRIER CONSOLE ON BODY - AR62.20-P-1310-02MCC > Shown on model 451.3 1. Sand mating surfaces down to bare metal in the cross-hatched areas. TESTING & REPAIR > PREPARE FRONT AXLE CARRIER CONSOLE FOR INSTALLATION - AR62.20-P-1310-03MCC > 1. Drill holes for plug welding on front axle carrier console (1) (areas A, B, C, D, E and F). Fig 1: Identifying Front Axle Carrier Console Sanding Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind front axle carrier console (1) down to bare metal in shaded areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2955 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Front Axle Carrier Console Drilling Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Grind front axle carrier console (1) down to bare metal in shaded areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2956 · Applies to: 450, 451, 452, 454
Fig 2: Identifying Front Axle Carrier Console Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Front Axle Carrier Console Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL FRONT AXLE CARRIER CONSOLE AND WELD IN. -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2957 · Applies to: 450, 451, 452, 454
AR62.20-P-1310-04MCC > Shown on model 451.3 1. Fit front axle carrier console (1) with straightening tool and fasten with vise grip pliers and C-clamps. 2. Front axle carrier console (1) (areas A, B, C, D, E, F and G). 3. Grind all weld joints down flat if required. 4. Clean all other weld joints with wire brush TESTING & REPAIR > REPLACE FRONT AXLE CARRIER CONSOLE - AR62.20-P- 1310MCC > MODEL 451.3/4 Shown on model 451.3 Fig 1: Fitting Front Axle Carrier Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2958 · Applies to: 450, 451, 452, 454
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
AH91.00-P-0002- 01SM Fig 1: Identifying Front Axle Carrier Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
welding on vehicles¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2959 · Applies to: 450, 451, 452, 454
with airbags and ETR units Notes on replacing body parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, Ø 6 mm Vise grip pliers Inert gas welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to prevent damage from flying sparks.
3 Remove crossmember reinforcement On model 451.4 AR62.30-P- 1351MCO 4 Set up straightening bench with straightening bracket and attach vehicle Observe set-up plans.Set-up planshttp://gotis.aftersales.mercedes- benz.com
5 Separate front axle carrier console (1)
AR62.20-P-1310- 01MCC 6 Prepare connecting points for front axle
AR62.20-P-1310- 02MCC
carrier console (1) on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2960 · Applies to: 450, 451, 452, 454
body 7 Prepare front axle carrier console (1) for installation
AR62.20-P-1310- 03MCC Install
8 Install front axle carrier console (1) and weld in
AR62.20-P-1310- 04MCC 9 Install crossmember reinforcement On model 451.4 AR62.30-P- 1351MCO 10 Loosen vehicle and remove from straightening bench
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 waxArt. no.: 122.73Q *BR00.45-Z- 1008-05A 17 Reinstall all detachable parts removed
AUXILIARY REPAIR MATERIALS
caused by welding¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2962 · Applies to: 450, 451, 452, 454
spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. 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 Notes on replacing body parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cartridge gun Drill (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to prevent damage from flying sparks.
3 Pry out sheet metal lugs (arrows) on front axle carrier tapping plate (1)
specification 6069.20¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2964 · Applies to: 450, 451, 452, 454
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 > REMOVE WINDSHIELD CROSSMEMBER - AR62.25-P-1120-01MCC
Shown on model 451.3 1. Scribe separation line on windshield crossmember (1) and cut (area A). Completely cut windshield crossmember (1). 2. Remove damaged section (1.2). 3. Scribe separation line on windshield crossmember (1) and cut (area B). Only cut upper area of windshield crossmember (1). 4. Expose spot welds on windshield crossmember (1) and cut out (areas C and D). 5. Remove damaged section (1.1). 6. Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PREPARE CONNECTING POINTS FOR WINDSHIELD CROSSMEMBER ON BODY - AR62.25-P-1120-02MCC > Fig 1: Removing Damaged Windshield 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. 2965 · Applies to: 450, 451, 452, 454
- Grind connecting flange 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. TESTING & REPAIR > PREPARE WINDSHIELD CROSSMEMBER FOR INSTALLATION - AR62.25-P-1120-03MCC >
- Scribe separation line on upper windshield crossmember (1) and cut (area A). Transfer dimension for cut A from vehicle. Fig 1: Identifying Windshield Crossmember Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Windshield Crossmember Cutting And Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Remove section (1.1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2966 · Applies to: 450, 451, 452, 454
- Scribe separation line on lower windshield crossmember (2) and cut (area B). Transfer dimension for cut B from vehicle.
- Remove section (2.1).
- Grind section (1.1) and section (2.1) down to bare metal in cross-hatched areas.
Grind area C down to bare metal from inside. Sand down spot weld flanges to bare metal on both
sides. Coat insides of spot weld flanges with zinc dust paint.
TESTING & REPAIR > INSTALL WINDSHIELD CROSSMEMBER - AR62.25-P-1120-04MCC
Shown on model 451.3
- Fit lower windshield crossmember (1), upper windshield crossmember (2), A-pillar inner section, bottom A-pillar reinforcement, longitudinal member inner shell, suspension strut tower, wheel well locking lug and section of side wall paneling with straightening tool and fix in place using vise grip pliers.
- Tack weld lower windshield crossmember (1) from bottom (area A).
- Remove upper windshield crossmember (2).
- Lower windshield crossmember (1) (area A).
- Grind connecting flange on lower windshield crossmember (1) down flat (areas A 1 and A 2).
- Fit upper windshield crossmember (2) and fix in place using clamping pliers. Fig 1: Fitting Windshield Crossmember Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Upper windshield crossmember (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2967 · Applies to: 450, 451, 452, 454
(areas C and D). 8. Upper windshield crossmember (2) (area B). 9. Grind upper windshield crossmember (2) down flat (area B). 10. Clean all other weld joints with wire brush. 11. Remove A-pillar inner section, bottom A-pillar reinforcement, longitudinal member inner shell, suspension strut tower, wheel well locking lug and section of side wall paneling. TESTING & REPAIR > REMOVE, INSTALL WINDSHIELD CROSSMEMBER - AR62.25-P- 1120MCC > MODEL 451.3/4 Partial replacement 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 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 Upper And Lower Windshield Crossmembers Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
inhaling welding fumes.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2968 · Applies to: 450, 451, 452, 454
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 Notes on replacing body parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Inert gas welder Spot welder Weld protection blanket http://gotis.aftersales.mercedes- benz.com
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 avoid damage from flying sparks.
3 Partially remove side wall On model 451.3 AR63.10-P-
paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2969 · Applies to: 450, 451, 452, 454
0115MCC On model 451.4 AR63.10-P- 0115MCO 4 Remove front wheel well locking lug
AR63.20-P- 0013MCC 5 Partially remove side wall reinforcement
AR63.20-P- 0862MCC 6 Remove A-pillar outer section On model 451.4 AR63.20-P- 1102MCO 7 Remove upper A-pillar outer paneling On model 451.4 AR63.20-P- 1105MCO 8 Remove upper A-pillar reinforcement On model 451.3 AR63.20-P- 1113MCC On model 451.4 AR63.20-P- 1113MCO 9 Remove lower A-pillar reinforcement On model 451.3 AR63.20-P- 1114MCC On model 451.4 AR63.20-P- 1114MCO 10 Remove A-pillar inner section
AR63.20-P- 1104MCC 11 Partially remove side longitudinal member reinforcement
AR63.30-P- 0818MCC 12 Partially remove outer longitudinal member inner shell on entrance
AR63.30-P- 1143MCC 13 Remove suspension strut tower
AR62.20-P- 1232MCC 14 Partially remove windshield crossmember
AR62.25-P-1120- 01MCC 15 Prepare mating surfaces on vehicle for upper windshield crossmember (1) and lower windshield crossmember (2)
AR62.25-P-1120- 02MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 16 Prepare upper windshield crossmember (1) and lower windshield crossmember (2) for installation.
AR62.25-P-1120- 03MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
17 Install upper windshield
AR62.25-P-1120-
crossmember (1) and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2970 · Applies to: 450, 451, 452, 454
lower windshield crossmember (2) 04MCC 18 Install suspension strut tower
AR62.20-P- 1232MCC 19 Partially install longitudinal member inner shell on entrance
AR63.30-P- 1143MCC 20 Partially install side longitudinal member reinforcement
AR63.30-P- 0818MCC 21 Install A-pillar inner section
AR63.20-P- 1104MCC 22 Install lower A-pillar reinforcement in case of model 451.3 AR63.20-P- 1114MCC On model 451.4 AR63.20-P- 1114MCO 23 Install upper A-pillar reinforcement On model 451.3 AR63.20-P- 1113MCC On model 451.4 AR63.20-P- 1113MCO 24 Install upper A-pillar outer paneling On model 451.4 AR63.20-P- 1105MCO 25 Install A-pillar outer section On model 451.4 AR63.20-P- 1102MCO 26 Partially install side wall reinforcement
AR63.20-P- 0862MCC 27 Install front wheel well locking lug
AR63.20-P- 0013MCC 28 Partially install side wall paneling On model 451.3 AR63.10-P- 0115MCC On model 451.4 AR63.10-P- 0115MCO 29 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
30 Prime area to be repaired using primer filler
31 Supply standard seam seals with body sealant
AR97.10-P- 4000MCC Sealant *BR00.45-Z-1003- 01A
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2972 · Applies to: 450, 451, 452, 454
9.7.10 Special tool added Operation step 2 Remove
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 Risk of injury caused by cutting wire tearing or heating up while using it to cut out components that are glued into place. Wear protective gloves and safety glasses. AS65.00-Z-0001-01A Notes on removal/installation of firewall
AH62.25-P-1000- 01MCC 1 Remove detachable parts in the repair area
2 Remove firewall (1) Aid of helper required. AR62.25-P-5753- 01MCC Cutting wireCup suction tool gotis://K_67.0_03.0 Wet and dry vacuum cleaner gotis://P_00.12_06.0 *450589086300 Fig 1: Identifying Firewall Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TS adhesive (with isopropanol¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2973 · Applies to: 450, 451, 452, 454
cleaner) *BR00.45-Z-1041- 02B Install
3 Align firewall (1) in body opening Suction lifting device gotis://K_67.0_03.0 AR62.25-P-5753- 09MCC 4 Prepare firewall (1) for bonding in
AR62.25-P-5753- 06MCC TS adhesive (with isopropanol cleaner) *BR00.45-Z-1041- 02B 5 Prepare body flange for gluing in fire wall (1)
AR62.25-P-5753- 08MCC TS adhesive (with isopropanol cleaner) BR00.45-Z-1041- 02B 6 Apply adhesive material Install firewall (1) on body flange within 2 minutes after applying adhesive material, to prevent adhesion problems of the adhesive material.The curing time is approx. 2 h measured from the time the firewall (1) is installed. The rated accident strength is achieved only after approx. 8 h.Uniformly apply adhesive bead at a height of approx. 12 mm. AR62.25-P-5753- 07MCC Intermediate pieceCartridge heater gotis://K_67.0_02.0 Cartridge gun gotis://K_67.0_02.0 Cup suction tool gotis://K_67.0_03.0 000589866300 TS adhesive (with isopropanol cleaner) BR00.45-Z-1041- 02B 7 Glue in firewall (1) Suction lifting device gotis://K_67.0_03.0 AR62.25-P-5753- 05MCC TS adhesive (with isopropanol cleaner) BR00.45-Z-1041- 02B 8 If required, paint repair area and adjacent surfaces
Notes on paintwork repairs AH98.00-P-9408- 02MCC
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2974 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1041-02B TS adhesive (with isopropanol cleaner) A 451 989 00 71 TESTING & REPAIR > REMOVE SIDE FIREWALL SEGMENT - AR62.25-P-5754-01MCC > Fig 2: Identifying Intermediate Piece (000 589 86 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Cutting Wire (450 589 08 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Side Firewall Segment 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. 2975 · Applies to: 450, 451, 452, 454
- Expose spot welds on firewall segment (1) and cut out (areas A and B).
- Heat connecting flange with hot air blower (area B). Area B is bonded.
- Remove damaged firewall segment (1).
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PREPARE CONNECTION POINTS FOR SIDE FIREWALL SEGMENT ON BODY CONNECTING POINTS - AR62.25-P-5754-02MCC > Shown on model 451.3
- 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, otherwise adhesion of the 2-component adhesive may be adversely affected. 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. TESTING & REPAIR > PREPARE SIDE FIREWALL SEGMENT FOR INSTALLATION - AR62.25-P-5754-03MCC >
- Grind firewall segment (1) down to bare metal in 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Fig 1: Identifying Side Firewall Segment Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE SIDE FIREWALL SEGMENT - AR62.25-P-5754-04MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2976 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Side Firewall Segment Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Fitting Side Firewall Segment Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2978 · Applies to: 450, 451, 452, 454
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 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 Fig 1: Identifying Side Firewall Segment Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2982 · Applies to: 450, 451, 452, 454
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 > SEPARATE FRONT FRAME CROSSMEMBER - AR62.30-P-0001- 01MCC > Shown on model 451.3 1. Expose spot welds on front frame crossmember (1) and cut out (areas A and B). 2. Expose spot welds on front frame crossmember (1) and drill with Ø 6.5 mm bit (areas C and D). Fig 1: Identifying Front Frame Crossmember Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Remove damaged front frame crossmember (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2983 · Applies to: 450, 451, 452, 454
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PREPARE CONNECTING POINTS FOR FRONT FRAME CROSSMEMBER. - AR62.30-P-0001-02MCC > Shown on model 451.3
- Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > PREPARE FRONT FRAME CROSS MEMBER FOR INSTALLATION - AR62.30-P-0001-07MCC >
- Grind mating surfaces on front frame crossmember (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. Fig 1: Identifying Front Frame Crossmember Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > WELD IN FRONT FRAME CROSSMEMBER - AR62.30-P-0001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2984 · Applies to: 450, 451, 452, 454
08MCC > Shown on model 451.3 1. Fit front frame crossmember (1), firewall segment, 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 with straightening tool and fix in place using vise grip pliers. Observe set-up plans. 2. Drill Ø 6.5 mm rivet holes (areas A and B). 3. Remove front frame crossmember (1), firewall segment, 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. Fig 1: Identifying Front Frame Crossmember Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Fitting Front Frame Crossmember Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Deburr rivet holes on front frame crossmember (1) and body on both sides.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2985 · Applies to: 450, 451, 452, 454
- Fit front frame crossmember (1) and fix in place using manual temporary fasteners and vise grip pliers. If required, fit firewall segment, suspension strut tower, wheel well, longitudinal member, longitudinal member striking plate and longitudinal member console.
- Front frame crossmember (1) (areas C and D).
- Rivet front frame crossmember (1) with Polygrip flat round head rivet, 6.4 x 14 (areas A and B).
- Grind all weld joints down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR > POSITION CROSSMEMBER BELOW INSTRUMENT PANEL - AR62.30-P-1250-01MCC > FRONT END ASSEMBLY WITH FRONT REINFORCEMENT Number Designation Model 451.3/4 BA62.30-P-1001- 02B Bolt for crossmember on A-pillars Nm 25 Fig 2: Identifying Front Frame Crossmember Rivet Holes Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Lay crossmember (1) into vehicle, insert assembly wedge (2) into crossmember (1) and close¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2986 · Applies to: 450, 451, 452, 454
doors. The assembly wedge (2) should be in the lowest position 2. Position crossmember (1) in vehicle and secure against falling with one drift (5) each on left and right. Aid of helper required 3. Completely unscrew knurled screw (3) and position push-in device (4) as shown. Fig 1: Identifying Drift (450 589 02 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Installation Tool (452 589 01 23 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Align crossmember (1) in relation to markings on left A-pillar and screw in bolts (6, 7) on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2987 · Applies to: 450, 451, 452, 454
crossmember (1) up to stop Aid of helper required Ensure that bolts (6, 7) do not fall into A-pillar opening. 5. Remove left drift (5) from crossmember (1). Fig 3: Positioning Crossmember Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Crossmember & Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Aid of helper required.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2988 · Applies to: 450, 451, 452, 454
- Align crossmember (1) in relation to markings on right A-pillar. Aid of helper required If it is not possible to align crossmember (1) with drift (5) inserted, remove.
- Align assembly wedge (2) with push-in device (4) by turning knurled screw (3).
- Remove right drift (5) from crossmember (1). Aid of helper required. Fig 5: Aligning Crossmember Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. Screw bolts (8, 9) on crossmember (1) to stop.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2989 · Applies to: 450, 451, 452, 454
Aid of helper required. Ensure that bolts (8, 9) do not fall into A-pillar opening. 10. Tighten bolts (6, 7, 8, 9) with specified tightening torque. Aid of helper required. TESTING & REPAIR > POSITION CROSSMEMBER BELOW INSTRUMENT PANEL - AR62.30-P-1250-01MCF > 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 BA62.30-P-1001- 02B Bolt for crossmember on A-pillars Nm 25 Fig 6: Identifying Crossmember & Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Unscrew bolt (2) and remove vertical strut (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2990 · Applies to: 450, 451, 452, 454
- Tighten vertical strut (1) to crossmember (4) with bolts (3). Fig 1: Identifying Drift (450 589 02 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Installation Tool (452 589 01 23 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Locating Vertical Strut With Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Lay crossmember (4) into vehicle, insert assembly wedge (12) into crossmember (4) and close¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2991 · Applies to: 450, 451, 452, 454
doors. The assembly wedge (12) should be in the lowest position 4. Position crossmember (4) in vehicle and secure against falling down with one drift (5) each on left and right Aid of helper required 5. Completely unscrew knurled screw (13) and position push-in device (14) as shown. Fig 4: Identifying Vertical Strut To Crossmember Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Loosely screw in bolts (6, 7, 8, 9) for crossmember (4).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2992 · Applies to: 450, 451, 452, 454
Aid of helper required Ensure that bolts (6, 7, 8, 9) do not fall into A-pillar opening. 7. Align installation position of crossmember (4) according to specified adjustment dimensions (a to c) in relation to firewall (10) and vehicle floor carrier (11). Dimension a = outer edge of crossmember (area of lower bearing shell) to firewall, dimension b = outer edge of crossmember (area of rear H-profile) to firewall, dimension c = lower edge of Fig 5: Positioning Crossmember Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Crossmember Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
crossmember (area of lower H-profile) to vehicle floor carrier.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2993 · Applies to: 450, 451, 452, 454
Fig 7: Aligning Installation Position Of Crossmember Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Identifying Crossmember Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove bolts (18) and remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2997 · Applies to: 450, 451, 452, 454
18 Remove bolts (18) and remove power window convenience feature control unit (N57/2) When replacing crossmember (1) on vehicles with code (V43) Power window.
19 Remove bolts (19) and remove restraint systems control unit (N2/7) When replacing crossmember (1).
Install
20 Position restraint system control unit (N2/7) on crossmember (1) and tighten bolts (19) according to tightening sequence (a, b, c) If crossmember (1) was replaced.
21 Position power window convenience feature control unit (N57/2) on crossmember (1) and tighten bolts (18) If crossmember (1) was replaced on vehicles with code (V43) Power windows.
22 Install sheet metal nuts on crossmember (1) If crossmember (1) was replaced. Eight sheet metal nuts must be present on the crossmember (1).
23 Position and fasten crossmember (1). If markings for positioning crossmember (1) are present. AR62.30-P-1250- 01MCC BA62.30-P-1001-02B Drift 450589021500 Press-in tool 452589012300 If markings for positioning crossmember (1) are not present. AR62.30-P-1250- 01MCF Outer edge of crossmember (area, lower bearing shell) to firewall BE62.30-P-1001-01A Outer edge of crossmember (area, rear H-profile) to firewall BE62.30-P-1002-01A Lower edge of crossmember (area, lower H-profile) to carrier vehicle floor BE62.30-P-1003-01A
BA62.30-P-1001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2999 · Applies to: 450, 451, 452, 454
02B Bolt for crossmember on A-pillars Nm 25 BA62.30-P-1002- 02B Bolt for vertical strut to crossmember Nm 8 BA62.30-P-1010- 02B Bolt for diagonal strut on crossmember Nm 10 TESTING & REPAIR > REPLACE CROSSMEMBER REINFORCEMENT - AR62.30-P- 1351MCO > MODEL 451.4 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.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3000 · Applies to: 450, 451, 452, 454
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 Crossmember Reinforcement & Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3001 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cartridge gun Drill (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fire-proof tarp to prevent damage from flying sparks.
3 Expose spot welds on crossmember reinforcement (1) and cut out (areas A and B)
4 Remove damaged crossmember reinforcement (1)
5 Grind mating surfaces on longitudinal member and crossmember down to bare metal in shaded areas
6 Drill holes for plug welding on crossmember reinforcement (1) (areas C and D)
7 Grind crossmember reinforcement (1) down to
Shown on model 451.3 with code (I01) Air conditioning Plus¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3003 · Applies to: 450, 451, 452, 454
Shown on model 451.3 with code (I01) Air conditioning Plus Fig 1: Identifying Electrical Connectors, Front Headlamp Units, Clip And Screws Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
As of 31.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3004 · Applies to: 450, 451, 452, 454
Shown on model 451.3 with code (I01) Air conditioning Plus Fig 2: Identifying Front Module Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Locating Front Module, Screw And Washer Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3005 · Applies to: 450, 451, 452, 454
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00-P- 0001-01A 1 Remove front CBS
AR88.00-P- 1010MCC 2 Remove paneling on center piece in front of the windshield
AR88.00-P- 2792MCC 3 Remove wiper arms
AR82.30-P- 6100MCC 4 Disconnect electrical connectors (1, 2) from left front lamp unit (E1) and right front lamp unit (E2)
5 Loosen bolts (3)
6 Remove clip (4) from left and right fender liner.
7 Unscrew left and right bolt (5) at side of front module (6)
8 Unscrew bolt (8)
9 Unclip outside temperature indicator temperature sensor (B14) and lay down to side with line connected.
Fig 4: Identifying Radiator Unit, Bracket, Electrical Connector And Frontal Acceleration Sensors Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unclip retaining clips on front module¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3006 · Applies to: 450, 451, 452, 454
10 Unclip retaining clips on front module (6).
11 Disconnect electrical connector from left front fog lamp and right front fog lamp On vehicles with code (V07) Front fog lamps (FFO)
12 Expose wiring harness on left front fog lamp and right front fog lamp in marked area (arrow C) on front module (6)
13 Separate electrical connectors (13) on the horn (H2) On vehicles with code (V55) Twin-tone horn, a second horn (H2), whose electrical connectors must also be separated, is also installed in the marked area (arrow B).
14 Unscrew bolt (9) from bracket (12) on wiper motor (M6/1)
15 Unscrew bolts (15) and remove washers (16) As of 31.8.10 Observe installation position of washers (16).
16 Disconnect electrical connector (14) from driver-side frontal acceleration sensor (B48/1) and passenger-side frontal acceleration sensor (B48/2) and expose wiring harnesses
17 Unscrew bolts (7) from front module (6).
18 Lift front module (6) in area of wiper linkage (arrows A), remove with aid of helper and insert mounts (10) into radiator unit (11). Aid of helper required. Installation: Ensure that the rubber guides in the area of the wiper linkage (arrows A) and the bracket (12) are positioned correctly.
Fixture *451589013100 19 Install in the reverse order
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3008 · Applies to: 450, 451, 452, 454 · AR: BA62.00-Z-9999CZ
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 front MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA62.30-P-1000-02B 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- Bolt on CMS front Nm 25 25 25
SPECIAL TOOLS > 452 589 01 23 00 PRESS-IN TOOL - WS62.00-P-0136K >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3010 · Applies to: 450, 451, 452, 454
FG 62/Set K MODEL 450, 451, 452 Use: Press-in device for pressing in clamping wedge between A-pillar and CQT (cockpit lateral carrier). NOTE: Tool is preassembled for use on cars with left-hand steering (LHS) when shipped. For use on vehicles with right-hand steering (RHS) reattach the threaded block on the opposite side and turn the guide slide for the clamping wedge.smart no.: 001 5809 V000 0000 00. SPECIAL TOOLS > SPECIAL TOOLS: SMART: FRONT END AND FIRE WALL - WS62.00-Z- Fig 1: Identifying Punch (450 589 02 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Press-In Tool (452 589 01 23 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3011 · Applies to: 450, 451, 452, 454
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 450 589 02 15 00 Punch FG 62/Set B WS62.00-P- 0045B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K 452 589 01 23 00 Press-in tool FG 62/Set K WS62.00-P- 0136K
GENERAL INFORMATION > NOTES ON REMOVAL/INSTALLATION OF FIREWALL -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3012 · Applies to: 450, 451, 452, 454
AH62.25-P-1000-01MCC > Model 450.3/4, 451.3/4, 452.3/4, 454.0 Adhesive kit for isopropanol cleaner Adhesive kit with heptane cleaner Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use individual components as described in table below.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3013 · Applies to: 450, 451, 452, 454
Deviation is not permissible, otherwise adhesive force of bonded connection is not ensured. Allow corresponding primer to flash off for at least 10 minutes, however, for max. 15 minutes. The crank window in the driver door must be opened during the curing time to prevent the component glued in from being pressed out by the air when the doors are closed. Avoid to open and close doors. Designation Note Use Hot application: Short processing time Adhesive material for: Full roof (with code (E23) Full roof (FFO)) Model 450, 451, 454 Glass roof (with code (E22) Glass roof (FFO)) Model 450, 451 Glass roof (with code (E55) Glass Type Fig 2: Identifying Adhesive Kit With Heptane Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Adhesive¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3014 · Applies to: 450, 451, 452, 454
cartridge (4) Durability is achieved after approx. 2 h measured from the time the component is installed. The rated accident strength is achieved only after approx. 8 h. roof with un protection (FFO)) 454 Glass sliding roof module (with code (V29) Electric glass sliding roof (FFO)) Model 450, 454 Windshield All Rear window Model 452, 454 Firewall segment All The adhesive cartridge (4) is heated in cartridge heater.
Plastic primer (5) Apply with wool wiper (13). Primer for: Full roof (with code (E23) Full roof (FFO)) Model 450, 451, 454 Glass roof (with code (E55) Glass roof with sun protection (FFO)) Type 454 Glass sliding roof module (with code (V29) Electric glass sliding roof (FFO)) Model 450, 454 Allow primer to flash off for at least 10 - 15 minutes, otherwise the adhesive force of the bonded joint starts to decrease.
Primer¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3015 · Applies to: 450, 451, 452, 454
stick (6) PC primer Primer for Glass roof (with code (E22) Glass roof (FFO)) Model 450, 451 Windshield All Rear window Model 452, 454 Firewall segment All Body flange All Allow primer to flash off for at least 10 - 15 minutes, otherwise the adhesive force of the bonded joint starts to decrease.
Heptane cleaner 3350 (7) Apply with cloth (9). Cleaner for primer surface: Full roof (with code (E23) Full roof (FFO)) Model 450, 451, 454 Glass roof (with code (E55) Glass roof with sun protection (FFO)) Type 454 Glass sliding roof module (with code (V29) Electric glass sliding roof (FFO)) Model 450, 454 Cleaner for primer surface: Glass roof (with code Model 450,
Cleaning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3016 · Applies to: 450, 451, 452, 454
cloth (8) Cleaning cloth containing isopropanol and cleaning drying cloth (E22) Gla roof (FFO)) 451 Windshield All Rear window Model 452, 454 Firewall segment All Body flange All Cloth (9) Color blue-green For applying: Heptane cleaner 3350 (7) Spacer (10)
Spacer (10) for: Full roof (with code (E23) Full roof (FFO)) Model 450, 451, 454 Glass roof (with code (E22) Glass roof (FFO)) Model 450, 451 Glass roof (with code (E55) Glass roof with sun protection (FFO)) Type 454 Glass sliding roof module (with code (V29) Electric glass sliding roof (FFO)) Type 454 Model
Windshield¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3017 · Applies to: 450, 451, 452, 454
450, 451, 454 Rear window Model 452, 454 Cutting wire (11) Cut out with cutting wire (11) and the two handles included in the window removal kit. To cut out: Full roof (with code (E23) Full roof (FFO)) Model 450, 451, 454 Glass roof (with code (E22) Glass roof (FFO)) Model 450, 451 Glass roof (with code (E55) Glass roof with sun protection (FFO)) Type 454 Glass sliding roof module (with code (V29) Electric glass sliding roof (FFO)) Model 450, 454 Windshield All Rear window Model 452, 454 Firewall segment All Application nozzle (12) Nozzle tips are already cut to size Application of adhesive material in combination with adhesive cartridge (4) Wool wiper (13)
Applying plastic primer (5)
Remove driver¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3020 · Applies to: 450, 451, 452, 454
5 Remove driver ide frontal acceleration en or (B48/1) and passenger-side frontal acceleration sensor (B48/2) When replacing front CMS (1). AR91 60 P- 0750MCU 6 Install in the reverse order
TESTING & REPAIR > PREPARE BODY FOR WELDING IN WHEEL WELL - AR62.20-P- 1200-13MCC > Shown on model 451.3 1. Grind connecting flange down to bare metal in cross-hatched area. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > INSTALL AND WELD IN WHEEL WELL - AR62.20-P-1200-17MCC > Fig 1: Identifying Wheel Well Welding Areas - Shown On Model 451.3 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3021 · Applies to: 450, 451, 452, 454
- Fit 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 with straightening tool and fix in place with vise grip pliers. Observe set-up plans.
- Tack weld wheel well (1) (area A).
- Remove 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.
- Wheel well (1) (area A).
- Grind all weld joints down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR > PREPARE WHEEL WELL FOR INSTALLATION - AR62.20-P-1200- 19MCC >
- Grind wheel well (1) down to bar metal on cross-hatched area. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Wheel Well Welding Areas - Shown On Model 451.3 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE WHEEL WELL - AR62.20-P-1200-21MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3022 · Applies to: 450, 451, 452, 454
Shown on model 451.3 1. Expose spot welds on wheel well (1) and cut out (area A). 2. Remove damaged wheel well (1). 3. Remove drilling shavings with wet/dry vacuum cleaner. Fig 1: Identifying Wheel Well Grinding Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL FRONT LONGITUDINAL MEMBER - AR62.20-P-1242-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3023 · Applies to: 450, 451, 452, 454
03MCC > All following work steps are shown on model 451.3. 1. Fit front longitudinal member (1) and console on front longitudinal member (1) with straightening tool and fasten using vise grip pliers and C-clamps. Observe set-up plans. Fig 1: Identifying Wheel Well Cutting Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Longitudinal Member With Rivet Holes Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill Ø 6.5 mm rivet holes (area A).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3024 · Applies to: 450, 451, 452, 454
- Remove front longitudinal member (1) and longitudinal member console.
- Deburr rivet holes on front longitudinal member (1) and body on both sides.
- Apply 2-component adhesive glue to mating surfaces in 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. Observe manufacturer's specifications for drying and processing time of adhesive.
- Fit front longitudinal member (1) and console on front longitudinal member (1) using straightening tool and fix in place using vise grip pliers, manual temporary fasteners and C-clamps. Fig 2: Identifying Adhesive Application Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Fitting Front Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Rivet front longitudinal member (1) with Polygrip flat round head rivet, 6.4 x 14 (area A).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3025 · Applies to: 450, 451, 452, 454
- Weld in front longitudinal member (1) with (area B). All other connections are completed later.
- Grind all weld joints down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR > REMOVE SUSPENSION STRUT TOWER - AR62.20-P-1232-01MCC > Fig 4: Identifying Front Longitudinal Member With Rivet 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. 3026 · Applies to: 450, 451, 452, 454
- Expose spot welds on suspension strut tower (1) and cut out (areas A, B, C and D).
- Remove damaged suspension strut tower (1).
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PREPARE MATING SURFACES ON VEHICLE FOR SUSPENSION STRUT TOWER - AR62.20-P-1232-02MCC > Fig 1: Identifying Suspension Strut Tower With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Suspension Strut Tower With Grinding 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. 3027 · Applies to: 450, 451, 452, 454
- Grind connection flange down to bare metal in cross-hatched area. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > PREPARE SUSPENSION STRUT TOWER FOR INSTALLATION - AR62.20-P-1232-03MCC >
- Grind suspension strut tower (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. TESTING & REPAIR > INSTALL SUSPENSION STRUT TOWER - AR62.20-P-1232-04MCC > Fig 1: Identifying Suspension Strut Tower With Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3029 · Applies to: 450, 451, 452, 454
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 Notes on replacing body parts
AH60.00- P-0027- 01FF General information on repairs to body
AH60.00- P-0001- 01FF Fig 1: Identifying Suspension Strut Tower Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The following workshop equipment and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3030 · Applies to: 450, 451, 452, 454
tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Weld protection blanket
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 Partially remove longitudinal member AR63.30-
reinforcement¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3031 · Applies to: 450, 451, 452, 454
7 reinforcement
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 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
AR62.20- P- 1242MCC 13 Remove wheel well
AR62.20- P- 1200MCC 14 Remove suspension strut tower (1).
AR62.20- P-1232- 01MCC 15 Prepare mating surfaces on vehicle for suspension strut tower (1).
AR62.20- P-1232- 02MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 16 Prepare suspension strut tower (1) for installation
AR62.20- P-1232- 03MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
17 Install suspension strut tower (1).
AR62.20- P-1232- 04MCC 18 Install wheel well
AR62.20- P- 1200MCC 19 Install front longitudinal member
AR62.20- P- 1242MCC
Partially install longitudinal member inner¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3032 · Applies to: 450, 451, 452, 454
20 Partially install longitudinal member inner shell on entrance
AR63.30- P- 1143MCC 21 Install console on bottom front longitudinal member
AR62.20- P- 1265MCC 22 Install front longitudinal member locking lug.
AR62.20- P- 1267MCC 23 Install wheel well locking lug
AR63.20- P- 0013MCC 24 Partially install longitudinal member reinforcement
AR63.30- P- 0818MCC 25 Partially install side wall reinforcement
AR63.20- P- 0862MCC 26 Install lower A-pillar reinforcement On model 451.3 AR63.20- P- 1114MCC On model 451.4 AR63.20- P- 1114MCO 27 Install lower outer A-pillar On model 451.4 AR63.20- P- 1102MCO 28 Partially install side wall paneling On model 451.3 AR63.10- P- 0115MCC On model 451.4 AR63.10- P- 0115MCO 29 Install front diagonal strut console on longitudinal member On model 451.4 AR61.10- P- 5140MCO 30 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
31 Prime area to be repaired using primer filler
32 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC Sealant *BR00.45- Z-1003- 01A
Supplement standard underbody protection¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3033 · Applies to: 450, 451, 452, 454
33 Supplement standard underbody protection with permanent underbody sealant Underfloor protection *BR00.45- Z-1001- 05A 34 Paint area repaired and adjacent surfaces
Notes on paintwork repairs AH98.00- P-9408- 02MCC 35 Apply additional cavity preservation
AR97.20- P-1500FF Teroson protective wax *BR00.45- Z-1008- 05A 36 Reinstall all detachable parts removed
AUXILIARY 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 GmbH Arabellastrasse 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 > REMOVE FRONT LONGITUDINAL MEMBER - AR62.20-P-1242- 01MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3034 · Applies to: 450, 451, 452, 454
- Expose spot welds on front longitudinal member (1) and cut out (area A). Shown on model 451.3
- Expose spot weld on front longitudinal member (1) and cut out (area B).
- Expose spot welds on front longitudinal member (1) and drill using Ø 6.5 mm bit (area C).
- Heat connecting flange with hot air blower (area C). Area C is bonded.
- Remove damaged front longitudinal member (1). Fig 1: Identifying Front Longitudinal Member With Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front Longitudinal Member With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Remove drilling shavings with wet/dry vacuum cleaner.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3035 · Applies to: 450, 451, 452, 454
TESTING & REPAIR > PREPARE CONNECTING POINTS FOR FRONT LONGITUDINAL MEMBER ON BODY. - AR62.20-P-1242-02MCC > Shown on model 451.3 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, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. TESTING & REPAIR > INSTALL FRONT LONGITUDINAL MEMBER - AR62.20-P-1242- 03MCC > Fig 1: Identifying Front Longitudinal Member With Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
All following work steps are shown on model 451.3.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3036 · Applies to: 450, 451, 452, 454
- Fit front longitudinal member (1) and console on front longitudinal member (1) with straightening tool and fasten using vise grip pliers and C-clamps. Observe set-up plans.
- Drill Ø 6.5 mm rivet holes (area A).
- Remove front longitudinal member (1) and longitudinal member console.
- Deburr rivet holes on front longitudinal member (1) and body on both sides.
- Apply 2-component adhesive glue to mating surfaces in cross-hatched areas. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion Fig 1: Fitting Front Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front Longitudinal Member With Adhesive Glue Application Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
of the 2-component adhesive may be adversely affected.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3037 · Applies to: 450, 451, 452, 454
Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. 6. Fit front longitudinal member (1) and console on front longitudinal member (1) using straightening tool and fix in place using vise grip pliers, manual temporary fasteners and C-clamps. 7. Rivet front longitudinal member (1) with Polygrip flat round head rivet, 6.4 x 14 (area A). 8. Weld in front longitudinal member (1) with (area B). All other connections are completed later. 9. Grind all weld joints down flat if required. 10. Clean all other weld joints with wire brush. Fig 3: Fitting Front Longitudinal Member & Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE FRONT LONGITUDINAL MEMBER FOR INSTALLATION -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3038 · Applies to: 450, 451, 452, 454
AR62.20-P-1242-04MCC > 1. Grind front longitudinal member (1) down to bare metal in 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 pre-treatment of bonding surfaces. TESTING & REPAIR > REMOVE/INSTALL FRONT LONGITUDINAL MEMBER - AR62.20-P- 1242MCC > Fig 4: Identifying Front Longitudinal Member With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Longitudinal Member With Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3039 · Applies to: 450, 451, 452, 454
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 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 Pretreatment of bonding surfaces
AH60.00- P-0008- 01MCC Measures for preventing damage to vehicles or components when performing electric welding work
AH00.00- P-0005- 01FF Fig 1: Identifying Front Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Note on performing repair, body work and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3040 · Applies to: 450, 451, 452, 454
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 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 longitudinal member reinforcement
AR63.30- P- 0818MCC
Remove front wheel well locking lug¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3041 · Applies to: 450, 451, 452, 454
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- 13A 16 Partially install longitudinal member inner shell on entrance
AR63.30- P- 1143MCC
In tall mounting con ole on bottom front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3042 · Applies to: 450, 451, 452, 454
17 In tall mounting con ole 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 Underfloor protection BR00.45- Z-1001-
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3044 · Applies to: 450, 451, 452, 454
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 Button Longitudinal Member With Mounting Consoles - Shown On Model 451.3 (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Button Longitudinal Member With Mounting Consoles - Shown On Model 451.3 (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of injury caused by scraping or¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3045 · Applies to: 450, 451, 452, 454
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 Notes on replacing body parts
AH60.00- P-0027- 01FF General information on repairs to body
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cartridge gun Drill (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Tarp (fire-resistant)
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 Expose spot welds on console (1) and cut out (areas A and B)
4 Remove damaged console (1)
5 Grind mating surfaces on lower longitudinal member (2) down to bare metal in cross- hatched areas.
6 Remove protective paint in welding area of new console (1) and grind connecting
flange down to bare metal in shaded areas¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3046 · Applies to: 450, 451, 452, 454
Install
7 Fit console (1) with front crossmember When fitting observe correct distances.
8 Console (1) (areas C and D)
9 Level spot welds (areas C and D)
10 Clean sheet metal flange with wire brush and clean areas to repaired
11 Prime area to be repaired using primer filler
12 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC Sealant *BR00.45- Z-1003- 01A 13 Paint area repaired and adjacent surfaces
Notes on paintwork repairs AH98.00- P-9408- 02MCC 14 Apply additional cavity preservation
AR97.20- P-1500FF Teroson protective wax *BR00.45- Z-1008- 05A 15 Reinstall all detachable parts removed
AUXILIARY 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 LONGITUDINAL MEMBER LOCKING LUG - AR62.20-P- 1267-01MCC >
Shown on model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3047 · Applies to: 450, 451, 452, 454
- Expose spot welds on longitudinal member locking lug (1) and cut out (areas A, B and C).
- Remove damaged longitudinal member locking lug (1). TESTING & REPAIR > PREPARE CONNECTIONS POINTS FOR LONGITUDINAL MEMBER LOCKING LUG ON BODY. - AR62.20-P-1267-02MCC > Shown on model 451.3
- Sand mating surfaces down to bare metal in the cross-hatched areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Longitudinal Member Locking Lug With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE LONGITUDINAL MEMBER LOCKING LUG FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3048 · Applies to: 450, 451, 452, 454
INSTALLATION - AR62.20-P-1267-03MCC > 1. Separate protrusion (arrows) from brake line bracket (2) and grind welding area down to bare metal. Fig 1: Identifying Longitudinal Member Mating Surface Sanding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Line Bracket Protrusion Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind welding area for brake line bracket (2) down to bare metal on longitudinal member locking lug¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3049 · Applies to: 450, 451, 452, 454
(1). 3. Position brake line bracket (2) on longitudinal member locking lug (1) and (area C). Transfer position from removed part. 4. Drill holes for plug welding on longitudinal member locking lug (1) (areas A and B). 5. Grind longitudinal member locking lug (1) down to bare metal in shaded areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > INSTALL LONGITUDINAL MEMBER LOCKING LUG AND WELD IN. - AR62.20-P-1267-04MCC > Shown on model 451.3 1. Fit longitudinal member locking lug (1) and fasten with vise grip pliers and C-clamps. 2. Longitudinal member locking lug (1) (areas C, D, E, F and G). 3. Longitudinal member locking lug (1) (areas A and B). 4. Grind all weld joints down flat if required. 5. Clean all other weld joints with wire brush Fig 2: Identifying Longitudinal Member Locking Lug And Brake Line Bracket Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3051 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Longitudinal Member End Section And Brake Line Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3052 · Applies to: 450, 451, 452, 454
body
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fire-proof tarp to prevent damage from flying sparks.
3 Remove longitudinal member locking lug (1)
AR62.20- P-1267- 01MCC 4 Prepare connection points on longitudinal member locking lug (1) on body.
AR62.20- P-1267- 02MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A
AR62.20- P-1267- 03MCC
Prepare longitudinal member locking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3053 · Applies to: 450, 451, 452, 454
5 Prepare longitudinal member locking lug (1) for installation Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
6 Install longitudinal member locking lug (1) and weld in
AR62.20- P-1267- 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- Henkel Loctite Deutschland GmbH Arabellastrasse 1781925
Z-1008-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3054 · Applies to: 450, 451, 452, 454
05A Teroson protective waxArt. no.: 122.73Q 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 > REMOVE WINDSHIELD CROSSMEMBER - AR62.25-P-1120-01MCC
Shown on model 451.3 1. Scribe separation line on windshield crossmember (1) and cut (area A). Completely cut windshield crossmember (1). 2. Remove damaged section (1.2). 3. Scribe separation line on windshield crossmember (1) and cut (area B). Only cut upper area of windshield crossmember (1). 4. Expose spot welds on windshield crossmember (1) and cut out (areas C and D). 5. Remove damaged section (1.1). 6. Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PREPARE CONNECTING POINTS FOR WINDSHIELD CROSSMEMBER ON BODY - AR62.25-P-1120-02MCC > Shown on model 451.3 Fig 1: Identifying Windshield Crossmember Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Grind connecting flange down to bare metal in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3055 · Applies to: 450, 451, 452, 454
Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > PREPARE WINDSHIELD CROSSMEMBER FOR INSTALLATION - AR62.25-P-1120-03MCC > 1. Scribe separation line on upper windshield crossmember (1) and cut (area A). Transfer dimension for cut A from vehicle. 2. Remove section (1.1). Fig 1: Identifying Connecting Flange Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Windshield Crossmember Cutting And Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Scribe separation line on lower windshield crossmember (2) and cut (area B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3056 · Applies to: 450, 451, 452, 454
Transfer dimension for cut B from vehicle. 4. Remove section (2.1). 5. Grind section (1.1) and section (2.1) down to bare metal in cross-hatched areas. Grind area C down to bare metal from inside. Sand down spot weld flanges to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > INSTALL WINDSHIELD CROSSMEMBER - AR62.25-P-1120-04MCC
Shown on model 451.3 1. Fit lower windshield crossmember (1), upper windshield crossmember (2), A-pillar inner section, bottom A-pillar reinforcement, longitudinal member inner shell, suspension strut tower, wheel well locking lug and section of side wall paneling with straightening tool and fix in place using vise grip pliers. 2. Tack weld lower windshield crossmember (1) from bottom (area A). 3. Remove upper windshield crossmember (2). 4. Lower windshield crossmember (1) (area A). 5. Grind connecting flange on lower windshield crossmember (1) down flat (areas A 1 and A 2). 6. Fit upper windshield crossmember (2) and fix in place using clamping pliers. 7. Upper windshield crossmember (2) (areas C and D). Fig 1: Identifying Windshield Crossmember Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Upper windshield crossmember (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3057 · Applies to: 450, 451, 452, 454
(area B). 9. Grind upper windshield crossmember (2) down flat (area B). 10. Clean all other weld joints with wire brush. 11. Remove A-pillar inner section, bottom A-pillar reinforcement, longitudinal member inner shell, suspension strut tower, wheel well locking lug and section of side wall paneling. TESTING & REPAIR > REMOVE, INSTALL WINDSHIELD CROSSMEMBER - AR62.25-P- 1120MCC > MODEL 451.3 /4 Partial replacement 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 Upper And Lower Windshield Crossmembers Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measures for preventing damage to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3058 · Applies to: 450, 451, 452, 454
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 Notes on replacing body parts
AH60.00- P-0027- 01FF General information on repairs to body
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Inert gas welder Spot welder Weld protection blanket
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 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
Remove front wheel well locking lug¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3059 · Applies to: 450, 451, 452, 454
4 Remove front wheel well locking lug
AR63.20- P- 0013MCC 5 Partially remove side wall reinforcement
AR63.20- P- 0862MCC 6 Remove A-pillar outer section On model 451.4 AR63.20- P- 1102MCO 7 Remove upper A-pillar outer paneling On model 451.4 AR63.20- P- 1105MCO 8 Remove upper A-pillar reinforcement On model 451.3 AR63.20- P- 1113MCC On model 451.4 AR63.20- P- 1113MCO 9 Remove lower A-pillar reinforcement On model 451.3 AR63.20- P- 1114MCC On model 451.4 AR63.20- P- 1114MCO 10 Remove A-pillar inner section
AR63.20- P- 1104MCC 11 Partially remove side longitudinal member reinforcement
AR63.30- P- 0818MCC 12 Partially remove outer longitudinal member inner shell on entrance
AR63.30- P- 1143MCC 13 Remove suspension strut tower
AR62.20- P- 1232MCC 14 Partially remove windshield crossmember
AR62.25- P-1120- 01MCC 15 Prepare mating surfaces on vehicle for upper windshield crossmember (1) and lower windshield crossmember (2)
AR62.25- P-1120- 02MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A
Prepare upper windshield crossmember (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3060 · Applies to: 450, 451, 452, 454
16 Prepare upper windshield crossmember (1) and lower windshield crossmember (2) for installation.
AR62.25- P-1120- 03MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
17 Install upper windshield crossmember (1) and lower windshield crossmember (2)
AR62.25- P-1120- 04MCC 18 Install suspension strut tower
AR62.20- P- 1232MCC 19 Partially install longitudinal member inner shell on entrance
AR63.30- P- 1143MCC 20 Partially install side longitudinal member reinforcement
AR63.30- P- 0818MCC 21 Install A-pillar inner section
AR63.20- P- 1104MCC 22 Install lower A-pillar reinforcement in case of model 451.3 AR63.20- P- 1114MCC On model 451.4 AR63.20- P- 1114MCO 23 Install upper A-pillar reinforcement On model 451.3 AR63.20- P- 1113MCC On model 451.4 AR63.20- P- 1113MCO 24 Install upper A-pillar outer paneling On model 451.4 AR63.20- P- 1105MCO 25 Install A-pillar outer section On model 451.4 AR63.20- P- 1102MCO 26 Partially install side wall reinforcement
AR63.20- P- 0862MCC 27 Install front wheel well locking lug
AR63.20- P-
0013MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3061 · Applies to: 450, 451, 452, 454
28 Partially install side wall paneling On model 451.3 AR63.10- P- 0115MCC On model 451.4 AR63.10- P- 0115MCO 29 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
30 Prime area to be repaired using primer filler
31 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC Sealant BR00.45- Z-1003- 01A 32 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 33 Paint area repaired and adjacent surfaces
Notes on paintwork repairs AH98.00- P-9408- 02MCC 34 Apply additional cavity preservation
AR97.20- P-1500FF Teroson protective wax *BR00.45- Z-1008- 05A 35 Reinstall all detachable parts removed
AUXILIARY 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 GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49-899268-0Fax +49- 899101978www.Loctite.de BR00.45- Z-1001- Zinc dust paint suitable for spot welding A 000 986 34 42
TESTING & REPAIR > REMOVE FIREWALL - AR62.25-P-5753-01MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3062 · Applies to: 450, 451, 452, 454
07A TESTING & REPAIR > REMOVE FIREWALL - AR62.25-P-5753-01MCC > Shown on model 451.4 1. Heat cutting wire and press through adhesive bead on firewall (1) 2. Cut adhesive bead of firewall (1) using cutting wire. Aid of helper required. 3. Remove firewall (1). TESTING & REPAIR > GLUE IN FIREWALL - AR62.25-P-5753-05MCC > Shown on model 451.4 Fig 1: Identifying Firewall Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Center firewall (1) in body opening and position on body flange to coincide with cover strips¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3063 · Applies to: 450, 451, 452, 454
(arrows). 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. Aid of helper required Ensure that clamps (2) are seated correctly on welding flanges of crossmember. 2. Firmly press on firewall (1) all-round. The curing time is approx. 2 h measured from the time the firewall (1) is installed. The rated accident strength is achieved only after approx. 8 h. 3. Remove clamps (2) after approx. 2 h. TESTING & REPAIR > PREPARE FIREWALL FOR GLUING IN. - AR62.25-P-5753-06MCC > Adhesive kit for isopropanol cleaner Fig 1: Identifying Firewall And Clamps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The bonded area (broken line) on the firewall (1) must be absolutely free of dust and grease, otherwise¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3064 · Applies to: 450, 451, 452, 454
the dirt can decrease the adhesive force of the adhesive material. 1. Clean bonded area (broken line) on firewall (1) with cleaning cloth from repair kit. 2. Coat bonded area (broken line) on firewall (1) with primer with primer stick included in repair kit. Allow primer to flash off for min. 10 - 15 minutes. 3. Install spacer in cross-hatched areas. Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Clips & Bonded Area On Firewall Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use spacers included with firewall (1) only¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3065 · Applies to: 450, 451, 452, 454
- Attach clips (2) at positions shown on firewall (1) Use clips (2) included with firewall (1) TESTING & REPAIR > APPLY ADHESIVE MATERIAL - AR62.25-P-5753-07MCC > Schematic for application of sealant Install firewall (1) on body flange within 2 minutes after applying adhesive material, to prevent adhesion problems of the adhesive material. The curing time is approx. 2 h measured from the time the firewall (1) is installed. The rated accident strength is achieved only after approx. 8 h.
- Guide application nozzle (3) along bonding surface (broken line) on firewall (1) and uniformly apply adhesive material in shape of a bead with a height (b) of approx. 12 mm and a width of approx. 8 mm. Completely press out glue not required immediately following application (disposal). Fig 1: Identifying Firewall & Bonding Surface Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Sealant Application Schematic Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE BODY FLANGE FOR GLUING IN - AR62.25-P-5753-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3066 · Applies to: 450, 451, 452, 454
08MCC > Adhesive kit for isopropanol cleaner Do not apply primer to remaining adhesive on body flange. The gluing area (1) on the body flange must be absolutely free of dust and grease to prevent paint adhesion problems of the adhesive material. Cut back remaining adhesive material on body flange max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts with the ambient air which can lead to adhesion problems. Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Cut off residual adhesive material on body flange down to a height of maximum 2 mm using suitable¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3067 · Applies to: 450, 451, 452, 454
scraper. Remove adhesive material residues. 2. Clean painted adhesive surface on body flange with cleaning cloth included in repair kit. 3. Repair paint damage to body flange with primer stick. 4. Apply primer to body flange using primer stick from repair kit, in areas where residual adhesive material is missing or damaged. Allow primer to flash off for min. 10 - 15 minutes. TESTING & REPAIR > ALIGN FIREWALL IN BODY OPENING - AR62.25-P-5753-09MCC > Shown on model 451.4 Fig 2: Identifying Gluing Area On Body Flange Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3069 · Applies to: 450, 451, 452, 454
9.7.10 Special tool added Operation step 2 Remove
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 Risk of injury caused by cutting wire tearing or heating up while using it to cut out components that are glued into place. Wear protective gloves and safety glasses. AS65.00- Z-0001- 01A Notes on removal/installation of firewall
AH62.25- P-1000- 01MCC 1 Remove detachable parts in the repair area
Aid of helper required. AR62.25- P-5753- Fig 1: Identifying Firewall Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove firewall (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3070 · Applies to: 450, 451, 452, 454
2 Remove firewall (1) 01MCC Cutting wireCup suction toolWet and dry vacuum cleaner Fig 3 TS adhesive (with isopropanol cleaner) *BR00.45- Z-1041- 02B Install
3 Align firewall (1) in body opening Suction lifting device AR62.25- P-5753- 09MCC 4 Prepare firewall (1) for bonding in
AR62.25- P-5753- 06MCC TS adhesive (with isopropanol cleaner) *BR00.45- Z-1041- 02B 5 Prepare body flange for gluing in fire wall (1)
AR62.25- P-5753- 08MCC TS adhesive (with isopropanol cleaner) BR00.45- Z-1041- 02B 6 Apply adhesive material Install firewall (1) on body flange within 2 minutes after applying adhesive material, to prevent adhesion problems of the adhesive material.The curing time is approx. 2 h measured from the time the firewall (1) is installed. The rated accident strength is achieved only after approx. 8 h.Uniformly apply adhesive bead at a height of approx. 12 mm. AR62.25- P-5753- 07MCC Intermediate pieceCartridge heaterCartridge gunCup suction tool Fig 2 TS adhesive (with isopropanol cleaner) BR00.45- Z-1041- 02B 7 Glue in firewall (1) Suction lifting device AR62.25- P-5753- 05MCC TS adhesive (with isopropanol cleaner) *BR00.45- Z-1041- 02B 8 If required, paint repair area and adjacent surfaces
Notes on paintwork repairs AH98.00- P-9408-
02MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3071 · Applies to: 450, 451, 452, 454
REPAIR MATERIALS Number Designation Order number BR00.45-Z-1041-02B TS adhesive (with isopropanol cleaner) A 451 989 00 71 TESTING & REPAIR > REMOVE SIDE FIREWALL SEGMENT - AR62.25-P-5754-01MCC > Fig 2: Identifying Intermediate Piece (000 589 86 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Cutting Wire (450 589 08 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Side Firewall Segment With 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. 3072 · Applies to: 450, 451, 452, 454
- Expose spot welds on firewall segment (1) and cut out (areas A and B).
- Heat connecting flange with hot air blower (area B). Area B is bonded.
- Remove damaged firewall segment (1).
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PREPARE CONNECTION POINTS FOR SIDE FIREWALL SEGMENT ON BODY CONNECTING POINTS - AR62.25-P-5754-02MCC > Shown on model 451.3
- 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, otherwise adhesion of the 2-component adhesive may be adversely affected. 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. TESTING & REPAIR > PREPARE SIDE FIREWALL SEGMENT FOR INSTALLATION - AR62.25-P-5754-03MCC >
- Grind firewall segment (1) down to bare metal in 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Fig 1: Identifying Side Firewall Segment Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE SIDE FIREWALL SEGMENT - AR62.25-P-5754-04MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3073 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Firewall Segment Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Side Firewall Segment With Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3075 · Applies to: 450, 451, 452, 454
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 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 Pretreatment of bonding surfaces
AH60.00- P-0008- 01MCC Fig 1: Identifying Firewall Segment Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on riveting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3076 · Applies to: 450, 451, 452, 454
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
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
Remove longitudinal member locking lug¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3077 · Applies to: 450, 451, 452, 454
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
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 BR00.45-
Rivet¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3078 · Applies to: 450, 451, 452, 454
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 bottom front longitudinal member
AR62.20- P- 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 Install front diagonal strut console on AR61.10-
longitudinal member¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3079 · Applies to: 450, 451, 452, 454
31 longitudinal member On model 451.4 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
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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3080 · Applies to: 450, 451, 452, 454
13A Blind rivet 6.4x14 A 003 990 35 97 TESTING & REPAIR > SEPARATE FRONT FRAME CROSSMEMBER - AR62.30-P-0001- 01MCC > Shown on model 451.3 1. Expose spot welds on front frame crossmember (1) and cut out (areas A and B). 2. Expose spot welds on front frame crossmember (1) and drill with Ø 6.5 mm bit (areas C and D). 3. Remove damaged front frame crossmember (1). 4. Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PREPARE CONNECTING POINTS FOR FRONT FRAME CROSSMEMBER. - AR62.30-P-0001-02MCC > Shown on model 451.3 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Front Frame Crossmember With Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE FRONT FRAME CROSS MEMBER FOR INSTALLATION -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3081 · Applies to: 450, 451, 452, 454
AR62.30-P-0001-07MCC > 1. Grind mating surfaces on front frame crossmember (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. TESTING & REPAIR > WELD IN FRONT FRAME CROSSMEMBER - AR62.30-P-0001- 08MCC > Fig 1: Identifying Front Frame Crossmember Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Frame Crossmember Grinding 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. 3082 · Applies to: 450, 451, 452, 454
- Fit front frame crossmember (1), firewall segment, 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 with straightening tool and fix in place using vise grip pliers. Observe set-up plans.
- Drill Ø 6.5 mm rivet holes (areas A and B).
- Remove front frame crossmember (1), firewall segment, 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.
- Deburr rivet holes on front frame crossmember (1) and body on both sides. Fig 1: Identifying Front Frame Crossmember Rivet Holes Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front Frame Crossmember With Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Fit front frame crossmember (1) and fix in place using manual temporary fasteners and vise grip¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3083 · Applies to: 450, 451, 452, 454
pliers. If required, fit firewall segment, suspension strut tower, wheel well, longitudinal member, longitudinal member striking plate and longitudinal member console. 6. Front frame crossmember (1) (areas C and D). 7. Rivet front frame crossmember (1) with Polygrip flat round head rivet, 6.4 x 14 (areas A and B). 8. Grind all weld joints down flat if required. 9. Clean all other weld joints with wire brush. TESTING & REPAIR > REMOVE/INSTALL FRONT FRAME CROSS MEMBER - AR62.30-P- 0001MCC > 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 Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly AS00.00- Z-0007- Fig 1: Identifying Front Cross Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
caused by welding spatter and UV light while¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3084 · Applies to: 450, 451, 452, 454
welding. Risk of poisoning caused by inhaling welding fumes. inflammable materials from the hazard area. Use air extractor system. 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 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
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 On model 451.3 AR63.20- P-
Remove lower A-pillar reinforcement¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3085 · Applies to: 450, 451, 452, 454
5 Remove lower A-pillar reinforcement 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 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
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
AR62.25- P- 5754MCC 16 Remove front frame crossmember (1)
AR62.30- P-0001- 01MCC 17 Prepare mating surfaces on vehicle for front frame crossmember (1)
AR62.30- P-0001- 02MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A
AR62.30- P-0001-
Prepare front frame cross member (1) for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3086 · Applies to: 450, 451, 452, 454
18 Prepare front frame cross member (1) for installation 07MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
19 Install front frame crossmember (1)
AR62.30- P-0001- 08MCC Rivet *BR00.45- Z-1001- 13A 20 Install firewall segment
AR62.25- P- 5754MCC 21 Install suspension strut tower
AR62.20- P- 1232MCC 22 Install wheel well
AR62.20- P- 1200MCC 23 Install front longitudinal member
AR62.20- P- 1242MCC 24 Partially install longitudinal member inner shell on entrance
AR63.30- P- 1143MCC 25 Install mounting console on bottom front longitudinal member
AR62.20- P- 1265MCC 26 Install longitudinal member locking lug
AR62.20- P- 1267MCC 27 Install front wheel well locking lug
AR63.20- P- 0013MCC 28 Partially install side longitudinal member reinforcement
AR63.30- P- 0818MCC 29 Partially install side wall reinforcement
AR63.20- P- 0862MCC 30 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. 3087 · Applies to: 450, 451, 452, 454
AR63.20- P- 1114MCO 31 Install lower outer A-pillar On model 451.4 AR63.20- P- 1102MCO 32 Partially install side wall paneling On model 451.3 AR63.10- P- 0115MCC On model 451.4 AR63.10- P- 0115MCO 33 Install front diagonal strut console on longitudinal member On model 451.4 AR61.10- P- 5140MCO 34 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
35 Prime area to be repaired using primer filler
36 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC Sealant BR00.45- Z-1003- 01A 37 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 38 Paint area repaired and adjacent surfaces
Notes on paintwork repairs AH98.00- P-9408- 02MCC 39 Apply additional cavity preservation
AR97.20- P-1500FF Teroson protective wax *BR00.45- Z-1008- 05A 40 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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3088 · Applies to: 450, 451, 452, 454
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 > POSITION CROSSMEMBER BELOW INSTRUMENT PANEL - AR62.30-P-1250-01MCC > FRONT END ASSEMBLY WITH FRONT REINFORCEMENT Number Designation Model 451.3/4 BA62.30-P-1001-02B Bolt for crossmember on A-pillars Nm 25 1. Lay crossmember (1) into vehicle, insert assembly wedge (2) into crossmember (1) and close Fig 1: Identifying Drift (450 589 02 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Installation Tool (452 589 01 23 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
doors.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3089 · Applies to: 450, 451, 452, 454
The assembly wedge (2) should be in the lowest position 2. Position crossmember (1) in vehicle and secure against falling with one drift (5) each on left and right. Aid of helper required 3. Completely unscrew knurled screw (3) and position push-in device (4) as shown. 4. Align crossmember (1) in relation to markings on left A-pillar and screw in bolts (6, 7) on crossmember (1) up to stop Aid of helper required Ensure that bolts (6, 7) do not fall into A-pillar opening. Fig 3: Positioning Crossmember Below Instrument Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove left drift (5) from crossmember (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3090 · Applies to: 450, 451, 452, 454
- Remove left drift (5) from crossmember (1). Aid of helper required.
- Align crossmember (1) in relation to markings on right A-pillar. Aid of helper required If it is not possible to align crossmember (1) with drift (5) inserted, remove. Fig 4: Identifying Crossmember With Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Aligning Crossmember In Relation To Markings On Right A-Pillar Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Align assembly wedge (2) with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3091 · Applies to: 450, 451, 452, 454
push-in device (4) by turning knurled screw (3). 8. Remove right drift (5) from crossmember (1). Aid of helper required. 9. Screw bolts (8, 9) on crossmember (1) to stop. Aid of helper required. Ensure that bolts (8, 9) do not fall into A-pillar opening. 10. Tighten bolts (6, 7, 8, 9) with specified tightening torque. Aid of helper required. TESTING & REPAIR > POSITION CROSSMEMBER BELOW INSTRUMENT PANEL - AR62.30-P-1250-01MCF > 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 BA62.30-P-1001-02B Bolt for crossmember on A-pillars Nm 25 Fig 6: Identifying Crossmember With Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Unscrew bolt (2) and remove vertical strut (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3092 · Applies to: 450, 451, 452, 454
- Tighten vertical strut (1) to crossmember (4) with bolts (3). Fig 1: Identifying Drift (450 589 02 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Installation Tool (452 589 01 23 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Vertical Strut With Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Lay crossmember (4) into vehicle, insert assembly wedge (12) into crossmember (4) and close¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3093 · Applies to: 450, 451, 452, 454
doors. The assembly wedge (12) should be in the lowest position 4. Position crossmember (4) in vehicle and secure against falling down with one drift (5) each on left and right Aid of helper required 5. Completely unscrew knurled screw (13) and position push-in device (14) as shown. Fig 4: Identifying Vertical Strut To Crossmember & Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Loosely screw in bolts (6, 7, 8, 9) for crossmember (4).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3094 · Applies to: 450, 451, 452, 454
Aid of helper required Ensure that bolts (6, 7, 8, 9) do not fall into A-pillar opening. 7. Align installation position of crossmember (4) according to specified adjustment dimensions (a to c) in relation to firewall (10) and vehicle floor carrier (11). Dimension a = outer edge of crossmember (area of lower bearing shell) to firewall, dimension b = outer edge of crossmember (area of rear H-profile) to firewall, dimension c = lower edge of Fig 5: Positioning Push-In Device On Crossmember Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Crossmember Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
crossmember (area of lower H-profile) to vehicle floor carrier.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3095 · Applies to: 450, 451, 452, 454
Fig 7: Aligning Installation Position Of Crossmember Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Identifying Crossmember Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3097 · Applies to: 450, 451, 452, 454
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 Fig 2: Identifying Crossmember Components Under Instrument Panel (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Crossmember, Restraint Systems Control Unit & Mounting Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove bottom section of dashboard on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3098 · Applies to: 450, 451, 452, 454
2 Remove bottom section of dashboard on driver's side On vehicles as of 31.8.10. AR68.10- P- 1501MCC 3 Loosen steering column tube from crossmember (1), tie upward with cable tie and cover with rag.
AR46.10- P- 0400MCU 4 Mark installation position of crossmember (1) on both A-pillars with suitable pen. Only if markings are not removed during further repair, such as repair on A-pillar.
5 Remove front CBS
AR88.00- P- 1010MCC 6 Unscrew nuts (2) from brackets (3) and remove bracket (3).
7 Remove protective foils above bolts (4, 5, 6, 7)
8 Disconnect electrical connectors (8) from power window convenience feature control unit (N57/2) On vehicles with code (V43) Power window
9 Disconnect electrical connectors (14) from restraint systems control unit (N2/7)
10 Loosen wiring harness on crossmember (1) and expose. Observe installation position of wiring harness on crossmember (1).
11 Unscrew bolts (13) on vertical strut (12) from crossmember (1).
12 Unscrew bolts (16) on diagonal strut (15) from crossmember (1).
13 Close doors
14 Unscrew bolts (6, 7) Ensure that bolts (6, 7) do not fall into A-pillar opening.
15 Unscrew bolts (4, 5) Ensure that bolts (4, 5) do not fall into A-pillar opening.
16 Open doors, slide assembly wedge (10) downward and remove crossmember (1) from vehicle with aid of helper.
17 Remove sheet metal nuts from crossmember (1). When replacing crossmember (1). Eight sheet metal nuts are on the crossmember (1).
18 Remove bolts (18) and remove power window convenience feature control unit (N57/2) When replacing crossmember (1) on vehicles with code (V43) Power window.
19 Remove bolts (19) and remove restraint systems control unit (N2/7) When replacing crossmember (1).
Install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3099 · Applies to: 450, 451, 452, 454
20 Position restraint system control unit (N2/7) on crossmember (1) and tighten bolts (19) according to tightening sequence (a, b, c) If crossmember (1) was replaced.
21 Position power window convenience feature control unit (N57/2) on crossmember (1) and tighten bolts (18) If crossmember (1) was replaced on vehicles with code (V43) Power windows.
22 Install sheet metal nuts on crossmember (1) If crossmember (1) was replaced. Eight sheet metal nuts must be present on the crossmember (1).
23 Position and fasten crossmember (1). If markings for positioning crossmember (1) are present. AR62.30- P-1250- 01MCC BA62.30- P-1001- 02B Drift Figure Press-in tool Figure If markings for positioning crossmember (1) are not present. AR62.30- P-1250- 01MCF Outer edge of crossmember (area, lower bearing shell) to firewall BE62.30- P-1001- 01A Outer edge of crossmember (area, rear H-profile) to firewall BE62.30- P-1002- 01A Lower edge of crossmember (area, lower H-profile) to carrier vehicle floor BE62.30- P-1003- 01A *BA62.30- P-1001- 02B Drift Figure Press-in tool Figure 24 Loosen knurled screw (9) and remove push-in device (11) Press-in tool Figure 25 Open door
26 Tighten bolts (16) on diagonal strut (15) on crossmember (1). *BA62.30- P-1010- 02B
Tighten bolts (13) on vertical strut (12) on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3100 · Applies to: 450, 451, 452, 454
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 BA62.30-P-1001-02B Bolt for crossmember on A-pillars Nm 25 BA62.30-P-1002-02B Bolt for vertical strut to crossmember Nm 8 BA62.30-P-1010-02B Bolt for diagonal strut on crossmember Nm 10
Shown on model 451.3 with code (I01) Air conditioning Plus¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3102 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Electrical Connectors, Left And Right Front Headlamp Units, Clip And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
As of 31.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3103 · Applies to: 450, 451, 452, 454
Shown on model 451.3 with code (I01) Air conditioning Plus Fig 2: Identifying Front Module Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Front Module, Screw And Washer Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3104 · Applies to: 450, 451, 452, 454
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Remove front CBS
AR88.00- P- 1010MCC 2 Remove paneling on center piece in front of the windshield
AR88.00- P- 2792MCC 3 Remove wiper arms
AR82.30- P- 6100MCC 4 Disconnect electrical connectors (1, 2) from left front lamp unit (E1) and right front lamp unit (E2)
5 Loosen bolts (3)
6 Remove clip (4) from left and right fender liner.
7 Unscrew left and right bolt (5) at side of front module (6)
8 Unscrew bolt (8)
Fig 4: Identifying Radiator Unit, Bracket, Electrical Connector And Driver-Side Frontal Acceleration Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unclip outside temperature indicator¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3105 · Applies to: 450, 451, 452, 454
9 Unclip outside temperature indicator temperature sensor (B14) and lay down to side with line connected.
10 Unclip retaining clips on front module (6).
11 Disconnect electrical connector from left front fog lamp and right front fog lamp On vehicles with code (V07) Front fog lamps (FFO)
12 Expose wiring harness on left front fog lamp and right front fog lamp in marked area (arrow C) on front module (6)
13 Separate electrical connectors (13) on the horn (H2) On vehicles with code (V55) Twin- tone horn, a second horn (H2), whose electrical connectors must also be separated, is also installed in the marked area (arrow B).
14 Unscrew bolt (9) from bracket (12) on wiper motor (M6/1)
15 Unscrew bolts (15) and remove washers (16) As of 31.8.10 Observe installation position of washers (16).
16 Disconnect electrical connector (14) from driver-side frontal acceleration sensor (B48/1) and passenger-side frontal acceleration sensor (B48/2) and expose wiring harnesses
17 Unscrew bolts (7) from front module (6).
18 Lift front module (6) in area of wiper linkage (arrows A), remove with aid of helper and insert mounts (10) into radiator unit (11). Aid of helper required. Installation: Ensure that the rubber guides in the area of the wiper linkage (arrows A) and the bracket (12) are positioned correctly.
Fixture Fig 5 19 Install in the reverse order
Fig 5: Identifying Support (451 589 01 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TEST & ADJUSTMENT VALUES > CROSSMEMBER - BE62.30-P-1000-01A >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3108 · Applies to: 450, 451, 452, 454
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. SPECIAL TOOLS > 452 589 01 23 00 PRESS-IN TOOL - WS62.00-P-0136K > FG 62/Set K MODEL 450, 451, 452 Use: Fig 1: Identifying Punch (450 589 02 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Press-in device for pressing in clamping wedge between A-pillar and CQT (cockpit lateral carrier).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3109 · Applies to: 450, 451, 452, 454
NOTE: Tool is preassembled for use on cars with left-hand steering (LHS) when shipped. For use on vehicles with right-hand steering (RHS) reattach the threaded block on the opposite side and turn the guide slide for the clamping wedge.smart no.: 001 5809 V000 0000 00. SPECIAL TOOLS > SPECIAL TOOLS: SMART: FRONT END AND FIRE WALL - WS62.00-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 450 589 02 15 00 Punch FG 62/Set B WS62.00-P-0045B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K 452 589 01 23 00 Press-in tool FG 62/Set K WS62.00-P-0136K Fig 1: Identifying Press-In Tool (452 589 01 23 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > INSTALL BRABUS SHIFT LEVER KNOB - AN68.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3110 · Applies to: 450, 451, 452, 454
0004MCC > MODEL 451.3/4 with CODE (V11) Softouch - automatic shift program (FFO) Removing
1 Pull shift lever knob upward Do not press button (3), otherwise shift lever knob can be damaged. Install
2 Install BRABUS shift lever knob (2) Do not press button (3), otherwise BRABUS shift lever knob (2) can be damaged. 3 Glue on circuit diagram adhesive label (1) as shown. The selector lever cover should be free of dust and grease in area of circuit diagram adhesive label (1). TESTING & REPAIR > REMOVE/INSTALL VERTICAL STRUT PANELING - AR68.00-P- 1500MCC > MODEL 451.3/4 Fig 1: Identifying BRABUS Shift Lever Knob Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3111 · Applies to: 450, 451, 452, 454
1 Insert pliers (2) into interior socket (X58/1) and turn until pliers (2) arrest Pliers 169589003700 2 Carefully pull out metal insert in interior socket (X58/1) approx. 1.5 cm using pliers (2) Pliers 169589003700 3 Remove bolts (4)
4 Pivot vertical strut paneling (1) toward rear in lower area and remove until electrical connector (5) of interior socket (X58/1) as well as electrical connector (6) of data link connector (X11/4) are accessible
5 Disconnect electrical connector (5) on interior socket (X58/1) and electrical connector (6) on data link connector (X11/4)
6 Disconnect electrical Vehicles as of 31.8.10 with
Fig 1: Identifying Vertical Strut Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL DASHBOARD TOP SECTION - AR68.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3116 · Applies to: 450, 451, 452, 454
1020MCU > MODEL 451.3/4 Fig 1: Identifying Instrument Panel Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying Dashboard Top Section Components (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3117 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Dashboard Top Section Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3118 · Applies to: 450, 451, 452, 454
Remove/install
Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Legal Fig 3: Identifying Firewall Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
requirement on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3119 · Applies to: 450, 451, 452, 454
handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Remove paneling on passenger side
AR68.10- P- 1502MCU 3 Remove instrument cluster
AR54.30- P- 6015MCU 4 Remove bolt (13) in area of instrument panel opening.
5 Detach bracket (17) on wiring harness
6 Remove left side paneling (4) from dashboard
AR68.10- P- 1503MCU 7 Remove left side air vent (3). up to 30.8.10 AR68.10- P- 1100MCC 8.1 Remove bolt (5) behind left side air vent (3). up to 30.8.10
8.2 Unscrew bolt (5.1) at side of instrument panel upper section (1) As of 31.8.10
9.1 Remove additional instrument Up to 30.8.10 with code (V31) Cockpit and tachometer package AR54.30- P- 6080MCC 9.2 Separate additional instruments connector (A15x1) As of 31.8.10 with code (V31) Cockpit and tachometer package
10 Remove center Up to 30.8.10 AR68.10- P- 1150MCU
air vent¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3120 · Applies to: 450, 451, 452, 454
As of 31.8.10 AR68 10 P- 1150MCF 11 Remove tweeter and lay down to side with electrical lines connected Up to 30.8.10 with code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO) or with code (C54) Sound system 2 AR82.62- P- 1000MCC 12 Disconnect electrical connector (green) (8) and electrical connector (yellow) (6) on front passenger airbag unit (10)
13 Remove screws (9) from passenger airbag (10) *BA91.60- P-1001- 01C 14 Remove bolt (7) from dashboard top section (1).
15 Remove expansion clips (2) from dashboard top section (1) in area of instrument cluster.
16 Lift dashboard top section (1) with aid of helper, guide toward rear and remove from vehicle. Installation: Glue adhesive foil (15) to brackets (16) on firewall (14).Remove retaining clips (12) from instrument panel upper section (1) and insert brackets (16) into firewall (14). Ensure that retaining clips (12) are seated correctly in brackets (16).The instrument panel upper section (1) should arrest correctly in the retaining clamps (12) on the firewall (14) when installing.
17 Unscrew nuts (11) from front passenger airbag (10) and remove front passenger airbag (10) downward. When replacing dashboard top section (1). Open only specified bolted connections. The front passenger airbag unit (10) may not be disassembled, otherwise it must be replaced. Installation: Observe tightening sequence (A to D) of nuts (11).
*BA91.60- P-1004- 01C Remove all sheet
metal nuts and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3121 · Applies to: 450, 451, 452, 454
18 metal nuts and retaining clamps from dashboard top section (1) When replacing dashboard top section (1).
19 Remove additional instrument As of 31.8.10 with code (V31) Cockpit and tachometer package when replacing instrument panel upper section (1). AR54.30- P- 6080MCF 20 Remove right side air vent (3). When replacing dashboard top section (1). AR68.10- P- 1100MCC 21 Remove left side air vent (3). As of 31.8.10 when replacing instrument panel upper section (1). AR68.10- P- 1100MCC 22 Unclip GPS antenna from instrument upper section (1) As of 31.8.10 with code (527) Radio High-Line when replacing instrument panel upper section (1).
23 Install in the reverse order
AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1001- 01C Bolt of front passenger airbag unit to dashboard mounting Nm 10 10 BA91.60-P-1004- 01C Nut, front passenger airbag unit to dashboard Nm 2 2 TESTING & REPAIR > REMOVE/INSTALL LOWER SECTION OF DASHBOARD - AR68.10- P-1040MCU > MODEL 451.3/4
With code (294) Kneebag¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3122 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Dashboard 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. 3123 · Applies to: 450, 451, 452, 454
Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR
AH91.00- P-0002- 01SM Fig 2: Identifying Dashboard Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Dashboard Lower Section, Driver-Side Paneling And Passenger Side Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
units¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3124 · Applies to: 450, 451, 452, 454
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1 Remove vertical strut paneling
AR68.00- P- 1500MCC 2 Remove cockpit switch group
AR54.25- P- 1000MCC 3 Remove paneling at side of dashboard
AR68.10- P- 1503MCU 4 Unscrew left and right bolts (4) below instrument panel lower section (1)
5 Unscrew nuts (8) on power window control unit convenience feature (N57/2) With code (294) Kneebag
6 Remove power window control unit convenience feature (N57/2) and lay down to side with electrical lines connected With code (294) Kneebag
7 Unscrew bolts (9) from bracket (10) With code (294) Kneebag
*BA91.60- P-1012- 01C 8 Unscrew bolts (12) from bracket (11) With code (294) Kneebag
*BA91.60- P-1012- 01C 9 Unscrew bolts (2) in center of instrument panel lower section (1)
10 Unscrew left and right bolt (5) from instrument panel lower section (1)
11 Pivot instrument panel lower section (1) out in lower area (arrow A) Do not pivot instrument panel lower section (1) too far out to prevent damage.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3126 · Applies to: 450, 451, 452, 454
1 Remove center mounting console reinforcement
AR68.20- P- 2340MCC 2 Turn air distribution control lever (8) to footwell ventilation position
3 Move adjustment lever (7) for temperature and fan stage to uppermost position
Fig 1: Identifying Center Air Nozzle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Eye And Relay Lever Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3128 · Applies to: 450, 451, 452, 454
1.1 Remove air conditioning pushbutton control unit On vehicles with code (I01) Air conditioning Plus AR83.25- P- 1124MCC 1.2 Remove heater/ventilation operating unit On vehicles without code (I01) Air conditioning Plus AR83.20- P- 1850MCC 2 Remove bolts (2)
3 Expose electric wiring harnesses (3) in area of center air vent (1) and remove center air vent (1) Observe installation position of electric wiring harnesses (3).
4 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL GLOVE COMPARTMENT LID - AR68.10-P- 1200MCC > MODEL 451.3/4 with CODE (I63) Glove compartment Fig 1: Identifying Center Air Nozzle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3131 · Applies to: 450, 451, 452, 454
1 Remove top part of dashboard
AR68.10- P- 1020MCU 2 Remove steering wheel
AR46.10- P- 0100MCC 3 Remove wiper switch
AR54.25- P- 0003MCC 4 Remove combination switch
AR54.25- P- 2800MCC 5 Unclip left knee guard (6) (arrow A), loosen from guides (arrows B) and remove. On vehicles without code (294) Kneebag
6 Loosen retaining clip (2) from driver-side paneling (1)
7 Expose fanfare horns and airbag clock spring contact wiring
Fig 1: Identifying Driver Side Dashboard Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown up to 30.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3133 · Applies to: 450, 451, 452, 454
Remove/install
1.1 Remove radio On vehicles with code (C50) smart radio 10 orwith code (C57) smart radio 9 or with code (516) RADIO WITH USBINTERFACE or with code (527) Radio High-Line AR82.60- P- 7502MCU On vehicles without code (C50) smart AR68.10- Fig 2: Identifying Passenger Side Dashboard Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Passenger Side Bottom Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove center stowage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3134 · Applies to: 450, 451, 452, 454
1.2 Remove center stowage compartment. radio 10 orwithout code (C57) smart radio 9without code (516) RADIO WITH USB INTERFACE P- 1620MCC 2 Remove dashboard lower section (2)
AR68.10- P- 1040MCU 3 Remove right side paneling from dashboard
AR68.10- P- 1503MCU 4 Unclip right knee guard (4) (arrow A), loosen from guides (arrows B) and remove. Without code (294) Kneebag Installation: Route wiring harness (3) on upper control panel control unit in recess specified.
5 Disconnect wiring harness of external audio source separation point (X39/45) on communication control unit (N4) (arrow C) With retrofitted communication control unit (N4). The communication control unit (N4) is fastened at the rear to the crossmember below the instrument panel (7).
6 Open cover (11) on glove box. On vehicles with code (I63) Glove box
7 Remove expansion clips (5) on passenger-side paneling (1)
8 Close glove box lid On vehicles with code (I63) Glove box
9 Unscrew bolts (6) on passenger-side paneling (1) Rechargeable drill / screwdriver gotis://G_58.0_01.1
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
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3137 · Applies to: 450, 451, 452, 454
Remove/install
1 Remove shift lever knob (1)
AR26.60- P- 6601MCU 2 Pull parking brake lever
3 Remove power top switch (S84) On model 451.4 AR77.39- P- 1000MCU 4 Unclip cap (4) with suitable screwdriver and remove
5 Unscrew bolt (5) below cap (4) on center console (3)
6 Carefully press center console (3) together in front area in direction of arrow and detach bracket (arrow A)
7 Remove center console (3) until electrical connector (6) of selector lever position display is accessible
8 Disconnect electrical connector (6)
9 Remove selector lever cover When replacing center console (3). AR68.20- P- 2309MCU Fig 1: Identifying Center Console Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1010MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3140 · Applies to: 450, 451, 452, 454
2 Remove passenger seat
AR91.10- P- 1020MCU 3 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 4 Remove electronic accelerator pedal
AR30.20- P- 2000MCC 5 Remove pedal assembly seal
AR29.10- P- 0341MCC 6 Remove vertical strut paneling
AR68.00- P- 1500MCC 7 Remove center console
AR68.20- P- 2000MCU 8 Remove mounting plate (2)
9 Loosen retaining clip (3) on floor covering (1) on heater/AC housing
10 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.
11 Remove floor covering (1) from vehicle
12 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL COVER AT SELECTOR LEVER - AR68.20-P- 2309MCU > Illustrated on model 451.4
Vehicles as of 31.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3142 · Applies to: 450, 451, 452, 454
Remove/install
1.1 Remove dashboard bottom section on driver's side (7) On vehicles up to 30.8.10. AR68.10- P- 1501MCU 1.2 Remove bottom section of dashboard on front passenger side On vehicles as of 31.8.10. AR68.10- P- 1502MCU 2 Remove knee guard (6) from driver side instrument panel On vehicles without code (294) Kneebag
Fig 1: Identifying Center Console Reinforcement Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Center Console Reinforcement Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
lower section (7)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3143 · Applies to: 450, 451, 452, 454
3 Unscrew bolts (5) from driver side instrument panel lower section (7) On vehicles as of 31.8.10.
4 Unscrew bolts (2) from center console reinforcement (1)
5 Remove electrical lines (3) and remove center console reinforcement (1) Installation: Ensure that center console reinforcement (1) is seated correctly in guides next to lower bolts (2).
6 Remove sheet metal nuts (4) from center console reinforcement (1). When replacing center console reinforcement (1).
7 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL COVER ON CENTER CONSOLE - AR68.20-P- 2350MCC > MODEL 451.3/4 up to 30.8.10 Remove/install
1 Remove cockpit switch group (S6/1)
AR54.25-P- 1000MCC 2 Unscrew bolt (2)
Carefully detach cover (1), Fig 1: Removing/Installing Center Console Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Loosen cover (1) in upper area¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3144 · Applies to: 450, 451, 452, 454
3 Loosen cover (1) in upper area using assembly wedge (3), as shown otherwise dashboard upper section can be damaged.
Mounting wedge *110589035900 4 Lift cover (1) in rear area and remove upward
5 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL COVER ON CENTER CONSOLE - AR68.20-P- 2350MCF > MODEL 451.3/4 as of 31.8.10 Shown on vehicle with code (516) RADIO WITH USB INTERFACE Remove/install
Fig 2: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Center Console Cover Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
retaining clips¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3146 · Applies to: 450, 451, 452, 454
3.1 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)
3.2 Remove bolts from lashing eyes On vehicles with code (I05) Separation protection between luggage compartment and passenger compartment (DFO) or with code (S02) Top Tether (child seat equipment) Bolts are installed instead of retaining clips (2) Installation: Observe installation position of spacer sleeves between body and floor covering.
BA68.50- P-1003- 03D BA91.20- P-1002- 01C 4 Expose load compartment floor covering (1) in area of left and right paneling in trunk.
5 Remove load compartment floor covering (1) When removing load compartment floor covering (1), ensure that this is not damaged by breaking or cracking.
6 Install in the reverse order
CARGO RETAINER, DIVIDER Number Designation Model 451.3 Model 451.4 BA68.50-P-1003- 03D Bolt, divider bracket to vehicle floor Nm 22 22 CHILD SEATS Number Designation Model 451.3/4 BA91.20-P-1002- 01C Bolt, child seat anchorage to body Nm 22 TESTING & REPAIR > REMOVE/INSTALL FOOTREST ON PASSENGER SIDE - AR68.30-P- 1340MCC > MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3147 · Applies to: 450, 451, 452, 454
1 Move right seat toward rear
2 Remove clip (2)
3 Fold down floor covering (1) in area of passenger's side footwell Do not break or tear floor covering (1) when folding down. 4 Remove sheet metal nut (4).
5 Remove passenger-side footrest (3)
6 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL INTERIOR PANELING ON ROLL BAR - AR68.30- P-1380MCU > MODEL 451.4 Fig 1: Identifying Passenger Side Footrest Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Roll Bar Paneling And Rollover Bar Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3148 · Applies to: 450, 451, 452, 454
1 Completely open soft top
2 Detach roll bar paneling (1) with snap-release tool and remove
The catch hooks are damaged when removing the roll bar paneling (1), for this reason always replace roll bar paneling (1). *452589016300 3 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL STEERING COLUMN TRIM - AR68.30-P- 2000MCC > MODEL 451.3/4 Fig 2: Identifying Snap-Release Tool (452 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3150 · Applies to: 450, 451, 452, 454
1 Remove paneling from front roof frame Model 451.3 AR68.30- P- 4450MCU Model 451.4 AR68.30- P- 4450MCV 2 Loosen edge guard (3) in area of A-pillar paneling (1)
3 Loosen edge guard (3) in area of side roof frame paneling (2) On model 451.3
4 Remove bolt (4) from side roof frame paneling (2) On model 451.3
5 Unhook bracket (arrow B) on side roof frame paneling (2) from A-pillar paneling (1) On model 451.3
6 Unclip side roof frame paneling (2) in front area and unhook in area (arrow A) of A- pillar paneling (1) On model 451.3 Loosen only the first three clips on the side roof frame paneling (2).
7 Unscrew bolt (5) from A-pillar paneling (1)
8 Unclip A-pillar paneling (1) and remove Installation: Check clips (6), replace if necessary.
Fig 1: Identifying A-Pillar 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. 3151 · Applies to: 450, 451, 452, 454
9 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL FRONT ROOF FRAME PANELING - AR68.30-P- 4450MCV > MODEL 451.4 Remove/install
1 Remove front interior lamp
AR82.20-P- 0110MCU 2 Remove left and right sun visor
AR68.60-P- 5480MCU 3 Remove inside rearview mirror
AR68.40-P- 0001MCU 4 Mask off left and right A-pillar paneling (9) in transition areas (arrows A) to roof frame paneling (1) using suitable masking tape
Unscrew bolts (3) from Fig 1: Identifying Front Roof Frame Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
roof frame paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3152 · Applies to: 450, 451, 452, 454
5 roof frame paneling (1) and remove bracket (4)
6 Unscrew bolts (2) from roof frame paneling (1) Installation: First tighten bolt (2) in marked area (arrow B).
7 Carefully unclip left and right retaining clip (7) on roof frame paneling (1) using snap-release tool On vehicles as of 31.8.10 and with code (876) Interior light package, disconnect electrical connector for ambiance illumination in roof frame paneling (1) when removing roof frame paneling (1). Clip remover Installation: Before clipping in roof frame paneling (1), position edge guard (8) in area of A-pillar paneling (9) on roof frame paneling (1). Open soft top approx. 20 cm and position edge guard (8) in area of soft top on roof frame paneling (1) after clipping in roof frame paneling (1). *452589016300 8 Carefully lift roof frame paneling (1) over left and right A- pillar paneling (9)
9 Push brackets (6) on roof frame paneling (1) toward front out of guides (5) and remove roof frame paneling (1) until electrical connector on automatic child seat recognition airbag OFF indicator lamp (E16) is accessible Installation: Guide electric wiring harness on front interior lamps through opening into roof frame paneling (1).
10 Disconnect electrical connector from automatic child seat recognition airbag OFF indicator lamp (E16) and remove roof frame paneling (1)
11 Unclip automatic child seat recognition airbag OFF indicator lamp (E16) from roof frame paneling (1) and remove When replacing roof frame paneling (1).
Unclip ambiance
illumination from roof¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3153 · Applies to: 450, 451, 452, 454
12 illumination from roof frame paneling (2) and remove When replacing roof frame paneling (2) on vehicles as of 31.8.10 and with code (876) Interior light package.
13 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL SIDE PANELING IN TRUNK - AR68.30-P- 4800MCU > MODEL 451.3/4 Shown on right side on model 451.3 Driver side, as of 31.8.10 Fig 2: Identifying Snap-Release Tool (452 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Trunk Side Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3154 · Applies to: 450, 451, 452, 454
1 Adjust left and right seat toward front
2 Unclip belt end fitting tensioner cover (7) Driver side, as of 31.8.10 3.1 Unclip cap (2) below right trunk paneling (1) and remove When removing right trunk paneling (1). 3.2 Unclip cover (3) on left trunk paneling (1) and remove When removing left trunk paneling (1). 4 Unscrew bolt (4) from trunk paneling (1) The bolt (4) is located on the right trunk paneling (1) behind the cap (2). 5 Unclip trunk paneling (1) and remove With code (C17) smart surround sound system, disconnect electrical connector on left rear and right rear speaker. Installation: Check clips (6) on trunk paneling (1), replace if necessary.Position edge guard on lower rear-end door in area of trunk paneling (1) with suitable tool. 6 Remove insulating mat (5) When replacing trunk paneling (1). 7 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL INSIDE REARVIEW MIRROR - AR68.40-P- 0001MCU > MODEL 451.3/4 Fig 2: Identifying Trunk Paneling And Belt End Fitting Tensioner Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fold left and right sun visor (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3156 · Applies to: 450, 451, 452, 454 · AR: AZ68.30-P-0006MCC
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). RETROFITTING & CONVERSION > RETROFIT SPECTACLE POCKET - AZ68.10-P- 0010MCC > MODEL 451.3/4 Install
1 Align eyeglass compartment (1) in upper third of instrument panel (3) as shown. Ensure that the cover of the eyeglass compartment (1) can be opened easily and the eyeglasses are accessible. 2 Tighten eyeglass compartment (1) with bolts (2) included in scope of delivery
RETROFITTING & CONVERSION > RETROFIT TRIM - AZ68.30-P-0006MCC > MODEL 451.3/4 Trim parts Fig 1: Identifying Eyeglass Compartment, Bolts And Instrument Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3157 · Applies to: 450, 451, 452, 454
1 Unclip left front door panel cover (1) and right front door panel cover (2) from front area of door panel (7) First loosen left front door panel cover (1) and right front door panel cover (2) in lower area with
Fig 1: Identifying Retrofit Trim And Related Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Retrofit Trim And Related Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3159 · Applies to: 450, 451, 452, 454
Removing
1 Move seats forward
2 Remove clips (2) and fold trunk floor covering (1) toward front Do not break or tear floor covering in trunk (1) when folding down.
Install
3 Drill dia. 5 mm holes in trunk floor covering (1) in area of holding lug (3), according to markings on trunk floor covering (1) from bottom Cordless drill/driver and Wet/dry vacuum cleaner http://gotis.aftersales.mercedes- benz.com
*450589017000 4 Tighten holding lugs (3) on trunk floor covering (1) using bolts, nuts and shims included in package contents
5 Fold over trunk floor covering (1), align and install clips (2)
6 Hook luggage net (4) into holding lugs (3)
7 Move seats to starting position
Fig 1: Identifying Floor Covering, Clip, Retaining Eye And Luggage Net Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT LUGGAGE-RETAINING NET IN TRUNK¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3160 · Applies to: 450, 451, 452, 454 · AR: AZ68.50-P-0003MCC
SIDE - AZ68.50-P-0003MCC > MODEL 451.3/4 Removing 1 Remove cover (1) from luggage compartment lining at side Install 2 Position carrier (2) for luggage net in trunk side (3) in area of bracket (arrows A) on cover (1) 3 Lift carrier (2) at sides over cover (1) and position (arrows B) Fig 2: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Cover, Carrier And Luggage Net In Trunk Side Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Position luggage net in trunk side (3) in guided areas (arrows A, B, C) so that the cover¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3161 · Applies to: 450, 451, 452, 454
4 Position luggage net in trunk side (3) in guided areas (arrows A, B, C) so that the cover (1) can be inserted easily into the luggage compartment lining at side 5 Install cover (1) in luggage compartment lining at side RETROFITTING & CONVERSION > INSTALL ANCHORING FOR DIVIDER ON VEHICLE FLOOR - AZ68.50-P-0005-01MCC > CARGO RETAINER, DIVIDER Number Designation Model 451.3 Model 451.4 BA68.50-P-1003- 03D Bolt, divider bracket to vehicle floor Nm 22 22 1. Move seats forward. 2. Remove trunk luggage cover (3). Only on vehicles with trunk luggage cover (3) installed. The trunk luggage cover (3) is no longer required. 3. Unclip retaining clips (2) from trunk floor covering (1). 4. Fold trunk floor covering (1) toward front. 5. Position spacer sleeves (4) between body and trunk floor covering (1) instead of retaining clips The chamfer on the spacer sleeves (4) should point upward. 6. Fold back trunk floor covering (1) and align. Fig 1: Identifying Trunk Floor Covering, Retaining Clips And Luggage Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Position anchorings (6) above spacer sleeves and tighten bolts (5).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3162 · Applies to: 450, 451, 452, 454
The ring on the anchorings (6) should point in direction of travel. RETROFITTING & CONVERSION > INSTALL SEPARATION GUARD BETWEEN LUGGAGE Fig 2: Positioning Spacer Sleeves Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Anchorings And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
AND PASSENGER COMPARTMENT - AZ68.50-P-0005MCO >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3163 · Applies to: 450, 451, 452, 454 · AR: AZ68.50-P-0005MCO
MODEL 451.4 Install
1 Install lower anchorings (6) for divider (1) on vehicle floor AZ68.50-P-0005- 01MCC *BA68.50-P- 1003-03D 2 Position left and right belt (2) over roll bar and arrest in corresponding seat belt buckle (3)
3 Hook divider (1) into lower anchorings (6) and tension belts (5).
4 Insert divider (1) on left and right luggage compartment lining (4).
5 Add special equipment to the vehicle data card and to the online vehicle data card Enter code (I05) Divider between luggage and passenger compartment.
CARGO RETAINER, DIVIDER Number Designation Model 451.4 BA68.50-P-1003- 03D Bolt for divider mount on vehicle floor Nm 22 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: INTERIOR EQUIPMENT - Fig 1: Identifying Divider, Seat Belt Buckle, Trunk Lining, Belt And Lower Anchorings Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA68.00-Z-9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3164 · Applies to: 450, 451, 452, 454 · AR: BA68.00-Z-9999CZ
MODEL all Cargo retainers MODEL 450.3, 451.3 /4, 452.3 BA68.50-P-1000-03D Center console MODEL 450.3 /4, 452.3 /4, 454.0 BA68.20-P-1000-01C Cross member below instrument panel MODEL 454.0 BA68.10-P-1000-02B Curtains/sun shades MODEL 450.3 BA68.50-P-1000-01C Handles MODEL 454 BA68.70-P-1000-02B TORQUE SPECIFICATIONS > CARGO RETAINERS - BA68.50-P-1000-03D > Model 450, 451, 452 CARGO RETAINER, DIVIDER Number Designation Model 450.3 Model 451.3 Model 451.4 Model 452.3 BA68.50-P-1001- 03D Bolt, partition to body Nm - - - 45 BA68.50-P-1002- 03D Bolt, upper bracket to body Nm 10 - - - BA68.50-P-1003- 03D Bolt, divider bracket to vehicle floor Nm - 22 22 - BA68.50-P-1004- 03D Bolt, divider bracket to rear roof frame Nm - 12 - - SPECIAL TOOLS > 452 589 01 63 00 CLIP REMOVER - WS68.00-P-0012K > FG 61/67/68/72/82/88/ 91/ Set K MODEL all Use: Clip remover for removing paneling parts, strips, covers, taillamp and roof spoiler. NOTE: smart-no.: 001 5807 V000 0000 00.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: INTERIOR EQUIPMENT - WS68.00-Z-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3165 · Applies to: 450, 451, 452, 454
9999CZ > MODEL all 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 450 589 00 43 00 Punching template GROUP 68/Set K WS68.00-P-0011K 450 589 07 99 00 Assembly tool set FG 68/91/Set B WS91.00-P-0031B 450 589 09 63 00 Hollow punch GROUP 68/Set B WS68.00-P-0010B 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P- 0012K Fig 1: Identifying Clip Remover (452 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > INSTALL BRABUS SHIFT LEVER KNOB - AN68.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3166 · Applies to: 450, 451, 452, 454
0004MCC > MODEL 451.3 /4 with CODE (V11) Softouch - automatic shift program (FFO) Removing
1 Pull shift lever knob upward Do not press button (3), otherwise shift lever knob can be damaged. Install
2 Install BRABUS shift lever knob (2) Do not press button (3), otherwise BRABUS shift lever knob (2) can be damaged. 3 Glue on circuit diagram adhesive label (1) as shown. The selector lever cover should be free of dust and grease in area of circuit diagram adhesive label (1). TESTING & REPAIR > NOTES ON SELF-LOCKING NUTS AND BOLTS - AH00.00-N-0001- 01A > All models Important repair information Bolts with locking splines, micro-encapsulated bolts and self-locking nuts must always be replaced after being used once. There is an increased risk of injury when unscrewing micro-encapsulated bolts due to the sudden breakaway torque. Before new micro-encapsulated bolts are screwed in, the mating thread must be re-cut in order to remove all Fig 1: Identifying BRABUS Shift Lever Knob And Pushbutton Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
the re idue of the old bolt locking compound¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3167 · Applies to: 450, 451, 452, 454
TESTING & REPAIR > REMOVE/INSTALL VERTICAL STRUT PANELING - AR68.00-P- 1500MCC > MODEL 451.3 /4 Remove/install
1 Insert pliers (2) into interior socket (X58/1) and turn until pliers (2) arrest Pliers Fig 2 2 Carefully pull out metal insert in interior socket (X58/1) approx. 1.5 cm using pliers (2) Pliers Fig 2 3 Remove bolts (4)
4 Pivot vertical strut paneling (1) toward rear in lower area and remove until electrical connector (5) of interior socket (X58/1) as well as electrical connector (6) of data link connector (X11/4) are accessible
5 Disconnect electrical connector (5) on interior socket (X58/1) and electrical connector (6) on data link connector (X11/4)
6 Disconnect electrical connectors on footwell Vehicles as of 31.8.10 with code (876) Interior light package
Fig 1: Identifying Vertical Strut Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL DASHBOARD TOP SECTION - AR68.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3172 · Applies to: 450, 451, 452, 454
1020MCU > MODEL 451.3 /4 Fig 1: Identifying Instrument Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying Dashboard Top Section Components (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3173 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Dashboard Top Section Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3174 · Applies to: 450, 451, 452, 454
Remove/install
Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Legal Fig 3: Identifying Retaining Clamp, Firewall, Adhesive Foil And Brackets (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
requirement on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3175 · Applies to: 450, 451, 452, 454
handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Remove paneling on passenger side
AR68.10- P- 1502MCU 3 Remove instrument cluster
AR54.30- P- 6015MCU 4 Remove bolt (13) in area of instrument panel opening.
5 Detach bracket (17) on wiring harness
6 Remove left side paneling (4) from dashboard
AR68.10- P- 1503MCU 7 Remove left side air vent (3). up to 30.8.10 AR68.10- P- 1100MCC 8.1 Remove bolt (5) behind left side air vent (3). up to 30.8.10
8.2 Unscrew bolt (5.1) at side of instrument panel upper section (1) As of 31.8.10
9.1 Remove additional instrument Up to 30.8.10 with code (V31) Cockpit and tachometer package AR54.30- P- 6080MCC 9.2 Separate additional instruments connector (A15x1) As of 31.8.10 with code (V31) Cockpit and tachometer package
10 Remove center Up to 30.8.10 AR68.10- P- 1150MCU
air vent¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3176 · Applies to: 450, 451, 452, 454
As of 31.8.10 AR68 10 P- 1150MCF 11 Remove tweeter and lay down to side with electrical lines connected Up to 30.8.10 with code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO) or with code (C54) Sound system 2 AR82.62- P- 1000MCC 12 Disconnect electrical connector (green) (8) and electrical connector (yellow) (6) on front passenger airbag unit (10)
13 Remove screws (9) from passenger airbag (10) *BA91.60- P-1001- 01C 14 Remove bolt (7) from dashboard top section (1).
15 Remove expansion clips (2) from dashboard top section (1) in area of instrument cluster.
16 Lift dashboard top section (1) with aid of helper, guide toward rear and remove from vehicle. Installation: Glue adhesive foil (15) to brackets (16) on firewall (14).Remove retaining clips (12) from instrument panel upper section (1) and insert brackets (16) into firewall (14). Ensure that retaining clips (12) are seated correctly in brackets (16).The instrument panel upper section (1) should arrest correctly in the retaining clamps (12) on the firewall (14) when installing.
17 Unscrew nuts (11) from front passenger airbag (10) and remove front passenger airbag (10) downward. When replacing dashboard top section (1). Open only specified bolted connections. The front passenger airbag unit (10) may not be disassembled, otherwise it must be replaced. Installation: Observe tightening sequence (A to D) of nuts (11).
*BA91.60- P-1004- 01C Remove all sheet
metal nuts and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3177 · Applies to: 450, 451, 452, 454
18 metal nuts and retaining clamps from dashboard top section (1) When replacing dashboard top section (1).
19 Remove additional instrument As of 31.8.10 with code (V31) Cockpit and tachometer package when replacing instrument panel upper section (1). AR54.30- P- 6080MCF 20 Remove right side air vent (3). When replacing dashboard top section (1). AR68.10- P- 1100MCC 21 Remove left side air vent (3). As of 31.8.10 when replacing instrument panel upper section (1). AR68.10- P- 1100MCC 22 Unclip GPS antenna from instrument upper section (1) As of 31.8.10 with code (527) Radio High-Line when replacing instrument panel upper section (1).
23 Install in the reverse order
AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1001- 01C Bolt of front passenger airbag unit to dashboard mounting Nm 10 10 BA91.60-P-1004- 01C Nut, front passenger airbag unit to dashboard Nm 2 2 TESTING & REPAIR > REMOVE/INSTALL LOWER SECTION OF DASHBOARD - AR68.10- P-1040MCU > MODEL 451.3 /4
With code (294) Kneebag¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3178 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Lower Dashboard Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3179 · Applies to: 450, 451, 452, 454
Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR
AH91.00- P-0002- 01SM Fig 2: Identifying Lower Dashboard Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Lower Dashboard Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
units¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3180 · Applies to: 450, 451, 452, 454
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1 Remove vertical strut paneling
AR68.00- P- 1500MCC 2 Remove cockpit switch group
AR54.25- P- 1000MCC 3 Remove paneling at side of dashboard
AR68.10- P- 1503MCU 4 Unscrew left and right bolts (4) below instrument panel lower section (1)
5 Unscrew nuts (8) on power window control unit convenience feature (N57/2) With code (294) Kneebag
6 Remove power window control unit convenience feature (N57/2) and lay down to side with electrical lines connected With code (294) Kneebag
7 Unscrew bolts (9) from bracket (10) With code (294) Kneebag
*BA91.60- P-1012- 01C 8 Unscrew bolts (12) from bracket (11) With code (294) Kneebag
*BA91.60- P-1012- 01C 9 Unscrew bolts (2) in center of instrument panel lower section (1)
10 Unscrew left and right bolt (5) from instrument panel lower section (1)
11 Pivot instrument panel lower section (1) out in lower area (arrow A) Do not pivot instrument panel lower section (1) too far out to prevent damage.
Shown up to 30.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3182 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Passenger Side Dashboard Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Passenger Side Dashboard Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3183 · Applies to: 450, 451, 452, 454
1.1 Remove radio On vehicles with code (C50) smart radio 10 orwith code (C57) smart radio 9 or with code (516) RADIO WITH USBINTERFACE or with code (527) Radio High-Line AR82.60- P- 7502MCU 1.2 Remove center stowage compartment. On vehicles without code (C50) smart radio 10 orwithout code (C57) smart radio 9without code (516) RADIO WITH USB INTERFACE AR68.10- P- 1620MCC 2 Remove dashboard lower section (2)
AR68.10- P- 1040MCU 3 Remove right side paneling from dashboard
AR68.10- P- 1503MCU 4 Unclip right knee guard (4) (arrow A), loosen from guides (arrows B) and remove. Without code (294) Kneebag Installation: Route wiring harness (3) on upper control panel control unit in recess specified.
5 Disconnect wiring harness of external audio source separation point (X39/45) on communication control unit (N4) (arrow C) With retrofitted communication control unit (N4). The communication control unit (N4) is fastened at the rear to the crossmember below the instrument panel (7).
6 Open cover (11) on glove box. On vehicles with code (I63) Glove box
7 Remove expansion clips (5) on passenger-side paneling (1)
8 Close glove box lid On vehicles with code (I63) Glove box
Fig 3: Identifying Passenger Side Paneling, Clamping Ring, Expander And Sheet Metal Nut Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3185 · Applies to: 450, 451, 452, 454
1 Remove center mounting console reinforcement
AR68.20- P- 2340MCC 2 Turn air distribution control lever (8) to footwell ventilation position
3 Move adjustment lever (7) for temperature and fan stage to uppermost position
Fig 1: Identifying Center Air Nozzle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Eye And Relay Lever Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3187 · Applies to: 450, 451, 452, 454
1.1 Remove air conditioning pushbutton control unit On vehicles with code (I01) Air conditioning Plus AR83.25- P- 1124MCC 1.2 Remove heater/ventilation operating unit On vehicles without code (I01) Air conditioning Plus AR83.20- P- 1850MCC 2 Remove bolts (2)
3 Expose electric wiring harnesses (3) in area of center air vent (1) and remove center air vent (1) Observe installation position of electric wiring harnesses (3).
4 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL GLOVE COMPARTMENT LID - AR68.10-P- 1200MCC > MODEL 451.3 /4 with CODE (I63) Glove compartment Fig 1: Identifying Center Air Nozzle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3190 · Applies to: 450, 451, 452, 454
1 Remove top part of dashboard
AR68.10- P- 1020MCU 2 Remove steering wheel
AR46.10- P- 0100MCC 3 Remove wiper switch
AR54.25- P- 0003MCC 4 Remove combination switch
AR54.25- P- 2800MCC 5 Unclip left knee guard (6) (arrow A), loosen from guides (arrows B) and remove. On vehicles without code (294) Kneebag
6 Loosen retaining clip (2) from driver-side paneling (1)
7 Expose fanfare horns and airbag clock spring contact wiring
Fig 1: Identifying Driver Side Dashboard Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown up to 30.8.10¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3192 · Applies to: 450, 451, 452, 454
Remove/install
1.1 Remove radio On vehicles with code (C50) smart radio 10 orwith code (C57) smart radio 9 or with code (516) RADIO WITH USBINTERFACE or with code (527) Radio High-Line AR82.60- P- 7502MCU Fig 2: Identifying Passenger Side Dashboard Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Clamping Ring, Expander, Sheet Metal Nut, Passenger Side Paneling And Clamping Ring Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove center stowage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3193 · Applies to: 450, 451, 452, 454
1.2 Remove center stowage compartment. On vehicles without code (C50) smart radio 10 orwithout code (C57) smart radio 9without code (516) RADIO WITH USB INTERFACE AR68.10- P- 1620MCC 2 Remove dashboard lower section (2)
AR68.10- P- 1040MCU 3 Remove right side paneling from dashboard
AR68.10- P- 1503MCU 4 Unclip right knee guard (4) (arrow A), loosen from guides (arrows B) and remove. Without code (294) Kneebag Installation: Route wiring harness (3) on upper control panel control unit in recess specified.
5 Disconnect wiring harness of external audio source separation point (X39/45) on communication control unit (N4) (arrow C) With retrofitted communication control unit (N4). The communication control unit (N4) is fastened at the rear to the crossmember below the instrument panel (7).
6 Open cover (11) on glove box. On vehicles with code (I63) Glove box
7 Remove expansion clips (5) on passenger-side paneling (1)
8 Close glove box lid On vehicles with code (I63) Glove box
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
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3198 · Applies to: 450, 451, 452, 454
1 Remove driver seat
AR91.10- P- 1010MCU 2 Remove passenger seat
AR91.10- P- 1020MCU 3 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 4 Remove electronic accelerator pedal
AR30.20- P- 2000MCC 5 Remove pedal assembly seal
AR29.10- P- 0341MCC 6 Remove vertical strut paneling
AR68.00- P- 1500MCC 7 Remove center console
AR68.20- P- 2000MCU 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. 3202 · Applies to: 450, 451, 452, 454
1.1 Remove dashboard bottom section on driver's side (7) On vehicles up to 30.8.10. AR68.10- P- 1501MCU 1.2 Remove bottom section of dashboard on front passenger side On vehicles as of 31.8.10. AR68.10- P- 1502MCU 2 Remove knee guard (6) from driver side instrument panel lower section (7) On vehicles without code (294) Kneebag
3 Unscrew bolts (5) from driver side instrument panel lower section (7) On vehicles as of 31.8.10.
4 Unscrew bolts (2) from center console reinforcement (1)
5 Remove electrical lines (3) and remove center console reinforcement (1) Installation: Ensure that center console reinforcement (1) is seated correctly in guides next to lower bolts (2).
6 Remove sheet metal nuts (4) from center console reinforcement (1). When replacing center console reinforcement (1).
7 Install in the reverse order
Fig 2: Identifying Center Console Reinforcement Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL COVER ON CENTER CONSOLE - AR68.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3203 · Applies to: 450, 451, 452, 454
2350MCC > MODEL 451.3 /4 up to 30.8.10 Remove/install
1 Remove cockpit switch group (S6/1)
AR54.25- P- 1000MCC 2 Unscrew bolt (2)
3 Loosen cover (1) in upper area using assembly wedge (3), as shown Carefully detach cover (1), otherwise dashboard upper section can be damaged.
Mounting wedge Fig 2 4 Lift cover (1) in rear area and remove upward
5 Install in the reverse order
Fig 1: Identifying Center Console Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL COVER ON CENTER CONSOLE - AR68.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3204 · Applies to: 450, 451, 452, 454
2350MCF > MODEL 451.3 /4 as of 31.8.10 Shown on vehicle with code (516) RADIO WITH USB INTERFACE Remove/install
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
Fig 2: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Center Console Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove bolts¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3206 · Applies to: 450, 451, 452, 454
3.2 Remove bolts from lashing eyes Bolts are installed instead of retaining clips (2) Installation: Observe installation position of spacer sleeves between body and floor covering.
BA68.50- P-1003- 03D BA91.20- P-1002- 01C 4 Expose load compartment floor covering (1) in area of left and right paneling in trunk.
5 Remove load compartment floor covering (1) When removing load compartment floor covering (1), ensure that this is not damaged by breaking or cracking.
6 Install in the reverse order
CARGO RETAINER, DIVIDER Number Designation Model 451.3 Model 451.4 BA68.50-P-1003-03D Bolt, divider bracket to vehicle floor Nm 22 22 CHILD SEATS Number Designation Model 451.3/4 BA91.20-P-1002-01C Bolt, child seat anchorage to body Nm 22 TESTING & REPAIR > REMOVE/INSTALL FOOTREST ON PASSENGER SIDE - AR68.30-P- 1340MCC > MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3207 · Applies to: 450, 451, 452, 454
1 Move right seat toward rear
2 Remove clip (2)
3 Fold down floor covering (1) in area of passenger's side footwell Do not break or tear floor covering (1) when folding down. 4 Remove sheet metal nut (4).
5 Remove passenger-side footrest (3)
6 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL STEERING COLUMN TRIM - AR68.30-P- 2000MCC > MODEL 451.3/ 4 Fig 1: Identifying Passenger Side Footrest Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3209 · Applies to: 450, 451, 452, 454
1 Remove paneling from front roof frame Model 451.3 AR68.30- P- 4450MCU Model 451.4 AR68.30- P- 4450MCV 2 Loosen edge guard (3) in area of A-pillar paneling (1)
3 Loosen edge guard (3) in area of side roof frame paneling (2) On model 451.3
4 Remove bolt (4) from side roof frame paneling (2) On model 451.3
5 Unhook bracket (arrow B) on side roof frame paneling (2) from A-pillar paneling (1) On model 451.3
6 Unclip side roof frame paneling (2) in front area and unhook in area (arrow A) of A- pillar paneling (1) On model 451.3 Loosen only the first three clips on the side roof frame paneling (2).
7 Unscrew bolt (5) from A-pillar paneling (1)
8 Unclip A-pillar paneling (1) and remove Installation: Check clips (6), replace if necessary.
Fig 1: Identifying A-Pillar 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. 3210 · Applies to: 450, 451, 452, 454
9 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL FRONT ROOF FRAME PANELING - AR68.30-P- 4450MCU > MODEL 451.3 Remove/install
1 Remove front interior lamp
AR82.20- P- 0110MCU 2 Remove left and right sun visor
AR68.60- P- 5480MCU 3 Remove inside rearview mirror
AR68.40- P- 0001MCU 4 Unscrew bolts (3) from roof frame paneling (2) and remove bracket (4)
5 Unscrew bolts (1) from roof frame paneling (2) Installation: First tighten bolt (1) in marked area (arrow B).
Fig 1: Identifying Front Roof Frame Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Lift roof frame paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3211 · Applies to: 450, 451, 452, 454
6 Lift roof frame paneling (2) over side paneling in marked areas (arrows A) and loosen catch (arrows C) on roof frame paneling (2)
7 Push brackets (6) on roof frame paneling (2) toward front out of guides (7) and remove roof frame paneling (2) until electrical connector (5) is accessible On vehicles as of 31.8.10 and with code (876) Interior light package, disconnect electrical connector for ambiance illumination in the roof frame paneling (2) when removing roof frame paneling (2). Installation: Guide electric wiring harness on front interior lamps through opening into roof frame paneling (2).
8 Disconnect electrical connector (5) from automatic child seat recognition airbag OFF indicator lamp (E16) and remove roof frame paneling (2)
9 Unclip automatic child seat recognition airbag OFF indicator lamp (E16) from roof frame paneling (2) and remove When replacing roof frame paneling (2).
10 Unclip ambiance illumination from roof frame paneling (2) and remove When replacing roof frame paneling (2) on vehicles as of 31.8.10 and with code (876) Interior light package.
11 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL REAR ROOF FRAME PANELING - AR68.30-P- 4470MCC > MODEL 451.3
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3212 · Applies to: 450, 451, 452, 454
1 Move seats forward
2 Unscrew bolt (3) on left and right from roof frame paneling (1).
3 Unclip clips (5) from roof frame paneling (1) in marked area (arrows A). Installation: Clip clips (5) on roof frame paneling (1) into body and position edge guard (2) above roof frame paneling (1). 4 Loosen catch hook (4) on roof frame paneling (1) in marked area (arrows C).
5 Carefully slide roof frame paneling (1) forward and unhook brackets (6) of roof frame paneling (1) from body in marked area (arrows B) and remove.
6 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL SIDE ROOF FRAME PANELING - AR68.30-P- 4480MCU > MODEL 451.3 Fig 1: Identifying Rear Roof Frame Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on vehicle with code (I52) Head airbag, left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3213 · Applies to: 450, 451, 452, 454
Shown on vehicle with code (I52) Head airbag, left side of vehicle Remove/install
1 Remove rear roof frame trim
AR68.30- P- 4470MCC 2 Unscrew bolts (5) from side roof frame paneling (1) On vehicles without code (I52) Head
Fig 1: Identifying Side Roof Frame Paneling Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Side Roof Frame Paneling Components (2 Of 2) 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. 3215 · Applies to: 450, 451, 452, 454
Driver side, as of 31.8.10 Shown on right side of vehicle Fig 1: Identifying B-Pillar Components (Shown On Right Side Of Vehicle) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying B-Pillar Components (Shown On Driver Side Of Vehicle) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3216 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V 1 Move left and right seat to front-most position and fold toward front 2 Unhook seat belt (2) from belt guide (1) on seat
3 Unclip and remove cover (3) When removing paneling from B-pillar (7) on front passenger side.
4 Detach wiring harness from bracket (5) and disconnect belt tensioning sensor connector (B48/3x1) When removing paneling from B-pillar (7) on front passenger side. Observe installation position (arrow A) of wiring harness.
5 Remove bolt (4) from lower belt end fitting of seat belt (2) When removing paneling from B-pillar (7) on front passenger side.Up to 30.8.10, when removing B-pillar paneling (7) on driver side.
*BA91.40- Fig 3: Identifying B-Pillar Components (Shown On Right Side Of Vehicle) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
P-1001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3217 · Applies to: 450, 451, 452, 454
01G 6 Turn lock (arrow) in lock (15) of seat belt (2) 90° clockwise and remove seat belt (2) from belt end fitting tensioner (17) As of 31.8.10, when removing B-pillar paneling (7) on driver side. Installation: Ensure that lock (15) is seated correctly in mount (16) and observe installation position of seat belt (2).
7 Loosen edge guard (6) in area of side roof frame paneling (10)
8 Loosen edge guard (6) in area of B-pillar paneling (7)
9 Remove left or right side paneling in trunk
AR68.30- P- 4800MCU 10 Remove rear roof frame trim
AR68.30- P- 4470MCC 11 Unscrew bolt (11) from side roof frame paneling (10)
12 Unclip side roof frame paneling (10) in rear area On vehicles without code (I52) Head airbag Installation: Position edge guard (9) above side roof frame paneling (10).
13 Detach side roof frame paneling (10) from guides (12) in marked areas (arrows B). On vehicles without code (I52) Head airbag
14 Carefully push side roof frame paneling (10) to side until bolts (8) are accessible. On vehicles without code (I52) Head airbag
15 Remove side roof frame paneling (10) On vehicles with code (I52) Head airbag
16 Unscrew bolts (8, 13) from B- pillar paneling (7)
17 Remove B-pillar paneling (7) and guide seat belt (2) through opening into B-pillar paneling (7) Installation: Position edge guard (9) above B-pillar paneling (7).
18 Remove damping material (14) from B-pillar paneling (7) When replacing B-pillar paneling (7).
19 Install in the reverse order
SEAT BELTS/EMERGENCY TENSIONING RETRACTORS
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3218 · Applies to: 450, 451, 452, 454
Designation Model 451.3/4 BA91.40-P-1001-01G Screw on belt end fitting Nm 35 TESTING & REPAIR > REMOVE/INSTALL SIDE PANELING IN TRUNK - AR68.30-P- 4800MCU > MODEL 451.3 /4 Shown on right side on model 451.3 Driver side, as of 31.8.10
Remove/install
1 Adjust left and right seat toward front
Fig 1: Identifying Trunk Side Paneling Components (Shown On Right Side) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Trunk Paneling And Belt End Fitting Tensioner Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Unclip belt end fitting tensioner¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3219 · Applies to: 450, 451, 452, 454
2 Unclip belt end fitting tensioner cover (7) Driver side, as of 31.8.10 3.1 Unclip cap (2) below right trunk paneling (1) and remove When removing right trunk paneling (1). 3.2 Unclip cover (3) on left trunk paneling (1) and remove When removing left trunk paneling (1). 4 Unscrew bolt (4) from trunk paneling (1) The bolt (4) is located on the right trunk paneling (1) behind the cap (2). 5 Unclip trunk paneling (1) and remove With code (C17) smart surround sound system, disconnect electrical connector on left rear and right rear speaker. Installation: Check clips (6) on trunk paneling (1), replace if necessary.Position edge guard on lower rear-end door in area of trunk paneling (1) with suitable tool. 6 Remove insulating mat (5) When replacing trunk paneling (1). 7 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL INSIDE REARVIEW MIRROR - AR68.40-P- 0001MCU > MODEL 451.3 /4
Remove/install
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. Fig 1: Identifying Rearview Mirror Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
is accessible¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3222 · Applies to: 450, 451, 452, 454
4 Detach electrical connector (1) on the combination switch (S4) and remove combination switch (S4)
5 Release cap (2) by applying suitable knife to combination switch (S4) and remove When replacing the combination switch (S4) 6 Install in the reverse order
7 Conduct function test of combination switch (S4)
TESTING & REPAIR > REMOVE/INSTALL BASS MODULE SPEAKER - AR82.62-P- 7839MCC > MODEL 451.3 /4 with CODE (C54) Sound system 2 MODEL 451.3 /4 as of 31.8.10 with CODE (C17) smart surround sound system
Remove/Install
1 Remove left seat (1) * not for USA* for USA only AR91.10-P- 1000MCCAR91.10-P- 101MCU 2 Disconnect electrical connector (2) from subwoofer (H4/29)
3 Fold back floor covering in marked area (arrows) and take subwoofer (H4/29) up and out installation : The subwoofer H4/29) must be aligned with the attachment points of the left seat (1).
Fig 1: Identifying Bass Module Speaker Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install in the reverse¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3223 · Applies to: 450, 451, 452, 454
4 Install in the reverse order
5 Perform function test on subwoofer (H4/29)
TESTING & REPAIR > REMOVE/INSTALL HANDLE AT GEARSHIFT LEVER - AR26.60-P- 6601MCU > TRANSMISSION 717.4 in MODEL 451.3/4
Remove/Install
1 Switch on ignition and move transmission Fig 2 2 Use an assembly wedge to loosen cover of selector lever (3) from the center console (4)
3 Move transmission into park position, switch off ignition and remove transmitter key
4 Raise cover of selector lever (3), grasp sleeve (2) with thumbs and index fingers of both hands and turn approx. Ensure that the electrical connectors of the components located on the cover of the selectro lever (3)
Fig 1: Identifying Gearshift Lever Handle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
45° counterclockwise¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3224 · Applies to: 450, 451, 452, 454
are not separated. The cast seam (arrow) on the sleeve (2) seves as a reference point. In the locked condition of the shift lever knob (1) it is transverse to the vehicle longitudinal axis (picture A) and in the unlocked condition of teh shift lever knob (1) it is twisted approx. 45° to the rear (picture B). Installation : Ensure that the shift lever knob (1) is locked correctly in the sleeve (2). 5 Detach shift lever knob (1) upwaards off the selector lever
6 Install in the reverse order TESTING & REPAIR > REMOVE/INSTALL COVER AT SELECTOR LEVER - AR68.20-P- 2309MCU > MODEL 451.3 /4 Fig 2: Identifying Mounting Wedge (110589035900) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
order¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3226 · Applies to: 450, 451, 452, 454
TESTING & REPAIR > REMOVE/INSTALL ADDITIONAL INSTRUMENTS - AR54.30-P- 6080MCF > MODEL 451.3 /4 as of 31.8.10 with CODE (V31) Cockpit clock and tachometer package
Remove/Install
1 Remove insturment cluster (A1) * not for USA* for USA only AR54.30-P- 6015MCCAR54.30-P- 6015MCU 2 Remove covering (2) of additional instruments (A15)
3 Remove bolt (3) of additional instruments (A15)
4 Adjust driver seat to the rear
5 Unhook wiring harness for additional instrumens (1) from holders (arrows) at bottom of instrument panel upper section The wiring additional instrument (1) can be accessed from the driver footwell.
6 Detach the additional
Fig 1: Identifying Eyeglass Compartment, Bolts And Instrument Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3229 · Applies to: 450, 451, 452, 454 · AR: AZ68.30-P-0006MCC
Designation Model 451.3 Model 451.4 BA91.60-1011- 01c Nut, bracket to kneebag Nm 5 5 RETROFITTING & CONVERSION > RETROFIT SPECTACLE POCKET - AZ68.10-P- 0010MCC > MODEL 451.3 /4 Install
1 Align eyeglass compartment (1) in upper third of instrument panel (3) as shown. Ensure that the cover of the eyeglass compartment (1) can be opened easily and the eyeglasses are accessible. 2 Tighten eyeglass compartment (1) with bolts (2) included in scope of delivery
RETROFITTING & CONVERSION > RETROFIT TRIM - AZ68.30-P-0006MCC > MODEL 451.3 /4 Trim parts Fig 1: Identifying Eyeglass Compartment, Bolts And Instrument Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3230 · Applies to: 450, 451, 452, 454
1 Unclip left front door panel cover (1) and right front door panel cover (2) from front area of door panel (7) with First loosen left front door panel cover (1) and right front door panel cover (2) in lower area with assembly wedge (8) as shown.
Fig 1: Identifying Retrofit Trim And Related Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Retrofit Trim And Related Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
assembly wedge (8)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3231 · Applies to: 450, 451, 452, 454 · AR: AZ68.50-P-0002MCC
Figure 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. Figure 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
Figure 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 > MODEL 451.3 /4 Fig 3: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3232 · Applies to: 450, 451, 452, 454
1 Move seats forward
2 Remove clips (2) and fold trunk floor covering (1) toward front Do not break or tear floor covering in trunk (1) when folding down.
Install
3 Drill dia. 5 mm holes in trunk floor covering (1) in area of holding lug (3), according to markings on trunk floor covering (1) from bottom Cordless drill/driver and Wet/dry vacuum cleaner
Fig 2 4 Tighten holding lugs (3) on trunk floor covering (1) using bolts, nuts and shims included in package contents
5 Fold over trunk floor covering (1), align and install clips (2)
6 Hook luggage net (4) into holding lugs (3)
7 Move seats to starting position
Fig 1: Identifying Floor Covering, Clip, Retaining Eye And Luggage Net Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > RETROFIT LUGGAGE-RETAINING NET IN TRUNK¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3233 · Applies to: 450, 451, 452, 454 · AR: AZ68.50-P-0003MCC
SIDE - AZ68.50-P-0003MCC > MODEL 451.3 /4 Removing 1 Remove cover (1) from luggage compartment lining at side Install 2 Position carrier (2) for luggage net in trunk side (3) in area of bracket (arrows A) on cover (1) 3 Lift carrier (2) at sides over cover (1) and position Fig 2: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Cover, Carrier And Luggage Net In Trunk Side Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(arrows B)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3234 · Applies to: 450, 451, 452, 454
4 Position luggage net in trunk side (3) in guided areas (arrows A, B, C) so that the cover (1) can be inserted easily into the luggage compartment lining at side 5 Install cover (1) in luggage compartment lining at side RETROFITTING & CONVERSION > INSTALL ANCHORING FOR DIVIDER ON VEHICLE FLOOR - AZ68.50-P-0005-01MCC > CARGO RETAINER, DIVIDER Number Designation Model 451.3 Model 451.4 BA68.50-P-1003-03D Bolt, divider bracket to vehicle floor Nm 22 22 1. Move seats forward. 2. Remove trunk luggage cover (3). Only on vehicles with trunk luggage cover (3) installed. The trunk luggage cover (3) is no longer required. 3. Unclip retaining clips (2) from trunk floor covering (1). 4. Fold trunk floor covering (1) toward front. 5. Position spacer sleeves (4) between body and trunk floor covering (1) instead of retaining clips The chamfer on the spacer sleeves (4) should point upward. Fig 1: Identifying Trunk Floor Covering, Retaining Clips And Luggage Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Fold back trunk floor covering (1) and align.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3235 · Applies to: 450, 451, 452, 454
- Position anchorings (6) above spacer sleeves and tighten bolts (5). The ring on the anchorings (6) should point in direction of travel. RETROFITTING & CONVERSION > INSTALL ANCHORINGS FOR DIVIDER ON ROOF Fig 2: Identifying Trunk Floor Covering And Spacer Sleeves Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Anchorings And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FRAME - AZ68.50-P-0005-02MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3236 · Applies to: 450, 451, 452, 454
CARGO RETAINER, DIVIDER Number Designation Model 451.3 BA68.50-P-1004-03D Bolt, divider bracket to rear roof frame Nm 12 Fig 1: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fasten adhesive tape (4) to counterplates (2) as shown.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3237 · Applies to: 450, 451, 452, 454
Adhesive tape (4) should not be attached to the contact surface of the counterplates (2) because this would decrease the strength of the bolted connection. 2. Use left or right counterplate (2) to match recess (arrow A) in roof frame. 3. Guide left and right counterplate (2) through opening in roof frame and position above holes (5). The adhesive tape (4) serves as an installation aid due to the limited clearance when inserting and positioning the counterplates (2). 4. Position anchorings (1) at top on holes (5) and tighten bolts (3) to left and right counterplate (2). The chamfer (arrow B) on the anchorings (1) should be pointed to the center of the vehicle. Fig 3: Identifying Adhesive Tape, Counter Plates And Holes Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Provide for recesses (9) on roof frame paneling (7) according to perforation (arrow D).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3238 · Applies to: 450, 451, 452, 454 · AR: AZ68.50-P-0005MCC
The perforation (arrow D) on the roof frame paneling (7) serves as reinforcement and should not be damaged: otherwise, the covers (6) are no longer held properly. Position graduated bit at corresponding center point and drill hole up to perforation (arrow D). Cut or mill out remaining pieces at side until the recess (9) corresponds to the perforation (arrow D). Cordless drill/driver 6. Drill holes (8) in roof frame paneling (7) according to perforation (arrow E). The perforation (arrow E) on the roof frame paneling (7) serves as reinforcement and should not be damaged; otherwise the covers (6) are no longer held properly. 7. Position cover (6) on roof frame paneling (7) and turn 90° The recesses (arrows C) on the covers (6) should point toward rear when installed. RETROFITTING & CONVERSION > INSTALL DIVIDER BETWEEN LUGGAGE AND PASSENGER COMPARTMENT - AZ68.50-P-0005MCC > MODEL 451.3 Fig 4: Identifying Roof Paneling, Recesses, Drill Holes And Covers Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3239 · Applies to: 450, 451, 452, 454
1 Remove rear roof frame trim
Remove/install rear roof frame paneling AR68.30- P- 4470MCC Install
2 Install lower anchorings (5) for divider (1) on vehicle floor
AZ68.50- P-0005- 01MCC *BA68.50- P-1003- 03D 3 Install upper anchorings (2) for divider (1) on roof frame
AZ68.50- P-0005- 02MCC *BA68.50- P-1004- 03D Figure For cordless drill/driver Figure 4 Install rear roof frame trim
Remove/install rear roof frame paneling AR68.30- P- 4470MCC 5 Hook divider (1) into upper anchorings (2).
Fig 1: Identifying Divider, Anchorings, Trunk Lining And Belt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Hook divider (1) into lower anchorings¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3240 · Applies to: 450, 451, 452, 454 · AR: BA68.00-Z-9999CZ
6 Hook divider (1) into lower anchorings (5) and tension belts (4).
7 Insert divider (1) on left and right luggage compartment lining (3).
8 Add special equipment to the vehicle data card and to the online vehicle data card Enter code (I05) Divider between luggage and passenger compartment.
CARGO RETAINER, DIVIDER Number Designation Model 451.3 BA68.50-P-1003-03D Bolt for divider mount on vehicle floor Nm 22 BA68.50-P-1004-03D Bolt, divider mount on rear roof frame Nm 12 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: INTERIOR EQUIPMENT - BA68.00-Z-9999CZ > MODEL all Cargo retainers MODEL 450.3, 451.3 /4, 452.3 BA68.50-P-1000-03D Center console MODEL 450.3 /4, 452.3 /4, BA68.20-P-1000-01C Fig 2: Identifying Graduated Drill (450 589 00 28 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Cross member below¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3241 · Applies to: 450, 451, 452, 454
454.0 Cross member below instrument panel MODEL 454.0 BA68.10-P-1000-02B Curtains/sun shades MODEL 450.3 BA68.50-P-1000-01C Handles MODEL 454 BA68.70-P-1000-02B TORQUE SPECIFICATIONS > CARGO RETAINERS - BA68.50-P-1000-03D > Model 450, 451, 452 CARGO RETAINER, DIVIDER Number Designation Model 450.3 Model 451.3 Model 451.4 Model 452.3 BA68.50-P- 1001-03D Bolt, partition to body Nm - - - 45 BA68.50-P- 1002-03D Bolt, upper bracket to body Nm 10 - - - BA68.50-P- 1003-03D Bolt, divider bracket to vehicle floor Nm - 22 22 - BA68.50-P- 1004-03D Bolt, divider bracket to rear roof frame Nm - 12 - - SPECIAL TOOLS > 452 589 01 63 00 CLIP REMOVER - WS68.00-P-0012K > FG 61/67/68/72/82/88/ 91/ Set K MODEL all Use: Clip remover for removing paneling parts, strips, covers, taillamp and roof spoiler. NOTE: smart-no.: 001 5807 V000 0000 00.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: INTERIOR EQUIPMENT - WS68.00-Z-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3242 · Applies to: 450, 451, 452, 454
9999CZ > MODEL all 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 450 589 00 43 00 Punching template GROUP 68/Set K WS68.00-P-0011K 450 589 07 99 00 Assembly tool set FG 68/91/Set B WS91.00-P-0031B 450 589 09 63 00 Hollow punch GROUP 68/Set B WS68.00-P-0010B 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P-0012K Fig 1: Identifying Clip Remover (452 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > NOTES ON PAINTWORK CARE - AH98.00-P-0001-01SM >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3243 · Applies to: 450, 451, 452, 454
Model 450, 451, 452, 454 The plant paintwork must not be treated with aggressive paint cleaners. Otherwise permanent paint damage will occur. The frequency of paintwork care depends among others on vehicle use, parking habits (e. g. garage or under trees), the times of year and weather or environmental influences. Stone marks and contaminants, such as insects, bird excrement, tree resin, oils, greases and fuels should be eliminated immediately. CAUTION: Do not wash or polish a vehicle in direct sunlight or when it has been heated up by the sun. The wheels and hubcaps have a two-coat metallic finish. Like the bodywork, they therefore may only be cleaned and maintained with products that will not harm the paintwork. Under no circumstances should scouring agent, agents containing acid or strong alkali agents or scouring sponges as well as high pressure hot water cleaning equipment be used. Brake dust that has been deposited should be eliminated weekly with suitable means used for cleaning the body. Please only use the checked and approved products from the DaimlerChrysler product range. The use specifications on the packaging must be observed. GENERAL INFORMATION > NOTES ON PAINT DIAGNOSIS - AH98.00-P-0002-01MCC > Model 451.3/4
Subject to technical modifications by DaimlerChrysler.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3244 · Applies to: 450, 451, 452, 454
Depending on the purpose and place of use, today's vehicle surface coatings are exposed to considerable environmental influences. These include: mechanical stress e.g. scratches or stone chipping; organic stress e.g. tree sap or bird lime, chemical stress e.g. road salts or industrial deposits. As even modern vehicle paintwork based on the latest technology can only withstand some of the above- mentioned items, it is possible that surface coatings are subject to a certain amount of wear or alteration. By following the care instructions and using the materials specified by DaimlerChrysler, the vehicle paintwork can be given long-lasting protection against various types of environmental pollution. The vehicle paintwork of the smart vehicles is applied using ultra-modern surface coating methods and is subject to ongoing quality control during and after production. Inspection zones As it is not necessary to subject all paint surfaces to the highest quality requirements, the paint surfaces have been subdivided into two inspection zones: Inspection zone 1 (Z1) relates to surfaces that are in the direct visible range and where irregularities are therefore particularly irritating and noticeable. Inspection zone 2 (Z2) relates to surfaces that are not in the direct visible range and where irregularities are therefore not particularly noticeable. Using the following information, DaimlerChrysler makes it possible for you to assess paint irregularities about which a complaint has been made and deduce appropriate measures to adequately remedy the complaints. The procedure for assessing the paintwork complaints in warranty cases is described in the subsequent Fig 1: Identifying Paint Surface Inspection Zones Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
guideline and mu t be complied with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3245 · Applies to: 450, 451, 452, 454
Definition of guidelines for paint inspections Fundamentals of an objective assessment Fault types Table of guidelines and assessment Fundamentals of an objective assessment: The vehicle must be assessed or examined in a well-lit room or in daylight (neon light is not permissible). The assessment must be carried out at a distance of at least 60 cm from the vehicle. The vehicle must be cleaned beforehand (i.e. at least one car wash) and must be dry. The assessor must be able to provide proof of expert knowledge in the field of paint finishes. The viewing time per complaint should not last longer than 15 s. The specific stipulations of inspection zone 1 (Z1) and inspection zone 2 (Z2) must be adhered to. Fault types The fault types and specifications listed below apply to the body (Safety Metal Body Frame SMB, Tridion) and to the plastic body panels (CBS). If a repair of the plastic body panels (CBS) is defined by our evaluation key, then these parts will not be reworked, instead they will be replaced. All paint variants can be treated like conventional paints (two-coat finish). In the event of transport damage, follow the specified reporting process described in the smart-Guide. This information can be found under Quality environment management/Sales/Order management and Logistics/Transport. IMPORTANT: Documentation requirements If the repair is a warranty case, proceed with the plastic body panels (CBS) as per the valid stipulations for warranty parts return. If follow-up operations are required on the tridion, pictures must be produced to clearly document the damage. In most cases, Polaroid photos are not adequate. These pictures must be stored in archives with the warranty documentation and made available to DaimlerChrysler upon request. When in doubt, consult with your service manager. The release form (cost estimate) must be signed by the Market Performance Center (MPC); the costs released in it must not be exceeded. This form must be stored in archives with the warranty documentation.
see:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3246 · Applies to: 450, 451, 452, 454
Paint complaint sheet OF98.00-P-3000-01O Fault type: Scratch Description: Damage to the surface caused by mechanical action Receipt of new vehicle: For relatively long and noticeable scratches → Shipping damage Service order: For relatively long and noticeable scratches → no warranty Remarks: Scratches in inspection zone 1 and inspection zone 2 up to 2 mm long and not noticeable are not complaints. Fault type: Blotches Description: Overpolished areas Receipt of new vehicle: Warranty Service order: No warranty Remarks: Note documentation requirements Fig 2: Identifying Scratches On Inspection Zones Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Paint blisters¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3247 · Applies to: 450, 451, 452, 454
Description: Paint flaking on the components caused by mechanical action Receipt of new vehicle: Shipping damage Service order: No warranty Remarks: Note documentation requirements Fault type: Defect Description: Unpainted spots on the components Receipt of new vehicle: Warranty Service order: Warranty (presuming that there has been no paint repair) Remarks: Assessment and release by the MPC required Fig 3: Identifying Overpolished Areas (Blotches) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Paint Flaking On Components (Paint Blisters) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Fog, dull and rough¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3248 · Applies to: 450, 451, 452, 454
Description: Oversprays and deposits of powder that have not spread out evenly, matt and some rough surfaces Receipt of new vehicle: Warranty Service order: Warranty (presuming that there has been no paint repair) Remarks: Assessment and release by the MPC required Fault type: Runs Description: Formation of droplets, severe accumulation and undulated runoff Receipt of new vehicle: Warranty Service order: Warranty (presuming that there has been no paint repair) Remarks: Note documentation requirements Fig 5: Identifying Unpainted Spots On Components (Defect) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Oversprays And Deposits Of Powder Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Orange peel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3249 · Applies to: 450, 451, 452, 454
Description: Orange peel is a pitting of the dried paintwork Receipt of new vehicle: Warranty Service order: Warranty Remarks: An approval by MPC is required for inspection zone 1 and inspection zone 2; will only be accepted as a warranty case, if adjacent surfaces are different Fault type: Color deviation Description: Different color hues Receipt of new vehicle: Warranty Service order: Warranty Remarks: An approval by MPC is required for inspection zone 1 and inspection zone 2 Fig 7: Identifying Formation Of Droplets Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Identifying Orange Peel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Polishing marks¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3250 · Applies to: 450, 451, 452, 454
Description: Polishing creates circular, light areas Receipt of new vehicle: Warranty Service order: No Warranty Remarks: Assessment and release by the MPC required Fault type: Clouding Description: Gradation of metallic finishes through dark and light areas Receipt of new vehicle: Warranty Service order: Warranty Remarks: Inspection and approval by MPC are required for inspection zone 1 and inspection zone 2 Fig 9: Identifying Different Color Hues Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 10: Identifying Polishing Marks Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Streaks¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3251 · Applies to: 450, 451, 452, 454
Description: Change in surface finish Receipt of new vehicle: Warranty Service order: Warranty Remarks: Inspection and approval by MPC are required for inspection zone 1 and inspection zone 2 Fault type: Dent Description: Slight punctiform deformation from outside inward Receipt of new vehicle: Shipping damage Service order: No warranty Remarks: - Fig 11: Identifying Gradation Of Metallic Finishes (Clouding) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 12: Identifying Change In Surface Finish (Streaks) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Bump¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3252 · Applies to: 450, 451, 452, 454
Description: Slight punctiform deformation from inside outward Receipt of new vehicle: Warranty Service order: No warranty Remarks: Inspection and approval by MPC are required for inspection zone 1 and inspection zone 2 Fault type: Sanding marks/sanding spots Description: Visible recess on the surface, without damage to paintwork Receipt of new vehicle: Warranty Service order: Warranty (presuming that there has been no paint repair) Remarks: Inspection zone 2 longer than 2 mm and not noticeable are not defects; inspection and approval by the MPC required Fig 13: Locating Slight Punctiform Deformation From Outside Inward (Dent) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 14: Locating Slight Punctiform Deformation From Inside Outward (Bump) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Inclusion of dirt or craters¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3253 · Applies to: 450, 451, 452, 454
Description: Visible foreign objects in the paintwork impairing the visual appearance Receipt of new vehicle: See table of guidelines Service order: See table of guidelines Remarks: Assessment, see table of guidelines Fault type: Pinpricks and micropores Description: Coating defects in the form of recesses that must not go all the way through to the substrate Receipt of new vehicle: See table of guidelines Service order: See table of guidelines Remarks: Assessment and release by the MPC required Fig 15: Identifying Visible Recess On Surface (Sanding Marks/Sanding Spots) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 16: Identifying Inclusion Of Dirt Or Craters Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TABLE OF GUIDELINES FOR TRIDION BODY¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3254 · Applies to: 450, 451, 452, 454
Error type Inspection zone 1:Countable faults per assessment zone (assessment radius is 300 mm) Inspection zone 2:Countable faults per assessment zone (assessment radius is 300 mm) Inclusions and craters Up to 4 faults smaller than 2 mm in dia. are not defects.For more faults, an approval from MPC is required Up to 7 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required Pinpricks and micropores Up to 5 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required Up to 8 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required The listed faults relate to the faults per component in the particular zone (inspection zones 1 and 2). TABLE OF GUIDELINES FOR PLASTIC BODY PANELS (CBS) Error type Inspection zone 1:Countable faults per assessment zone Inspection zone 2:Countable faults per assessment zone Dirt Up to 3 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required Up to 3 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required Blisters Are defects.Release by MPC required Are defects.Release by MPC required Pores Are defects.Release by MPC required Up to 3 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required The listed faults relate to the faults per component in the particular inspection zone 1 and inspection zone 2. In the event of a deviation, a release must be requested from the Market Performance Center (MPC). All the warranty cases must be photographed and stored in archives with the warranty documentation. GENERAL INFORMATION > DAMAGE AND STRESS CAUSED TO PAINTWORK BY Fig 17: Identifying Coating Defects Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
EXTERNAL INFLUENCES - AH98.00-P-8070-02SM >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3255 · Applies to: 450, 451, 452, 454
Model 450, 451, 452, 454 Stress to paint Temperature (cold, heat) Humidity and UV rays Aggressive pollutants Mechanical effects such as dust, sand, scratches Structure of a one-coat finish Structure of a two-coat finish In addition to the effects caused by chemical or biological substances such as sulfurous acid (acid rain), oil soot, road salt, surfactants, tree resin, insects, bird droppings and mechanical damage caused by washing brushes and stone chipping, damage can also be caused by moisture and UV radiation from the sun. The pigmented standard finishes are particularly endangered by the type of damage mentioned last. The fine plastic film of synthetic resin surrounding and protecting the coloring pigment particles is destroyed in the course of time by the effect of UV radiation exposing the coloring pigment. This makes the paint surface dull. When the pigment protecting synthetic layer is removed by polishing with products containing abrasive Fig 1: Identifying Structure Of One-Coat Finish Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Structure Of Two-Coat Finish Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
agents, even on new vehicles, the pigment weathering process begins even earlier. The degree of damage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3256 · Applies to: 450, 451, 452, 454
depends on the intensity and duration of the UV radiation which cannot be avoided even with the best paints. For this reason, careful care of the paint repeated at proper intervals as well as technical maintenance helps preserve the value of the vehicle. With good paint care, the beauty of the new paintwork can be maintained significantly longer. GENERAL INFORMATION > NOTES ON PAINTWORK REPAIRS - AH98.00-P-9408-02MCC
Model 451.3/4, 454.0 Notes on paintwork repairs The use of DaimlerChrysler approved materials is absolutely necessary for proper repair because the material characteristics of the recommended products influence the work results and working time. Only the cleaning agents released by DaimlerChrysler are to be used for reconditioning powder-coated parts (see care instructions). Plastic parts with recorded working time are always removed for painting. General preparatory work for painting: General preparatory work for painting includes masking, preparing the paint, cleaning or degreasing and sanding the part; furthermore preparing the filler and setting up and cleaning the machines; in addition, transport of the vehicle to the workplace as well as wearing protective clothing. Additional preparatory work for painting: Additional preparatory work for painting includes e.g. matching the color. The time values specified by DaimlerChrysler relate to the actual painting work with the general preparatory work for painting. The assembly operations and bodywork required are not included. WARNING: Vehicles with diesel engines should on no account be started up when in the spraying or drying booth. There is a risk of explosion due to preglow. The following steps should be observed before and during repair work: Disconnect the battery at the negative pole (secure the radio code beforehand). Open convertible soft tops. Mask off rear lamps, rear side windows and the headlamps with heat reflecting material. Only open tank cap slightly once in drying booth and close again immediately after drying. Remove spray cans or similar other objects representing a fire risk from the vehicle. The drying temperature (or object temperature) of 60°C must not be exceeded. The stages for paintwork on body panels are categorized into 3 paint stages: Stage 1 is categorized into: 1-E New part paintwork of welded-in body panels with complete paintwork structure (e.g. following sectional repair). 1-M New part paintwork of removed body panels with complete paintwork structure (e.g. doors, flaps).
1-J Body inner surfaces.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3257 · Applies to: 450, 451, 452, 454
Stage 2: Surface paintwork (e.g. with minor paint damage without spackle application). Stage 3: Post-repair refinishing with a spackle application of up to 50 % (e.g. following dent removal). Very minor damage on Tridion: Immediately cover minor paint damage such as scratches, gashes or stone chipping by means of a gravity cup gun or other means of repair (e.g. spray can, touch-up paint pen) to avoid corrosion formation. When corrosion starts, the corrosion points should be rectified immediately and thoroughly. Finally corrosion protection primer is first applied to the point before the top coat is applied. The outside of the vehicle must be clean and dry for painting work. Ambient temperature should be at least +15°C. The primary coat must not be damaged! Rectifying cracks in seam seal: Lift up the windshield surround and fix in position. Remove powder paint in the seam area without damaging the joining radius. Remove the old seam, for example, with a suitable compressed air milling machine. Then remove the grinding dust and smooth the edge areas. Then mask off the edges of the join so that the bonding edge is under the joining radius. Apply repair sealing and then smooth immediately. Then remove adhesive tape immediately. Observe the manufacturer's drying specifications. Protect the rest of TRIDION from paint mist. Notes on applying paintwork to plastic The use of DaimlerChrysler 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. In the event of more severe damage with substrate damage, replacing the plastic paneling with a painted new part or a raw part that is to be painted is to be preferred to a repair. In the plant, the dyed plastic paneling is provided with a UV protective paint. If the protective paint is damaged by scratches, stone chipping or gashes, the damaged areas should be repaired immediately, otherwise discolorations may occur on the exposed substrate. Depending on the climate and application location, differences in color shade can occur between genuine parts and replaced parts during the entire vehicle operating time. DaimlerChrysler therefore recommends that the customers' attention be drawn to these color changes. The following description relates to the paint repair of plastic paneling coated with UV protective paint. Safety measures: The drying temperature (or object temperature) of 60°C must not be exceeded. Plastic parts to be painted should be removed from the vehicle for painting. To ensure that the shape of the plastic parts is retained during force drying, suitable painting stands must be
used.¶
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For drying temperatures in excess of 60°C, irreversible changes in shape may occur. General preparatory work for painting: General preparatory work for painting includes preparing the paint, cleaning or degreasing and sanding the part; furthermore setting up and cleaning the machines; in addition, transport of the plastic part to the workplace as well as wearing protective clothing. Additional preparatory work for painting: Additional preparatory work for painting includes e.g. matching the color. The paintwork of plastic parts is applied in one paint stage: Stage 2 (applying the top coat and special-effect painting): Surface paintwork (with minor paint damage without spackle application or primed or filled new and repair parts). Repair of plastic parts DaimlerChrysler approved materials may be used for the repair of plastic parts. The manufacturer's data on the use and processing must be observed. Preparation of substrate: The intact paint surface as well as all substrates to be processed must be clean and free from dust and grease. All substrates must be properly ground and washed off with demineralized water. GENERAL INFORMATION > NOTES ON FORCE DRYING OF VEHICLE PAINTS - AH98.00- P-9408-03SM > Model 450, 451, 452, 454 The vehicles must be thoroughly cleaned before they are brought into the painting facility. Greases and oils in particular must be thoroughly removed from the external skin as they can yellow the top coat at temperatures of around 80°C. When the object temperature on the vehicle is approx. 60°C, the following measures are necessary: Open the fuel filler cap. Disconnect ground cable of battery Cover rear lamp units. Remove outside temperature sensor if an outside thermometer is installed (not with electric outside thermometer). Mask registration stamp on license plate Remove fire extinguishers, aerosols, fuel canisters, CDs, music cassettes and other loose articles from the interior Electronic components such as control units, sensors, airbags, and emergency tensioning
retractors may only be heated up to a max. object temperature of 90°C.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3259 · Applies to: 450, 451, 452, 454
In cases of doubt, a series of measurements is to be performed to check the temperature at these points (remove the electronic components beforehand) using a mercury maximum thermometer during the baking phase. If the maximum permissible temperature is not exceeded, the electronic components need not be removed. GENERAL INFORMATION > GENERAL NOTES ON COMPLAINTS ABOUT PAINTWORK REPAIRS - AH98.00-P-9408-05SM > Model 450, 451, 452, 454 In the case of complaints concerning paint repairs, it is assumed that the specified materials have been used in accordance with the paint manufacturer's guidelines and working specifications, and that the paintshop foreman responsible was satisfied that all parameters were within the specified tolerances and that a defect in workmanship can therefore be ruled out. A lot of paintwork defects, e.g. dirt inclusions, overspray, paint runs and loss of gloss, can be eliminated using inexpensive polishing (in other words without paintwork rectification). Causes for complaint: In connection with the original factory finish (primarily for color deviations) With the painting of genuine parts Problems in connection with the materials. NOTE: In the event of customer complaints about faulty paintwork that are to be remedied under warranty or as goodwill, prior approval must be obtained by the Market Performance Center (MPC). GENERAL INFORMATION > NOTES ON REPAIR PAINTWORK IN BONDING AREA OF WINDOWS AND COMPONENTS - AH98.00-P-9408-07MCC > Model 451.3/4 Front roof frame shown on model 451.3
Evaluation of bonding area on body flange¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3260 · Applies to: 450, 451, 452, 454
Individual paint chips up to approx. 2 cm 2 Individual paint chips up to approx. 2 cm 2, as well as paint chips in base coat (1) and paint chips in clear coat (2), are permissible. In the event of paint chips or damage resulting from removal down to the sheet metal, it is necessary to prime these surfaces with the approved materials. Paint chips in the base coat (1) or paint chips in the clear coat (2) may be treated only outside of the bonding surface of the adhesive bead (3) with the approved material, base coat and clear coat. It is necessary to reinstate the corrosion protection on the body as a matter of principle. Numerous paint chips over 2 cm 2 In the case of paint chips over 2 cm 2, as well as paint chips in the base coat (1) or larger area paint chips in the clear coat (2), repaint the entire gluing area. In the bonding area for the windshield or the bonding area for the roof paneling, the entire paint structure must be sanded down to the coat of electrolytic immersion paint. Grinding all the way down to the sheet steel are acceptable. Residual coating thickness approx. 20 μm. New paintwork structure Use materials from an approved paint system for the new paint structure consisting of filler primer for completely sanded spots, EP filler, base coat and clear coat. Recommended coat thicknesses Fig 1: Identifying Paint Chips On Base And Clear Coats And Adhesive Bead Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
EP filler 45 to 70 m for function surfaces¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3261 · Applies to: 450, 451, 452, 454
120 μm maximum for visible surfaces (before sanding) Base coat 15 to 25 μm Clear coat 50 to 70 μm Drying process If no information on the inlet temperature and drying times are available from the paint manufacturers, use the following specifications. Inlet temperature: 72°C (for 60°C object temperature) Drying time: EP filler 90 minutes Base coat 60 minutes Clear coat 90 minutes Gluing area Paint the bonding surface (A) only with EP filler (5). After applying the adhesive material (7) ensure that the bonding surface (A) is covered 80 %. After installing the windshield or roof paneling, the EP filler (5) should be covered with adhesive material (7). Ensure that the side subject to weathering is always completely covered with adhesive material to ensure proper corrosion protection (7). GENERAL INFORMATION > ABBREVIATIONS IN THE PAINTING SECTOR - AH98.00-P- 9409-01SM > Model 450, 451, 452, 454 General abbreviations AbfG Waste Disposal Law Fig 2: Identifying Bonding Surface & EP Filler Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
AbfNachwV¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3262 · Applies to: 450, 451, 452, 454
Wa te Verification Act AbwAG Waste Water Disposal Law AVwV General Administrative Regulation ATL Anodic immersion painting ATV Specifications governing waste water handling as set forth in the German Waste Water Association e.V. bar (atmospheres) Measurement of air pressure BImSchG Law for the Protection Against Harmful Environmental Effects of Air Pollution, Federal Emissions Law DD Two-component polyurethane paint with designation "Desmophen Desmodur" DIN German Institute for Standardization DNA Committee for German Standards Elex V Regulations on Electrical Facilities in Hazardous Locations EPC Electro powder coating (ETL) ETL Electro immersion painting GPSG Technical working materials and consumer products act GefStoffV Hazardous Substances Act GGVS Hazardous Goods Transport Regulations Sulfuric acid anodizing Impulse limit volume spray HS High solid KTL Cathodic immersion painting KH Artificial resin KS Plastic MAK Maximum workplace concentration MBL Mercedes-Benz Delivery Specifications ms Medium solid OWiG Infringement Law PVK Pigment volume concentration pH-value Potential hydrogenium concentration of hydrogen ions in a hydrous solution RAL "Reich" Committee for Terms of Delivery and Quality Assurance at the Committee for German Standards TA Noise German Noise Act TA Air German Clean Air Act TRbF Technical Rules for Flammable Liquids
TRgA¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3263 · Applies to: 450, 451, 452, 454
Technical Rules for Hazardous Materials Trg A Technical Directives for Hazardous Materials TRGS Technical Rules for Hazardous Substances USB Environment officer UWS Environmental protection VAwS Directive on Facilities for the Storage, Bottling and Turnaround of Substances Harmful to Ground Water VBF (Front control panel) Directive on Flammable Liquids VDI Directives of the Association of German Engineers VLwF Directive on the Storage of Liquids Harmful to Ground Water WHG Water Resources Law μm 1 micrometer=1/1000 mm, unit of measurement of coating thickness 2 K Two-component Abbreviations for hazardous materials classes A I Flash point below 21°C A II Flash point above 21°C to 55°C A III Flash point above 55°C to 100°C Abbreviations for plastics ABS Acrylonitrile-butadiene-styrene AMMA Acrylonitrile-methylmethacrylate BFK Boron filament reinforced plastic CA Cellulose acetate CAB Cellulose acetate butyrate CFK Carbon-fiber reinforced plastic EP Epoxy FEP Perfluoroethylene propylene GF Glass fiber GFK Glass fiber reinforced plastic HDPE High density polyethylene LDPE Low density polyethylene MF Melamine formaldehyde PA Polyamide PBTP Polybutylene terephthalate
Polycarbonate¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3264 · Applies to: 450, 451, 452, 454
PC Polycarbonate PE Polyethylene PEC Chlorinated polyethylene PETP Polyethylene terephthalate PF Phenol formaldehyde PIB Polyisobutylene PMMA Polymethyl methacrylate POM Polyoxymethylene, polyformaldehyde (a polyacetate) PP Polypropylene PP-EPDM Polypropylene ethylene propylene diene copolymer PP-PMMA Polypropylene polymethyl methacrylate PPO Polyphenylene oxide PPS Polyphenylene sulfide PSU Polysulfone PS Polystyrene PTFE Polytetrafluor ethylene PUR Polyurethane PVC Polyvinyl chloride PVCC Chlorinated polyvinyl chloride PVDC Polyvinylidene chloride PVDF Polyvinylidene fluoride PVF Polyvinyl fluoride RTPU-GF Reinforced Thermoplastic Polyurethane - glass-fiber reinforced PUR polyurethane SAN Styrene-acrylonitrile Std. Styrene-butadiene SI Silicone SMS Styrene-alpha-methylstyrene UF Urea formaldehyde VP Unsaturated polyester VPE Vulcanized polyethylene GENERAL INFORMATION > GENERAL INFORMATION ON MB MATERIALS - AH98.00-P- 9409-03SM > Model 450, 451, 452, 454
The MB materials for paint and corrosion protection have been replaced with materials from our system¶
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partners. The DaimlerChrysler approved and checked materials from the following companies are to be used: Du Pont Performance Coatings www.performance-coatings.org BASF Coatings AG www.basf-coatings.de PPG Industries International www.ppg.com Care, cleaning and preservation agents as well as materials for paint repair (paint touch-up pens and paint spray cans) are still available as genuine parts from the Global Logistics Center (GLC) in Germersheim. For the leather paints, only the current standard colors are available from the GLC in Germersheim. All other shades can be ordered from the Lindgens company. GENERAL INFORMATION > GENERAL NOTES ON TOUCH-UP APPLICATORS AND PAINT SPRAY CANS - AH98.00-P-9409-06SM > Model 450, 451, 452, 454 Touch-up paint pens and paint spray cans are only suitable for temporarily touching up minor paint damage such as stone marks or scratches. They must not be used on the MB original paintwork repairs on the outer skin, since it is not possible to restore the original condition using this method. Repairing minor paintwork damage With this kind of damage, and also in the repair of this damage, the entire paint structure is often damaged right down to the sheet metal. For reasons of quality and corrosion protection, a primer must be applied before touching up the top coat in such cases. Processing instructions are printed on the touch-up paint pens and in the leaflet provided inside the caps of the spray cans. Touch-up applicators: Primer stick for metal parts The cap contains a rust scraper that should be used to eliminate rust spots and loose paint. Top coat touch-up paint pens for standard and metallic paint Body outer skin (tridion) Paintwork set (base coat and clearcoat, gloss) Detachable plastic parts (customized body panel=CBS) Paintwork set (base coat and clearcoat, gloss)
Paint spray cans:¶
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Priming spray can for metal parts The cap contains a repair kit (rust scraper, abrasive paper and filler paste) for eliminating minor rust spots and other uneven areas. Do not use for repairing plastic parts. Top coat spray cans (standard finish and metallic finish) Body outer skin Paintwork set (base coat and clearcoat, gloss) Detachable plastic parts Paintwork set (base coat and clearcoat, gloss) GENERAL INFORMATION > NOTES AND REPAIR OPTIONS FOR PAINTING DETACHABLE PLASTIC COMPONENTS - AH98.20-P-9410-01MCC > Model 451 The detachable plastic parts (e.g. CBS front, CBS rear) are supplied as a dyed part painted with clearcoat or as a raw part painted with base coat and clearcoat in the corresponding vehicle color. Water-based paints are used. Repair options: 1. Replacing parts 1. If major damage has occurred such as cracks or deep scratches in plastic, the parts must be replaced. 2. We also recommend replacing small parts such as outside mirror housings, hubcaps, and door handles in the event of paint damage. 2. Paint repair 1. For slight damage such as short or flat scratches, stone marks or when being painted in another color, a post-repair refinishing is possible. The plastic parts to be painted should be removed from the vehicle for painting. Integrated parts must be removed. In the event of damage with substrate damage or if the paint coat has been sanded through, it is necessary to replace the plastic paneling with a painted new part. The components are made of PP (polypropylene) and joined by applying a flame; this procedure is not yet available at this time in the event of a repair. The DaimlerChrysler approved system partners are currently working on repair solutions. When they are used, the processing specifications of the manufacturer must be observed. The detachable plastic parts must be placed or suspended for painting in such a way that their shape remains intact during force drying.
TESTING & REPAIR > PAINTWORK BONDING AREA FOR WINDSHIELD - AR98.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3269 · Applies to: 450, 451, 452, 454
0900MCC > MODEL 451.3/4 Shown on model 451.3 Fig 1: Identifying Body Flange & Bonding Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Windshield Gluing Area And Body Flange Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of poisoning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3272 · Applies to: 450, 451, 452, 454
Inhaling paint vapors and spray mist can pose a health hazard! Contact with paint vapors can cause irritation to skin and eyes. Paint contains hazardous substances such as: Cancer causing substances (e.g. benzene, zinc chromate) Poisonous substances (e.g. zinc chromate, phenol), Genetically hazardous substances (e.g. ethyl glycol acetate/ethyl acetate) Rules of conduct and safety precautions No smoking! No open flames! Always use protective clothing, gloves, safety goggles and skin cream. Paint in a spray booth. Ensure adequate ventilation and always wear a protective respiratory mask. Paints require special identification. Poisonous and cancer causing substances (marked with a T, skull and crossbones) may only be handled by specially qualified personnel. When handling these materials, please observe the safety guidelines (UVV-VBG 23), the Ordinance on Hazardous Substances and the Environmental Protection Regulations (according to the hazardous substance ID on the container and the safety data information sheets from the supplier). In export countries, please observe your country-specific accident prevention and protection regulations. First aid measures Eyes Rinse eye thoroughly for several minutes with lukewarm water while protecting the non-affected eye. Eyelid must be wide open. Request victim to move the eye in all directions as it is being rinsed out. Consult a physician (eye doctor) and be sure to state measures already taken. Respiratory paths Fresh air; perform artificial respiration if victim is no longer breathing, if necessary administer oxygen, keep warm, keep calm. Contact physician. Skin Paint splashed onto skin must be immediately and carefully washed off with plenty of soap and water. If necessary, clean skin again with a suitable skin cleaning agent. SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY CAUSTIC BURNS DUE TO CONTACT WITH METAL DUST REMOVER. - AS98.00-Z-0003-01A > Avoid contact. Wear tight-fitting safety glasses and acid-resistant gloves. Risk of injury Metal dust remover contains oxal and phosphoric acids. Contact or swallowing can result in acid burns. Safety instructions/precautions
Wear acid-resistant protective clothing (apron, protective gloves) as well as safety glasses. Observe¶
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safety regulations! Wear tight-fitting safety glasses, acid-resistant gloves and protective clothing. Avoid all contact with eyes and skin. Do not eat or drink while performing this work. Keep metal dust remover away from food and beverages. Work only in well ventilated rooms. First aid measures In case of ingestion Consult physician immediately, only allow victim to induce vomiting if fully conscious. Rinse out mouth and drink large quantities of water. In case of eye contact Rinse thoroughly with water and consult physician (eye doctor) immediately. In case of inhalation Move victim to fresh air and consult physician. In case of skin contact Immediately wash with plenty of soap and water, apply protective skin ointment. Consult physician if skin irritation continues. SAFETY PRECAUTIONS > SAFETY INFORMATION: PAINTWORK - AS98.00-Z-9999ZZ > MODEL all Explosion hazard when handling organic peroxide hardeners. Injury hazard for skin and eyes from organic peroxide hardeners MODEL 405.210/230 with BODY 405.830 nur fur USA/Kanada AS98.00-Z-0005- 01NA Risk of explosion caused by handling organic peroxide hardeners. Risk of injury caused by skin and eye contact with organic peroxide hardeners MODEL 199, 405, 957... AS98.00-Z-0005- 01A Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. MODEL all AS98.00-Z-0002- 01A Risk of injury caused by caustic burns due to contact with metal dust remover. MODEL all AS98.00-Z-0003- 01A BASIC KNOWLEDGE > TABLE OF CONTENTS FOR PAINTWORK AND ANTICORROSION MATERIALS IN SERIES PRODUCTION - GF98.00-P-0991A >
Detachable parts on model 451.3¶
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Item Designation (MODEL 451.3) Material Delivery condition of replacement part 1.1 Front CBS Polypropylene (PP) (ED230HP)
1.2 Front fog lamp covering
1.3 Bottom grille
1.4 Top grille
1.5 Engine hood PP (ED230HP)
1.6 Cowl
1.7 Roof Polycarbonate
1.8 Spoiler
1.9 Liftgate panel PP (ED230HP)
1.10 B-pillar paneling PP (ED230HP)
1.11 Rear CBS PP (ED230HP)
1.12 Intake air cover PP (ED230HP)
Fig 2: Identifying Detachable Parts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Door handle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3278 · Applies to: 450, 451, 452, 454
1.13 Door handle PP (ED230HP)
1.14 Tridon safety cell Steel
1.15 Longitudinal member paneling PP (ED230HP)
1.16 Door PP (ED230HP)
1.17 Window channel strip
1.18 Exterior rearview mirrors PP (ED230HP)
Color code, model 451.4 Detachable parts on model 451.4 Fig 3: Identifying Steel And Plastic Parts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Item¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3279 · Applies to: 450, 451, 452, 454
Designation (MODEL 451.4) Material Delivery condition of replacement part 2.1 Front CBS PP (ED230HP)
2.2 Front fog lamp covering
2.3 Bottom grille
2.4 Top grille
2.5 Engine hood PP (ED230HP)
2.6 Cowl
2.7 Roof rail PP (ED230HP)
2.8 Spoiler
2.9 Liftgate panel PP (ED230HP)
2.10 Rear CBS PP (ED230HP)
2.11 Intake air cover PP (ED230HP)
2.12 Door handle PP (ED230HP)
2.13 Tridon safety cell Steel
Fig 4: Identifying Detachable Parts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3281 · Applies to: 450, 451, 452, 454
1 Remove cargo area floor cover
AR68.20-P- 4810MCU 2 Unclip retaining clip (3) of wiring harness
3 Detach electrical connector (4) from parking brake indicator switch (S12)
4 Remove bolts (5) Installation: Perform function test of hand brake lever (1).If the hand brake cannot be operated, push the clamping piece (2) upwards to enable it to engage in the pull rod's toothing (6).
*BA42.20-P-1002- 01D 5 Remove hand brake lever (1) The teeth on the pull rod (6) can be disengaged by completely releasing the hand brake lever (1). Should the pull rod (6) not release, the clamping piece (2) can be unlocked
Fig 1: Identifying Hand Brake Lever Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
by pressing with a¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3282 · Applies to: 450, 451, 452, 454
screwdriver. Installation: The 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
GENERAL INFORMATION > NOTES ON PAINTWORK CARE - AH98.00-P-0001-01SM >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3283 · Applies to: 450, 451, 452, 454
Model 450, 451, 452, 454 The plant paintwork must not be treated with aggressive paint cleaners. Otherwise permanent paint damage will occur. The frequency of paintwork care depends among others on vehicle use, parking habits (e. g. garage or under trees), the times of year and weather or environmental influences. Stone marks and contaminants, such as insects, bird excrement, tree resin, oils, greases and fuels should be eliminated immediately. CAUTION: Do not wash or polish a vehicle in direct sunlight or when it has been heated up by the sun. The wheels and hubcaps have a two-coat metallic finish. Like the bodywork, they therefore may only be cleaned and maintained with products that will not harm the paintwork. Under no circumstances should scouring agent, agents containing acid or strong alkali agents or scouring sponges as well as high pressure hot water cleaning equipment be used. Brake dust that has been deposited should be eliminated weekly with suitable means used for cleaning the body. Please only use the checked and approved products from the DaimlerChrysler product range. The use specifications on the packaging must be observed. GENERAL INFORMATION > NOTES ON PAINT DIAGNOSIS - AH98.00-P-0002-01MCC > Model 451.3/4
Subject to technical modifications by DaimlerChrysler.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3284 · Applies to: 450, 451, 452, 454
Depending on the purpose and place of use, today's vehicle surface coatings are exposed to considerable environmental influences. These include: mechanical stress e.g. scratches or stone chipping; organic stress e.g. tree sap or bird lime, chemical stress e.g. road salts or industrial deposits. As even modern vehicle paintwork based on the latest technology can only withstand some of the above- mentioned items, it is possible that surface coatings are subject to a certain amount of wear or alteration. By following the care instructions and using the materials specified by DaimlerChrysler, the vehicle paintwork can be given long-lasting protection against various types of environmental pollution. The vehicle paintwork of the smart vehicles is applied using ultra-modern surface coating methods and is subject to ongoing quality control during and after production. Inspection zones As it is not necessary to subject all paint surfaces to the highest quality requirements, the paint surfaces have been subdivided into two inspection zones: Inspection zone 1 (Z1) relates to surfaces that are in the direct visible range and where irregularities are therefore particularly irritating and noticeable. Inspection zone 2 (Z2) relates to surfaces that are not in the direct visible range and where irregularities are therefore not particularly noticeable. Using the following information, DaimlerChrysler makes it possible for you to assess paint irregularities about which a complaint has been made and deduce appropriate measures to adequately remedy the complaints. The procedure for assessing the paintwork complaints in warranty cases is described in the subsequent Fig 1: Identifying Inspection Zones Of Paint Surface Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
guideline and mu t be complied with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3285 · Applies to: 450, 451, 452, 454
Definition of guidelines for paint inspections Fundamentals of an objective assessment Fault types Table of guidelines and assessment Fundamentals of an objective assessment: The vehicle must be assessed or examined in a well-lit room or in daylight (neon light is not permissible). The assessment must be carried out at a distance of at least 60 cm from the vehicle. The vehicle must be cleaned beforehand (i.e. at least one car wash) and must be dry. The assessor must be able to provide proof of expert knowledge in the field of paint finishes. The viewing time per complaint should not last longer than 15 s. The specific stipulations of inspection zone 1 (Z1) and inspection zone 2 (Z2) must be adhered to. Fault types The fault types and specifications listed below apply to the body (Safety Metal Body Frame SMB, Tridion) and to the plastic body panels (CBS). If a repair of the plastic body panels (CBS) is defined by our evaluation key, then these parts will not be reworked, instead they will be replaced. All paint variants can be treated like conventional paints (two-coat finish). In the event of transport damage, follow the specified reporting process described in the smart-Guide. This information can be found under Quality environment management/Sales/Order management and Logistics/Transport. IMPORTANT: Documentation requirements If the repair is a warranty case, proceed with the plastic body panels (CBS) as per the valid stipulations for warranty parts return. If follow-up operations are required on the tridion, pictures must be produced to clearly document the damage. In most cases, Polaroid photos are not adequate. These pictures must be stored in archive with the warranty documentation and made available to DaimlerChrysler upon request. When in doubt, consult with your service manager. The release form (cost estimate) must be signed by the Market Performance Center (MPC); the costs released in it must not be exceeded. This form must be stored in archive with the warranty documentation.
see:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3286 · Applies to: 450, 451, 452, 454
Paint complaint sheet OF98.00-P-3000-01O Fault type: Scratch Description: Damage to the surface caused by mechanical action Receipt of new vehicle: For relatively long and noticeable scratches → Shipping damage Service order: For relatively long and noticeable scratches → no warranty Remarks: Scratches in inspection zone 1 and inspection zone 2 up to 2 mm long and not noticeable are not complaints. Fault type: Blotches Description: Overpolished areas Receipt of new vehicle: Warranty Service order: No warranty Remarks: Note documentation requirements Fig 2: Identifying Scratches On Inspection Zones Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Paint blisters¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3287 · Applies to: 450, 451, 452, 454
Description: Paint flaking on the components caused by mechanical action Receipt of new vehicle: Shipping damage Service order: No warranty Remarks: Note documentation requirements Fault type: Defect Description: Unpainted spots on the components Receipt of new vehicle: Warranty Service order: Warranty (presuming that there has been no paint repair) Remarks: Assessment and release by the MPC required Fig 3: Identifying Overpolished Areas (Blotches) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Paint Flaking On Components (Paint Blisters) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Fog, dull and rough¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3288 · Applies to: 450, 451, 452, 454
Description: Oversprays and deposits of powder that have not spread out evenly, matt and some rough surfaces Receipt of new vehicle: Warranty Service order: Warranty (presuming that there has been no paint repair) Remarks: Assessment and release by the MPC required Fault type: Runs Description: Formation of droplets, severe accumulation and undulated runoff Receipt of new vehicle: Warranty Service order: Warranty (presuming that there has been no paint repair) Remarks: Note documentation requirements Fig 5: Identifying Unpainted Spots On Components (Defect) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Oversprays And Deposits Of Powder Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Orange peel¶
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Description: Orange peel is a pitting of the dried paintwork Receipt of new vehicle: Warranty Service order: Warranty Remarks: An approval by MPC is required for inspection zone 1 and inspection zone 2; will only be accepted as a warranty case, if adjacent surfaces are different Fault type: Color deviation Description: Different color hues Receipt of new vehicle: Warranty Service order: Warranty Remarks: An approval by MPC is required for inspection zone 1 and inspection zone 2 Fig 7: Identifying Formation Of Droplets Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Identifying Orange Peel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Polishing marks¶
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Description: Polishing creates circular, light areas Receipt of new vehicle: Warranty Service order: No Warranty Remarks: Assessment and release by the MPC required Fault type: Clouding Description: Gradation of metallic finishes through dark and light areas Receipt of new vehicle: Warranty Service order: Warranty Remarks: Inspection and approval by MPC are required for inspection zone 1 and inspection zone 2 Fig 9: Identifying Different Color Hues Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 10: Identifying Polishing Marks Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Streaks¶
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Description: Change in surface finish Receipt of new vehicle: Warranty Service order: Warranty Remarks: Inspection and approval by MPC are required for inspection zone 1 and inspection zone 2 Fault type: Dent Description: Slight punctiform deformation from outside inward Receipt of new vehicle: Shipping damage Service order: No warranty Remarks: - Fig 11: Identifying Gradation Of Metallic Finishes (Clouding) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 12: Identifying Change In Surface Finish (Streaks) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Bump¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3292 · Applies to: 450, 451, 452, 454
Description: Slight punctiform deformation from inside outward Receipt of new vehicle: Warranty Service order: No warranty Remarks: Inspection and approval by MPC are required for inspection zone 1 and inspection zone 2 Fault type: Sanding marks/sanding spots Description: Visible recess on the surface, without damage to paintwork Receipt of new vehicle: Warranty Service order: Warranty (presuming that there has been no paint repair) Remarks: Inspection zone 2 longer than 2 mm and not noticeable are not defects; inspection and approval by the MPC required Fig 13: Locating Slight Punctiform Deformation From Outside Inward (Dent) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 14: Locating Slight Punctiform Deformation From Inside Outward (Bump) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fault type: Inclusion of dirt or craters¶
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Description: Visible foreign objects in the paintwork impairing the visual appearance Receipt of new vehicle: See table of guidelines Service order: See table of guidelines Remarks: Assessment, see table of guidelines Fault type: Pinpricks and micropores Description: Coating defects in the form of recesses that must not go all the way through to the substrate Receipt of new vehicle: See table of guidelines Service order: See table of guidelines Remarks: Assessment and release by the MPC required Fig 15: Identifying Visible Recess On Surface (Sanding Marks/Sanding Spots) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 16: Identifying Inclusion Of Dirt Or Craters Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TABLE OF GUIDELINES FOR TRIDION BODY¶
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Error type Inspection zone 1:Countable faults per assessment zone (assessment radius is 300 mm) Inspection zone 2:Countable faults per assessment zone (assessment radius is 300 mm) Inclusions and craters Up to 4 faults smaller than 2 mm in dia. are not defects.For more faults, an approval from MPC is required Up to 7 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required Pinpricks and micropores Up to 5 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required Up to 8 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required The listed faults relate to the faults per component in the particular zone (inspection zones 1 and 2). TABLE OF GUIDELINES FOR PLASTIC BODY PANELS (CBS) Error type Inspection zone 1:Countable faults per assessment zone Inspection zone 2:Countable faults per assessment zone Dirt Up to 3 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required Up to 3 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required Blisters Are defects.Release by MPC required Are defects.Release by MPC required Pores Are defects.Release by MPC required Up to 3 faults smaller than Ø 2 mm are not defects.For more faults, an approval from MPC is required The listed faults relate to the faults per component in the particular inspection zone 1 and inspection zone 2. In the event of a deviation, a release must be requested from the Market Performance Center (MPC). All the warranty cases must be photographed and stored in archive with the warranty documentation. GENERAL INFORMATION > DAMAGE AND STRESS CAUSED TO PAINTWORK BY Fig 17: Identifying Coating Defects Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
EXTERNAL INFLUENCES - AH98.00-P-8070-02SM >¶
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Model 450, 451, 452, 454 Stress to paint Temperature (cold, heat) Humidity and UV rays Aggressive pollutants Mechanical effects such as dust, sand, scratches Structure of a one-coat finish Structure of a two-coat finish In addition to the effects caused by chemical or biological substances such as sulfurous acid (acid rain), oil soot, road salt, surfactants, tree resin, insects, bird droppings and mechanical damage caused by washing brushes and stone chipping, damage can also be caused by moisture and UV radiation from the sun. The pigmented standard finishes are particularly endangered by the type of damage mentioned last. The fine plastic film of synthetic resin surrounding and protecting the coloring pigment particles is destroyed in the course of time by the effect of UV radiation exposing the coloring pigment. This makes the paint surface dull. When the pigment protecting synthetic layer is removed by polishing with products containing abrasive Fig 1: Identifying Painted Part, Dip Prime Coat, Filler And Top Coat (One-Coat Finish Structure) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Painted Part, Dip Prime Coat, Filler And Top Coat (Two-Coat Finish Structure) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
agents, even on new vehicles, the pigment weathering process begins even earlier. The degree of damage¶
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depends on the intensity and duration of the UV radiation which cannot be avoided even with the best paints. For this reason, careful care of the paint repeated at proper intervals as well as technical maintenance helps preserve the value of the vehicle. With good paint care, the beauty of the new paintwork can be maintained significantly longer. GENERAL INFORMATION > METHODS OF PAINTWORK REPAIR - AH98.00-P-9408-01SM > Model 450, 451, 452, 454 The automotive industry, paint manufacturers, various specialist associations and automotive insurance companies have recently taken a closer interest in improved painting techniques, new painting materials and cost-effective repair methods. Because of this development there are sometimes differences of opinion in the assessment and definition of painting work. According to the trial results and practical experience available to us, we will now be describing the various repair methods. By complying with the instructions below and reaching a clear agreement with the customers, erroneous assessments and differences of opinion regarding the type and scope of necessary paintwork repairs can be avoided. Partial painting Two-coat finish, standard finish or metallic finish Several methods are available for the partial touching-up of a two-coat finish, the use of which depends on the case of damage (scope of damage, affected part, condition and age of the vehicle, paint). We urgently recommend that the customer be advised accordingly. If necessary service adviser should consult a paint specialist. Method 1 (painting "up to the edge") Painting the entire part with base coat and clear lacquer. This is a low-cost repair, mainly for new or almost-new vehicles. Major color deviations can occur with this method on older vehicles subject to high wear. These differences in shade generally occur in the base coat. Mat spots and luster differences in the clear varnish can usually be buffed out. Method 2 (blending effect on the part) Applying the base coat to the defective area on the part and blending it in to the surrounding area. Painting the entire part with clear varnish. This method should always be used wherever possible. Method 3 (effect blending on adjacent parts) Either painting of entire part with base coat and run-out on adjacent parts. Or painting the entire part and all adjacent parts with clear lacquer. When painting one (or more) entire parts, this method provides the best results with regard to color matching. With a smooth transition from standard paintwork to blending to standard paintwork, any color difference is no longer visible.
Method 4 (touching up)¶
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Blending the base coat and overlapping blending of the clear varnish. After drying, buffing out the blended clear lacquer. Touch-up painting is only applicable to old vehicles in terms of the long-term quality concerns of DaimlerChrysler. The use of lower quality painting methods must be discussed or agreed with the owner after appropriate specialist and financial advice. In spite of the greater amount of work in comparison to painting an adjacent part, we recommend this method particularly for repairs on side areas, repairs in the middle of the side areas, for colors with close process tolerances and on older vehicles subject to high wear (here possibly also paint horizontal surfaces). This method can be still used on bulges, e.g. on the rear pillar, narrow areas and in subordinate locations (rear center section and bumper area). An absolute, total color match is just not possible with paintwork repairs. A difference that is detectable to the human eye is far more likely to occur with metallic finishes than with solid colors. This depends especially on the color mixing, manufacture and blending of the paint etc. Slight detectable off shades must therefore be accepted. Gloss finishes When the damage to the vehicle's paintwork is so extensive that a sectional repair using the methods described above is no longer cost-effective, a complete paint job will be necessary. Only the materials tested and approved by DaimlerChrysler and manufactured by the following companies may be used for paint repairs: Du Pont Performance Coatings www.performance-coatings.org (Standox, Spies Hecker, Du Pont Refinish) BASF Coatings AG www.basf-coatings.de (Glasurit, RM) PPG Industries International www.ppg.com (PPG Auto Refinish) The working specifications must be strictly complied with. Furthermore, specialist skills and experience are essential Even so, color differences are still possible with paintwork repairs. This must be taken into account when selecting the repair method. GENERAL INFORMATION > NOTES ON PAINTWORK REPAIRS - AH98.00-P-9408-02MCC
Model 451.3/4, 454.0 Notes on paintwork repairs The use of DaimlerChrysler approved materials is absolutely necessary for proper repair because the material characteristics of the recommended products influence the work results and working time. Only the cleaning agents released by DaimlerChrysler are to be used for reconditioning powder-coated parts (see care instructions). Plastic parts with recorded working time are always removed for painting.
General preparatory work for painting:¶
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General preparatory work for painting includes masking, preparing the paint, cleaning or degreasing and sanding the part; furthermore preparing the filler and setting up and cleaning the machines; in addition, transport of the vehicle to the workplace as well as wearing protective clothing. Additional preparatory work for painting: Additional preparatory work for painting includes e.g. matching the color. The time values specified by DaimlerChrysler relate to the actual painting work with the general preparatory work for painting. The assembly operations and bodywork required are not included. WARNING: Vehicles with diesel engines should on no account be started up when in the spraying or drying booth. There is a risk of explosion due to preglow. The following steps should be observed before and during repair work: Disconnect the battery at the negative pole (secure the radio code beforehand). Open convertible soft tops. Mask off rear lamps, rear side windows and the headlamps with heat reflecting material. Only open tank cap slightly once in drying booth and close again immediately after drying. Remove spray cans or similar other objects representing a fire risk from the vehicle. The drying temperature (or object temperature) of 60°C must not be exceeded. The stages for paintwork on body panels are categorized into 3 paint stages: Stage 1 is categorized into: 1-E New part paintwork of welded-in body panels with complete paintwork structure (e.g. following sectional repair). 1-M New part paintwork of removed body panels with complete paintwork structure (e.g. doors, flaps). 1-J Body inner surfaces. Stage 2: Surface paintwork (e.g. with minor paint damage without spackle application). Stage 3: Post-repair refinishing with a spackle application of up to 50 % (e.g. following dent removal). Very minor damage on Tridion: Immediately cover minor paint damage such as scratches, gashes or stone chipping by means of a gravity cup gun or other means of repair (e.g. spray can, touch-up paint pen) to avoid corrosion formation. When corrosion starts, the corrosion points should be rectified immediately and thoroughly. Finally corrosion protection primer is first applied to the point before the top coat is applied. The outside of the vehicle must be clean and dry for painting work. Ambient temperature should be at least +15°C.
The primary coat must not be damaged!¶
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Rectifying cracks in seam seal: Lift up the windshield surround and fix in position. Remove powder paint in the seam area without damaging the joining radius. Remove the old seam, for example, with a suitable compressed air milling machine. Then remove the grinding dust and smooth the edge areas. Then mask off the edges of the join so that the bonding edge is under the joining radius. Apply repair sealing and then smooth immediately. Then remove adhesive tape immediately. Observe the manufacturer's drying specifications. Protect the rest of TRIDION from paint mist. Notes on applying paintwork to plastic The use of DaimlerChrysler 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. In the event of more severe damage with substrate damage, replacing the plastic paneling with a painted new part or a raw part that is to be painted is to be preferred to a repair. In the plant, the dyed plastic paneling is provided with a UV protective paint. If the protective paint is damaged by scratches, stone chipping or gashes, the damaged areas should be repaired immediately, otherwise discolorations may occur on the exposed substrate. Depending on the climate and application location, differences in color shade can occur between genuine parts and replaced parts during the entire vehicle operating time. DaimlerChrysler therefore recommends that the customers' attention be drawn to these color changes. The following description relates to the paint repair of plastic paneling coated with UV protective paint. Safety measures: The drying temperature (or object temperature) of 60°C must not be exceeded. Plastic parts to be painted should be removed from the vehicle for painting. To ensure that the shape of the plastic parts is retained during force drying, suitable painting stands must be used. For drying temperatures in excess of 60°C, irreversible changes in shape may occur. General preparatory work for painting: General preparatory work for painting includes preparing the paint, cleaning or degreasing and sanding the part; furthermore setting up and cleaning the machines; in addition, transport of the plastic part to the workplace as well as wearing protective clothing. Additional preparatory work for painting: Additional preparatory work for painting includes e.g. matching the color. The paintwork of plastic parts is applied in one paint stage: Stage 2 (applying the top coat and special-effect painting): Surface paintwork (with minor paint damage without spackle application or primed or filled new and repair parts).
Repair of plastic parts¶
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DaimlerChrysler approved materials may be used for the repair of plastic parts. The manufacturer's data on the use and processing must be observed. Preparation of substrate: The intact paint surface as well as all substrates to be processed must be clean and free from dust and grease. All substrates must be properly ground and washed off with demineralized water. GENERAL INFORMATION > NOTES ON FORCE DRYING OF VEHICLE PAINTS - AH98.00- P-9408-03SM > Model 450, 451, 452, 454 The vehicles must be thoroughly cleaned before they are brought into the painting facility. Greases and oils in particular must be thoroughly removed from the external skin as they can yellow the top coat at temperatures of around 80°C. When the object temperature on the vehicle is approx. 60°C, the following measures are necessary: Open the fuel filler cap. Disconnect ground cable of battery Cover rear lamp units. Remove outside temperature sensor if an outside thermometer is installed (not with electric outside thermometer). Mask registration stamp on license plate Remove fire extinguishers, aerosols, fuel canisters, CDs, music cassettes and other loose articles from the interior Electronic components such as control units, sensors, airbags, and emergency tensioning retractors may only be heated up to a max. object temperature of 90°C. In cases of doubt, a series of measurements is to be performed to check the temperature at these points (remove the electronic components beforehand) using a mercury maximum thermometer during the baking phase. If the maximum permissible temperature is not exceeded, the electronic components need not be removed. GENERAL INFORMATION > GENERAL NOTES ON COMPLAINTS ABOUT PAINTWORK REPAIRS - AH98.00-P-9408-05SM > Model 450, 451, 452, 454 In the case of complaints concerning paint repairs, it is assumed that the specified materials have been used in accordance with the paint manufacturer's guidelines and working specifications, and that the paintshop foreman responsible was satisfied that all parameters were within the specified tolerances and that a defect in workmanship can therefore be ruled out. A lot of paintwork defects, e.g. dirt inclusions, overspray, paint runs and loss of gloss, can be eliminated using inexpensive polishing (in other words without paintwork rectification).
Causes for complaint:¶
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In connection with the original factory finish (primarily for color deviations) With the painting of genuine parts Problems in connection with the materials. NOTE: In the event of customer complaints about faulty paintwork that are to be remedied under warranty or as goodwill, prior approval must be obtained by the Market Performance Center (MPC). GENERAL INFORMATION > NOTES ON REPAIR PAINTWORK IN BONDING AREA OF WINDOWS AND COMPONENTS - AH98.00-P-9408-07MCC > Model 451.3/4 Front roof frame shown on model 451.3 Evaluation of bonding area on body flange Individual paint chips up to approx. 2 cm 2 Individual paint chips up to approx. 2 cm 2, as well as paint chips in base coat (1) and paint chips in clear coat (2), are permissible. Fig 1: Identifying Paint Chips On Base And Clear Coats And Adhesive Bead (Shown On Model 451) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
In the event of paint chips or damage resulting from removal down to the sheet metal, it is necessary to prime¶
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these surfaces with the approved materials. Paint chips in the base coat (1) or paint chips in the clear coat (2) may be treated only outside of the bonding surface of the adhesive bead (3) with the approved material, base coat and clear coat. It is necessary to reinstate the corrosion protection on the body as a matter of principle. Numerous paint chips over 2 cm 2 In the case of paint chips over 2 cm 2, as well as paint chips in the base coat (1) or larger area paint chips in the clear coat (2), repaint the entire gluing area. In the bonding area for the windshield or the bonding area for the roof paneling, the entire paint structure must be sanded down to the coat of electrolytic immersion paint. Grinding all the way down to the sheet steel are acceptable. Residual coating thickness approx. 20 μm. New paintwork structure Use materials from an approved paint system for the new paint structure consisting of filler primer for completely sanded spots, EP filler, base coat and clear coat. Recommended coat thicknesses EP filler 45 to 70 m for function surfaces 120 μm maximum for visible surfaces (before sanding) Base coat 15 to 25 μm Clear coat 50 to 70 μm Drying process If no information on the inlet temperature and drying times are available from the paint manufacturers, use the following specifications. Inlet temperature: 72°C (for 60°C object temperature) Drying time: EP filler 90 minutes Base coat 60 minutes Clear coat 90 minutes Gluing area
Paint the bonding surface (A) only with EP filler (5).¶
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After applying the adhesive material (7) ensure that the bonding surface (A) is covered 80 %. After installing the windshield or roof paneling, the EP filler (5) should be covered with adhesive material (7). Ensure that the side subject to weathering is always completely covered with adhesive material to ensure proper corrosion protection (7). GENERAL INFORMATION > GENERAL INFORMATION ON MB MATERIALS - AH98.00-P- 9409-03SM > Model 450, 451, 452, 454 The MB materials for paint and corrosion protection have been replaced with materials from our system partners. The DaimlerChrysler approved and checked materials from the following companies are to be used: Du Pont Performance Coatings www.performance-coatings.org BASF Coatings AG www.basf-coatings.de PPG Industries International www.ppg.com Care, cleaning and preservation agents as well as materials for paint repair (paint touch-up pens and paint spray cans) are still available as genuine parts from the Global Logistics Center (GLC) in Germersheim. For the leather paints, only the current standard colors are available from the GLC in Germersheim. All other shades can be ordered from the Lindgens company. GENERAL INFORMATION > GENERAL NOTES ON TOUCH-UP APPLICATORS AND PAINT SPRAY CANS - AH98.00-P-9409-06SM > Model 450, 451, 452, 454 Fig 2: Identifying Bonding Surface With EP Filler Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Touch-up paint pens and paint spray cans are only suitable for temporarily touching up minor paint¶
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damage such as stone marks or scratches. They must not be used on the MB original paintwork repairs on the outer skin, since it is not possible to restore the original condition using this method. Repairing minor paintwork damage With this kind of damage, and also in the repair of this damage, the entire paint structure is often damaged right down to the sheet metal. For reasons of quality and corrosion protection, a primer must be applied before touching up the top coat in such cases. Processing instructions are printed on the touch-up paint pens and in the leaflet provided inside the caps of the spray cans. Touch-up applicators: Primer stick for metal parts The cap contains a rust scraper that should be used to eliminate rust spots and loose paint. Top coat touch-up paint pens for standard and metallic paint Body outer skin (tridion) Paintwork set (base coat and clearcoat, gloss) Detachable plastic parts (customized body panel=CBS) Paintwork set (base coat and clearcoat, gloss) Paint spray cans: Priming spray can for metal parts The cap contains a repair kit (rust scraper, abrasive paper and filler paste) for eliminating minor rust spots and other uneven areas. Do not use for repairing plastic parts. Top coat spray cans (standard finish and metallic finish) Body outer skin Paintwork set (base coat and clearcoat, gloss) Detachable plastic parts Paintwork set (base coat and clearcoat, gloss) GENERAL INFORMATION > NOTES AND REPAIR OPTIONS FOR PAINTING DETACHABLE PLASTIC COMPONENTS - AH98.20-P-9410-01MCC > Model 451 The detachable plastic parts (e.g. CBS front, CBS rear) are supplied as a dyed part painted with clearcoat or as a raw part painted with base coat and clearcoat in the corresponding vehicle color. Water-based paints are used.
Checking¶
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1 Check vehicle paintwork Check painted outer surfaces (B) and area (A) stone-chip prone for damage, if necessary repair vehicle paintwork subject to separate repair order.
Damage and stress caused to paintwork by external influences AH98.00- P-8070- 02SM MAINTENANCE > PRODUCTS FOR THE CARE OF MB VEHICLE PAINTWORK - AP98.30- P-8070-06SM > AUXILIARY REPAIR MATERIALS Number Designation Order number BR00.45-Z-1002- 04A Car shampoo A 001 986 41 71 BR00.45-Z-1013- 04A Polish, silicone free 5 l, DB supply specification 7545.00 A 000 986 45 74 BR00.45-Z-1014- 04A Gloss preservation, 500 ml, DB supply specification 7551.10 A 000 986 44 74 BR00.45-Z-1015- 04A Fine polishing paste, polish 1 l, DB supply specification 7543.00 A 000 986 43 74 BR00.45-Z-1016- 04A Paint cleaner A 001 986 37 71 Fig 1: Identifying Area Subjected To Stone Impact And Painted External Surface Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Clean and degrease body flange (2).¶
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- Mask bonding area (1) using adhesive tape. Dimensions: TESTING & REPAIR INDEX > PAINTWORK BONDING AREA FOR WINDSHIELD - AR98.00- P-0900MCC > MODEL 451.3 /4 Shown on model 451.3 Fig 1: Identifying Body Flange, Bonding Area With Dimensions (Shown On Model 451.3 On Body Shell) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Painting¶
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Overview of smart materials and their use
AR98.00-P- 0270MCC Notes on repair paintwork in bonding area of windows and components
AH98.00-P-9408- 07MCC 1 Mask interior compartment using adhesive tape
2 Mask exterior area and remaining components using adhesive tape On vehicles with previous body repairs, adapt the area covered to the repair performed.
3 Sand down body flange (2) and bonding area for windshield (1) Residual coating thickness approx. 20 μm.In the bonding area for the windshield (1), sand the complete paintwork structure down to the coat of electrolytic immersion paint.Grinding all the way down to the sheet steel are acceptable.
Completely Fig 1: Identifying Windshield Gluing Area And Body Flange Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
clean area to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3312 · Applies to: 450, 451, 452, 454
4 clean area to be painted The paint manufacturer' pecification mu t be complied with in full.
5 Degrease area to be painted The paint manufacturer's specifications must be complied with in full.If glue is detached, repeat operation steps 1 and 2, if necessary.
6 Apply EP primer filler Apply to the entire area to be painted. Use approved materials only. The paint manufacturer's specifications must be complied with in full.
General information on MB materials AH98.00-P-9409- 03SM 7 Mask bonding surface for windshield (1) If necessary, remove any protruding markings. Use materials approved by the paint manufacturers only. AR98.00-P-0900- 01MCC *BR00.45- Z-1034-02B 8 Apply base coat and clear varnish of selected paint system The paint manufacturer's specifications must be complied with in full.
General information on MB materials AH98.00-P-9409- 03SM 9 Perform over drying The paint manufacturer's specifications must be complied with in full.
Notes on force drying of vehicle paints AH98.00-P-9408- 03SM 10 Remove masking and bonding material
REPAIR MATERIALS Number Designation Order number BR00.45-Z-1034-02B Tesa 7140 adhesive tape (12 mm) A 009 989 10 85 TESTING & REPAIR INDEX > PRINT OUT TEMPLATE, TRANSFER - AR98.00-P-0905- 01MCC >
Application¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3313 · Applies to: 450, 451, 452, 454
- Determine dimensions "A" and "B" from drawing.
- Determine scaling factor "x": specify dimension "A" / determine dimension "A" = scaling factor "x"
- Copy template (1) with calculated scaling factor "x" to original size.
- Check dimension "C". If the template (1) has been enlarged properly, dimension "C" should be 100 mm.
- Cut out template (1) along cutting contours "D".
- Mount template (1) and transfer at left and right onto body flange. Use suitable pin, as otherwise the paintwork structure may be damaged. TESTING & REPAIR INDEX > MASK BONDING SURFACES FOR ROOF USING ADHESIVE TAPE - AR98.00-P-0905-02MCC > REPAIR MATERIALS Number Designation Order number BR00.45-Z-1034-02B Tesa 7140 adhesive tape (12 mm) A 009 989 10 85 Fig 1: Identifying Template And Cutting Contour Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on body-in-white¶
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- Clean and degrease bonding area (1) on body flange (2).
- Mask bonding area (1) using adhesive tape. Use 12 mm wide hand roller. Observe distances. Attach adhesive tape in line with previously made markings. Dimensions: TESTING & REPAIR INDEX > PAINTWORK, BONDING AREA FOR ROOF - AR98.00-P- 0905MCC > MODEL 451.3 Fig 1: Identifying Bonding Area On Body Flange (Shown On Body-In-White) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Painting¶
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Overview of smart materials and their use
AR98.00-P- 0270MCC Notes on repair paintwork in bonding area of windows and components
AH98.00-P-9408- 07MCC 1 Mask interior compartment using adhesive tape
2 Mask exterior area and remaining components using adhesive tape On vehicles with previous body repairs, adapt the area covered to the repair performed.
3 Sand down body flange (2) and bonding area for roof (1) Residual coating thickness approx.20 μm.In the bonding area for the roof (1), sand the complete paintwork structure down to the coat of electrolytic immersion paint. Grinding all the way down to the sheet steel are acceptable.
Completely Fig 1: Identifying Roof Bonding Area And Body Flange Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Always use protective clothing, gloves, safety goggles and skin cream.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3318 · Applies to: 450, 451, 452, 454
Paint in a spray booth. Ensure adequate ventilation and always wear a protective respiratory mask. Paints require special identification. Poisonous and cancer causing substances (marked with a T, skull and crossbones) may only be handled by specially qualified personnel. When handling these materials, please observe the safety guidelines (UVV-VBG 23), the Ordinance on Hazardous Substances and the Environmental Protection Regulations (according to the hazardous substance ID on the container and the safety data information sheets from the supplier). In export countries, please observe your country-specific accident prevention and protection regulations. First aid measures Eyes Rinse eye thoroughly for several minutes with lukewarm water while protecting the non-affected eye. Eyelid must be wide open. Request victim to move the eye in all directions as it is being rinsed out. Consult a physician (eye doctor) and be sure to state measures already taken. Respiratory paths Fresh air; perform artificial respiration if victim is no longer breathing, if necessary administer oxygen, keep warm, keep calm. Contact physician. Skin Paint splashed onto skin must be immediately and carefully washed off with plenty of soap and water. If necessary, clean skin again with a suitable skin cleaning agent. SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY CAUSTIC BURNS DUE TO CONTACT WITH METAL DUST REMOVER. - AS98.00-Z-0003-01A > Avoid contact. Wear tight-fitting safety glasses and acid-resistant gloves. Risk of injury Metal dust remover contains oxal and phosphoric acids. Contact or swallowing can result in acid burns. Safety instructions/precautions Wear acid-resistant protective clothing (apron, protective gloves) as well as safety glasses. Observe safety regulations! Wear tight-fitting safety glasses, acid-resistant gloves and protective clothing. Avoid all contact with eyes and skin. Do not eat or drink while performing this work. Keep metal dust remover away from food and beverages. Work only in well ventilated rooms. First aid measures In case of ingestion
Consult physician immediately, only allow victim to induce vomiting if fully conscious. Rinse out¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3319 · Applies to: 450, 451, 452, 454 · AR: AS98.00-Z-9999ZZ
mouth and drink large quantities of water. In case of eye contact Rinse thoroughly with water and consult physician (eye doctor) immediately. In case of inhalation Move victim to fresh air and consult physician. In case of skin contact Immediately wash with plenty of soap and water, apply protective skin ointment. Consult physician if skin irritation continues. SAFETY PRECAUTIONS > SAFETY INFORMATION: PAINTWORK - AS98.00-Z-9999ZZ > MODEL all Explosion hazard when handling organic peroxide hardeners. Injury hazard for skin and eyes from organic peroxide hardeners MODEL 405.210 /230 with BODY 405.830 nur fur USA/Kanada AS98.00- Z-0005- 01NA Risk of explosion caused by handling organic peroxide hardeners. Risk of injury caused by skin and eye contact with organic peroxide hardeners MODEL 199, 405, 957... AS98.00- Z-0005- 01A Risk of explosion caused by paint vapors igniting. Risk of poisoning caused by inhaling paint vapors. MODEL all AS98.00- Z-0002- 01A Risk of injury caused by caustic burns due to contact with metal dust remover. MODEL all AS98.00- Z-0003- 01A BASIC KNOWLEDGE > TABLE OF CONTENTS FOR PAINTWORK AND ANTICORROSION MATERIALS IN SERIES PRODUCTION - GF98.00-P-0991A > MODEL all
List for paintwork/corrosion protection - Series production, general
GF98.00- P-2099A
Notes on repair painting
GF98.00- P-8000A Notes for repairing plastic detachable parts Model 408, 418, 427, 435, 437, 638, 639, 667, 668, 669, 670, 901, 902, 903, 904, 950, 952, 953, 954, 957, 970, 972, 974, 975, 976 only GF98.00- N-8100A Model 129, 170, 202, 208 GF98.00- P-4070B GF98.00-
Index of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3320 · Applies to: 450, 451, 452, 454
paintwork/corrosion protection Model 140, 210, 215, 220 P-4070M Model 163 GF98.00- P-4070GH Model 164 GF98.00- P-4070GZ Model 168 GF98.00- P-4070GC Model 169 GF98.00- P-4070AK Model 171 GF98.00- P-4070V Model 203 GF98.00- P-4070P Model 204 GF98.00- P- 4070CW MODEL 209 GF98.00- P-4070Q Model 211 GF98.00- P-4070T Model 216 GF98.00- P-4070SX Model 219 GF98.00- P-4070TX Model 221 GF98.00- P-4070SY Model 230 GF98.00- P-4070R Model 240 GF98.00- P-4070H Model 245 GF98.00- P-4070BK Model 251 GF98.00- P-4070RT Model 414 GF98.00- D-4070V Model 405 GF98.00- G-4070UA Model 408, 418, 427, 435Model 437 up to 31.7.03 GF98.00- G-4070U Model 437.42 /43 GF98.00-
Detachable parts on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3322 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Steel And Plastic (Color Code, Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Detachable Parts (Substrates, Paintwork And Paintwork Structure) - Model 451.3 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Item¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3323 · Applies to: 450, 451, 452, 454
Designation (MODEL 451.3) Material Delivery condition of replacement part 1.1 Front CBS Polypropylene (PP) (ED230HP)
1.2 Front fog lamp covering
1.3 Bottom grille
1.4 Top grille
1.5 Engine hood PP (ED230HP)
1.6 Cowl
1.7 Roof Polycarbonate
1.8 Spoiler
1.9 Liftgate panel PP (ED230HP)
1.10 B-pillar paneling PP (ED230HP)
1.11 Rear CBS PP (ED230HP)
1.12 Intake air cover PP (ED230HP)
1.13 Door handle PP (ED230HP)
1.14 Tridon safety cell Steel
1.15 Longitudinal member paneling PP (ED230HP)
1.16 Door PP (ED230HP)
1.17 Window channel strip
1.18 Exterior rearview mirrors PP (ED230HP)
Color code, model 451.4
Detachable parts on model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3324 · Applies to: 450, 451, 452, 454
Fig 3: Identifying Steel And Plastic (Color Code, Model 451.4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Detachable Parts (Substrates, Paintwork And Paintwork Structure) - Model 451.4 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
RETROFITTING & CONVERSION > INSTALL BRABUS PEDAL COVER - AN29.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3326 · Applies to: 450, 451, 452, 454
0001MCC > MODEL 451.3/4 (except 451.391 /491) Removing
1 Remove rubber mounting (1) on brake pedal head of brake pedal
Install
2 Slide BRABUS pedal cover (3) from above onto the accelerator pedal sensor (B37) Do not use any antifriction agent as the frictional connection between the BRABUS pedal cover (3) and the accelerator pedal sensor (B37) is impaired as a result. 3 Position BRABUS pedal cover (2) on the brake pedal head of the brake pedal and put on Do not use any antifriction agent as the frictional connection between the BRABUS pedal cover (2) and the accelerator pedal sensor is impaired as a result. 4 Add special equipment to the vehicle data card and to the online vehicle data card
Fig 1: Installing Brabus Pedal Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: PEDAL ASSEMBLY -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3327 · Applies to: 450, 451, 452, 454 · AR: AR29.00-Z-9451CA, AR29.10-P-0340MCC, AR29.10-P-0340MCE, AR29.10-P-0330MCC, AR29.10-P-0300MCC (+4 more)
AR29.00-Z-9451CA > MODEL 451 Remove, install bellows at brake pedal MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle AR29.10-P-0340MCC Remove, install bellows at brake pedal MODEL 451.3## /4## 2# with CODE (RHD) Right-hand drive vehicle AR29.10-P-0340MCE Remove/install cover of brake pedal module MODEL 451.3/4 AR29.10-P-0330MCC Remove/install pedal assembly MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle AR29.10-P-0300MCC Remove/install pedal assembly MODEL 451.3## /4## 2# with CODE (RHD) Right-hand drive vehicle AR29.10-P-0300MCE Remove/install pedal assembly MODEL 451.3/4 AR29.10-P-0300MCU Remove/install pedal seal MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle AR29.10-P-0341MCC Remove/install pedal seal MODEL 451.3## /4## 2# with CODE (RHD) Right-hand drive vehicle AR29.10-P-0341MCE TESTING & REPAIR > REMOVE/INSTALL PEDAL ASSEMBLY - AR29.10-P-0300MCU > MODEL 451.3/4
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3328 · Applies to: 450, 451, 452, 454
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 1 Push down brake pedal several times To reduce any vacuum.
2 Remove maintenance flap
3 Unscrew cap of brake fluid expansion reservoir and drain brake fluid
4 Remove bellows at brake pedal
AR29.10-P- 0340MCC Fig 1: Identifying Pedal Assembly Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove diagonal struts¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3329 · Applies to: 450, 451, 452, 454
5 Remove diagonal struts On model 451.4 AR61.10-P- 5138MCU 6 Remove mechanical stop lamp switch
AR42.10-P- 0040MCC 7 Remove grommet (2) with electrical line (3) from pedal assembly (1) Installation: Pay attention to the correct seat of the grommet (2) otherwise damage can occur due to water entry.
8 Unhook electrical line (3) from brackets (4)
9 Unhook bracket (5) of wiring harness (7)
10 Unclip retaining clip (6) of wiring harness (7)
11 Pull vacuum line of brake booster (9) out of brake booster (8) Installation: Check the grommet of the brake booster vacuum line (9) in the brake booster (8), replace if necessary.
12 Remove retainer (10) and carefully press out expansion reservoir connecting line (11) at master brake cylinder (12) using a suitable tool Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: Check seals of expansion reservoir connecting line (11) in master brake cylinder (12), replace if necessary. Use pliers for installation.
*450589153700 13 Unhook electrical line (13) at brake line (14)
14 Check bolted connections of brake lines (14, 15) with the master brake cylinder (12) for color coding Installation: Identify brake lines (14, 15) accordingly. AR42.10-P- 0013-05MCC 15 Loosen bolted connections of the brake lines (14, 15) with the brake hose (12) and separate Collect brake fluid in a suitable container. Seal the connections using suitable plugs.
*BA42.10-P- 1005-04E
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (14, 15), pay attention to routing, leaktightness and clearance.If a brake line (14, 15) with a red color coding has been released, this brake line (14, 15) must be replaced.Refer to: ↓
Remove/install brake line from the master AR42.10-P-
brake cylinder to the ESP hydraulic unit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3330 · Applies to: 450, 451, 452, 454
0034MCU 16 Unscrew bolts (16, 17) *BA29.10-P- 1001-02C
*BA29.10-P- 1006-02C 17 Remove pedal assembly (1) with brake booster (8) and master brake cylinder (12) Pedal assembly (1), brake booster (8) and master brake cylinder (12) are supplied as one replacement part.
18 Install in the reverse order
19 Bleed brake system
AR42.10-P- 0010MCU PEDALS, BEARING BRACKET Number Designation Model 451.3/4 BA29.10-P-1001- 02C Bolt, brake pedal module to body Nm 25 BA29.10-P-1006- 02C Bolt, connection piece between brake pedal module and brake booster to body Nm 27 BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1005-04E Brake pipe to master brake cylinder Nm 16 TESTING & REPAIR > REMOVE/INSTALL COVER OF BRAKE PEDAL MODULE - AR29.10- P-0330MCC > MODEL 451.3/4 Illustrated on model 451.4 Fig 2: Identifying Pliers (450 589 15 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3331 · Applies to: 450, 451, 452, 454
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 http://gotis.aftersales.mercedes- benz.com
2 Pull down lug (2) on cover of brake pedal module (1) and remove cover of brake pedal module (1)
3 Clean contact surface of the brake pedal module cover (1) at the pedal assembly Replace brake pedal module cover (1).
4 Install in the reverse order
TESTING & REPAIR > REMOVE, INSTALL BELLOWS AT BRAKE PEDAL - AR29.10-P- 0340MCC > MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle Fig 1: Identifying Brake Pedal Module Cover And Lug Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3332 · Applies to: 450, 451, 452, 454
1 Adjust driver's seat to the rear
2 Unscrew bolt (2) and remove pedal head (3) Torx bit insert *450589030900 3 Compress the carrier (4) of the boot (1) in the marked area (arrows B) and pull upwards out of the floor panel The carrier (4) is anchored to the floor panel with the catch hooks (7) which are located on the left and right of the carrier (4).
4 Remove boot (1) with carrier (4) upwards
5 Remove the pedal assembly seal (5) upwards carefully and check the seals (6) If the seals (6) of the pedal assembly seal (5) are damaged or detached, the pedal assembly seal (5) should be replaced.
Install
6 Insert the pedal assembly seal (5) carefully in the floor covering Do not damage the seals (6) of the pedal assembly seal (5) as otherwise water entry may occur.
7 Position boot (1) on carrier (4)
Fig 1: Identifying Brake Pedal Bellows Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Clip carrier (4) with boot (1) in the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3333 · Applies to: 450, 451, 452, 454 · AR: AR29.10-P-0341MCC
8 Clip carrier (4) with boot (1) in the floor panel The catch hooks (7) on the left and right of the carrier (4) must latch in position in the floor panel.
9 Fit pedal head (3) and tighten bolt (2) The fixing drift (arrow A) on the brake pedal must match the bore in the pedal head (3).
Torx bit insert *450589030900 TESTING & REPAIR > REMOVE/INSTALL PEDAL SEAL - AR29.10-P-0341MCC > MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle Fig 2: Identifying Torx Bit Insert (450 589 03 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Pedal Seal Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3334 · Applies to: 450, 451, 452, 454
1 Adjust driver's seat to the rear
2 Unscrew bolt (2) and remove pedal head (3) *450589030900 3 Compress the carrier (4) of the boot (1) in the marked area (arrows B) and pull upwards out of the floor panel The carrier (4) is anchored to the floor panel with the catch hooks (7) which are located on the left and right of the carrier (4).
4 Remove boot (1) with carrier (4) upwards
5 Carefully lift off wheel brake cylinder (5) If the seals (6) of the pedal assembly seal (5) are damaged or detached, the pedal assembly seal (5) should be replaced.
Install
6 Insert the pedal assembly seal (5) carefully in the floor covering Do not damage the seals (6) of the pedal assembly seal (5) as otherwise water entry may occur.
7 Position boot (1) on carrier (4)
8 Clip carrier (4) with boot (1) in the floor panel The catch hooks (7) on the left and right of the carrier (4) must latch in position in the floor panel.
9 Fit pedal head (3) and tighten bolt (2) The fixing drift (arrow A) on the brake pedal must match the bore in the pedal head (3).
*450589030900 SAFETY PRECAUTIONS > SAFETY INFORMATION: PEDAL ASSEMBLY - AS29.00-Z- Fig 2: Identifying Torx Bit Insert (450 589 03 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9999ZZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3335 · Applies to: 450, 451, 452, 454 · AR: BA29.00-Z-9999CZ
MODEL all AR29.10-D-0300- 01A Removing and installing clutch pedal over-center helper spring. MODEL 901, 902, 903, 904 with ENGINE 111, 602 except CODE (G40) Automatik - Getriebe W4A028 AS29.10-Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: PEDAL ASSEMBLY - BA29.00-Z-9999CZ > MODEL all Pedals, bearing bracket MODEL 454.0 BA29.10-P-1000-02E Pedals, bearing bracket MODEL 450.3 /4, 451.3 /4, 452.3## /4## 1#, 452.3## /4## 2# BA29.10-P-1000- 02C TORQUE SPECIFICATIONS > PEDALS, BEARING BRACKET - BA29.10-P-1000-02C > Model 450, 451, 452 PEDALS, BEARING BRACKET Number Designation Model 450.3/4 Left-hand drive vehicle Model 450.3/4 Right-hand drive vehicle Model 451.3/4 BA29.10-P-1001- 02C Bolt, brake pedal module to body Nm 20 20 25 BA29.10-P-1002- 02C Bolt, brake pedal head Nm 9 20 - BA29.10-P-1003- 02C Bolt, accelerator pedal module to bracket Nm - - - BA29.10-P-1004- 02C Bolt of bracket to body Nm - - - BA29.10-P-1005- 02C Nut securing bracket to body Nm - - - BA29.10-P-1006- 02C Bolt, connection piece between brake pedal module and brake booster to body Nm - - 27 BA29.10-P-1007- 02C Bolt, pedal to brake pedal module Nm - - 20 PEDALS, BEARING BRACKET Model 452.3/4 Right-hand Model 452.3/4 left-hand
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3336 · Applies to: 450, 451, 452, 454 · AR: WS29.00-Z-9999CZ
Designation drive steering BA29.10-P-1001- 02C Bolt, brake pedal module to body Nm 20 20 BA29.10-P-1002- 02C Bolt, brake pedal head Nm 9 9 BA29.10-P-1003- 02C Bolt, accelerator pedal module to bracket Nm 9 9 BA29.10-P-1004- 02C Bolt of bracket to body Nm 9 9 BA29.10-P-1005- 02C Nut securing bracket to body Nm 3.7 3.7 BA29.10-P-1006- 02C Bolt, connection piece between brake pedal module and brake booster to body Nm - - BA29.10-P-1007- 02C Bolt, pedal to brake pedal module Nm - - SPECIAL TOOLS > SPECIAL TOOLS: SMART: PEDAL ASSEMBLY - WS29.00-Z-9999CZ > MODEL all 450 589 09 99 04 Box wrench bit FG29/42/Set B WS42.00-P-0070-04B
RETROFITTING & CONVERSION > INSTALL BRABUS PEDAL COVER - AN29.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3337 · Applies to: 450, 451, 452, 454
0001MCC > MODEL 451.3 /4 (except 451.391 /491) Removing
1 Remove rubber mounting (1) on brake pedal head of brake pedal
Install
2 Slide BRABUS pedal cover (3) from above onto the accelerator pedal sensor (B37) Do not use any antifriction agent as the frictional connection between the BRABUS pedal cover (3) and the accelerator pedal sensor (B37) is impaired as a result. 3 Position BRABUS pedal cover (2) on the brake pedal head of the brake pedal and put on Do not use any antifriction agent as the frictional connection between the BRABUS pedal cover (2) and the accelerator pedal sensor is impaired as a result. Fig 1: Installing Brabus Pedal Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Add special equipment to the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3338 · Applies to: 450, 451, 452, 454
4 Add special equipment to the vehicle data card and to the online vehicle data card
TESTING & REPAIR INDEX > REMOVE/INSTALL PEDAL ASSEMBLY - AR29.10-P- 0300MCU > MODEL 451.3 /4
Remove/install
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 Pedal Assembly Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Push down brake pedal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3339 · Applies to: 450, 451, 452, 454
1 Push down brake pedal several times To reduce any vacuum.
2 Remove maintenance flap
3 Unscrew cap of brake fluid expansion reservoir and drain brake fluid
4 Remove bellows at brake pedal
AR29.10- P- 0340MCC 5 Remove diagonal struts On model 451.4 AR61.10- P- 5138MCU 6 Remove mechanical stop lamp switch
AR42.10- P- 0040MCC 7 Remove grommet (2) with electrical line (3) from pedal assembly (1) Installation: Pay attention to the correct seat of the grommet (2) otherwise damage can occur due to water entry.
8 Unhook electrical line (3) from brackets (4)
9 Unhook bracket (5) of wiring harness (7)
10 Unclip retaining clip (6) of wiring harness (7)
11 Pull vacuum line of brake booster (9) out of brake booster (8) Installation: Check the grommet of the brake booster vacuum line (9) in the brake booster (8), replace if necessary.
12 Remove retainer (10) and carefully press out expansion reservoir connecting line (11) at master brake cylinder (12) using a suitable tool Collect brake fluid in a suitable container. Seal the connections using suitable plugs. Installation: Check seals of expansion reservoir connecting line (11) in master brake cylinder (12), replace if necessary. Use pliers for installation.
Fig 2 13 Unhook electrical line (13) at brake line (14)
14 Check bolted connections of brake lines (14, 15) with the master brake cylinder (12) for color coding Installation: Identify brake lines (14, 15) accordingly. AR42.10- P-0013- 05MCC Loosen bolted connections of the brake
lines (14, 15) with the¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3340 · Applies to: 450, 451, 452, 454
15 lines (14, 15) with the brake hose (12) and separate Collect brake fluid in a suitable container. Seal the connections using suitable plugs.
*BA42.10- P-1005- 04E
Installation: Use a 12 mm open-end wrench bit. Do not bend brake lines (14, 15), pay attention to routing, leaktightness and clearance.If a brake line (14, 15) with a red color coding has been released, this brake line (14, 15) must be replaced.Refer to: ↓
Remove/install brake line from the master brake cylinder to the ESP hydraulic unit AR42.10- P- 0034MCU 16 Unscrew bolts (16, 17) *BA29.10- P-1001- 02C
*BA29.10- P-1006- 02C 17 Remove pedal assembly (1) with brake booster (8) and master brake cylinder (12) Pedal assembly (1), brake booster (8) and master brake cylinder (12) are supplied as one replacement part.
18 Install in the reverse order
19 Bleed brake system
AR42.10- P- 0010MCU PEDALS, BEARING BRACKET Number Designation Model 451.3/4 BA29.10-P- 1001-02C Bolt, brake pedal module to body Nm 25 BA29.10-P- 1006-02C Bolt, connection piece between brake pedal module and brake booster to body Nm 27 BRAKE LINES, BRAKE HOSES Number Designation Model 451.3/4 BA42.10-P-1005-04E Brake pipe to master brake cylinder Nm 16
TESTING & REPAIR INDEX > REMOVE/INSTALL COVER OF BRAKE PEDAL MODULE -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3341 · Applies to: 450, 451, 452, 454 · AR: AR29.10-P-0330MCC
AR29.10-P-0330MCC > MODEL 451.3 /4 Illustrated on 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 lifting platform and remove underfloor paneling Rechargeable drill / screwdriver
2 Pull down lug (2) on cover of brake pedal module (1) and remove cover of brake pedal module (1)
3 Clean contact surface of the brake pedal module cover (1) Replace brake pedal module cover (1).
Fig 2: Identifying Pliers (450 589 15 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Pedal Module Cover And Lug Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
at the pedal assembly¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3342 · Applies to: 450, 451, 452, 454
4 Install in the reverse order
TESTING & REPAIR INDEX > REMOVE, INSTALL BELLOWS AT BRAKE PEDAL - AR29.10- P-0340MCC > MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle Removing
1 Adjust driver's seat to the rear
2 Unscrew bolt (2) and remove pedal head (3) Torx bit insert Fig 2 3 Compress the carrier (4) of the boot (1) in the marked area (arrows B) and pull upwards out of the floor panel The carrier (4) is anchored to the floor panel with the catch hooks (7) which are located on the left and right of the carrier (4).
4 Remove boot (1) with carrier (4) upwards
5 Remove the pedal assembly seal (5) upwards carefully and check the seals (6) If the seals (6) of the pedal assembly seal (5) are damaged or detached, the pedal assembly seal (5) should be replaced.
Install
Insert the pedal assembly seal (5) Do not damage the seals (6) of the pedal assembly seal (5) as otherwise water entry Fig 1: Identifying Brake Pedal Bellows Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
carefully in the floor covering¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3343 · Applies to: 450, 451, 452, 454 · AR: AR29.10-P-0341MCC
6 carefully in the floor covering may occur.
7 Position boot (1) on carrier (4)
8 Clip carrier (4) with boot (1) in the floor panel The catch hooks (7) on the left and right of the carrier (4) must latch in position in the floor panel.
9 Fit pedal head (3) and tighten bolt (2) The fixing drift (arrow A) on the brake pedal must match the bore in the pedal head (3).
Torx bit insert Fig 2 TESTING & REPAIR INDEX > REMOVE/INSTALL PEDAL SEAL - AR29.10-P-0341MCC > MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle Fig 2: Identifying Torx Bit Insert (450 589 03 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3344 · Applies to: 450, 451, 452, 454
1 Adjust driver's seat to the rear
2 Unscrew bolt (2) and remove pedal head (3) Figure 3 Compress the carrier (4) of the boot (1) in the marked area (arrows B) and pull upwards out of the floor panel The carrier (4) is anchored to the floor panel with the catch hooks (7) which are located on the left and right of the carrier (4).
4 Remove boot (1) with carrier (4) upwards
5 Carefully lift off wheel brake cylinder (5) If the seals (6) of the pedal assembly seal (5) are damaged or detached, the pedal assembly seal (5) should be replaced.
Install
6 Insert the pedal assembly seal (5) carefully in the floor covering Do not damage the seals (6) of the pedal assembly seal (5) as otherwise water entry may occur.
7 Position boot (1) on carrier (4)
8 Clip carrier (4) with boot (1) in the floor panel The catch hooks (7) on the left and right of the carrier (4) must latch in position in the floor panel.
Fig 1: Identifying Pedal Seal Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fit pedal head (3) and tighten bolt (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3345 · Applies to: 450, 451, 452, 454 · AR: BA29.00-Z-9999CZ
9 Fit pedal head (3) and tighten bolt (2) The fi ing drift (arrow A) on the brake pedal must match the bore in the pedal head (3).
Figure SAFETY PRECAUTIONS > SAFETY INFORMATION: PEDAL ASSEMBLY - AS29.00-Z- 9999ZZ > MODEL all Use care in removing and installing clutch pedal over-center helper spring! MODEL 901, 902, 903, 904 with ENGINE 111, 602 except CODE (G40) Automatik-Getriebe W4A028 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: PEDAL ASSEMBLY - BA29.00-Z-9999CZ > MODEL all
Pedals, bearing bracket MODEL 454.0 BA29.10-P-1000- 02E
Pedals, bearing bracket MODEL 450.3 /4, 451.3 /4, 452.3## /4## 1#, 452.3## /4## 2# BA29.10-P-1000- 02C TORQUE SPECIFICATIONS > PEDALS, BEARING BRACKET - BA29.10-P-1000-02C > Model 450, 451, 452 PEDALS, BEARING BRACKET Number Designation Model 450.3/4 Left-hand drive vehicle Model 450.3/4 Right-hand drive vehicle Model 451.3/4 BA29.10- P-1001- 02C Bolt, brake pedal module to body Nm 20 20 25 Fig 2: Identifying Torx Bit Insert (450 589 03 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA29.10-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3346 · Applies to: 450, 451, 452, 454 · AR: WS29.00-Z-9999CZ
P-1002- 02C Bolt, brake pedal head Nm 9 20 - BA29.10- P-1003- 02C Bolt, accelerator pedal module to bracket Nm - - - BA29.10- P-1004- 02C Bolt of bracket to body Nm - - - BA29.10- P-1005- 02C Nut securing bracket to body Nm - - - BA29.10- P-1006- 02C Bolt, connection piece between brake pedal module and brake booster to body Nm - - 27 BA29.10- P-1007- 02C Bolt, pedal to brake pedal module Nm - - 20 PEDALS, BEARING BRACKET Number Designation Model 452.3/4 Right-hand drive Model 452.3/4 left-hand steering BA29.10- P-1001- 02C Bolt, brake pedal module to body Nm 20 20 BA29.10- P-1002- 02C Bolt, brake pedal head Nm 9 9 BA29.10- P-1003- 02C Bolt, accelerator pedal module to bracket Nm 9 9 BA29.10- P-1004- 02C Bolt of bracket to body Nm 9 9 BA29.10- P-1005- 02C Nut securing bracket to body Nm 3.7 3.7 BA29.10- P-1006- 02C Bolt, connection piece between brake pedal module and brake booster to body Nm - - BA29.10- P-1007- 02C Bolt, pedal to brake pedal module Nm - - SPECIAL TOOLS > SPECIAL TOOLS: SMART: PEDAL ASSEMBLY - WS29.00-Z-9999CZ >
MODEL all¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3347 · Applies to: 450, 451, 452, 454
450 589 09 99 04 Box wrench bit FG29/42/Set B WS42.00-P-0070-04B
TESTING & REPAIR > PREPARE CONNECTING POINTS OF REAR LAMP INSERT ON¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3349 · Applies to: 450, 451, 452, 454
BODY - AR64.20-P-1061-02MCO > 1. Grind mating surfaces down to bare metal in 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. Fig 1: Identifying Rear Lamp Insert Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE REAR LAMP INSERT FOR INSTALLATION. - AR64.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3350 · Applies to: 450, 451, 452, 454
1061-03MCO > 1. Drill holes for plug welding on rear lamp insert (1) (area G). Transfer dimensions of holes for plug welding from vehicle. Fig 1: Identifying Rear Lamp Insert Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind rear lamp insert (1) down to bare metal in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3351 · Applies to: 450, 451, 452, 454
Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2- component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications of 2-component adhesive for drying and processing time. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR > INSTALL REAR LAMP INSERT AND WELD IN. - AR64.20-P-1061- 04MCO > 1. Apply 2-component adhesive material in 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. Observe manufacturer's specifications of 2- component adhesive for drying and processing time. Fig 1: Identifying Drill Holes For Plug Welding & Grinding Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3353 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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
AH91.00-P-0002-01SM Fig 1: Locating Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3356 · Applies to: 450, 451, 452, 454
- Expose spot welds on end crossmember inner section (1) and cut out (areas A, B and C).
- Remove damaged end crossmember inner section (1). TESTING & REPAIR > PREPARE END CROSSMEMBER INNER SECTION FOR INSTALLATION - AR64.20-P-1120-02MCC >
- Grind connecting flange on end crossmember inner section (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. Fig 1: Identifying Spot Welds On End Crossmember Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > WELD IN END CROSSMEMBER INNER SECTION - AR64.20-P-1120-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3357 · Applies to: 450, 451, 452, 454
03MCC > Shown on model 451.3 1. Fit end crossmember inner section (1) with straightening tool and fasten with vise grip pliers. 2. End crossmember inner section (1) (areas A, B and C). Fig 1: Identifying Connecting Flange Grinding Area On Crossmember Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Fitting Crossmember Inner Section 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. 3358 · Applies to: 450, 451, 452, 454
- Clean all other weld joints with wire brush. TESTING & REPAIR > PREPARE CONNECTING POINTS FOR END CROSSMEMBER INNER SECTION ON BODY. - AR64.20-P-1120-04MCC > Shown on model 451.3
- 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 > REPLACE END CROSSMEMBER INTERNAL PART - AR64.20-P- 1120MCC > MODEL 451.3/4 Shown on model 451.3 Fig 1: Identifying Grinding Areas On End Crossmember Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3359 · Applies to: 450, 451, 452, 454
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: View Of End Crossmember Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3360 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair Shank brush Grinding disk Hart metal ball cutter Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Straightening bench Straightening bracket set Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Set up straightening bench with straightening bracket and attach vehicle Observe set-up plans.Set-up plans http://gotis.aftersales.mercedes- benz.com
4 Remove end plate
AR64.20-P- 5731MCC 5 Remove end crossmember inner section (1)
AR64.20-P-1120- 01MCC 6 Prepare end
AR64.20-P-1120-
welding in the area of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3363 · Applies to: 450, 451, 452, 454
highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. hazard area. Use air extractor system. 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 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 following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Weld protection blanket http://gotis.aftersales.mercedes-
benz.com¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3364 · Applies to: 450, 451, 452, 454
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 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
AR63.40-P- 1180MCD
Scribe separation line on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3365 · Applies to: 450, 451, 452, 454
17 Scribe separation line on crossmember on rear floor assembly (1) and cut (area A) Support body with suitable jack stand (3) and secure with fastening aid (4) against tilting. Use tensioning strap (4) as fastening aid.
18 Remove damaged section from crossmember on rear floor assembly (1.1)
19 Scribe separation line on new crossmember on rear floor assembly (2) and cut (area C)
20 Remove section on new crossmember on rear floor assembly (2.1)
21 Grind mating surfaces on body and on section of new crossmember on rear floor assembly (2.1) down to bare metal in cross- hatched areas.
Install
22 Fit section of new crossmember on rear floor assembly (2.1) using straightening tool (5) and fix in place using vise grip pliers and C-clamps. Observe set-up plans.Setup plans http://gotis.aftersales.mercedes- benz.com
23 Tack weld section on new crossmember on rear floor assembly (2.1) (area B)
24 Remove rear main floor panel, front main floor panel, front longitudinal member, longitudinal member mounting console and longitudinal member inner shell
25 Section of new crossmember on rear floor assembly (2.1) (area B)
26 Grind all weld joints down flat, if required.
27 Clean all other weld joints using a shank brush
Partially install front main¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3366 · Applies to: 450, 451, 452, 454
28 Partially install front main floor panel
AR63.40-P- 1180MCC 29 Partially install rear main floor panel
AR63.40-P- 1180MCD 30 Install accelerator pedal mounting console
AR63.40-P- 1300MCC 31 Install center mounting console below front seat
AR63.40-P- 1192MCC 32 Partially install crossmember below front seat
AR63.40-P- 1189MCC 33 Install center main floor panel reinforcement
AR63.40-P- 1110MCC 34 Install front longitudinal member
AR62.20-P- 1242MCC 35 Partially install longitudinal member inner shell on entrance
AR63.30-P- 1143MCC 36 Install mounting console on bottom front longitudinal member
AR62.20-P- 1265MCC 37 Install longitudinal member locking lug
AR62.20-P- 1267MCC 38 Partially install longitudinal member reinforcement
AR63.30-P- 0818MCC 39 Partially install side wall reinforcement
AR63.20-P- 0862MCC 40 Install lower A-pillar reinforcement On model 451.3 AR63.20-P- 1114MCC
On model 451.4 AR63.20-P- 1114MCO 41 Install lower outer A-pillar On model 451.4 AR63.20-P- 1102MCO 42 Partially install side wall paneling On model 451.3 AR63.10-P- 0115MCC
On model 451.4 AR63.10-P- 0115MCO 43 Clean weld joints and sheet metal flange using a shank brush and clean repair areas.
44 Prime area to be repaired
using primer filler¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3367 · Applies to: 450, 451, 452, 454
45 Supply standard seam seals with body sealant
AR97.10-P- 4000MCC
Sealant BR00.45-Z-1003- 01A 46 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 47 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00-P-9408- 02MCC 48 Apply additional cavity preservation
AR97.20-P- 1500FF
Teroson protective wax *BR00.45-Z-1008- 05A 49 Reinstall all detachable parts removed
AUXILIARY 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 > REMOVE REAR FLOOR ASSEMBLY REINFORCEMENT - AR64.20- P-1141-01MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3368 · Applies to: 450, 451, 452, 454
- Expose spot welds on rear floor assembly reinforcement (1) and cut out (area A).
- Expose spot welds on rear floor assembly reinforcement (1) and cut out (areas B, C, D, E, and F).
- Remove damaged rear floor assembly reinforcement (1). Fig 1: Identifying Spot Welds On Rear Floor Assembly Reinforcement (Area A) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE REAR FLOOR ASSEMBLY REINFORCEMENT - AR64.20-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3369 · Applies to: 450, 451, 452, 454
P-1141-02MCC > 1. Grind rear floor assembly reinforcement (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. Fig 2: Identifying Spot Welds On Rear Floor Assembly Reinforcement (Areas B, C, D, E, and F) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > WELD IN REAR FLOOR ASSEMBLY REINFORCEMENT - AR64.20-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3370 · Applies to: 450, 451, 452, 454
P-1141-03MCC > 1. Fit rear floor assembly reinforcement (1) and fasten with vise grip pliers. Fig 1: Identifying Grinding Area On Rear Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Fitting Rear Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill 6.5 mm Ø rivet holes (area A).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3371 · Applies to: 450, 451, 452, 454
- Remove rear floor assembly reinforcement (1).
- Deburr rivet holes on rear floor assembly reinforcement (1) and body on both sides.
- Fit rear floor assembly reinforcement (1) and fasten with manual temporary fasteners and vise grip pliers.
- Rear floor assembly reinforcement (1) (areas B, C, D and E).
- Rivet rear floor assembly reinforcement (1) with 6.4 x 14 Polygrip flat/round head rivet (area A). Fig 2: Fitting Rear Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Riveting Rear Area On Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Grind all spot welds down flat if required.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3372 · Applies to: 450, 451, 452, 454
- Clean all other weld joints with wire brush. TESTING & REPAIR > PREPARE CONNECTION POINTS ON VEHICLE FOR REAR FLOOR ASSEMBLY REINFORCEMENT - AR64.20-P-1141-04MCC >
- Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > REPLACE REAR-END FLOOR REINFORCEMENT - AR64.20-P- 1141MCC > MODEL 451.3/4 Illustrated on model 451.3 Fig 1: Identifying Grinding Area On Rear Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3373 · Applies to: 450, 451, 452, 454
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 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
AH91.00-P-0002-01SM Fig 1: Locating Rear-End Floor Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3376 · Applies to: 450, 451, 452, 454
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 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 6.4 14 A 003 990 35 97 TESTING & REPAIR > REMOVE REAR FLOOR - AR64.20-P-1300-01MCC > Shown on model 451.3 1. Expose spot welds on rear floor assembly (1) and cut out (areas A, B and C). Fig 1: Identifying Spot Welds On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3377 · Applies to: 450, 451, 452, 454
- Expose spot welds on rear floor assembly (1) and cut out (areas D and E).
- Expose spot welds on rear floor assembly (1) and cut out (area F). Area F is bonded. Areas D and E are bonded. Fig 2: Identifying Spot Welds On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Bonded Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Expose spot welds on rear floor assembly (1) and cut out (areas G, H, J and K).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3378 · Applies to: 450, 451, 452, 454
Area H is bonded. 5. Heat bonded areas with hot air blower and remove damaged rear floor assembly (1). TESTING & REPAIR > PREPARE REAR FLOOR ASSEMBLY - AR64.20-P-1300-02MCC > 1. Drill holes for plug welding on rear floor assembly (1) (area B and C). Transfer position for holes for plug welding from vehicle. Fig 4: Identifying Spot Welds On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Drill Holes On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind rear floor assembly (1) down to bare metal in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3379 · Applies to: 450, 451, 452, 454
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 > INSTALL REAR FLOOR - AR64.20-P-1300-04MCC > Fig 2: Identifying Grinding Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Fitting Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit rear floor assembly (1) together with inner B-pillar, end crossmember inner section and rear end¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3380 · Applies to: 450, 451, 452, 454
panel and fix in place using vise grip pliers and straightening tools. Observe setup plans. http://gotis.aftersales.mercedes-benz.com 2. Drill Ø 6.5 mm rivet holes (area A). 3. Remove rear floor assembly (1), inner B-pillar, end crossmember inner section and rear end panel. 4. Apply 2-component adhesive to mating surfaces in 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. Observe manufacturer's specifications for drying and processing time for 2-component adhesive. Fig 2: Identifying Adhesive Application Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Fit rear floor assembly (1) together with inner B-pillar, end crossmember inner section and rear end¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3381 · Applies to: 450, 451, 452, 454
panel and fix in place using vise grip pliers, manual temporary fasteners and straightening tools. 6. Rear floor assembly (1) (areas B and C). 7. Remove inner B-pillar, end crossmember inner section and rear end panel. 8. Rivet rear floor assembly (1) using Polygrip flat round head rivet, 6.4 x 14 (area A). Fig 3: Fitting Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Riveting Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
9. Rear floor assembly (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3382 · Applies to: 450, 451, 452, 454
(areas F and G). 10. Rear floor assembly (1) (areas D and E). All other welds are completed after installing the crossmember below front seat. TESTING & REPAIR > PREPARE MATING SURFACES ON VEHICLE FOR REAR FLOOR ASSEMBLY - AR64.20-P-1300-10MCC > Shown on model 451.3 Fig 5: Identifying Spot Welds On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Grind Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE REAR FLOOR ASSEMBLY SECTION - AR64.20-P-1310-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3387 · Applies to: 450, 451, 452, 454
01MCC > 1. Scribe cut on rear floor assembly (1) and cut (areas A and B). 2. Expose spot welds on rear floor assembly (1) and cut out (area C). 3. Remove damaged section from rear floor assembly (1). TESTING & REPAIR > PREPARE REAR FLOOR ASSEMBLY SECTION - AR64.20-P-1310- 02MCC > 1. Scribe cut on rear floor assembly (1) and cut (areas A and B). Transfer dimensions from vehicle. Fig 1: Removing Damaged Section From Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill holes for plug welding in rear floor assembly section (1.1) (area C).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3388 · Applies to: 450, 451, 452, 454
Transfer dimensions of holes for plug welding from vehicle. 3. Grind mating surfaces on rear floor assembly section (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. Fig 1: Identifying Cut Areas On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE MATING SURFACES ON VEHICLE FOR REAR FLOOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3389 · Applies to: 450, 451, 452, 454
ASSEMBLY SECTION. - AR64.20-P-1310-03MCC > 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 2: Identifying Drill Holes & Grinding Surfaces On Rear Floor Assembly Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL REAR FLOOR ASSEMBLY SECTION - AR64.20-P-1310-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3390 · Applies to: 450, 451, 452, 454
04MCC > Shown on model 451.3 1. Fit rear floor assembly section (1) and fasten with vise grip pliers. 2. Rear floor assembly section (1) (areas A and B). 3. Rear floor assembly section (1) (area C). 4. Rear floor assembly section (1) (areas D and E). Fig 1: Identifying Grinding Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Grind all welds down flat, if required.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3391 · Applies to: 450, 451, 452, 454
- Clean all other welds with wire brush. TESTING & REPAIR > REPLACE REAR FLOOR ASSEMBLY SECTION - AR64.20-P- 1310MCC > MODEL 451.3/4 Shown on model 451.3 Fig 1: Fitting Rear Floor Assembly Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3392 · Applies to: 450, 451, 452, 454
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: View Of Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3393 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Remove side wall paneling section In case of model 451.3 AR63.10-P- 0115MCC
On model 451.4 AR63.10-P- 0115MCO 4 Remove side wall reinforcement section
AR63.20-P- 0862MCC 5 remove B-pillar reinforcement In case of model 451.3 AR63.20-P- 1351MCC
On model 451.4 AR63.20-P- 1351MCO 6 Remove rear lamp insert In case of model 451.3 AR64.20-P- 1061MCC
On model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3394 · Applies to: 450, 451, 452, 454
AR64.20-P- 1061MCO 7 Remove rear wheelhouse
AR63.10-P- 0661MCC 8 Remove B-pillar internal component
AR63.20-P- 1355MCC 9 Remove rear floor assembly section (1).
AR64.20-P-1310- 01MCC 10 Prepare connection points for rear floor assembly section (1) on body
AR64.20-P-1310- 03MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 11 Prepare rear floor assembly section (1) for installation
AR64.20-P-1310- 02MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
12 Install rear floor assembly section (1) and weld in
AR64.20-P-1310- 04MCC 13 Install B-pillar internal component
AR63.20-P- 1355MCC 14 Install rear wheelhouse
AR63.10-P- 0661MCC 15 Install rear lamp insert In case of model 451.3 AR64.20-P- 1061MCC
On model 451.4 AR64.20-P- 1061MCO 16 Install B-pillar reinforcement In case of model 451.3 AR63.20-P- 1351MCC
On model 451.4 AR63.20-P- 1351MCO 17 Install side wall reinforcement section
AR63.20-P- 0862MCC 18 Install side wall paneling section In case of 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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3395 · Applies to: 450, 451, 452, 454
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
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 > SEPARATE END PLATE - AR64.20-P-5731-01MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3396 · Applies to: 450, 451, 452, 454
- Expose spot welds on end plate (1) and cut out (areas A, B, C and D).
- Remove damaged end plate (1). TESTING & REPAIR > PREPARE END PLATE FOR INSTALLATION - AR64.20-P-5731- 02MCC > Shown on model 451.3
- Grind mating surfaces down to bare metal in cross-hatched areas on both sides and coat inside of spot weld flange with zinc dust paint.
- Drill holes for plug welding on end plate (1) (areas E and F). Transfer dimensions of hole for plug welding from vehicle.
- Grind connecting flange on end plate (1) down to bare metal in cross-hatched areas on both sides and coat inside of spot weld flange with zinc dust paint. Fig 1: Identifying Spot Welds On End Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Grinding Area On End Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > WELD IN END PLATE - AR64.20-P-5731-03MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3397 · Applies to: 450, 451, 452, 454
Shown on model 451.3 1. Fit end plate (1) and fasten with vise grip pliers. 2. End plate (1) (areas G, H, J and K). 3. End plate (1) (areas M and L). 4. Grind all spot welds down flat if required 5. Clean all other weld joints with wire brush. Fig 2: Identifying Grind Areas On Connecting Flange Of End Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3399 · Applies to: 450, 451, 452, 454
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: Locating End Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3400 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Remove end plate (1)
AR64.20-P-5731- 01MCC 4 Prepare connecting points on body and on end plate (1)
AR64.20-P-5731- 02MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
5 Install end plate (1) and weld in
AR64.20-P-5731- 03MCC 6 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
7 Prime area to be repaired
450 589 00 62 00 Record¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3403 · Applies to: 450, 451, 452, 454
release bolt GROUP 64/Set B WS64.00-P-0050B 450 589 01 23 00 Template Group 64/Set K WS64.00-P-0052K 450 589 02 11 00 Allen wrench Group 64/Set B WS64.00-P-0051B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K
TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS ON B-PILLAR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3405 · Applies to: 450, 451, 452, 454
REINFORCEMENT ON BODY - AR64.20-P-1061-02MCC > 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, otherwise adhesion of the 2- component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. Fig 1: Identifying Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE REAR LAMP INSERT FOR INSTALLATION. -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3406 · Applies to: 450, 451, 452, 454
AR64.20-P-1061-03MCC > Fig 1: Identifying Grind Area On B-Pillar Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Drill holes for plug welding on rear lamp insert (1) (areas H and K).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3407 · Applies to: 450, 451, 452, 454
Transfer dimensions of hole for plug welding from vehicle. 2. Grind rear lamp insert (1) down to bare metal in 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR INDEX > INSTALL REAR LAMP INSERT AND WELD IN. - AR64.20-P- 1061-04MCC > Fig 1: Identifying Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3409 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00- P-0008- Fig 1: Identifying Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
01MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3410 · Applies to: 450, 451, 452, 454
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- 0115MCC 4 Remove rear lamp insert (1)
AR64.20- P-1061- 01MCC 5 Prepare connecting points of rear lamp insert (1) on body
AR64.20- P-1061- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 6 Prepare rear lamp insert (1) for installation
AR64.20- P-1061- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
7 Install rear lamp insert (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-1061- 04MCC
Adhesive *BR00.45- Z-1092- 02A
Partially install side wall paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3411 · Applies to: 450, 451, 452, 454
8 Partially install side wall paneling
AR63 10 P- 0115MCC 9 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
10 Prime area to be repaired using primer filler
11 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant BR00.45- Z-1003- 01A 12 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 13 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 14 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 15 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 > PARTIALLY SEPARATE REAR LAMP INSERT - AR64.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3412 · Applies to: 450, 451, 452, 454
1062-01MCC > 1. Scribe cut on rear lamp insert (1) according to damage profile and separate (area A). 2. Expose spot welds on rear lamp insert (1) and cut out (areas B, C, D and E). 3. Heat rear lamp insert (1) with hot air gun (area C). Area (C) is bonded. 4. Remove damaged rear lamp insert (1). TESTING & REPAIR INDEX > PARTIALLY PREPARE CONNECTING POINTS FOR REAR LAMP INSERT ON BODY. - AR64.20-P-1062-02MCC > 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, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. Fig 1: Identifying Separate Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PARTIALLY PREPARE REAR LAMP INSERT FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3413 · Applies to: 450, 451, 452, 454
INSTALLATION - AR64.20-P-1062-03MCC > 1. Scribe cut on rear lamp insert (1) and separate (area F). Transfer dimension from vehicle. 2. Drill holes for plug welding on rear lamp insert section (1.1) (area E). Transfer dimensions of holes for plug welding from vehicle. Fig 1: Identifying Rear Lamp Insert On Body Connecting Points Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Grind rear lamp insert section (1) down to bare metal in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3414 · Applies to: 450, 451, 452, 454
Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications of 2-component adhesive for drying and processing time. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR INDEX > PARTIALLY INSTALL REAR LAMP INSERT AND WELD IN. - AR64.20-P-1062-04MCC > Fig 1: Identifying Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Apply 2-component adhesive material in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3415 · Applies to: 450, 451, 452, 454
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. 2. Fit rear lamp insert section (1) and fasten with vise grip pliers. 3. Rear lamp insert section (1) (areas G, J and K). 4. Rear lamp insert section (1) (area H). 5. Rear lamp insert section (1) (area L). 6. Grind all weld joints down flat if required. 7. Clean all other welds with wire brush TESTING & REPAIR INDEX > PARTIALLY REPLACE REAR LAMP INSERT - AR64.20-P- 1062MCC > MODEL 451.3 Fig 1: Identifying Rear Lamp Insert And Weld In Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3416 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00- P-0008- Fig 1: Identifying Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
01MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3417 · Applies to: 450, 451, 452, 454
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 rear lamp insert (1)
AR64.20- P-1062- 01MCC 4 Partially prepare connecting points on rear lamp insert (1) on body.
AR64.20- P-1062- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 5 Partially prepare rear lamp insert (1) for installation
AR64.20- P-1062- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
6 Partially install rear lamp insert (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-1062- 04MCC
Adhesive *BR00.45- Z-1092- 02A 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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3418 · Applies to: 450, 451, 452, 454
BR00.45- Z-1003- 01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 11 Paint repair areas and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 12 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective waxArt. no.: 122.73Q *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 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 > SEPARATE END CROSSMEMBER INNER SECTION - AR64.20-P-1120-01MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3419 · Applies to: 450, 451, 452, 454
- Expose spot welds on end crossmember inner section (1) and cut out (areas A, B and C).
- Remove damaged end crossmember inner section (1). TESTING & REPAIR INDEX > PREPARE END CROSSMEMBER INNER SECTION FOR INSTALLATION - AR64.20-P-1120-02MCC >
- Grind connecting flange on end crossmember inner section (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. Fig 1: Identifying End Crossmember Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > WELD IN END CROSSMEMBER INNER SECTION - AR64.20-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3420 · Applies to: 450, 451, 452, 454
P-1120-03MCC > Shown on model 451.3 1. Fit end crossmember inner section (1) with straightening tool and fasten with vise grip pliers. 2. End crossmember inner section (1) (areas A, B and C). Fig 1: Identifying End Crossmember Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying End Crossmember Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3422 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying End Crossmember Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3423 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair Shank brush Grinding disk Hart metal ball cutter Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Straightening bench Straightening bracket set Tarp (fire-resistant)
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 Set up straightening bench with straightening bracket and attach vehicle Observe set-up plans.Set- up plans
4 Remove end plate
AR64.20- P- 5731MCC 5 Remove end crossmember inner section (1)
AR64.20- P-1120- 01MCC 6 Prepare end crossmember inner section (1) for installation
AR64.20- P-1120- 02MCC
Zinc dust paint suitable for *BR00.45- Z-1001-
pot welding¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3424 · Applies to: 450, 451, 452, 454
07A 7 Prepare connecting points on body
AR64.20- P-1120- 04MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
8 Install end crossmember inner section (1) and weld in
AR64.20- P-1120- 03MCC 9 Install end panel
AR64.20- P- 5731MCC 10 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
11 Prime area to be repaired using primer filler
12 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant BR00.45- Z-1003- 01A 13 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 14 Paint area repaired and adjacent surfaces
Notes 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
caused by inhaling welding fumes.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3426 · Applies to: 450, 451, 452, 454
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 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 following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Weld protection blanket
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in Use fire-resistant weld protection blanket to prevent
vehicle (area to be repaired)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3427 · Applies to: 450, 451, 452, 454
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 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 AR63.40-
Partially remove front main floor panel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3428 · Applies to: 450, 451, 452, 454
15 Partially remove front main floor panel
P- 1180MCC 16 Partially remove rear main floor panel
AR63.40- P- 1180MCD 17 Scribe separation line on crossmember on rear floor assembly (1) and cut (area A) Support body with suitable jack stand (3) and secure with fastening aid (4) against tilting. Use tensioning strap (4) as fastening aid.
18 Remove damaged section from crossmember on rear floor assembly (1.1)
19 Scribe separation line on new crossmember on rear floor assembly (2) and cut (area C)
20 Remove section on new crossmember on rear floor assembly (2.1)
21 Grind mating surfaces on body and on section of new crossmember on rear floor assembly (2.1) down to bare metal in cross- hatched areas.
Install
22 Fit section of new crossmember on rear floor assembly (2.1) using straightening tool (5) and fix in place using vise grip pliers and C-clamps. Observe set-up plans.Setup plans
23 Tack weld section on new crossmember on rear floor assembly (2.1) (area B)
24 Remove rear main floor panel, front main floor panel, front longitudinal member, longitudinal member mounting console and longitudinal member inner shell
25 Section of new crossmember on rear floor assembly (2.1) (area B)
26 Grind all weld joints down flat, if required.
27 Clean all other weld joints using a shank brush
28 Partially install front main floor panel
AR63.40- P- 1180MCC 29 Partially install rear main floor panel
AR63.40- P- 1180MCD 30 Install accelerator pedal mounting console
AR63.40- P- 1300MCC
Install center mounting console below front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3429 · Applies to: 450, 451, 452, 454
31 Install center mounting console below front seat
AR63.40- P- 1192MCC 32 Partially install crossmember below front seat
AR63.40- P- 1189MCC 33 Install center main floor panel reinforcement
AR63.40- P- 1110MCC 34 Install front longitudinal member
AR62.20- P- 1242MCC 35 Partially install longitudinal member inner shell on entrance
AR63.30- P- 1143MCC 36 Install mounting console on bottom front longitudinal member
AR62.20- P- 1265MCC 37 Install longitudinal member locking lug
AR62.20- P- 1267MCC 38 Partially install longitudinal member reinforcement
AR63.30- P- 0818MCC 39 Partially install side wall reinforcement
AR63.20- P- 0862MCC 40 Install lower A-pillar reinforcement On model 451.3 AR63.20- P- 1114MCC
On model 451.4 AR63.20- P- 1114MCO 41 Install lower outer A-pillar On model 451.4 AR63.20- P- 1102MCO 42 Partially install side wall paneling On model 451.3 AR63.10- P- 0115MCC
On model 451.4 AR63.10- P- 0115MCO 43 Clean weld joints and sheet metal flange using a shank brush and clean repair areas.
Prime area to be repaired using primer filler¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3430 · Applies to: 450, 451, 452, 454
44 Prime area to be repaired using primer filler
45 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant BR00.45- Z-1003- 01A 46 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 47 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 48 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 49 Reinstall all detachable parts removed
AUXILIARY 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 > REMOVE REAR FLOOR ASSEMBLY REINFORCEMENT - AR64.20-P-1141-01MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3431 · Applies to: 450, 451, 452, 454
- Expose spot welds on rear floor assembly reinforcement (1) and cut out (area A).
- Expose spot welds on rear floor assembly reinforcement (1) and cut out (areas B, C, D, E, and F).
- Remove damaged rear floor assembly reinforcement (1). Fig 1: Identifying Rear Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Damaged Rear Floor Assembly Reinforcement
TESTING & REPAIR INDEX > PREPARE REAR FLOOR ASSEMBLY REINFORCEMENT -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3432 · Applies to: 450, 451, 452, 454
AR64.20-P-1141-02MCC > 1. Grind rear floor assembly reinforcement (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. Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > WELD IN REAR FLOOR ASSEMBLY REINFORCEMENT -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3433 · Applies to: 450, 451, 452, 454
AR64.20-P-1141-03MCC > 1. Fit rear floor assembly reinforcement (1) and fasten with vise grip pliers. Fig 1: Identifying Rear Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Rear Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill 6.5 mm Ø rivet holes (area A).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3434 · Applies to: 450, 451, 452, 454
- Remove rear floor assembly reinforcement (1).
- Deburr rivet holes on rear floor assembly reinforcement (1) and body on both sides.
- Fit rear floor assembly reinforcement (1) and fasten with manual temporary fasteners and vise grip pliers.
- Rear floor assembly reinforcement (1) (areas B, C, D and E).
- Rivet rear floor assembly reinforcement (1) with 6.4 x 14 Polygrip flat/round head rivet (area A). Fig 2: Identifying Rear Floor Assembly Reinforcement And Body Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Rivet Rear Area On Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Grind all spot welds down flat if required.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3435 · Applies to: 450, 451, 452, 454
- Clean all other weld joints with wire brush. TESTING & REPAIR INDEX > PREPARE CONNECTION POINTS ON VEHICLE FOR REAR FLOOR ASSEMBLY REINFORCEMENT - AR64.20-P-1141-04MCC >
- Grind mating surfaces down to bare metal in the cross-hatched 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 REAR-END FLOOR REINFORCEMENT - AR64.20- P-1141MCC > MODEL 451.3 /4 Illustrated on model 451.3 Fig 1: Identifying Connection Points On Rear Floor Assembly Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3436 · Applies to: 450, 451, 452, 454
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 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 General information on riveting
AH60.00- P-0003- Fig 1: Identifying Rear-End Floor Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
01MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3437 · Applies to: 450, 451, 452, 454
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
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
Remove rear-end floor reinforcement (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3438 · Applies to: 450, 451, 452, 454
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 reinforcement (1) for installation
AR64.20- P-1141- 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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3439 · Applies to: 450, 451, 452, 454
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
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 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 6.4 14 A 003 990 35 97
TESTING & REPAIR INDEX > REMOVE REAR FLOOR - AR64.20-P-1300-01MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3440 · Applies to: 450, 451, 452, 454
Shown on model 451.3 1. Expose spot welds on rear floor assembly (1) and cut out (areas A, B and C). Shown on model 451.3 2. Expose spot welds on rear floor assembly (1) and cut out (areas D and E). 3. Expose spot welds on rear floor assembly (1) and cut out (area F). Area F is bonded. Areas D and E are bonded. Fig 1: Identifying Spot Weld Area On Rear Floor Assembly (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Spot Weld Area On Rear Floor Assembly (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Expose spot welds on rear floor assembly (1) and cut out (areas G, H, J and K).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3441 · Applies to: 450, 451, 452, 454
Area H is bonded. 5. Heat bonded areas with hot air blower and remove damaged rear floor assembly (1). TESTING & REPAIR INDEX > PREPARE REAR FLOOR ASSEMBLY - AR64.20-P-1300- 02MCC > 1. Drill holes for plug welding on rear floor assembly (1) (area B and C). Transfer position for holes for plug welding from vehicle. Fig 3: Identifying Bonded Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Spot Weld Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind rear floor assembly (1) down to bare metal in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3442 · Applies to: 450, 451, 452, 454
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 > INSTALL REAR FLOOR - AR64.20-P-1300-04MCC > Fig 1: Identifying Drill Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Grind Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit rear floor assembly (1) together with inner B-pillar, end crossmember inner section and rear end¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3443 · Applies to: 450, 451, 452, 454
panel and fix in place using vise grip pliers and straightening tools. Observe setup plans. 2. Drill Ø 6.5 mm rivet holes (area A). 3. Remove rear floor assembly (1), inner B-pillar, end crossmember inner section and rear end panel. 4. Apply 2-component adhesive to mating surfaces in 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. Observe manufacturer's specifications for drying and processing time for 2-component adhesive. Fig 1: Identifying Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Fit rear floor assembly (1) together with inner B-pillar, end crossmember inner section and rear end¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3444 · Applies to: 450, 451, 452, 454
panel and fix in place using vise grip pliers, manual temporary fasteners and straightening tools. 6. Rear floor assembly (1) (areas B and C). Fig 2: Identifying Adhesive Applying Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Fitting Rear Floor Assembly With Inner B-Pillar Using Vise Grip Pliers Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Remove inner B-pillar, end crossmember inner section and rear end panel.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3445 · Applies to: 450, 451, 452, 454
- Rivet rear floor assembly (1) using Polygrip flat round head rivet, 6.4 x 14 (area A).
- Rear floor assembly (1) (areas F and G).
- Rear floor assembly (1) (areas D and E). All other welds are completed after installing the crossmember below front seat. TESTING & REPAIR INDEX > PREPARE MATING SURFACES ON VEHICLE FOR REAR FLOOR ASSEMBLY - AR64.20-P-1300-10MCC > Fig 4: Identifying Rivet Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Weld Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3446 · Applies to: 450, 451, 452, 454
- 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 > COMPLETELY REPLACE REAR FLOOR - AR64.20-P- 1300MCC > MODEL 451.3 /4 Illustrated on model 451.3 Fig 1: Identifying Mating Surfaces On Vehicle For Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3447 · Applies to: 450, 451, 452, 454
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 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 Pretreatment of bonding surfaces
AH60.00- P-0008- Fig 1: Identifying Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
01MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3448 · Applies to: 450, 451, 452, 454
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
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
Remove B-pillar inner section¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3449 · Applies to: 450, 451, 452, 454
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 AR63.20-
Install B-pillar inner section¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3450 · Applies to: 450, 451, 452, 454
17 Install B-pillar inner section
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 reinforcement
AR63.20- P- 0862MCC 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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3451 · Applies to: 450, 451, 452, 454
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 INDEX > REMOVE REAR FLOOR ASSEMBLY SECTION - AR64.20-P- 1310-01MCC > 1. Scribe cut on rear floor assembly (1) and cut (areas A and B). 2. Expose spot welds on rear floor assembly (1) and cut out (area C). 3. Remove damaged section from rear floor assembly (1).
TESTING & REPAIR INDEX > PREPARE REAR FLOOR ASSEMBLY SECTION - AR64.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3452 · Applies to: 450, 451, 452, 454
1310-02MCC > 1. Scribe cut on rear floor assembly (1) and cut (areas A and B). Transfer dimensions from vehicle. Fig 1: Identifying Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill holes for plug welding in rear floor assembly section (1.1) (area C).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3453 · Applies to: 450, 451, 452, 454
Transfer dimensions of holes for plug welding from vehicle. 3. Grind mating surfaces on rear floor assembly section (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. Fig 1: Identifying Scribe Area On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE MATING SURFACES ON VEHICLE FOR REAR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3454 · Applies to: 450, 451, 452, 454
FLOOR ASSEMBLY SECTION. - AR64.20-P-1310-03MCC > 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 2: Identifying Drill Area On Rear Floor Assembly Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > INSTALL REAR FLOOR ASSEMBLY SECTION - AR64.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3455 · Applies to: 450, 451, 452, 454
1310-04MCC > Shown on model 451.3 1. Fit rear floor assembly section (1) and fasten with vise grip pliers. 2. Rear floor assembly section (1) (areas A and B). 3. Rear floor assembly section (1) (area C). 4. Rear floor assembly section (1) (areas D and E). Fig 1: Identifying Grinding Area On Weld Flanges Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Grind all welds down flat, if required.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3456 · Applies to: 450, 451, 452, 454
- Clean all other welds with wire brush. TESTING & REPAIR INDEX > REPLACE REAR FLOOR ASSEMBLY SECTION - AR64.20-P- 1310MCC > MODEL 451.3/ 4 Shown on model 451.3 Fig 1: Identifying Grind Area On Rear Floor Assembly Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3457 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3458 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant)
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 Remove side wall paneling section In case of model 451.3 AR63.10- P- 0115MCC
On model 451.4 AR63.10- P- 0115MCO 4 Remove side wall reinforcement section
AR63.20- P- 0862MCC 5 remove B-pillar reinforcement In case of model 451.3 AR63.20- P- 1351MCC
On model 451.4 AR63.20- P- 1351MCO AR64.20-
Remove rear lamp insert¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3459 · Applies to: 450, 451, 452, 454
6 Remove rear lamp insert In case of model 451.3 P- 1061MCC
On model 451.4 AR64.20- P- 1061MCO 7 Remove rear wheelhouse
AR63.10- P- 0661MCC 8 Remove B-pillar internal component
AR63.20- P- 1355MCC 9 Remove rear floor assembly section (1).
AR64.20- P-1310- 01MCC 10 Prepare connection points for rear floor assembly section (1) on body
AR64.20- P-1310- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 11 Prepare rear floor assembly section (1) for installation
AR64.20- P-1310- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
12 Install rear floor assembly section (1) and weld in
AR64.20- P-1310- 04MCC 13 Install B-pillar internal component
AR63.20- P- 1355MCC 14 Install rear wheelhouse
AR63.10- P- 0661MCC 15 Install rear lamp insert In case of model 451.3 AR64.20- P- 1061MCC
On model 451.4 AR64.20- P- 1061MCO 16 Install B-pillar reinforcement In case of model 451.3 AR63.20- P- 1351MCC
On model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3460 · Applies to: 450, 451, 452, 454
AR63.20- P- 1351MCO 17 Install side wall reinforcement section
AR63.20- P- 0862MCC 18 Install side wall paneling section In case of 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
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- Henkel Loctite Deutschland GmbHArabellastrasse 1781925
Z-1008-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3461 · Applies to: 450, 451, 452, 454
05A Teroson protective waxArt. no.: 122.73Q 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 > SEPARATE END PLATE - AR64.20-P-5731-01MCC > Shown on model 451.3 1. Expose spot welds on end plate (1) and cut out (areas A, B, C and D). 2. Remove damaged end plate (1). TESTING & REPAIR INDEX > PREPARE END PLATE FOR INSTALLATION - AR64.20-P- 5731-02MCC > Shown on model 451.3 1. Grind mating surfaces down to bare metal in cross-hatched areas on both sides and coat inside of spot weld flange with zinc dust paint. 2. Drill holes for plug welding on end plate (1) (areas E and F). Fig 1: Identifying End Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Grind Area On End Plate (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Transfer dimensions of hole for plug welding from vehicle.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3462 · Applies to: 450, 451, 452, 454
- Grind connecting flange on end plate (1) down to bare metal in cross-hatched areas on both sides and coat inside of spot weld flange with zinc dust paint. TESTING & REPAIR INDEX > WELD IN END PLATE - AR64.20-P-5731-03MCC > Shown on model 451.3
- Fit end plate (1) and fasten with vise grip pliers.
- End plate (1) (areas G, H, J and K).
- End plate (1) (areas M and L).
- Grind all spot welds down flat if required
- Clean all other weld joints with wire brush. Fig 2: Identifying Grind Area On Connecting Flange Of End Plate (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3464 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying End Panel (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3465 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Tarp (fire-resistant)
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 Remove end plate (1)
AR64.20- P-5731- 01MCC 4 Prepare connecting points on body and on end plate (1)
AR64.20- P-5731- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
5 Install end plate (1) and weld in
AR64.20- P-5731- 03MCC 6 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
7 Prime area to be repaired using primer filler
8 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3466 · Applies to: 450, 451, 452, 454 · AR: BA64.00-Z-9999CZ
BR00.45- Z-1003- 01A 9 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 10 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 11 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 12 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 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: REAR WALL AND REAR END - BA64.00-Z-9999CZ > MODEL all Rear end MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA64.20-P-1000-01B TORQUE SPECIFICATIONS > REAR END - BA64.20-P-1000-01B > Model 450, 451, 452 CMS REAR END Model Model Model
450 589 00 62 00 Record¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3468 · Applies to: 450, 451, 452, 454
release bolt GROUP 64/Set B WS64.00-P-0050B 450 589 01 23 00 Template Group 64/Set K WS64.00-P-0052K 450 589 02 11 00 Allen wrench Group 64/Set B WS64.00-P-0051B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K
TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: ROOF - AR65.00-Z-9451CA¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3469 · Applies to: 450, 451, 452, 454 · AR: AR65.00-Z-9451CA, AR65.20-P-1006MCC, AR65.20-P-1006MCD, AR65.20-P-1008MCC, AR65.20-P-1008MCD (+5 more)
MODEL 451 Remove/install front roof frame MODEL 451.3 Upper front roof frame AR65.20-P-1006MCC Remove/install front roof frame MODEL 451.3 Lower front roof frame AR65.20-P-1006MCD Remove/install rear roof frame MODEL 451.3 Upper rear roof frame AR65.20-P-1008MCC Remove/install rear roof frame MODEL 451.3 Bottom rear roof frame AR65.20-P-1008MCD Remove/install roof paneling MODEL 451.3 AR65.10-P-5702MCC Remove/install roof paneling MODEL 451.4 AR65.10-P-5702MCO Remove/install side roof frame MODEL 451.3 Inner side roof frame AR65.20-P-1200MCD Remove/install side roof frame MODEL 451.4 AR65.20-P-1200MCO Replace roll bar MODEL 451.4 AR65.20-P-1056MCO Replace side roof frame reinforcement MODEL 451.3 AR65.20-P-1210MCC TESTING & REPAIR > REMOVE ROOF PANELING - AR65.10-P-5702-01MCO > Fig 1: View Of Roof Paneling Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Expose spot welds on roof paneling (1) and cut out (areas A and B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3470 · Applies to: 450, 451, 452, 454
- Heat roof paneling (1) in cross-hatched areas with hot air gun. Cross-hatched areas are bonded.
- Remove damaged roof paneling (1). TESTING & REPAIR > PREPARE ROOF PANELING FOR INSTALLATION. - AR65.10-P- 5702-02MCO >
- Grind roof paneling in cross-hatched areas (C and D) from inside down to bare metal. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications of 2-component adhesive for drying and processing time. Coat inside of spot weld flanges not bonded with zinc dust paint.
- Grind roof paneling in remaining cross-hatched areas down to bare metal on both sides. TESTING & REPAIR > INSTALL ROOF PANELING - AR65.10-P-5702-03MCO > Fig 1: Identifying Roof Paneling Grinding Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Apply 2-component adhesive to mating surfaces in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3471 · Applies to: 450, 451, 452, 454
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. 2. Fit roof paneling (1) and fasten with clamping pliers. 3. Roof paneling (1) (areas A and B). 4. Clean all welds with wire brush. TESTING & REPAIR > PREPARE CONNECTION POINTS FOR ROOF PANELING ON BODY - AR65.10-P-5702-04MCC > 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. Sand spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. Fig 1: Locating Adhesive Application Areas Of Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL ROOF PANELING - AR65.10-P-5702MCO >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3472 · Applies to: 450, 451, 452, 454 · AR: AR65.10-P-5702MCO
MODEL 451.4 MODIFICATION NOTES Fig 1: Identifying Connection Points For Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Information on alternative repair method added (structural bonding¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3473 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 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 Remove roof paneling (1)
AR65.10-P-5702- 01MCO 4 Prepare connecting points for roof paneling (1) on body
AR65.10-P-5702- 04MCO
Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A
BR00.45-Z-1001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3475 · Applies to: 450, 451, 452, 454 · AR: AR65.20-P-1056MCO
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 > REPLACE ROLL BAR - AR65.20-P-1056MCO > MODEL 451.4
Remove/install
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 Notes on replacing body parts
AH60.00- P-0027- 01FF General information on repairs to body
AH60.00- P-0001- 01FF Remove detachable parts in the Fig 1: Identifying Rollover Bar, Screws And Lugs Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
repair area¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3476 · Applies to: 450, 451, 452, 454 · AR: AR65.20-P-1200MCO
1 repair area
2 Pry out lugs (3) on roll bar (1)
3 Unscrew bolts (2) from roll bar (1)
4 Remove roll bar (1)
5 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL SIDE ROOF FRAME - AR65.20-P-1200MCO > 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 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 Always wear protective gloves when working on or near sharp and non- AS00.00-Z-0017- 01A Fig 1: Preparing Side Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
parts on sharp vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3477 · Applies to: 450, 451, 452, 454
parts 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 Notes on replacing body parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Cartridge gun Drill (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Remove roof paneling
AR65.10-P- 5702MCO 4 Remove upper A-pillar outer paneling
AR63.20-P- 1105MCO 5 Partially remove side wall paneling
AR63.10-P- 0115MCO 6 Partially remove side wall reinforcement
AR63.20-P- 0862MCC 7 Remove bottom A-pillar outer section
AR63.20-P- 1102MCO
Remove lower A-pillar¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3478 · Applies to: 450, 451, 452, 454
8 Remove lower A-pillar reinforcement
AR63.20-P- 1114MCO 9 Partially remove top A-pillar reinforcement.
AR63.20-P- 1116MCO 10 Expose spot welds on side roof frame (1) and cut out (areas A and B).
11 Remove damaged side roof frame (1).
12 Grind connection surfaces down to bare metal in cross-hatched areas. Coat insides of spot weld flanges with zinc dust paint.Zinc dust paint suitable for spot welding BR00.45-Z- 1001-07A 13 Grind new side roof frame (1) down to bare metal in cross-hatched areas. Coat insides of spot weld flanges with zinc dust paint.Zinc dust paint suitable for spot welding BR00.45-Z- 1001-07A Install
14 Fit new side roof frame (1) and fasten with vise grip pliers. When fitting observe correct distances.
15 New side roof frame (1) (areas C and D)
16 Level spot welds (areas C and D)
17 Partially install top A-pillar reinforcement.
AR63.20-P- 1116MCO 18 Install bottom A-pillar reinforcement
AR63.20-P- 1114MCO 19 Install bottom A-pillar outer section
AR63.20-P- 1102MCO 20 Partially install side wall reinforcement
AR63.20-P- 0862MCC 21 Partially install side wall paneling
AR63.10-P- 0115MCO 22 Install upper A-pillar outer paneling
AR63.20-P- 1105MCO 23 Install roof paneling
AR65.10-P- 5702MCO 24 Clean sheet metal flange with wire brush and clean areas to repaired
25 Prime area to be repaired using primer filler
26 Supply standard seam
AR97.10-P-
seals with body sealant¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3479 · Applies to: 450, 451, 452, 454 · AR: AS65.00-Z-9999ZZ
4000MCC
Sealant *BR00.45-Z- 1003-01A 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-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 SAFETY PRECAUTIONS > RISK OF INJURY. INJURY MAY RESULT IF THE CUTTING WIRE TEARS OR HEATS UP WHILE USING IT TO CUT OUT COMPONENTS THAT ARE GLUED INTO PLACE. - AS65.00-Z-0001-01A > Wear protective gloves and safety glasses. Risk of injury When using a cutting wire to cut out components that are glued into place, injury to the eyes and hand may result if the cutting wire tears or becomes heated. Safety instructions/precautions Wear protective gloves. Wear safety glasses when cutting out components. SAFETY PRECAUTIONS > SAFETY INFORMATION: ROOF - AS65.00-Z-9999ZZ > MODEL all Risk of death caused by falling down MODEL 903... AS65.00-Z-0002-
from the roof of the vehicle. Risk of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3480 · Applies to: 450, 451, 452, 454 · AR: WS65.00-Z-9999CZ
injury to other persons caused by falling objects during work in the area of the roof. 01B Risk of death caused by falling from vehicle roof. Risk of injury to other persons caused by falling objects during work in roof area. MODEL all AS65.00-Z-0002- 01A Risk of injury caused by slipping when clamping blade in the multicutter and by splinters when cutting out bonded windows MODEL 454.0, 212, 219.3 AS65.00-Z-0003- 01A Risk of injury. Injury may result if the cutting wire tears or heats up while using it to cut out components that are glued into place. MODEL 450.3/4, 451.3/4, 452.3/4, 454.0 AS65.00-Z-0001- 01A Risk of injury. Injury may result if the cutting wire tears or heats up while using it to cut out roofs that are glued into place. MODEL 240 AS65.10-Z-0001- 01A SPECIAL TOOLS > 451 589 00 09 00 SOCKET WRENCH - WS65.00-P-0043B > Group 65/Set B MODEL 451 Use: Socket wrench for removal of rear-end door at top of hinge (body side) SPECIAL TOOLS > SPECIAL TOOLS: SMART: ROOF - WS65.00-Z-9999CZ > MODEL all Fig 1: Identifying Socket Wrench (451 589 00 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
129 589 03 21 00 Feeler¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3481 · Applies to: 450, 451, 452, 454
gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P-0027K 450 589 08 63 00 Cutting wire FG 65/67/Set B WS67.00-P-0020B 451 589 00 09 00 Socket wrench Group 65/Set B WS65.00-P-0043B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K
GENERAL INFORMATION > NOTES ON REMOVING/INSTALLING ROOF - AH65.10-P-1000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3482 · Applies to: 450, 451, 452, 454
01MCE > Model 451.3 Adhesive kit for isopropanol cleaner Adhesive kit with heptane cleaner Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use individual components as described in table below. Deviation is not permissible, otherwise adhesive¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3483 · Applies to: 450, 451, 452, 454
force of bonded connection is not ensured. Allow corresponding primer to flash off for at least 10 minutes, however, for max. 15 minutes. The crank window in the driver door must be opened during the curing time to prevent the component glued in from being pressed out by the air when the doors are closed. Avoid to open and close doors. Designation Note Use Adhesive cartridge (4) Hot application: Short processing time Durability is achieved after approx. 2 h measured from the time the component is installed. The rated accident strength is achieved only after approx. 8 h. The adhesive cartridge (4) is heated in cartridge heater. Adhesive material for: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Plastic primer (5) for vehicles with code Apply with wool wiper (13). Allow plastic primer (5) to flash off for at least 10 - 15 minutes, Primer for: Full roof Fig 2: Identifying Adhesive Kit With Heptane Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(E23) Full roof¶
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(FFO) otherwi e the adhe ive force of the bonded joint starts to decrease. (with code (E23) Full roof (FFO)) Glass primer stick (6) for vehicles with code (E22) Glass roof (FFO) Allow glass primer to flash off for at least 10 - 15 minutes, otherwise the adhesive force of the bonded joint starts to decrease. Primer for: Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Body flange Heptane cleaner 3350 (7) for vehicles with code (E23) Full roof (FFO) Apply with cloth (9). Cleaner for primer surface: Full roof (with code (E23) Full roof (FFO)) Cleaning cloth (8) for vehicles with code (E22) Glass roof (FFO) Cleaning cloth (8) containing isopropanol and dry cloth Cleaner for primer surface: Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Body flange Cloth (9) Color blue-green For applying: Heptane cleaner 3350 (7) Spacer (10) for: Full roof (with code
Spacer (10)¶
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(E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Cutting wire (11) Cut out with cutting wire (11) and the two handles included in the window removal kit. To cut out: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Application nozzle (12) Nozzle tips are already cut to size. Application of adhesive material in combination with adhesive cartridge (4) Wool wiper (13)
Applying plastic primer (5) TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: ROOF - AR65.00-Z-9451CA
MODEL 451
Remove/install front roof frame MODEL 451.3 Upper front roof frame AR65.20-P- 1006MCC
Remove/install front roof frame MODEL 451.3 Lower front roof frame AR65.20-P- 1006MCD
Remove/install rear roof frame MODEL 451.3 Upper rear roof frame AR65.20-P- 1008MCC
Remove/install rear roof frame MODEL 451.3 Bottom rear roof frame AR65.20-P- 1008MCD
Remove/install roof paneling MODEL 451.3 AR65.10-P- 5702MCC
Remove/install roof paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3486 · Applies to: 450, 451, 452, 454
MODEL 451.4 AR65 10 P 5702MCO
Remove/install side roof frame MODEL 451.3 Inner side roof frame AR65.20-P- 1200MCD
Remove/install side roof frame MODEL 451.4 AR65.20-P- 1200MCO
Replace roll bar MODEL 451.4 AR65.20-P- 1056MCO
Replace side roof frame reinforcement MODEL 451.3 AR65.20-P- 1210MCC TESTING & REPAIR > REMOVE ROOF PANELING - AR65.10-P-5702-01MCC > Mask off upper edge of windshield as well as attachment and body parts in cutting area with masking tape to prevent damage by cutting wire. Aid of helper required for cut out and removal of roof paneling. 1. Press hollow needle on top edge of roof through adhesive seam (arrow B) and guide cutting wire from outside to inside through hollow needle. The recommended length of the cutting wire is 85 cm. Fig 1: Locating Sprues Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Cut out roof paneling with cutting wire.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3487 · Applies to: 450, 451, 452, 454
With code (E22) Glass roof (FFO): If the roof paneling is to be reinstalled, ensure that the sprues (arrows A) and the sealing paint on the roof paneling are not damaged, because if damaged, it will be necessary to replace the roof paneling. 3. Remove roof paneling. TESTING & REPAIR > PREPARE ROOF PANELING FOR INSTALLATION - AR65.10-P- 5702-02MCC > Adhesive kit for isopropanol cleaner The bonded area on the roof paneling (1) must be absolutely free of dust and grease, otherwise the dirt can decrease the adhesive force of the adhesive material. Do not damage sprues, retaining bolts (3) or sealing paint on roof paneling (1), otherwise it is necessary to replace the roof paneling (1). 1 Check surface of roof paneling (1) for scratches and damage, replace if necessary. Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2.1 Clean bonding area on roof paneling (1) with cleaning cloth from repair kit.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3488 · Applies to: 450, 451, 452, 454
When installing new roof paneling (1). 2.2 Cut off remaining adhesive material on roof paneling (1) down to maximum height of 2 mm using a scraper. Remove residual adhesive material. Cut back remaining adhesive material on roof paneling (1) max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts with the ambient air which can lead to adhesion problems. When reusing removed roof paneling (1). 3 Coat gluing area on roof paneling (1) with primer stick from repair kit. When installing new roof paneling (1). Allow primer to flash off for at least 10 - 15 minutes. 4.1 Attach sheet metal nuts (2) to retaining bolts (3). When installing new roof paneling (1). 4.2 Check sheet metal nuts (2) for damage, replace if necessary. When reusing removed roof paneling (1). Fig 2: Identifying Roof Paneling, Retaining Bolts And Nuts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5.1 Glue on spacers from repair kit to cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3489 · Applies to: 450, 451, 452, 454
When installing new roof paneling (1). Remove upper adhesive foil on spacers only after fitting roof paneling (1). 5.2 Replace damaged spacers with new spacers from repair kit. When reusing removed roof paneling (1). Remove upper adhesive foil on spacers only after fitting roof paneling (1). TESTING & REPAIR > PREPARE ROOF PANELING FOR INSTALLATION - AR65.10-P- 5702-02MCD > Adhesive kit with heptane cleaner The bonded area on the roof paneling (1) must be absolutely free of dust and grease, otherwise the dirt can decrease the adhesive force of the adhesive material. 1 Check roof paneling (1) for scratches and damage, replace if necessary. Fig 1: Identifying Adhesive Kit With Heptane Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2.1 Cut off remaining adhesive material on roof paneling (1) down to maximum height of 2 mm using¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3490 · Applies to: 450, 451, 452, 454
a scraper and remove loose remaining adhesive. Cut back remaining adhesive material on roof paneling (1) max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts with the ambient air which can lead to adhesion problems. When reusing removed roof paneling (1). 2.2 Clean bonded area on roof paneling (1) with heptane cleaner 3350 included in repair kit. When installing new roof paneling (1). Use cloth included in repair kit for applying heptane cleaner 3350. 3.1 Repair damaged primer layer on roof paneling (1) with plastic primer (red plug) included in repair kit. When reusing removed roof paneling (1). Allow primer to flash off for at least 10 - 15 minutes. Use wool wiper included in repair kit to coat. 3.2 Coat bonded area on roof paneling (1) with plastic primer (red plug) included in repair kit. When installing new roof paneling (1). Allow primer to flash off for at least 10 - 15 minutes. Fig 2: Identifying Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4.1 Replace damaged spacers with new spacers from repair kit.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3491 · Applies to: 450, 451, 452, 454
When reusing removed roof paneling (1). Remove upper adhesive foil of new spacers only after fitting roof paneling (1). 4.2 Glue on spacers from repair kit to cross-hatched areas. When installing new roof paneling (1). Remove upper adhesive foil of new spacers only after fitting roof paneling (1). TESTING & REPAIR > INSTALL ROOF PANELING - AR65.10-P-5702-03MCC > 1. Center roof paneling (1) above body opening with aid of helper and position on adhesive strips (arrows) to coincide. 2. Install roof paneling (1) on body flange. 3. Apply uniform pressure to roof paneling (1) with adhesive template (2) and sandbags until adhesive material is cured. The gross weight of the sandbags should be approx. 40 kg and should be distributed equally on the adhesive template (2) to prevent adhesion problems of the adhesive material and slipping of the adhesive template (2). Place sandbags in center first, then at rear and then at front. Adhesive template (2) is included in new part package. Durability is achieved after approx. 2 h measured from the time the roof paneling is installed. The rated accident strength is achieved only after approx. 8 h. Fig 1: Positioning Center Roof Paneling On Adhesive Strips Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE CONNECTING POINTS FOR ROOF PANELING ON BODY¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3492 · Applies to: 450, 451, 452, 454
- AR65.10-P-5702-04MCC > Adhesive kit for isopropanol cleaner Fig 2: Applying Pressure To Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Adhesive kit with heptane cleaner¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3493 · Applies to: 450, 451, 452, 454
Do not apply primer to gluing area (2). The gluing area (2) on the body flange (1) must be absolutely free of dust and grease to prevent paint adhesion problems of the adhesive material. Cut back remaining adhesive material on body flange (1) max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts with the ambient air which can lead to adhesion problems. Fig 2: Identifying Adhesive Kit With Heptane Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Cut off residual adhesive material on body flange (1) down to a height of max. 2 mm using suitable¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3494 · Applies to: 450, 451, 452, 454
scraper. Remove adhesive material residues. 2. Clean painted adhesive surface on body flange (1) with cleaning cloth included in repair kit. 3. Repair paint damage at body flange (1) with primer applicator. 4. Apply primer to body flange (1) using primer stick from repair kit, in areas where residual adhesive material is missing or damaged. Allow primer to flash off for at least 10 - 15 minutes. Use primer stick from adhesive kit with ispropanol cleaner only for vehicles with code (E22) Glass roof (FFO)). Plastic primer from adhesive kit with heptane cleaner only for vehicles with code (E23) Full roof (FFO)). 5. Glue on spacers from repair kit. Attach spacers to body flange (1) on inside (arrows). Remove upper adhesive strips on spacers only after fitting roof. TESTING & REPAIR > APPLY ADHESIVE MATERIAL - AR65.10-P-5702-05MCC > Install roof paneling (3) on body flange within 2 minutes after applying adhesive material, to prevent adhesion problems of the adhesive material. Durability is achieved after approx. 2 h measured from the time the roof paneling (3) is installed. The rated accident strength is achieved only after approx. 8 h. Fig 3: Identifying Body Flange And Gluing Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Uniformly apply adhesive material with application nozzle (2) in shape of a bead at a height (b) of approx. 12¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3495 · Applies to: 450, 451, 452, 454
mm and a width of approx. 8 mm. Fig 1: Identifying Adhesive Material Application Nozzle Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Bead Height On Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown with paneling with code (E22) Glass roof (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3496 · Applies to: 450, 451, 452, 454
- Guide application nozzle along cast-on line (broken line) on roof paneling (3) and apply adhesive material. The distance of the adhesive material to the front of the roof paneling (3) should be 10 mm to prevent leakage. The distance between the adhesive material and the side edge of the roof paneling (3) should be 2 mm. Completely press out adhesive material not required immediately following application (disposal). TESTING & REPAIR > ALIGN ROOF PANELING IN BODY OPENING. - AR65.10-P-5702- 06MCC >
- Position roof paneling (1) on spacers on body flange with aid of helper, align roof paneling (1) in relation to rear spoiler and center at side. The distance between roof paneling (1) and rear spoiler should be approx. 6 to 8 mm. The distance between roof paneling (1) and windshield is approx. 6 to 10 mm. If these values are not achieved, center roof paneling (1) to attain the rear value.
- Attach suitable strips of adhesive tape (arrows) and cut at edge of roof paneling (1).
- Remove roof paneling (1) from body flange with aid of helper. Fig 3: Identifying Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL ROOF PANELING - AR65.10-P-5702MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3497 · Applies to: 450, 451, 452, 454 · AR: AR65.10-P-5702MCC
MODEL 451.3 MODIFICATION NOTES 16.6.10 "Removal/installation of windowbag" added "Special tool cutting wire" added Step 4 and 13Step 5 Fig 1: Positioning Center Roof Paneling On Adhesive Strips Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
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Notes on removing/installing roof
AH65.10- P-1000- 01MCE
The following workshop equipment and tools are required for repair:Cup suction toolgotis://K_67.0_03.0 Wet and dry vacuum cleanergotis://P_00.12_06.0 Cartridge heatergotis://K_67.0_02.0 Cartridge gungotis://K_67.0_02.0
1 Open crank window in driver door The crank window in the driver door must be opened during the curing time to prevent the roof paneling (1) from being pressed out by the air when the doors are closed.
2 Remove roller sun blind On vehicles with code (E22) Glass roof (FFO) AR77.21- P- 0205MCC 3 Remove inner panelings in repair area. When reusing roof paneling (1).
4 Detach left windowbag and right windowbag and lay down in passenger compartment On vehicles with code (I52) Head airbag* for USA only Remove left windowbag and right windowbag from lug in front area of A-pillar AR91.60- P- 0693MCU Risk of injury caused by cutting wire tearing or heating up while using it to cut out components that are glued into place. Wear protective gloves and safety glasses. AS65.00- Z-0001- 01A 5 Cut out roof paneling (1) with cutting wire Aid of helper is required to cut out and remove roof paneling (1). AR65.10- P-5702- 01MCC
Cutting wire Fig 3 Checking
6 Check bonding area on body flange for paint chipping Damage from removing roof paneling (1) can be repaired with approved materials.
Notes on repair paintwork in bonding area of windows and components
AH98.00- P-9408- 07MCC 7.1 Repair paint chipping on body flange with approved materials On paint chips up to approx. 2 cm . Do not apply basic or clear varnish in boding area.
General notes on touch-up applicators
AH98.00- P-9409- 2
and paint spray cans¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3499 · Applies to: 450, 451, 452, 454
06SM 7.2 Renew paintwork structure on body flange On paint chips larger than approx. 2 cm . AR98.00- P- 0905MCC Install
8 Prepare body flange for installation The bonding area must be absolutely free of dust and grease. Dirt can lead to paint adhesion problems of adhesive material. AR65.10- P-5702- 04MCC TS adhesive (with isopropanol cleaner) BR00.45- Z-1041- 02B TS adhesive (with heptane cleaner) BR00.45- Z-1042- 02B 9 Align roof paneling (1) in body opening Aid of helper required. AR65.10- P-5702- 06MCC 10 Prepare roof paneling (1) for installation The gluing area on the roof paneling (1) must be absolutely free of dust and grease to prevent paint adhesion problems of the adhesive material when installing.
On vehicles with code (E22) Glass roof (FFO) AR65.10- P-5702- 02MCC TS adhesive (with isopropanol cleaner) BR00.45- Z-1041- 02B On vehicles with code (E23) Full roof (FFO) AR65.10- P-5702- 02MCD TS adhesive (with heptane cleaner) BR00.45- Z-1042- 02B Install roof paneling (1) on body flange within 2 minutes after applying adhesive material to prevent paint adhesion problems of the adhesive material when installing. If the paintwork structure on the body flange is renewed, apply adhesive material on body flange for corrosion protection reasons. Durability is achieved after approx. 2 h AR65.10- P-5702- 05MCC 2
Apply adhesive material¶
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11 Apply adhesive material measured from the time the roof paneling (1) is installed. The rated accident strength is achieved only after approx. 8 h. Uniformly apply adhesive bead at a height of approx. 12 mm. Intermediate piece Fig 2 TS adhesive (with isopropanol cleaner) BR00.45- Z-1041- 02B TS adhesive (with heptane cleaner) BR00.45- Z-1042- 02B 12 Install roof paneling (1) Aid of helper required. Fix in place roof paneling (1) with installation template and sandbags. AR65.10- P-5702- 03MCC 13 Install left windowbag and right windowbag On vehicles with code (I52) Head airbag* for USA only AR91.60- P- 0693MCU 14 Install inner paneling in repair area. When reusing roof paneling (1).
15 Install roller sun blind On vehicles with code (E22) Glass roof (FFO) AR77.21- P- 0205MCC Fig 2: Identifying Intermediate Piece (000 589 86 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
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Number Designation Order number BR00.45-Z-1041-02B TS adhesive (with isopropanol cleaner) A 451 989 00 71 BR00.45-Z-1042-02B TS adhesive (with heptane cleaner) A 451 989 01 71 TESTING & REPAIR > SEPARATE FRONT ROOF FRAME - AR65.20-P-1006-02MCC > 1. Expose spot welds on upper front roof frame (1) and cut out (areas A, B, C and D). 2. Pry out lugs on side roof frame (arrows). 3. Remove damaged upper front roof frame (1). Fig 3: Identifying Cutting Wire (450 589 08 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Spot Weld Area On Upper Front Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE FRONT ROOF FRAME FOR INSTALLATION - AR65.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3502 · Applies to: 450, 451, 452, 454
1006-04MCC > 1. Grind upper front roof frame (1) down to bare metal in cross-hatched areas. Grind spot weld flange down to bare metal on both sides and coat inside of spot weld flange with zinc dust paint. TESTING & REPAIR > INSTALL FRONT ROOF FRAME - AR65.20-P-1006-05MCC > 1. Fit upper front roof frame (1) and fasten with vise grip pliers. 2. Straighten side roof frame and fasten with vise grip pliers. 3. Upper front roof frame (1) (areas A and B). 4. Drill dia. 6.0 mm pilot hole in upper front roof frame (1) (areas C , C , D and D ). 5. Upper front roof frame (1) (areas C and D). 1 2 1 2 Fig 1: Identifying Grinding Area On Upper Front Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Grind all spot welds down flat if required¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3503 · Applies to: 450, 451, 452, 454
- Clean all other weld joints with wire brush TESTING & REPAIR > PREPARE MATING SURFACES ON VEHICLE FOR FRONT ROOF PANELING - AR65.20-P-1006-08MCC >
- Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flange down to bare metal on both sides and coat inside of spot weld flange with zinc dust paint. Fig 1: Identifying Drill Area On Upper Front Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL FRONT ROOF FRAME - AR65.20-P-1006MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3504 · Applies to: 450, 451, 452, 454 · AR: AR65.20-P-1006MCC
MODEL 451.3 Upper front roof frame Fig 1: Identifying Grind Area On Front Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3505 · Applies to: 450, 451, 452, 454
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 Fig 1: Identifying Upper Front Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on performing¶
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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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Inert gas welder Tarp (fire-resistant)
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 Separate upper front roof frame (1)
AR65.20-P-1006- 02MCC 4 Prepare connecting points on body
AR65.20-P-1006- 08MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A
Z-1008-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3508 · Applies to: 450, 451, 452, 454 · AR: AR65.20-P-1006MCD
05A Tero on protective waxArt. no.: 122.73Q 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 > REMOVE/INSTALL FRONT ROOF FRAME - AR65.20-P-1006MCD > MODEL 451.3 Lower front roof frame 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 Lower Front Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of injury¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3509 · Applies to: 450, 451, 452, 454
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 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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Inert gas welder Tarp (fire-resistant)
1 Remove detachable parts in the repair area
cavity preservation¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3511 · Applies to: 450, 451, 452, 454
Teroson protective wax *BR00.45-Z-1008- 05A 15 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 > REMOVE REAR ROOF FRAME - AR65.20-P-1008-01MCC > 1. Expose spot welds on upper rear roof frame (1) and cut out (areas A, B, C, D, E and F). 2. Pry out lug on side roof frame (arrows). 3. Remove damaged upper rear roof frame (1). TESTING & REPAIR > REMOVE REAR ROOF FRAME - AR65.20-P-1008-01MCD > Fig 1: Identifying Spot Weld Areas On Rear Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Expose spot welds on bottom rear roof frame (1) and cut out (area A).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3512 · Applies to: 450, 451, 452, 454
- Expose spot welds on bottom rear roof frame (1) and cut out (area B).
- Remove damaged bottom rear roof frame (1). TESTING & REPAIR > PREPARE REAR ROOF FRAME FOR INSTALLATION - AR65.20-P- 1008-02MCC >
- Grind upper rear roof frame (1) down to bare metal in cross-hatched areas. Grind spot weld flange down to bare metal on both sides and coat inside of spot weld flange with zinc dust paint. Fig 1: Identifying Spot Weld Area On Bottom Rear Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Damaged Bottom Rear Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE REAR ROOF FRAME FOR INSTALLATION - AR65.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3513 · Applies to: 450, 451, 452, 454
1008-02MCD > 1. Grind bottom rear roof frame (1) down to bare metal in cross-hatched areas. Grind spot weld flange down to bare metal on both sides and coat inside of spot weld flange with zinc dust paint. Fig 1: Identifying Grind Area On Upper Rear Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Grind Areas On Bottom Rear Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL REAR ROOF FRAME - AR65.20-P-1008-03MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3514 · Applies to: 450, 451, 452, 454
- Fit upper rear roof frame (1) and fasten with vise grip pliers.
- Straighten side roof frame and fasten with vise grip pliers (arrows).
- Upper rear roof frame (1) (areas A, B, C and D).
- Drill dia. 6.0 mm pilot hole in upper rear roof frame (1) (areas E , E , F and F ).
- Upper rear roof frame (1) (areas E and F).
- Grind all spot welds down flat if required
- Clean all other weld joints with wire brush TESTING & REPAIR > INSTALL REAR ROOF FRAME - AR65.20-P-1008-03MCD > 1 2 1 2 Fig 1: Identifying Spot Welds Grind Area On Side Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit bottom rear roof frame (1) together with top rear roof frame and fasten with vise grip pliers.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3515 · Applies to: 450, 451, 452, 454
- Remove upper rear roof frame.
- Bottom rear roof frame (1) (area A).
- Bottom rear roof frame (1) (area B).
- Grind all spot welds down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR > PREPARE MATING SURFACES ON VEHICLE FOR REAR ROOF PANELING - AR65.20-P-1008-04MCC >
- Grind connecting flange down to bare metal in cross-hatched areas. Grind spot weld flange down to bare metal on both sides and coat inside of spot weld flange with zinc dust paint. Fig 1: Identifying Grind Areas On Rear Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE MATING SURFACES ON VEHICLE FOR REAR ROOF¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3516 · Applies to: 450, 451, 452, 454
PANELING - AR65.20-P-1008-04MCD > 1. Grind connecting flange down to bare metal in shaded areas. Grind spot weld flange down to bare metal on both sides and coat inside of spot weld flange with zinc dust paint. Fig 1: Identifying Grind Areas On Rear Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL REAR ROOF FRAME - AR65.20-P-1008MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3517 · Applies to: 450, 451, 452, 454 · AR: AR65.20-P-1008MCC
MODEL 451.3 Upper rear roof frame Fig 1: Identifying Grind Areas On Rear Roof Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3518 · Applies to: 450, 451, 452, 454
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 Fig 1: Identifying Upper Rear Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on performing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3519 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Inert gas welder Tarp (fire-resistant)
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 Separate upper rear roof frame (1)
AR65.20-P-1008- 01MCC 4 Prepare connecting points on body
AR65.20-P-1008- 04MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A
Z-1008-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3521 · Applies to: 450, 451, 452, 454 · AR: AR65.20-P-1008MCD
05A Teroson protective waxArt. no.: 122.73Q 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 > REMOVE/INSTALL REAR ROOF FRAME - AR65.20-P-1008MCD > MODEL 451.3 Bottom rear roof frame 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 Bottom Rear Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of injury¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3522 · Applies to: 450, 451, 452, 454
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 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 following workshop equipment and tools are required for repair Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Inert gas welder Tarp (fire-resistant)
1 Remove detachable parts in the repair area
Cover all detachable¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3523 · Applies to: 450, 451, 452, 454
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- 0115MCC 4 Remove rear lamp insert
AR64.20-P- 1061MCC 5 Separate top rear roof frame
AR65.20-P- 1008MCC 6 Separate bottom rear roof frame (1)
AR65.20-P-1008- 01MCD 7 Prepare connecting points on body
AR65.20-P-1008- 04MCD Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 8 Prepare connecting points on bottom rear roof frame (1)
AR65.20-P-1008- 02MCD Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
9 Fit bottom rear roof frame (1) and weld in
AR65.20-P-1008- 03MCD 10 Fit top rear roof frame and weld in
AR65.20-P- 1008MCC 11 Install rear lamp insert
AR64.20-P- 1061MCC 12 Install side wall paneling
AR63.10-P- 0115MCC 13 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
14 Prime area to be repaired using primer filler
15 Supply standard seam seals with body sealant
AR97.10-P- 4000MCC Sealant BR00.45-Z-1003- 01A 16 Supplement standard Underfloor protection BR00.45-Z-1001-
TESTING & REPAIR > PREPARING SIDE ROOF FRAME FOR INSTALLATION - AR65.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3525 · Applies to: 450, 451, 452, 454
1200-02MCD > 1. Grind inner side roof frame (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. Fig 1: Identifying Spot Weld Areas On Inner Side Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Grind Area On Inner Side Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALLING SIDE ROOF FRAME AND WELDING IN - AR65.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3526 · Applies to: 450, 451, 452, 454
1200-03MCD > 1. Fit inner side roof frame (1) and fasten with vise grip pliers. 2. Inner side roof frame (1) (areas A, B and C). 3. Grind all weld joints down flat if required. 4. Clean all other weld joints with wire brush. TESTING & REPAIR > PREPARE CONNECTION POINTS ON SIDE ROOF FRAME ON BODY - AR65.20-P-1200-04MCD > 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat inside of spot welding flanges with zinc dust paint. Fig 1: Identifying Grind Area On Side Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL SIDE ROOF FRAME - AR65.20-P-1200MCD >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3527 · Applies to: 450, 451, 452, 454 · AR: AR65.20-P-1200MCD
MODEL 451.3 Inner side roof frame Fig 1: Identifying Grind Area On Side Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3528 · Applies to: 450, 451, 452, 454
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 Fig 1: Identifying Inner Side Roof Frame Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on performing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3529 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair Shank brush Hart metal ball cutter Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Tarp (fire-resistant)
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- 0115MCC 4 Remove side roof frame reinforcement
AR65.20-P- 1210MCC
removed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3531 · Applies to: 450, 451, 452, 454
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 > REMOVE SIDE ROOF FRAME REINFORCEMENT. - AR65.20-P-1210- 01MCC > 1. Scribe cut on rear lamp insert (2) according to damage profile and cut (area A). 2. Expose spot welds on rear lamp insert (2) and cut out (areas B, C and D). 3. Remove damaged rear lamp insert (2). 4. Expose spot welds on side roof frame reinforcement (1) and cut out (areas E, F, G, H and J). Fig 1: Identifying Spot Weld Area On Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Expose spot welds on side roof frame reinforcement (1) and cut out (area G).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3532 · Applies to: 450, 451, 452, 454
- Remove damaged side roof frame (1). TESTING & REPAIR > PREPARE CONNECTING POINTS FOR SIDE ROOF FRAME REINFORCEMENT ON BODY. - AR65.20-P-1210-02MCC >
- Grind mating surfaces down to bare metal in cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat inside of spot welding flanges with zinc dust paint. TESTING & REPAIR > PREPARE SIDE ROOF FRAME REINFORCEMENT FOR INSTALLATION - AR65.20-P-1210-03MCC > Fig 2: Identifying Spot Weld Area On Side Roof Frame Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Grind Area On Side Roof Frame Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Scribe cut on rear lamp insert (2) and cut (area A).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3533 · Applies to: 450, 451, 452, 454
Transfer dimension from vehicle. 2. Drill holes for plug welding on rear lamp insert (2) (area B). Transfer dimensions of hole for plug welding from vehicle. 3. Grind rear lamp insert (2) down to bare metal in cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. coat inside of spot weld flanges with zinc dust paint. 4. Grind side roof frame reinforcement (1) down to bare metal in cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat inside of spot weld flanges with zinc dust paint. Fig 1: Identifying Drill Area On Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL SIDE ROOF FRAME REINFORCEMENT AND WELD IN. -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3534 · Applies to: 450, 451, 452, 454
AR65.20-P-1210-04MCC > Fig 2: Identifying Grind Area On Side Roof Frame Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit side roof frame reinforcement (1) and fasten with vise grip pliers.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3535 · Applies to: 450, 451, 452, 454
- Side roof frame reinforcement (1) (area A).
- Side roof frame reinforcement (1) (areas D and E).
- Fit rear lamp insert (2) and fasten with vise grip pliers.
- Rear lamp insert (2) (areas H and J).
- Rear lamp insert (2) (area F).
- Rear lamp insert (2) (area G). Areas B and C are when installing side wall.
- Grind all weld joints down flat if required.
- Clean all other weld joints with wire brush TESTING & REPAIR > REPLACE SIDE ROOF FRAME REINFORCEMENT - AR65.20-P- 1210MCC > MODEL 451.3 Fig 1: Identifying Weld Joint Grind Area On Side Roof Frame Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3536 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Side Roof Frame Reinforcement And Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3537 · Applies to: 450, 451, 452, 454
body
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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- 0115MCC 4 Remove side roof frame reinforcement (1)
AR65.20- P-1210- 01MCC 5 Prepare connecting points for side roof frame reinforcement (1) on body
AR65.20- P-1210- 02MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A
Prepare side roof frame¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3538 · Applies to: 450, 451, 452, 454
6 Prepare side roof frame reinforcement (1) for installation
AR65.20- P-1210- 03MCC Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
7 Install side roof frame reinforcement (1) and weld in
AR65.20- P-1210- 04MCC 8 Partially install side wall paneling
AR63.10- P- 0115MCC 9 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
10 Prime area to be repaired using primer filler
11 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC Sealant BR00.45- Z-1003- 01A 12 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 13 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 14 Apply additional cavity preservation
AR97.20- P-1500FF Teroson protective wax *BR00.45- Z-1008- 05A 15 Reinstall all detachable parts removed
REPAIR MATERIALS Number Designation Order number BR00.45- Z-1003- Sealant, white, 310 ml, DB supply specification A 001 989 63 20
BR00.45-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3539 · Applies to: 450, 451, 452, 454 · AR: AS65.00-Z-9999ZZ
01A 6069.20 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 SAFETY PRECAUTIONS > RISK OF INJURY. INJURY MAY RESULT IF THE CUTTING WIRE TEARS OR HEATS UP WHILE USING IT TO CUT OUT COMPONENTS THAT ARE GLUED INTO PLACE. - AS65.00-Z-0001-01A > Wear protective gloves and safety glasses. Risk of injury When using a cutting wire to cut out components that are glued into place, injury to the eyes and hand may result if the cutting wire tears or becomes heated. Safety instructions/precautions Wear protective gloves. Wear safety glasses when cutting out components. SAFETY PRECAUTIONS > SAFETY INFORMATION: ROOF - AS65.00-Z-9999ZZ > MODEL all Risk of death caused by falling down from the roof of the vehicle. Risk of injury to other persons caused by falling objects during work in the area of the roof. MODEL 903... AS65.00- Z-0002- 01B Risk of death caused by falling from vehicle roof. Risk of injury to other persons caused by falling objects during work in roof area. MODEL all AS65.00- Z-0002- 01A Risk of injury caused by slipping when clamping blade in the multicutter and by splinters when cutting out bonded windows MODEL 454.0, 207, 212, 219.3 AS65.00- Z-0003- 01A Risk of injury. Injury may result if the cutting wire tears or heats up while using it to cut out components that are glued into place. MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 AS65.00- Z-0001- 01A Risk of injury. Injury may result if the cutting wire tears or heats up while using it to cut out roofs that are glued into place. MODEL 240 AS65.10- Z-0001- 01A SPECIAL TOOLS > 451 589 00 09 00 SOCKET WRENCH - WS65.00-P-0043B >
Group 65/Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3540 · Applies to: 450, 451, 452, 454 · AR: WS65.00-Z-9999CZ
MODEL 451 Use: Socket wrench for removal of rear-end door at top of hinge (body side) SPECIAL TOOLS > SPECIAL TOOLS: SMART: ROOF - WS65.00-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
450 589 08 63 00 Cutting wire FG 65/67/Set B WS67.00-P- 0020B
451 589 00 09 00 Socket wrench Group 65/Set B WS65.00-P- 0043B
452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P- 0107K Fig 1: Identifying Socket Wrench (451 589 00 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > NOTES ON PERFORMING REPAIR, BODY WORK AND¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3541 · Applies to: 450, 451, 452, 454
WELDING ON VEHICLES WITH AIRBAGS AND ETR UNITS - AH91.00-P-0002-01SM > Model 450.3/4, 451.3/4 Before and after a body repair, the fault memory must be read out and existing faults documented. Before carrying out any work on the airbag and emergency tensioning retractor units that requires electric circuit intervention (e.g. dismantling), the ignition key must always be removed and the ground line of the battery must be disconnected (wait approx. 60 s for processor power-down). Before carrying out any welding work, remove ignition key, disconnect/insulate ground line of battery and detach connector from restraint system control unit. No particular safety precautions are necessary before carrying out painting work with subsequent force drying. The airbag and ETR units can withstand temperatures of up to a maximum of 100°C without damage. Do not bring airbag and emergency belt tensioner units into contact with grease, oil or cleaning agents. Airbag or ETR units which have fallen from a height of more than 0.5 m must be replaced and must not be installed in a vehicle under any circumstances In order to be able to install emergency tensioning retractor units free from damage and dirt, they have been provided with a PVC film protective sleeve. This protective device must be removed after assembly. Do not use sharp-edged tools when removing PVC film protective sleeve to avoid damaging the belt. If a considerable amount of deformation has occurred, check the setting of the lateral acceleration sensor on the underside of the vehicle. After completing work on the airbag and ETR units, the fault memory must be read out. GENERAL INFORMATION > LEGAL REQUIREMENTS ON HANDLING AND STORING AIRBAGS AND EMERGENCY TENSIONING RETRACTOR UNITS - AH91.00-P-0004-01A > Model 124, 129, 140, 163, 164, 168, 169, 170, 171, 197, 199, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 219, 220, 221, 230, 240, 245, 251, Model 314, 316, 318, Model 414, Model 450.3/4, 451.3/4, 452.3/4, 454, Model 461, 463, Model 636, 638, 639.601/603/605/701/703/705/711/713/811/813/815, Model 668, 670, Model 690.6, 901, 902, 903, 904, 905, 906, Model 930, 932, 933, 934, 940, 942, 943, 944, 950, 952, 953, 954, 957, Model 970, 972, 974, 975, 976, Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 Legal regulations on handling and storing airbags and emergency tensioning retractors All subsequently listed legal requirements apply to the Federal Republic of Germany. In other countries, the valid national and local legal requirements must be observed. Airbag and emergency tensioning retractor units are class T1. pyrotechnical objects. Their handling, transport and storage are subject to the German Act Concerning Potentially Explosive Substances "Gesetz
uber explosionsgefahrliche Stoffe". Only a limited number of class T1 pyrotechnical objects may be stored in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3542 · Applies to: 450, 451, 452, 454
buildings which are used for commercial purposes. According to appendix 6 of the annex to the 2nd explosives directive, the maximum storage volumes listed in the following are permitted in commercially used buildings under consideration of certain conditions (e.g. steel cabinet) without special approval by the responsible authority: Work room, 10 kg net Storage room, 100 kg net In order to calculate it, the net mass of the explosive contained in the respective component, for which the legal explosive permit has been granted, must be used: Each driver airbag, 0.1 kg Each front passenger airbag, 0.3 kg Each sidebag, 0.05 kg Each emergency tensioning retractor, 0.002 kg Each windowbag, 0.004 kg Each kneebag, 0.025 kg Each pelvisbag, 0.015 kg Each headbag, 0.01 kg Airbags and emergency tensioning retractor units must not be stored in the immediate vicinity of easily/highly flammable and fire-inducing materials. Acquiring, transport, storage, installation and removal as well as scrapping may only be performed by trained personnel in observance of all applicable safety regulations. The use of a vehicle's passenger compartment to transport such materials is strictly prohibited! Always stow the airbag and emergency tensioning retractor units in their original packaging in the trunk or load compartment of the vehicle in a secure fashion so as to prevent them from sliding around. RETROFITTING & CONVERSION > RETROFIT FRONT SEAT ARM REST - AN91.27-P- 0001MCC > MODEL 451.3/4 as of 30.9.09
Fig 1: Identifying Armrest And Driver Seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3543 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Seat Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of injury cau ed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3550 · Applies to: 450, 451, 452, 454
by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Unhook seat belt (3) from belt guide (2) at driver seat (1)
3 Remove bolt (5) from belt end fitting of seat belt (3) up to 30.8.10 Installation: Ensure that the installation position of the seat belt (3) is correct.
*BA91.40- P-1001- 01G 4 Slide driver seat (1) forwards, fold down backrest and remove bolts (4) Push driver seat (1) backwards slightly to ensure that it has audibly engaged into both seat rails. Installation: Screw in bolts (4) up to contact surface, tighten right bolt first, then tighten left bolt (4). Move driver seat (1) to rearmost position, tighten left bolt and then tighten right bolt (6).
*BA91.10- P-1001- 01P 5 Move driver seat (1) to rearmost position and remove bolts (6) Push driver seat (1) forwards slightly to ensure that it has audibly engaged into both seat rails.Set seat backrest to vertical position. Installation: Screw in bolts (6) up to contact surface and move driver seat (1) to foremost position.
6 Expose wiring harness at holder (7) On vehicles without code (C54) Sound system 2, the bracket (7) is clipped into the front cross strut of the driver seat (1).
7 Tilt driver seat (1) backwards and expose wiring harness at bracket (8)
8 Disconnect driver seat heated cushion On vehicles with code (S17) Seat heaters (FFO)
Shown on vehicle with code (S17) seat heater (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3552 · Applies to: 450, 451, 452, 454
Remove/install
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Fig 1: Identifying Passenger Seat Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Passenger Seat Heater Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Disconnect ground line of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3553 · Applies to: 450, 451, 452, 454
1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Unhook seat belt (3) from belt guide (2) at front passenger seat (1)
3 Move front passenger seat (1) forward and fold over backrest
4 Unclip and remove cover (7)
5 Release wiring harness from bracket (6) and remove belt tension sensor connection (B48/3x1) Pay attention to installation position (arrow) of wiring harness.
6 Remove bolt (5) from lower belt end fitting of seat belt (3) *BA91.40- P-1001- 01G 7 Remove bolts (8) Push front passenger seat (1) backwards slightly to ensure that it has audibly engaged into both seat rails. Installation: Screw in bolts (8) up to contact surface, tighten right bolt first, then tighten left bolt (8).Move front passenger seat (1) to rearmost position, tighten left bolt and then tighten right bolt (4).
*BA91.10- P-1001- 01P 8 Move front passenger seat (1) to rearmost position and remove bolts (4) Push front passenger seat (1) forwards slightly to ensure that it has audibly engaged into both seat rails.Set seat backrest to vertical position. Installation: Screw in bolts (4) up to contact surface and move front passenger seat (1) to foremost position.
9 Tilt front passenger seat (1) backwards and expose wiring harness at bracket (9)
10 Disconnect front passenger seat heated cushion connector (X28/5) On vehicles with code (S17) Seat heaters (FFO)
11 Disconnect front passenger seat connector block (X55/4), front passenger head/ No other connectors must be disconnected, otherwise a new supporting seat frame must be
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3556 · Applies to: 450, 451, 452, 454
1 Remove cover for backrest from seat
AR91.10- P- 8656MCU 2 Carefully place seat with backrest on a suitable surface On vehicles with code (S17) Seat heaters (FFO)
3 Expose seat heater wiring harness (2) at the brackets (3) On vehicles with code (S17) Seat heaters (FFO)
4 Disconnect electrical connector (1) of seat heaters On vehicles with code (S17) Seat heaters (FFO)
5 Place seat on its rails On vehicles with code (S17) Seat heaters (FFO)
6 Remove cable tie (4)
Fig 2: Identifying Front Seat Backrest Foam Section Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3558 · Applies to: 450, 451, 452, 454
Risk of injury caused Fig 1: Identifying Seat Cushion Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Seat Cushion Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
by backrest suddenly¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3559 · Applies to: 450, 451, 452, 454
folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A The front passenger seat console (7) must not be dismantled.
1 Remove front passenger seat and carefully place on a suitable surface with backrest (8)
AR91.10- P- 1020MCU 2.1 Unclip sidebag plug (1) from seat heater plug (2) On vehicles with code (S17) Seat heaters (FFO)
2.2 Unclip sidebag plug (1) from bracket at seat console (7) On vehicles without code (S17) Seat heater (FFO)
3 Expose sidebag wiring harness from brackets (3, 5)
4 Unclip seat belt buckle plug (4) from bracket at seat console (7)
5 Expose seat belt buckle wiring harness (13) from brackets (3)
6 Expose heated seat wiring harness and disconnect heated cushion connector (6) On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable tie (arrow)
8 Place front passenger seat on its rails
9 Unclip belt tension sensor plug (15) and put to one side
Unclip belt tension
Shown on code (S17) Seat heaters (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3561 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Seat Cushion Cover 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. 3562 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00-Z- 0005-01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00-Z- 0001-01A 1 Remove driver seat
AR91.10-P- 1010MCU 2 Detach terminal strip (3) of seat cushion cover (1) in front and side area of seat console (2)
Fig 2: Identifying Seat Cushion Cover Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Place driver seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3563 · Applies to: 450, 451, 452, 454
3 Place driver seat on a suitable surface on its side
4 Unclip plug (7) of wiring harness for seat heater (10) at seat console (2) On vehicles with code (S17) Seat heaters (FFO)
5 Unlock catch hook (12) and detach plug (7) from plug (11) On vehicles with code (S17) Seat heaters (FFO)
6 Unclip wiring harness for seat heater (10) from brackets (8) and detach connector of left heated seat cushion or right heated seat cushion On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable ties (9) and expose seat heater (10) On vehicles with code (S17) Seat heaters (FFO)
8 Position extraction hook (6) at side on terminal strip (5) 450589079900 9 Pull the extraction hook (6) towards the arrow, release the terminal strip (5) from the seat console (2) and completely expose it 450589079900 10 Route terminal strip (5) of seat cushion cover (1) forwards between the seat cushion (4) and backrest
11 Place driver seat on its rails
Remove eat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3564 · Applies to: 450, 451, 452, 454
12 Remove eat cushion (4) with seat cushion cover (1) from the seat console (2) On vehicles with code (S17) Seat heaters (FFO) the seat heater wiring harness (10) also has to be routed when removing the seat cushion (4) with the seat cushion cover (1).
13 Fold seat cushion cover (1) in rear area as far forward as possible until the first Hog rings (15) are accessible Ensure that the seat cushion cover (1) is not torn and thus damaged, as it otherwise must be replaced.
14 Remove hog rings (15) using suitable side cutting pliers Fold seat cushion cover (1) forward piece by piece and remove exposed Hog rings (15). A total of 16 Hog rings (15) are installed in the marked areas (arrows D). Installation: Use new hog rings (15) (arrow B). Place hog ring (15) into padding clip pliers and hook into the eyes of the respective staple rail (13), then hook into wire of seat cushion (4) and press padding clip pliers together until hog ring (15) is fully closed (arrow C).Align seams (14) of seat cushion cover (1) and position in the cutouts in the seat cushion (4).
*454589033700 15 Remove seat cushion cover (1)
16 Install in the reverse order
Fig 3: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3566 · Applies to: 450, 451, 452, 454
Fig 2: Identifying Seat Cushion Cover Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Seat Cushion Cover Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of injury caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3567 · Applies to: 450, 451, 452, 454
backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00-Z- 0005-01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00-Z- 0001-01A 1 Remove front passenger seat and carefully place on a suitable surface with backrest (8)
AR91.10-P- 1020MCU 2.1 Unclip sidebag plug (1) from seat heater plug (2) On vehicles with code (S17) Seat heaters (FFO)
2.2 Unclip sidebag connector (1) from bracket on supporting seat frame (7) On vehicles without code (S17) Seat heater (FFO)
3 Expose sidebag wiring harness from brackets (3, 5)
4 Unclip seat belt buckle connector (4) from bracket on supporting seat frame (7)
5 Expose seat belt buckle wiring harness (13) from brackets (3)
6 Expose wiring harness for seat heater and disconnect heated cushion connector (6) On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable tie (arrow)
8 Place front passenger seat on guide rails
9 Unclip belt tension sensor plug (15) and put to one side
10 Unclip belt tension sensor retaining plate (14) in rear area and remove
11 Fold backrest (8) forward
Installation: Position backrest (8) on supporting seat frame (7) and turn bolts
Remove bolts (9) of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3568 · Applies to: 450, 451, 452, 454
12 Remove bolts (9) of backrest (8) (9, 11) all the way in. Tighten bolts (11) starting from the front. Move backrest (8) to its rearmost position and lock in place. Tighten bolts (9) starting from the rear. While doing so, press the backrest (8) backwards.
*BA91.10-P- 1002-01P 13 Lift backrest (8) in vicinity of seat belt buckle (12) and lead seat belt buckle wiring harness (13) out of supporting seat frame (7) Installation: Ensure that grommet (10) is seated correctly.
14 Remove bolts (11) from backrest (8) and remove backrest (8)
15 Place supporting seat frame (7) on seat cushion cover (18) and detach terminal strip (16) of seat cushion cover (18) in rear area of supporting seat frame (7)
16 Detach terminal strip (17) of seat cushion cover (18) in side and front area of supporting seat frame (7) Installation: The terminal strip (17) must audibly engage.
17 Place supporting seat frame (7) on guide rails
18 Start by folding down seat cushion cover (18) in rear area and then on sides and front until hog rings of side staple strips are accessible (arrows A) Ensure that the seat cushion cover (18) is not torn and thus damaged, as it otherwise must be replaced.
19 Remove hog rings of side staple strips using suitable side cutting pliers (arrows A). Next, fold back seat cushion cover (18) in front area until hog rings of center staple strip are accessible and remove them with the side cutting pliers (arrows B) Remove all hog rings as otherwise the seat cushion (19) or the seat cushion cover (18) can be damaged. Installation: Use new hog rings. Insert hog ring into the padding clip pliers and hook into the eyelet of the staple strips, then hook into the wire of the seat cushion (19) and push padding clip pliers together. Align all seams (20) of seat cushion cover (18) and position in the cutouts in the seat cushion (19).
*454589033700 Remove all hog rings as otherwise the
Continue folding back¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3569 · Applies to: 450, 451, 452, 454
20 Continue folding back seat cushion cover (18) until hog rings of rear staple strip are accessible and remove them with the side cutting pliers (arrows C) seat cushion (19) or the seat cushion cover (18) can be damaged. Installation: Use new hog rings. Insert hog ring into the padding clip pliers and hook into the eyelet of the staple strips, then hook into the wire of the seat cushion (19) and push padding clip pliers together.
*454589033700 21 Remove seat cushion cover (18) Further dismantling the supporting seat frame (7) is not permissible.
22 Install in the reverse order
FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002- 01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE/INSTALL FRONT SEAT BACKREST FRAME - AR91.10-P- 3331MCU > MODEL 451.3/4 Shown on left front seat Fig 4: Identifying Padding Clip Pliers (454 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on right front seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3570 · Applies to: 450, 451, 452, 454
Shown on right front seat Fig 1: Identifying Left Front Seat Backrest Frame Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Right Front Seat Backrest Frame Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3571 · Applies to: 450, 451, 452, 454
7.5.10 Removal/installation of center armrest mounting added Steps 11 and 12 Removing
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00-Z-0005-01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00-Z-0001-01A Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00-P-0001-01A 1.1 Remove driver seat When removing backrest frame (2) from driver seat. AR91.10-P- 1010MCU Fig 3: Identifying Right Front Seat Backrest Frame Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove pa¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3572 · Applies to: 450, 451, 452, 454
1 2 Remove pa enger eat When removing backre t frame (2) from front passenger seat. AR91 10 P 1020MCU 2 Remove bolt (5), place seat belt buckle (1) with wiring harness for seat belt buckle (4) to one side and detach grommet (6) from backrest frame (2)
3 Remove foam part for backrest
AR91.10-P- 1120MCU 4 Fold backrest frame (2) forward
5 Unclip belt tension sensor connector (B48/3x1) from the retaining plate (10) When removing backrest frame (2) from front passenger seat.
6 Unclip clip (11) Only if the clip (11) has been installed and when the backrest frame (2) is being removed from the front passenger seat.
7 Remove retaining plate (10)
8 Remove bolts (3) of backrest frame (2)
9 Remove backrest frame (2)
10 Remove fuse (9) When replacing the backrest frame (2).
11 Remove armrest support For vehicles with code (I50) Armrest or with retrofitted armrest
Install
12 Install support for armrest For vehicles with code (I50) Armrest or with retrofitted armrest
13 Clip retainer (9) to backrest frame (2) When replacing the backrest frame (2).
14 Position backrest frame (2) on seat console and screw in bolts (3) up to contact surface
15 Screw in bolts (3) opposite the seat belt buckle (1), starting from the front. Move backrest frame (2) to its rearmost position and lock in place. Screw in bolts (3) in vicinity of *BA91.10-P-1002- 01P
Shown on driver seat with code (S17) Seat heater (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3574 · Applies to: 450, 451, 452, 454
Remove/install
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A 1 Remove driver seat and carefully place on a suitable surface with backrest (6)
AR91.10- P- 1010MCU Unclip plug (1) on Fig 1: Identifying Seat Cushion Frame Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3576 · Applies to: 450, 451, 452, 454
Risk of injury caused Fig 1: Identifying Seat Cushion Frame Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Seat Cushion Frame Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
by backrest suddenly¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3577 · Applies to: 450, 451, 452, 454
folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A 1 Remove front passenger seat and carefully place on a suitable surface with backrest (8)
AR91.10- P- 1020MCU 2.1 Unclip head/thorax airbag connector (1) on seat heater connector (2) On vehicles with code (S17) Seat heaters (FFO)
2.2 Unclip head/thorax airbag connector (1) from bracket on seat- cushion frame (7) On vehicles without code (S17) Seat heater (FFO)
3 Expose sidebag wiring harness from brackets (3, 5)
4 Unclip seat belt buckle (4) from bracket on seat-cushion frame (7)
5 Expose seat belt buckle wiring harness (13) from brackets (3)
6 Expose wiring harness for seat heater and disconnect heated cushion connector (6) On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable tie (arrow)
8 Place front passenger seat on guide rails
9 Unclip belt tension sensor plug (15) and put to one side
Unclip belt tension sensor retaining plate
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3579 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00-Z-0005-01V 1 Insert assembly wedge (3) between seat frame (2) and handle (1), pry off handle (1) from adjusting shaft of backrest adjustment and remove The handle (1) is destroyed during removal.Pay attention to installation position of handle (1).
*110589035900 2 Remove spring clip (4) from adjusting shaft of backrest adjustment using suitable pliers Replace spring clip (4).Pay attention to installation position of spring clip (4).
Install
3 Clip spring clip (4) into catch hooks (5) at handle (1) corresponding to its locking direction
Fig 1: Identifying Seat Backrest Adjustment Handle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Position new handle (1) on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3580 · Applies to: 450, 451, 452, 454
4 Position new handle (1) on adjusting shaft of backrest adjustment and clip in The handle (1) can only be installed when the spring clip (4) is inserted correctly. The lever of the handle (1) must run downwards (arrow) parallel to the seat frame (2).
5 Perform function test of backrest adjustment
TESTING & REPAIR > MAKE CUTS FOR BELT GUIDE AT COVER OF FRONT SEAT BACKREST - AR91.10-P-8656-01MCC > 1. Feel for carrier (4) of belt guide in top section of seat and draw a reference point (2) onto the cover (1) corresponding to the corner (arrow A) of the carrier (4). 2. Feel for carrier (4) of belt guide in top section of seat and draw a reference point (3) onto the cover (1) corresponding to the corner (arrow B) of the carrier (4). Fig 2: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Cuts At Cover Of Backrest Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on code (S17) Seat heaters (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3582 · Applies to: 450, 451, 452, 454
MODIFICATION NOTES 7.5.10 Remove armrest added Operation step 4 Fig 2: Identifying Backrest Cover, Foam Rubber And Hog Ring Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Backrest Cover, Foam Rubber, Plastic Rails And Seam Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3583 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00-Z- 0005-01V 1 Remove belt guide Installation: When replacing the backrest cover (1), cuts must be made for the belt guide.See: ↓ AR91.45-P- 0500MCC
Make cuts for belt guide at cover of front seat backrest AR91.10-P- 8656-01MCC 2.1 Remove driver seat When removing backrest cover (1) from driver seat. AR91.10-P- 1010MCU 2.2 Remove passenger seat When removing backrest cover (1) from front passenger seat. AR91.10-P- 1020MCU 3 Remove sidebag unit
AR91.60-P- 0695MCU 4 Remove center armrest For vehicles with code (I50) Armrest or with retrofitted center armrest AR91.27-P- 1000MCC 5 Set seat backrest to vertical position
6 Remove hog rings (5) using suitable side cutting pliers Fold up backrest cover (1) piece by piece and remove exposed hog rings (5). A total of 18 hog rings (5) are installed in the marked areas (arrows D). Installation: Use new hog rings (5) (arrow B). Place hog ring (5) into padding clip pliers, hook padding clip pliers into eyelet on plastic rail (6), then hook onto wire of foam part (4) and press together until the hog ring (5) is completely closed (arrow C).Align seams (7) of backrest cover (1) and position in cutouts in foam section (4).
Padding clip pliers *454589033700 7 Take backrest cover (1) up and out
8 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL FRONT SEAT CENTER ARMREST - AR91.27-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3584 · Applies to: 450, 451, 452, 454
1000MCC > MODEL 451.3/4 as of 31.8.10 with CODE (I50) Armrest MODEL 451.3/4 Retrofitted center armrest Removing
1 Fold armrest (1) upward
2 Pry out catch spring (2) with a suitable screwdriver from trim ring (3) and then pull out upwards
3 Pull out armrest (1) from the bracket (5)
Fig 4: Identifying Padding Clip Pliers (454 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Armrest Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3587 · Applies to: 450, 451, 452, 454
Risk of injury caused Fig 1: Identifying Front Seat Heated Cushion Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front Seat Heated Cushion Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
by backrest suddenly¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3588 · Applies to: 450, 451, 452, 454
folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A The front passenger seat console (7) must not be dismantled.
1 Remove front passenger seat and carefully place on a suitable surface with backrest (8)
AR91.10- P- 1020MCU 2.1 Unclip sidebag plug (1) from seat heater plug (2) On vehicles with code (S17) Seat heaters (FFO)
2.2 Unclip sidebag plug (1) from bracket at seat console (7) On vehicles without code (S17) Seat heater (FFO)
3 Expose sidebag wiring harness from brackets (3, 5)
4 Unclip seat belt buckle plug (4) from bracket at seat console (7)
5 Expose seat belt buckle wiring harness (13) from brackets (3)
6 Expose wiring harness for seat heater and disconnect heated cushion connector (6) On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable tie (arrow)
8 Place front passenger seat on its rails
9 Unclip belt tension sensor plug (15) and put to one side
As of 31.8.10, shown at left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3592 · Applies to: 450, 451, 452, 454
Remove/install
Risk of injury caused by release of spring in the automatic belt retractor. Never disassemble automatic belt retractors. AS91.00- Z-0002- 01A Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Fig 1: Identifying Seat Belt With Emergency Tensioning Retractor Components (up To 30.8.10) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Seat Belt With Emergency Tensioning Retractor Components (As Of 31.8.10) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on performing repair, body work¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3593 · Applies to: 450, 451, 452, 454
and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Remove paneling on B-pillar Model 451.3 AR68.30- P- 4700MCU
Model 451.4 AR68.30- P- 4700MCV 3 Disconnect left emergency tensioning retractor squib connector (R12/1x1) or right emergency tensioning retractor squib connector (R12/2x1) and unclip wiring harness (3) from bracket (arrow) up to 30.8.10
4 Detach belt force limiter electrical connector (6) from driver belt force limiter (R12/27) As of 31.8.10
5 Detach reel tensioner squib electrical connector (7) from driver reel tensioner squib (R12/32) or front passenger reel tensioner squib (R12/33) As of 31.8.10
6 Remove bolt (5) from seat belt guide bracket of seat belt (4) Installation: The seat belt guide bracket of the seat belt (4) must be movable when the bolt (5) is screwed on tight.
*BA91.40- P-1002- 01G 7 Remove bolt (2) and remove automatic belt retractor (1) of seat belt (4) upwards Installation: Check automatic belt retractor (1) is correctly seated in guides and slide down.
*BA91.40- P-1004- 01G If the automatic belt retractor
emergency tensioning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3595 · Applies to: 450, 451, 452, 454
retractor units. greater than 100°C. When working on these units, disconnect the power supply. 01A Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V 1 Move seat to front-most position and fold toward front
2 Turn lock (arrow) in lock (3) of seat belt (4) through 90° clockwise and detach seat belt (4) from belt anchor fitting tensioner (1) Installation: Check lock (3) is correctly seated in mounting (2) and check for correct installation position of the seat belt (4).
3 Unclip and remove cover (5)
4 Detach driver anchor fitting tensioner connector (R12/37x1) from driver anchor fitting tensioner squib (R12/37)
5 Remove bolt (6) and remove belt anchor fitting tensioner (1) *BA91.40- P-1005- 01G
Installation: Check belt anchor fitting tensioner (1) is correctly seated in body cutout.If the belt anchor fitting tensioner (1) is replaced, the defective belt anchor fitting tensioner (1) has to be disposed of correctly.See: ↓
Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001-
Install in the reverse order¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3596 · Applies to: 450, 451, 452, 454
01A 6 Install in the reverse order
7 Check supplemental restraint system using STAR DIAGNOSIS When replacing the belt anchor fitting tensioner (1). AD00.00- P-2000- 04MCC SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1005-01G Bolt to belt anchor fitting tensioner Nm 35 TESTING & REPAIR > REMOVE SEAT BELT BUCKLE - AR91.40-P-1515-01MCU > 1. Fold backrest of seat forwards. 2. Place seat with backrest onto a suitable base. 3. Unclip plug (4) of seat belt buckle wiring harness (3) from seat. 4. Detach seat belt buckle wiring harness (3) from brackets (2) and expose. 5. Remove bolt (7) at belt buckle (5). 6. Remove bolts (6) and raise seat console slightly off the backrest frame (1). Fig 1: Identifying Seat Belt Buckle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Expose seat belt buckle wiring harness (3) in the direction of the seat belt buckle (5).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3597 · Applies to: 450, 451, 452, 454
- Pull grommet (8) of wiring harness for seat belt buckle (3) out of backrest frame (1).
- Remove bolt (7) and remove seat belt buckle (5) with seat belt buckle wiring harness (3). TESTING & REPAIR > INSTALL SEAT BELT BUCKLE - AR91.40-P-1515-02MCU > FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1003-01G Screw on seat belt buckle Nm 30
- Mount seat belt buckle (6) using bolt (5) onto backrest frame (1) and screw in bolt (5) up to the contact surface.
- Raise seat console slightly off the backrest frame (1) and route the wiring harness for the seat belt buckle (4) to the holders (9). The edge guard (3) must be positioned such that the wiring harness for the seat belt buckle (4) cannot suffer any chafe damage. The wiring harness for the seat belt buckle (4) must be routed in front of the holder (10).
- Insert grommet (7) of wiring harness for the seat belt buckle (4) into the opening (arrow).
4. Align seat console to the backrest frame (1) and screw in bolts (2) up to the contact surface.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3598 · Applies to: 450, 451, 452, 454
- Insert seat belt buckle wiring harness (4) into brackets (9).
- Clip plug (8) of seat belt buckle wiring harness (4) to seat console.
- Place seat onto guide rails and move backrest frame (1) to rearmost position, then lock in place.
- Tighten bolt (5) of seat belt buckle (6) to the specified tightening torque.
- Starting from the rear, tighten the bolts (2) in the area of the seat belt buckle (6) to the specified tightening torque. While doing so, press the backrest frame (1) backwards. TESTING & REPAIR > REMOVE/INSTALL SEAT BELT BUCKLE (FRONT SEAT) - AR91.40- P-1515MCU > MODEL 451.3/4 Fig 1: Identifying Seat Belt Buckle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3603 · Applies to: 450, 451, 452, 454
25.8.08 Value modified: Bolt, release unit to dashboard carrier *BA91.60-P-1002-01C
Remove/install
Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Remove vertical strut paneling
AR68.00- P- 1500MCC 3 Disconnect electrical connectors (1) from restraint systems control unit (N2/7)
4 Remove bolts (2) and remove restraint systems control unit (N2/7) Installation: Tighten the bolts (2) by following the tightening sequence (a, b, c).
*BA91.60- P-1002- 01C Fig 1: Identifying Restraint System Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
and emergency tensioning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3605 · Applies to: 450, 451, 452, 454
retractor units 01A If the driver airbag unit (1) is deployed the complete steering wheel (2) must always be replaced
1 Remove steering wheel (2) and place onto a suitable base For safety reasons, the steering wheel (2) must not be placed onto the driver airbag unit (1) or onto the fanfare horns and airbag clock spring contact (A54).A suitable base would be, e.g. the packaging (4) of a new steering wheel (2). AR46.10- P- 0100MCC 2 Remove coverings for steering wheel spokes
AR46.10- P- 0105MCC 3 Undo screws (3) on driver airbag unit (1) The screws (3) remain on the steering wheel (2).
*BA91.60- P-1005- 01C 4 Remove driver airbag unit (1) from steering wheel (2) until the electrical connectors (5, 6, 7) are accessible Installation: Before positioning the driver airbag unit (1) onto the steering wheel (2), make sure that the springs are correctly seated (arrows).There are three springs (arrows on the steering wheel (2).
5 Detach the electrical connector (lilac) (5), electrical connector (yellow) (6) and the electrical connectors (7) and place the driver airbag unit (1) to one side If driver airbag unit (1) is being replaced, the defective driver airbag unit (1) must be disposed of properly.Refer to: ↓
Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001- 01A 6 Install in the reverse order
7 Check supplemental restraint system using STAR DIAGNOSIS Only when replacing the driver airbag unit (1).
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1005- Bolt, airbag to steering wheel Nm 4 4
TESTING & REPAIR > REMOVE/INSTALL PASSENGER AIRBAG UNIT - AR91.60-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3606 · Applies to: 450, 451, 452, 454
01C TESTING & REPAIR > REMOVE/INSTALL PASSENGER AIRBAG UNIT - AR91.60-P- 0680MCU > MODEL 451.3/4
Remove/install
Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1 Disconnect ground line of battery
AR54.10- P- 0003MCC AR68.10- Fig 1: Identifying Passenger Airbag Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove trim on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3607 · Applies to: 450, 451, 452, 454
2 Remove trim on passenger-side
P- 1502MCU 3 Detach electrical connector (yellow) (2) and electrical connector (green) (3) on the front passenger airbag unit (1)
4 Remove screws (4) from passenger airbag (1) *BA91.60- P-1001- 01C 5 Unscrew nuts (5) from front passenger airbag (1) and remove front passenger airbag (1) downward. No more bolted connections may be opened. Do not disassemble front passenger airbag (1), otherwise it must be replaced.
*BA91.60- P-1004- 01C
Installation: Observe tightening sequence (A to D) of nuts (5).If the front passenger airbag unit (1) is being replaced, the faulty front passenger airbag unit (1) must be properly disposed of.Refer to: ↓
Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001- 01A 6 Install in the reverse order
7 Check supplemental restraint system using STAR DIAGNOSIS When installing new front passenger airbag unit (1).
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1001- 01C Bolt of front passenger airbag unit to instrument panel mounting Nm 10 10 BA91.60-P-1004- 01C Nut, front passenger airbag unit to instrument panel Nm 2 2 TESTING & REPAIR > REMOVE/INSTALL FRONT SEAT SIDEBAG UNIT - AR91.60-P- 0695MCU > MODEL 451.3/4
Fig 1: Identifying Backrest Upholstery, Closing Strip And Rail¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3608 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Closing Strip, Puller Hook, Side Closing Strip And Side Rail Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3609 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00-Z- 0005-01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00-Z- 0001-01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00-P- 0002-01SM Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00-P- 0004-01A 1.1 Remove driver seat When removing the sidebag unit (11) on the driver seat AR91.10-P- 1010MCU Fig 3: Identifying Front Seat Sidebag Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove passenger seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3610 · Applies to: 450, 451, 452, 454
1.2 Remove passenger seat When removing the sidebag unit (11) on the front passenger seat AR91.10-P- 1020MCU 2 Expose rear closing strip (2) at the sides (arrows A)
3 Unhook closing strip (2) by turning on rail (3) Installation: Insert closing strip (2) into rail (3) starting from the right.The position of the closing strip (2) to the rail (3) is marked.
4 Route extraction hook (4) behind backrest cover (1) in marked area (arrow B) and insert into side closing strip (5) 450589079900 5 Expose the lower section of the side closing strip (5) by pulling extraction hook (4) in direction of arrow 450589079900 6 Unhook side closing strip (5) by turning on side rail (6)
7 Route lower section of backrest cover (1) forward between seat cushion and backrest Ensure that the seat cover is not damaged by the rail (3), as it otherwise must be replaced.
8 Fold up backrest cover (1) in front area Ensure that the backrest cover (1) is not torn and thus damaged, as it otherwise must be replaced.
9 Fold over backrest
10 Fold over backrest cover (1) in rear area until sidebag unit (11) is accessible
11 Remove cable ties in area of white markings (7) Installation: Fasten cable ties on white markings (7) on sidebag unit wiring harness (8) or seat heater wiring harness.Pay attention to installation position of cable ties.
12 Unscrew nuts (9) of sidebag unit (11) Installation: Replace self-locking nuts (9). Before tightening nuts (9), ensure that electrical connector (10) is positioned in opening of backrest frame, as otherwise sidebag unit (11) or electrical connector (10) may be damaged.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3612 · Applies to: 450, 451, 452, 454
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Remove left and right side paneling in trunk
AR68.30- P- 4800MCU 3 Detach electrical connector (1) on the driver head/thoraxbag sensor (A53) or the front passenger head/thoraxbag sensor (A54)
4 Unscrew bolt (2) and remove driver head/ thoraxbag sensor (A53) or front passenger head/thoraxbag sensor (A54) Installation: If the bolt (2) cannot be tightened to the prescribed tightening torque, it must be replaced by a bolt listed in the parts ordering notes table (oversize repair bolt).
*BA91.60- P-1006- 01C 5 Install in the reverse order
6 Check supplemental restraint system using STAR When replacing the driver head/thoraxbag sensor (A53) or the front passenger head/
Fig 1: Identifying Thoraxbag Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
avoiding damage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3614 · Applies to: 450, 451, 452, 454
to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Remove driver seat
AR91.10- P- 1010MCU 2 Place driver seat (1) onto suitable base
3 Detach driver seat adjustment detection sensor connector (X28/10) from seat cushion frame Release shackle (arrow A) of driver seat adjustment detection sensor connector (X28/10).
4 Expose electrical wiring harness (2) of driver seat adjustment detection sensor (B3)
5 Remove bolt (3) from driver seat adjustment detection sensor (B3)
6 Remove driver seat adjustment detection sensor (B3) from seat rail (4) Use suitable tool to pry pin (arrow B) of driver seat adjustment detection sensor (B3) out of seat rail (4), then lift up tab of driver seat adjustment detection sensor (B3) towards arrow and remove driver seat adjustment detection sensor (B3) from seat rail (4). Installation: Check pin (arrow B) and collar (arrow C) are correctly seated in seat rail (4).
7 Install in the reverse order
8 Check driver seat adjustment detection sensor (B3) with Star Diagnosis When replacing driver seat adjustment detection sensor (B3). AD00.00- P-2000- 04MCC TESTING & REPAIR > REMOVE/INSTALL FRONTAL ACCELERATION SENSOR - AR91.60- P-0750MCU > MODEL 451.3/4
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3615 · Applies to: 450, 451, 452, 454
1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Remove front CBS
AR88.00- P- 1010MCC 3 Undo bolt (3) on driver-side frontal acceleration sensor (B48/1) or on the passenger-side frontal acceleration sensor (B48/2) Replace self-locking bolt (3). Counterhold the driver-side frontal acceleration sensor (B48/1) or the passenger-side frontal acceleration sensor (B48/2) at the rear.
*BA91.60- P-1008- 01C 4 Remove driver-side frontal acceleration sensor (B48/1) or the passenger-side frontal acceleration sensor (B48/2) from the CMS front (1) and detach the electrical connector (4) Installation: The guide (2) must be inserted into the CMS front (1).
5 Install in the reverse order
6 Check supplemental restraint system using STAR DIAGNOSIS When replacing the driver-side frontal acceleration sensor (B48/1) or passenger-side frontal acceleration sensor (B48/2)
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC AIRBAG Fig 1: Identifying Frontal Acceleration Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3616 · Applies to: 450, 451, 452, 454
- Designation
- Model 451.3
- Model 451.4
- BA91.60-P-1008-
- 01C
- Torx screw, frontal acceleration sensor to
- CMS front
- Nm
- 8
- 8
- SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY PERFORMING TESTING OR
- REPAIR WORK ON AIRBAG OR EMERGENCY TENSIONING RETRACTOR UNITS. -
- AS91.00-Z-0001-01A >
- Store airbag units with deployment side facing up; do not expose to temperatures greater than
- 100°C. When working on these units, disconnect the power supply.
- Risk of injury
- caused by flying objects if an airbag or emergency tensioning retractor unit is triggered accidentally or if an
- airbag unit is stored with its deployment side face down. When scrapping airbags or emergency tensioning
- retractor units by means of controlled ignition, a danger is also present if an insufficient safe distance is kept
- or when opening with cutting torches or other cutting tools, or due to smelting or if parts that have not yet
- ignited end up in a blaze or a smoldering fire at landfills.
- Safety instructions/precautions
- Always store removed airbag units with the deployment side facing up.
- Acquisition, transportation, storage, testing and assembly work should only be performed or
- supervised by properly trained personnel.
- Install airbag units or seat belt emergency tensioning retractors immediately after taking them from the
- storage room.
- Airbags units and seat belt emergency tensioning retractors must be protected from flying sparks,
- open flames and temperatures of > 100°C.
- Do not transport airbags and emergency tensioning retractors in the passenger compartment, but
- rather stow them securely in the load compartment of the vehicle in their original replacement part
- packaging so as to prevent any slippage.
- Do not let airbag units and emergency tensioning retractors come into contact with grease, oil or
- cleaning agents.
- Perform system tests using approved testing equipment only and only when the units are properly
- installed and the vehicle is unoccupied.
- Before the initial hookup of the battery or an external power supply, the ignition must be switched on
- and the vehicle unoccupied.
- Airbag units and emergency tensioning retractors that have dropped from a height of more than 0.5 m
- must be replaced.
- The airbag units and emergency tensioning retractors must be disposed of in their original packaging through the MeRSy (Renz) disposal channel in a professional and environmentally acceptable manner. In all countries except national regulations governing proper disposal must be complied with. A safe distance of at least 10 meters must be maintained when scrapping airbag units and emergency tensioning retractors with controlled triggering.
The following steps must be taken before starting any bodywork or aftermarket installations, work on airbag¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3617 · Applies to: 450, 451, 452, 454 · AR: AS91.00-Z-9999ZZ
units or emergency tensioning retractors, or work on components connected to airbag units or emergency tensioning retractors or work that involves the electric circuits of the airbag units or emergency tensioning retractors (e.g. removal of the steering wheel): Withdraw ignition key. Disconnect any external power sources (e.g. battery chargers). Disconnect control unit connector prior to performing any work in the interior and prior to any welding work. On vehicles with Keyless Go (KG) Ensure that no circuit is on. SAFETY PRECAUTIONS > RISK OF INJURY. INJURY MAY RESULT WHEN THE TENSION IN THE SPRING IN THE AUTOMATIC BELT RETRACTOR IS RELEASED. - AS91.00-Z-0002- 01A > Never disassemble automatic belt retractors. Risk of injury Disassembling an automatic belt retractor may cause the sudden release of spring tension and result in injuries. Safety guidelines/precautions Never disassemble automatic belt retractors! SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY BACKREST SUDDENLY FOLDING FORWARD IF RELEASE LEVER IS ACCIDENTALLY OPERATED DURING INSPECTION AND REPAIR WORK - AS91.00-Z-0005-01V > When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. Risk of injury When working near a backrest, particularly if the backrest cushion has been removed, injuries may result if the backrest latch mechanism is accidentally released allowing the backrest to suddenly fold forward. Safety precautions/instructions If the work situation allows, fold backrest forward in a controlled manner prior to working on a front seat which has its backrest cushion removed. Keep body parts clear of the backrest travel range. Do not accidentally operate the backrest release lever. SAFETY PRECAUTIONS > SAFETY INFORMATION: SEATS, BUNKS, RESTRAINT SYSTEMS - AS91.00-Z-9999ZZ > MODEL all
Injury hazard when performing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3618 · Applies to: 450, 451, 452, 454
check and repair work in area of rollover bar MODEL 208.435 /444 /445 /447 /448 /465 /470 AS91.00-Z-0003- 01KA Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work MODEL 171, 172, 451 AS91.00-Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. MODEL 129, 163, 164, 168, 169, 170, 171, 172, 197, 199, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 251, 314, 316, 318, 414, 450, 451, 452, 454, 461, 463, 636, 638, 639, 667, 668, 670, 901, 902, 903, 904, 905, 906, 930, 932, 933, 934, 940, 942, 943, 944, 950, 952, 953, 954, 957, 970, 972, 974, 975, 976... AS91.00-Z-0001- 01A Risk of injury caused by testing or repair work on roll bar units with pyrotechnical actuator MODEL 207.4 AS91.00-Z-0006- 01A Risk of injury caused by testing or repairing airbag or emergency tensioning retractor units. MODEL 690.6, 901, 902, 903, 904, 905 AS91.00-Z-0001- 01D Risk of injury. Injuries may result when performing testing or repair work on airbag or emergency tensioning retractor units. MODEL 124, 126, 129 up to 30.6.93, 140, 202 up to 30.6.93 AS91.00-Z-0001- 01B Risk of injury. Injuries may result when performing testing or repair work on airbag or emergency tensioning retractor units. MODEL 210, 215, 220, 230 AS91.00-Z-0001- 01C Risk of injury. Injury may occur when performing check and repair work in the area of the roll bar MODEL 209.4 AS91.00-Z-0003- 01QA Risk of injury. Injury may result when the tension in the spring in the automatic belt retractor is released. MODEL all AS91.00-Z-0002- 01A Risk of injury when performing check and repair work in area of MODEL 207.4 AS91.00-Z-0003- 01A
roll bar¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3619 · Applies to: 450, 451, 452, 454 · AR: BA91.00-Z-9999CZ
Risk of injury when performing check and repair work in area of roll bar MODEL 230 except CODE (P99) Special model "AMG Black Series" AS91.00-Z-0003- 01R TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: SEATS, BUNKS, RESTRAINT SYSTEMS - BA91.00-Z-9999CZ > MODEL all Airbag MODEL 454.0 BA91.60-P-1000- 01D Airbag MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA91.60-P-1000- 01C Bench seat MODEL 454.0 BA91.22-P-1000-01A Child seats MODEL 452.3 /4, 451.3 /4 BA91.20-P-1000- 01C Front seats MODEL 451.3/4 BA91.10-P-1000- 01P Front seats MODEL 454.0 BA91.10-P-1000-01J Front seats MODEL 450.3 /4, 452.3 /4 BA91.10-P-1000- 01G Seat belts/emergency tensioning retractors MODEL 454.0 BA91.40-P-1000-01J Seat belts/emergency tensioning retractors MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA91.40-P-1000- 01G TORQUE SPECIFICATIONS > FRONT SEATS - BA91.10-P-1000-01P > Model 451 FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1001- 01P Bolt, seat to floor panel Nm 35 BA91.10-P-1002- 01P Bolt of backrest frame to seat frame Nm 45 BA91.10-P-1003- 01P Nut, backrest frame side piece to backrest frame Nm 20 TORQUE SPECIFICATIONS > CHILD SEATS - BA91.20-P-1000-01C > Model 451, 452 MODIFICATION NOTES
Value modified: Retaining rail, quick attachment to front¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3620 · Applies to: 450, 451, 452, 454
1.4.08 Value modified: Retaining rail, quick attachment to front passenger seat Model 451.3/4 CHILD SEATS Number Designation Model 451.3/4 Model 452.3/4 BA91.20-P-1001- 01C Retaining rail, quick attachment to front passenger seat Nm 25 25 BA91.20-P-1002- 01C Bolt, child seat anchorage to body Nm 22 - TORQUE SPECIFICATIONS > SEAT BELTS/EMERGENCY TENSIONING RETRACTORS - BA91.40-P-1000-01G > Model 450, 451, 452 MODIFICATION NOTES 14.2.07 Screw on belt end fitting Model 451.3/4 Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA91.40-P-1001- 01G Screw on belt end fitting Nm 30 35 30 BA91.40-P-1002- 01G Bolt to upper seat belt guide bracket Nm 30 30 30 BA91.40-P-1003- 01G Bolt on seat belt buckle Nm 30 30 30 BA91.40-P-1004- 01G Automatic belt retractor bolt Nm 30 30 30 BA91.40-P-1005- 01G Screw/bolt at belt end fitting tensioner Nm - 35 - TORQUE SPECIFICATIONS > AIRBAG - BA91.60-P-1000-01C > Model 450, 451, 452 MODIFICATION NOTES 25.8.08 Value changed: Screw/bolt, release unit to instrument panel carrier Model 451.3/4 AIRBAG Number Designation Model 450.3/4 Model 451.3 Model 451.4 BA91.60-P-1001- 01C Bolt of front passenger airbag unit to dashboard mounting Nm 8 10 10
BA91.60-P-1002-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3621 · Applies to: 450, 451, 452, 454
01C Bolt, release unit to dashboard carrier Nm 8 10 10 BA91.60-P-1003- 01C Screw for sidebag to seat backrest Nm 6 - - BA91.60-P-1004- 01C Nut, front passenger airbag unit to dashboard Nm - 2 2 BA91.60-P-1005- 01C Bolt, airbag to steering wheel Nm - 4 4 BA91.60-P-1006- 01C Bolt, sensor for head airbag/thoraxbag to body Nm - 3 3 BA91.60-P-1007- 01C Nut, sidebag to backrest Nm - 10 10 BA91.60-P-1008- 01C Torx screw, frontal acceleration sensor to CMS front Nm - 8 8 BA91.60-P-1009- 01C Screw, windowbag unit to roof frame Nm - 3 - BA91.60-P-1010- 01C Bolt, windowbag inflator Nm - 8 - BA91.60-P-1011- 01C Nut, bracket to kneebag Nm - 5 5 BA91.60-P-1012- 01C Screw/bolt, kneebag bracket to crossmember Nm - 4 4 AIRBAG Number Designation Model 452.3/4 BA91.60-P-1001- 01C Bolt of front passenger airbag unit to dashboard mounting Nm 14 BA91.60-P-1002- 01C Bolt, release unit to dashboard carrier Nm 9 BA91.60-P-1003- 01C Screw for sidebag to seat backrest Nm 6 BA91.60-P-1004- 01C Nut, front passenger airbag unit to dashboard Nm - BA91.60-P-1005- 01C Bolt, airbag to steering wheel Nm - BA91.60-P-1006- 01C Bolt, sensor for head airbag/thoraxbag to body Nm - BA91.60-P-1007- 01C Nut, sidebag to backrest Nm - BA91.60-P-1008- 01C Torx screw, frontal acceleration sensor to CMS front Nm -
General information¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3623 · Applies to: 450, 451, 452, 454
With the integrated seat heater, it is possible to heat the seat cushions and backrests in two heating stages. The heated cushions are heated until they reach the defined maximum temperature. The maximum energizing time depends on the interior temperature. At level 2, the energizing takes place with a higher heat output than at level 1. The maximum temperature is therefore reached more quickly at level 2. The function status is indicated by two light-emitting diodes that are integrated in the heated seat switches. Operating keys and switches Left seat heater switch Right seat heater switch Function requirements: Circuit 15 On No overvoltage or undervoltage Switch on seat heater (2nd stage) The 2nd stage of the seat heater is activated by a one-time actuation of the heated seat switch. At the same time, the heated seats control unit measures the interior temperature (once only) using an integrated temperature sensor. The heated seats control unit energizes the respective heated cushion in heat-up mode at maximum output. The duration of the actuation in heat-up mode depends on the measured interior temperature. Then the heated cushion is actuated in continuous heating mode at 50 % of the maximum output. Switch on seat heater (1st stage) The 1st stage of the seat heater is activated by actuating the heated seat switch twice. Fig 1: Seat Heater (SIH) Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Function requirements¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3627 · Applies to: 450, 451, 452, 454
Circuit 15 On Function The supplemental restraint system serves passive occupant safety. The following events can be recorded and distinguished: Head-on collision Rear end collision Side-on collision Roll-over Impact detection Fig 1: Supplemental Restraint System (SRS) Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The restraint systems control unit records the acceleration values using an internal sensor. The following¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3628 · Applies to: 450, 451, 452, 454
sensors are also read in: Driver head/thoraxbag sensor Front passenger head/thoraxbag sensor Driver-side frontal acceleration sensor Passenger-side frontal acceleration sensor Depending on the severity and nature of the impact, the following restraint equipment may be activated: Driver airbag unit Front passenger airbag unit Driver head/thoraxbag Front passenger head/thoraxbag Left emergency tensioning retractor Right emergency tensioning retractor The emergency tensioning retractors are not activated for seat belts that are not being worn. This is monitored by the restraint systems control unit via the signals from the seat belt buckle restraint systems switches. The occupancy of the front passenger seat is also evaluated in order to assess the situation in the vehicle interior. This is done by determining the weight on the front passenger seat by means of a pressure measurement from the seat occupied recognition pressure sensor in a seat mat filled with silicone. The force that is introduced via the seat belt is measured by the belt tension sensor so that weight classification corrections can be made if necessary. These two measured values are used to calculate a weight classification for the weight on the seat by the weight sensing system (WSS) control unit, which is then transmitted via CAN-B to the instrument cluster, which acts as a gateway and relays the data to the restraint systems control unit via CAN. The following conditions are defined depending on the weight classification: Seat unoccupied: the front passenger airbag unit, the front passenger head/ thoraxbag and the right emergency tensioning retractor unit are shut off Seat occupied: Light weight (e.g. child seat) and belt applied: the front passenger airbag unit, the front passenger sidebag unit and the right emergency tensioning retractor unit are shut off Person detected: required restraint equipment enabled If the restraint equipment is switched off at the front passenger side, the automatic child seat recognition airbag OFF indicator lamp illuminates. Actuation takes place via the restraint systems control unit. Frontal impact
The restraint systems control unit evaluates the data from the frontal acceleration sensors and the internal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3629 · Applies to: 450, 451, 452, 454
sensor in the event of a frontal impact. Depending on the severity of the impact and the situation in the vehicle interior, the following squibs for the respective restraint systems can be triggered: Driver airbag ignition squib 1 Driver airbag ignition squib 2 Front passenger airbag squib 1 Passenger airbag squib 2 Left emergency tensioning retractor squib Right emergency tensioning retractor squib Rear end collision The restraint systems control unit evaluates the data from the internal sensor in the event of a rear end collision. Depending on the severity of the impact and the situation in the vehicle interior, the following squibs for the respective restraint systems can be triggered: Left emergency tensioning retractor squib Right emergency tensioning retractor squib Side-on collision The restraint systems control unit evaluates information from the following components in order to detect a side-on collision: Sensor integrated into the restraint systems control unit Driver head/thoraxbag sensor Front passenger head/thoraxbag sensor Depending on the severity of the impact and the situation in the vehicle interior, the following squibs for the respective restraint systems can be triggered: Driver head/thoraxbag squib Front passenger head/thoraxbag squib Left emergency tensioning retractor squib Right emergency tensioning retractor squib Rollover along the longitudinal vehicle axis The restraint systems control unit evaluates information from the following components in order to detect a rollover: Sensor integrated into the restraint systems control unit Driver head/thoraxbag sensor
Front passenger head/thoraxbag sensor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3630 · Applies to: 450, 451, 452, 454
Depending on the severity of the impact and the situation in the vehicle interior, the following squibs for the respective restraint systems can be triggered: Left emergency tensioning retractor squib Right emergency tensioning retractor squib Driver head/thoraxbag squib Front passenger head/thoraxbag squib Capacitor The supplemental restraint system is equipped with a capacitor in the restraint systems control unit. If the battery is disconnected, then the voltage supply is assured for at least 150 ms. System monitoring When the ignition is switched on, the airbag indicator and warning lamp illuminates in the instrument cluster for approximately 4 s and goes off if the restraint systems control unit self-test runs successfully. If a fault occurs during the cyclic self-tests, the airbag warning lamp is permanently actuated. As well as triggering the restraint equipment, the following interventions are controlled by the restraint systems control unit: Automatic engine shutoff Automatic emergency opening of the central locking Activation of hazard warning lamp function Switch on the interior illumination Automatic engine shutoff In the event of an impact the engine can be automatically shut off. The restraint systems control unit transmits the crash signal via CAN to the ME-SFI [ME] control unit, which shuts off the engine and interrupts the fuel supply via the fuel pump with fuel level sensor (M3/3). Automatic emergency opening of the central locking In the event of an impact the doors are automatically unlocked. The restraint systems control unit transmits the crash signal to the SAM control unit via CAN. This actuates the following components to unlock the doors: Right door CL motor (M14/5) Left front door central locking motor (M14/6) Activation of hazard warning lamp function In the event of an impact the hazard warning function is automatically activated. The restraint systems control unit transmits the crash signal via CAN to the SAM control unit, which actuates the hazard warning flasher. Switching on the interior illumination
General¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3634 · Applies to: 450, 451, 452, 454
The restraint systems control unit controls the supplemental restraint system and is a subscriber on the Controller Area Network (data bus/CAN bus) (CAN). If an accident occurs, the restraint systems control unit specifically deploys the restraint units. This includes the airbag units and the emergency tensioning retractor units. The restraint systems control unit has self-monitoring and fault monitoring features. Frontal, side-on and rear-end collisions and a rollover along the longitudinal vehicle axis are detected and differentiated. Scope of tasks Self-test and continuous monitoring of supplemental restraint system Storage of faults that have occurred Fault output via the diagnosis communication System readiness indication via CAN to the instrument cluster (A1) Power supply Driver head/thoraxbag sensor (A53) Front passenger head/thoraxbag sensor (A54) Driver-side frontal acceleration sensor (B48/1) Passenger-side frontal acceleration sensor (B48/2) Accident detection and ignition time determination Restraint equipment triggering Capacitor for the event of a battery disconnection in the event of a collision Evaluation of the sensor integrated in the restraint systems control unit Seat belt reminder warning request Evaluation of front passenger seat occupied recognition Direct entries Tml. 15 Tml. 31 Driver head/thoraxbag sensor Front passenger head/thoraxbag sensor Driver-side frontal acceleration sensor Passenger-side frontal acceleration sensor Driver side seat belt buckle restraint systems switch (S68/3) Front passenger-side seat belt buckle restraint systems switch (S68/4) Direct outputs
Task¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3638 · Applies to: 450, 451, 452, 454
The WSS control unit determines the weight on the front passenger seat. This is determined via a pressure measurement in a gel mat filled with silicone. The pressure measurement is performed by the pressure sensor of the seat occupied recognition (B48/4). The tractive force at the belt is transmitted via the belt tension sensor (B48/3) to the WSS control unit. The WSS control unit uses the pressure and belt tension to calculate the corresponding weight class and forwards this to the instrument cluster (A1) via the Controller Area Network bus class B (interior) (CAN-B). Discrete inputs Circuit 30 Circuit 31 Belt tension sensor Seat occupied recognition pressure sensor Discrete outputs Power supply from: Belt tension sensor Pressure sensor of seat occupied recognition BASIC KNOWLEDGE > HEAD/THORAXBAG, COMPONENT DESCRIPTION - GF91.60-P- 4100MCU > MODEL 451.3/4 Location The head/thoraxbag units are located in the outboard side of the driver and front passenger seat backrests. Fig 1: Locating Weight Sensing System Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM OF AIRBAG (AB), EMERGENCY TENSIONING¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3642 · Applies to: 450, 451, 452, 454
RETRACTOR (ETR) - PE91.00-P-2000-97MCU > Code: Designation: Position: A1 Instrument cluster 35L A45 Fanfare horns and airbag clock spring contact 18H A45x1 Clock spring contact and airbag connector
A53 Driver head/thorax sensor 14L A54 Front passenger head/thorax sensor 10L B48/1 Driver-side frontal acceleration sensor 12L B48/2 Passenger-side frontal acceleration sensor 8L B48/3 Belt tension sensor 41L B48/3x1 Belt tension sensor connector
B48/4 Seat occupied recognition pressure sensor 43L B48/4x1 Seat occupied recognition pressure sensor connector
E16 Automatic child seat recognition airbag OFF indicator lamp 6L N10/10 SAM control unit 3L N10/10f18 Fuse 18 4L N110 Weight Sensing System (WSS) control unit 42A N110 Weight Sensing System (WSS) control unit 38A N2/7 Restraint systems control module 34A N2/7 Restraint systems control module 28A N2/7 Restraint systems control module 20A N2/7 Restraint systems control module 12A N2/7 Restraint systems control module 4A R12/1 Left emergency tensioning retractor squib 21L R12/13 Driver airbag ignition squib 1 18L R12/14 Driver airbag ignition squib 2 19L R12/1x1 Left emergency tensioning retractor squib connector
R12/2 Right emergency tensioning retractor squib 23L R12/20 Driver head/thoraxbag squib 26L R12/21 Front passenger head/thoraxbag squib 25L
R12/2x1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3643 · Applies to: 450, 451, 452, 454
Right emergency tensioning retractor squib connector
R12/4 Front passenger airbag ignition squib 1 15L R12/5 Front passenger airbag ignition squib 2 17L S68/3 Driver-side seat belt buckle restraint systems switch 29L S68/4 Passenger-side seat belt buckle restraint systems switch 31L W26 Ground (transmission tunnel) 2G W7 Ground (right wheelhousing in trunk) 40L X28/6 Driver head/thoraxbag connector 26G X28/7 Front passenger head/thoraxbag connector 24G X28/8 Driver seat ETR [GUS] connector (2-pin) 28G X28/9 Passenger seat ETR [GUS] connector (2-pin) 30G X55/4 Front passenger seat contacting strip 37G Z3/17 Circuit 15 (fused) connector sleeve 39L Z3/17 Circuit 15 (fused) connector sleeve 31E Z3/17 Circuit 15 (fused) connector sleeve 29E Z3/17 Circuit 15 (fused) connector sleeve 4G Z37/2 CAN engine bus (low) connector sleeve 34G Z37/3 CAN engine bus (high) connector sleeve 35G
Fig 1: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3644 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3645 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM OF AIRBAG (AB), EMERGENCY TENSIONING¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3646 · Applies to: 450, 451, 452, 454
RETRACTOR (ETR) - PE91.00-P-2000-97MCV > Code: Designation: Position: A1 Instrument cluster 56L A45 Fanfare horns and airbag clock spring contact 29L A53 Driver head/thoraxbag sensor 23L Fig 3: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Passenger head/thoraxbag sensor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3647 · Applies to: 450, 451, 452, 454
A54 Passenger head/thoraxbag sensor 17L B3 Driver seat adjustment detection sensor 8L B48/1 Driver-side frontal acceleration sensor 19L B48/2 Passenger-side frontal acceleration sensor 14L B48/3 Belt tension sensor 62L B48/3x1 Belt tension sensor connector
B48/4 Seat occupied recognition pressure sensor 64L B48/4x1 Seat occupied recognition pressure sensor connector
B48/7 Driver door pressure sensor 44L B48/8 Front passenger door pressure sensor 49L E16 Automatic child seat recognition airbag OFF indicator lamp 6L N10/10 SAM control unit 3L N10/10f18 Fuse 18 4L N110 Weight Sensing System (WSS) control unit 63A N110 Weight Sensing System (WSS) control unit 60A N2/7 Restraint systems control unit 5A N2/7 Restraint systems control unit 12A N2/7 Restraint systems control unit 20A N2/7 Restraint systems control unit 28A N2/7 Restraint systems control unit 36A N2/7 Restraint systems control unit 45A N2/7 Restraint systems control unit 53A R12/16 Left windowbag squib 9L R12/17 Right windowbag squib 10L R12/20 Driver head/thoraxbag squib 37L R12/21 Front passenger head/thoraxbag squib 35L R12/24 Front passenger kneebag squib 52L R12/25 Driver kneebag squib 51L R12/27 Driver belt force limiter 11L R12/32 Driver reel tensioner squib 32L R12/33 Front passenger reel tensioner squib 33L R12/37 Driver-side anchor fitting tensioner squib 13L R12/37x1 Driver anchor fitting tensioner connector
R12/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3648 · Applies to: 450, 451, 452, 454
Front passenger airbag squib 1 25L R12/5 Front passenger airbag squib 2 26L S68/3 Driver seat belt buckle restraint systems switch 39L S68/4 Front passenger seat belt buckle restraint systems switch 42L U592 Valid for windowbag 8A W26 Ground (transmission tunnel) 2G W6 Ground (left wheelhouse in luggage compartment) 20K W7 Ground (right wheelhouse in luggage compartment) 61K W7 Ground (right wheelhouse in luggage compartment) 15K W83 Ground (transmission tunnel) 46K X28/10 Driver seat adjustment detection sensor connector 7G X28/6 Driver head/thoraxbag connector 37G X28/7 Front passenger head/thoraxbag connector 35G X28/8 Driver seat ETR [GUS] connector (2-pin) 39G X28/9 Front passenger seat ETR [GUS] connector (2- pin) 41G X35/1 Left door separation point 44G X35/2 Right door separation point 48G X55/4 Front passenger seat connector block 58G X99/17 Kneebag separation point 51G Z169 Shielding connector sleeve 46C Z20/52 Wire end tracer wire connector sleeve 16J Z20/52 Wire end tracer wire connector sleeve 21J Z20/53 Left tracer wire connector sleeve 21H Z20/53 Left tracer wire connector sleeve 45E Z20/54 Right tracer wire connector sleeve 16H Z20/54 Right tracer wire connector sleeve 48E Z3/17 Circuit 15 (fused) connector sleeve 60K Z3/17 Circuit 15 (fused) connector sleeve 42E Z3/17 Circuit 15 (fused) connector sleeve 39E Z3/17 Circuit 15 (fused) connector sleeve 4G
Z37/2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3649 · Applies to: 450, 451, 452, 454
CAN engine bus (low) connector sleeve 55G Z37/3 CAN engine bus (high) connector sleeve 56G Fig 1: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (1 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3650 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (3 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3651 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3652 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
S6/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3655 · Applies to: 450, 451, 452, 454
Cockpit switch group 8L S6/1s3 Left seat heater switch
S6/1s4 Right seat heater switch
W10 Ground (battery) 8E W14 Left floor interior compartment ground 12E W7 Ground (right wheelhouse in luggage compartment) 14E W9 Ground (left front, at lamp unit) 5E X28/4 Driver seat heated cushion connector 11H X28/5 Front passenger seat heated cushion connector 13H Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve 3E
MODEL 199, 240 as of 1.8.06¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3658 · Applies to: 450, 451, 452, 454
MODEL 164, 203, 209, 211, 216, 219, 221, 230, 251 with CODE (494) USA version MODEL 451 with CODE (494) USA version MODEL 451 with CODE (L27) Canada Use: Plates for checking the weight sensing system in the front passenger seat. SPECIAL TOOLS > 454 589 03 37 00 PADDING CLIP PLIERS - WS91.00-P-0043B > FG 91/Set B MODEL 451, 454 Use: Pliers for installing padding clips when replacing the seat cover. Fig 1: Identifying Plates (211 589 00 32 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: SEATS, BUNKS, RESTRAINT SYSTEMS -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3659 · Applies to: 450, 451, 452, 454 · AR: WS91.00-Z-9999CZ
WS91.00-Z-9999CZ > MODEL all 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P- 0274K 126 589 00 10 00 Screwdriver bit FG 46/91/14/32/ Set B WS46.00-P- 0033B 129 589 00 21 00 126-pin socket box FG 00/42/54/91 / Set B WS54.00-P- 0008B 211 589 00 32 00 Plates FG 91/Set B WS91.00-P- 0034B 450 589 07 99 00 Assembly tool set FG 68/91/Set B WS91.00-P- 0031B 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P- 0012K 454 589 01 37 00 Pliers FG 91/Set B WS91.00-P- 0039B 454 589 02 37 00 Pliers FG 91/Set B WS91.00-P- 0040B 454 589 03 37 00 Padding clip pliers FG 91/Set B WS91.00-P- 0043B Fig 1: Identifying Padding Clip Pliers (454 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
GENERAL INFORMATION > NOTES ON PERFORMING REPAIR, BODY WORK AND¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3660 · Applies to: 450, 451, 452, 454
WELDING ON VEHICLES WITH AIRBAGS AND ETR UNITS - AH91.00-P-0002-01SM > Model 450.3/4, 451.3/4 Before and after a body repair, the fault memory must be read out and existing faults documented. Before carrying out any work on the airbag and emergency tensioning retractor units that requires electric circuit intervention (e.g. dismantling), the ignition key must always be removed and the ground line of the battery must be disconnected (wait approx. 60 s for processor power-down). Before carrying out any welding work, remove ignition key, disconnect/insulate ground line of battery and detach connector from restraint system control unit. No particular safety precautions are necessary before carrying out painting work with subsequent force drying. The airbag and ETR units can withstand temperatures of up to a maximum of 100°C without damage. Do not bring airbag and emergency belt tensioner units into contact with grease, oil or cleaning agents. Airbag or ETR units which have fallen from a height of more than 0.5 m must be replaced and must not be installed in a vehicle under any circumstances In order to be able to install emergency tensioning retractor units free from damage and dirt, they have been provided with a PVC film protective sleeve. This protective device must be removed after assembly. Do not use sharp-edged tools when removing PVC film protective sleeve to avoid damaging the belt. If a considerable amount of deformation has occurred, check the setting of the lateral acceleration sensor on the underside of the vehicle. After completing work on the airbag and ETR units, the fault memory must be read out. GENERAL INFORMATION > LEGAL REQUIREMENTS ON HANDLING AND STORING AIRBAGS AND EMERGENCY TENSIONING RETRACTOR UNITS - AH91.00-P-0004-01A > Model 124, 129, 140, 163, 164, 168, 169, 170, 171, 172, 197, 199, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 251, Model 314, 316, 318, Model 414, Model 450.3/4, 451.3/4, 452.3 /4, 454, Model 461, 463, Model 636, 638, 639.601/603/605/701/703/ 705/711/713/811/813/815, Model 668, 670,
Model 690.6, 901, 902, 903, 904, 905, 906,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3661 · Applies to: 450, 451, 452, 454
Model 930, 932, 933, 934, 940, 942, 943, 944, 950, 952, 953, 954, 957, Model 970, 972, 974, 975, 976, Model WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 Legal regulations on handling and storing airbags and emergency tensioning retractors All subsequently listed legal requirements apply to the Federal Republic of Germany. In other countries, the valid national and local legal requirements must be observed. Airbag and emergency tensioning retractor units are class T1. pyrotechnical objects. Their handling, transport and storage are subject to the German Act Concerning Potentially Explosive Substances "Gesetz uber explosionsgefahrliche Stoffe". Only a limited number of class T1 pyrotechnical objects may be stored in buildings which are used for commercial purposes. According to appendix 6 of the annex to the 2nd German explosive directive, the maximum storage volumes listed in the following are permitted in commercially used buildings under consideration of certain requirements (such as, e.g. a steel cabinet) without special approval by the responsible authority: Work room, 10 kg net Storage room, 100 kg net To calculate it, use the net mass of the explosive contained in the that component for which the legal explosive permit has been granted: Each driver airbag, 0.1 kg Each front passenger airbag, 0.3 kg Each sidebag, 0.05 kg Each emergency tensioning retractor, 0.002 kg Each windowbag, 0.004 kg Each kneebag, 0.025 kg Each pelvisbag, 0.015 kg Each headbag, 0.01 kg Airbags and emergency tensioning retractor units must not be stored in the immediate vicinity of easily/highly flammable and oxidizing materials. Acquiring, transport, storage, installation and removal as well as scrapping may only be performed by trained personnel in observance of all applicable safety regulations. The use of a vehicle's passenger compartment to transport such materials is strictly prohibited! Always stow the airbag and emergency tensioning retractor units in their original packaging in the trunk or load compartment of the vehicle in a secure fashion so as to prevent them from sliding around. GENERAL INFORMATION > NOTE ON FUNCTION RELIABILITY OF WINDOWBAG - AH91.60-P-0693-01B >
Model 451.3 with code (I52) Head airbag¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3662 · Applies to: 450, 451, 452, 454
For retrofits Before carrying out any welding work, remove ignition key, disconnect/insulate ground line of battery and detach connector from restraint system control unit. No particular safety precautions are necessary before carrying out painting work with subsequent force drying. The windowbag units can withstand temperatures of up to 100°C without sustaining any damage. Do not allow windowbag units to come into contact with grease, oil or cleaning agents. Otherwise, windowbag units may not be installed in a vehicle under any circumstances. For repair work Note tensioning straps of windowbag units! The functionality of the windowbag units may not be impaired by aftermarket installations, e.g. by wrapping, removing or changing the tensioning straps of the windowbag units. Safety note The windowbag units may not be opened, removed or installed in another vehicle. Danger of malfunctions and injuries! RETROFITTING & CONVERSION > RETROFIT FRONT SEAT ARM REST - AN91.27-P- 0001MCC > MODEL 451.3 /4 as of 30.9.09 Fig 1: Identifying Armrest And Driver Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3663 · Applies to: 450, 451, 452, 454
AR91.10- Fig 2: Identifying Retrofit Front Seat Arm Rest Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Retrofit Front Seat Arm Rest Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove driver seat (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3664 · Applies to: 450, 451, 452, 454
1 Remove driver seat (2) * not for USA P- 1000MCC
- for USA only AR91.10- P- 1010MCU 2 Carefully cut off net at backrest cover (3) with a sharp knife directly at the seam On vehicles as of 31.8.10. The net is no longer required.
3 Remove backrest cover (3) until bracket (5) can be inserted at the right in backrest frame (6) Only remove bottom five hog rings.
-
not for USA AR91.10- P- 8656MCC
-
for USA only AR91.10- P- 8656MCU 4 Loosen nut (4) for sidebag unit For code (I53) Head/thoraxbag
5 Remove cable ties (7)
Install
6 Lift off foam part (8) from backrest frame (6) and insert bracket (5) into the planned holes
7 Screw in bolts (9)
8 Attach new cable tie (7) where the lines are routed
9 Lay foam part (8) over the bracket (5) and cut out a passage for the bracket (5) in the foam part (8); position foam part (8) Ensure that foam part (8) is not damaged by tearing.
10 Tighten nut (4) of sidebag unit For code (I53) Head/thoraxbag
*BA91.60- P-1007- 01C 11 Install backrest cover (3) * not for USA AR91.10- P- 8656MCC
- for USA only AR91.10- P- 8656MCU
Use new hog rings.For vehicles with code (I53) Head/thoraxbag, continue to tighten the nuts (4) on the sidebag unit.
1010MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3667 · Applies to: 450, 451, 452, 454
Remove/install driver seat cushion MODEL 451.3 /4 AR91.10- P- 1070MCU
Remove/install emergency tensioning retractor MODEL 451.3 /4 as of 31.8.10 belt anchor fitting tensioner on driver-side AR91.40- P- 1011MCU
Remove/install front seat MODEL 451.3 /4 AR91.10- P- 1000MCC
Remove/install front seat backrest foam section MODEL 451.3 /4 AR91.10- P- 1120MCC
Remove/install front seat backrest foam section MODEL 451.3 /4 AR91.10- P- 1120MCU
Remove/install front seat backrest frame MODEL 451.3 /4 AR91.10- P- 3331MCC
Remove/install front seat backrest frame MODEL 451.3 /4 AR91.10- P- 3331MCU
Remove/install front seat center armrest MODEL 451.3 /4 as of 31.8.10 with CODE (I50) Armrest MODEL 451.3 /4 Retrofitted center armrest AR91.27- P- 1000MCC
Remove/install front seat sidebag unit MODEL 451.3/4 with CODE (I53) Head/ thorax airbag AR91.60- P- 0695MCC
Remove/install front seat sidebag unit MODEL 451.3 /4 AR91.60- P- 0695MCU
Remove/install frontal acceleration sensor MODEL 451.3 /4 AR91.60- P- 0750MCU
Remove/install heated cushion at front seat backrest MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO) AR91.30- P- 0006MCC
Remove/install heated cushion at front seat backrest MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO) AR91.30- P- 0006MCU
Remove/install heated cushion on front seat cushion MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO) AR91.30- P- 0005MCC
Remove/install heated cushion on MODEL 451.3 /4 with CODE (S17) Seat AR91.30- P-
front seat cushion¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3668 · Applies to: 450, 451, 452, 454
heater (FFO) driver seat 0005MCU
Remove/install heated cushion on front seat cushion MODEL 451.3 /4 Front passenger seat AR91.30- P- 0005MCV
Remove/install heated seats control unit MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO) AR91.30- P- 0030MCC
Remove/install heated seats control unit MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO) AR91.30- P- 0030MCU
Remove/install ISOFIX child seat attachment MODEL 451... AR91.10- P- 0002MCC
Remove/install kneebag MODEL 451.3 /4 with CODE (294) Kneebag AR91.60- P- 0050MCU
Remove/install passenger airbag unit MODEL 451.3 /4 AR91.60- P- 0680MCC
Remove/install passenger airbag unit MODEL 451.3 /4 AR91.60- P- 0680MCU
Remove/install passenger seat MODEL 451.3 /4 AR91.10- P- 1020MCU
Remove/install seat belt buckle (front seat) MODEL 451.3 /4 Front passenger seat without seat belt buckle detection AR91.40- P- 1515MCC
Remove/install seat belt buckle (front seat) MODEL 451.3 /4 Driver seat AR91.40- P- 1515MCE
Remove/install seat belt buckle (front seat) MODEL 451.3 /4 AR91.40- P- 1515MCU
Remove/install seat belt guide MODEL 451.3 /4 AR91.45- P- 0500MCC
Remove/install seat belt with emergency tensioning retractor MODEL 451.3 /4 AR91.40- P- 0630MCC
Remove/install seat belt with emergency tensioning retractor MODEL 451.3 /4 AR91.40- P- 0630MCU AR91.10- P-
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3670 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Unhook seat belt (3) from belt guide (2) at driver seat (1)
Remove bolt (5) from Fig 1: Identifying Driver Seat Remove/Install Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
belt end fitting of eat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3671 · Applies to: 450, 451, 452, 454
3 belt end fitting of eat belt (3) up to 30 8 10 Installation: En ure that the installation position of the seat belt (3) is correct.
*BA91.40- P-1001- 01G 4 Slide driver seat (1) forwards, fold down backrest and remove bolts (4) Push driver seat (1) backwards slightly to ensure that it has audibly engaged into both seat rails. Installation: Screw in bolts (4) up to contact surface, tighten right bolt first, then tighten left bolt (4). Move driver seat (1) to rearmost position, tighten left bolt and then tighten right bolt (6).
*BA91.10- P-1001- 01P 5 Move driver seat (1) to rearmost position and remove bolts (6) Push driver seat (1) forwards slightly to ensure that it has audibly engaged into both seat rails.Set seat backrest to vertical position. Installation: Screw in bolts (6) up to contact surface and move driver seat (1) to foremost position.
6 Expose wiring harness at holder (7) On vehicles without code (C54) Sound system 2, the bracket (7) is clipped into the front cross strut of the driver seat (1).
7 Tilt driver seat (1) backwards and expose wiring harness at bracket (8)
8 Disconnect driver seat heated cushion connector (X28/4) On vehicles with code (S17) Seat heaters (FFO)
9 Disconnect driver head/thoraxbag connector (X28/6) and 2-pin ETR connector at driver seat (X28/8)
10 Detach sensor connector for driver seat adjustment detection (X28/10) As of 31.8.10
11 Remove driver seat (1) from vehicle Carefully remove driver seat (1) out of vehicle with a helper, as otherwise trim parts and detachable parts may be damaged.
12 Install in the reverse order
13 Check supplemental restraint system using
AD00.00- P-2000-
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3673 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Unhook seat belt (3) from belt guide (2) at front passenger seat (1)
3 Move front passenger seat (1) forward and fold over backrest
4 Unclip and remove cover (7)
5 Release wiring harness from bracket (6) and remove belt tension sensor connection (B48/3x1) Pay attention to installation position (arrow) of wiring harness.
6 Remove bolt (5) from lower belt end fitting of seat belt (3) *BA91.40- P-1001- 01G 7 Remove bolts (8) Push front passenger seat (1) backwards slightly to ensure that it has audibly engaged into both seat rails. Installation: Screw in bolts (8) up to contact surface, tighten right bolt first, then tighten left bolt (8).Move front pa enger eat (1) to rearmo t po ition, tighten
Fig 2: Identifying Passenger Seat Components - Shown On Vehicle With Code (S17) Seat Heater (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
left bolt and then tighten right bolt (4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3674 · Applies to: 450, 451, 452, 454
*BA91.10- P-1001- 01P 8 Move front passenger seat (1) to rearmost position and remove bolts (4) Push front passenger seat (1) forwards slightly to ensure that it has audibly engaged into both seat rails.Set seat backrest to vertical position. Installation: Screw in bolts (4) up to contact surface and move front passenger seat (1) to foremost position.
9 Tilt front passenger seat (1) backwards and expose wiring harness at bracket (9)
10 Disconnect front passenger seat heated cushion connector (X28/5) On vehicles with code (S17) Seat heaters (FFO)
11 Disconnect front passenger seat connector block (X55/4), front passenger head/thoraxbag connector (X28/7) and 2- pin front passenger seat ETR connector (X28/9) No other connectors must be disconnected, otherwise a new supporting seat frame must be installed.
12 Remove front passenger seat (1) from vehicle Carefully remove front passenger seat (1) out of vehicle with a helper, as otherwise trim parts and detachable parts may be damaged.
13 Install in the reverse order
14 Program new blank value for seat occupied recognition and check supplemental restraint system using STAR DIAGNOSIS
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1001-01P Bolt, seat to floor panel Nm 35 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS
Shown on code (S17) Seat heaters (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3676 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Front Seat Backrest Foam Section Components - Shown On Code (S17) Seat Heaters (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3677 · Applies to: 450, 451, 452, 454
1 Remove cover for backrest from seat
AR91.10- P- 8656MCU 2 Carefully place seat with backrest on a suitable surface On vehicles with code (S17) Seat heaters (FFO)
3 Expose seat heater wiring harness (2) at the brackets (3) On vehicles with code (S17) Seat heaters (FFO)
4 Disconnect electrical connector (1) of seat heaters On vehicles with code (S17) Seat heaters (FFO)
5 Place seat on its rails On vehicles with code (S17) Seat heaters (FFO)
Remove cable tie Fig 2: Identifying Front Seat Backrest Foam Section Remove/Install Components - Shown On Code (S17) Seat Heaters (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose sidebag¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3678 · Applies to: 450, 451, 452, 454
6 (4)
7 Expose sidebag wiring harness (5) and (if necessary) seat heater wiring harness (2) at backrest frame (7) and at foam part (6) (arrow B) The seat heater wiring harness (2) is only installed in vehicles with code (S17) Seat heater (FFO).Remove cable ties for fastening sidebag wiring harness (5) and (if necessary) cable ties for fastening seat heater wiring harness (2).Pay attention to installation position of cable ties. Installation: The position of the cable ties is specified by a white marking on the sidebag wiring harness (5) and on the seat heater wiring harness (2).
8 Route lower area (arrow C) of foam section (6) forward between backrest frame (7) and seat cushion Installation: Pay attention to positioning of foam section (6) in area of sidebag.On vehicles with code (S17) Seat heater (FFO), the seat heater wiring harness (2) must be routed through the cutout (arrow A) in the foam part (6).
9 Remove foam section (6) upward Installation: If a new foam part (6) is installed in vehicles with code (S17) Seat heater (FFO), a new left heated seat cushion (R13/1) or new right heated seat cushion (R13/3) must be installed.See: ↓
Remove/install heated cushion at front seat backrest AR91.30- P- 0006MCU 10 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION - AR1.10-P-3310MCU > Front passenger seat Shown on code (S17) Seat heaters (FFO)
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3679 · Applies to: 450, 451, 452, 454
Risk of injury caused Fig 1: Identifying Seat Cushion Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Seat Cushion Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
by backrest suddenly¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3680 · Applies to: 450, 451, 452, 454
folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A The front passenger seat console (7) must not be dismantled.
1 Remove front passenger seat and carefully place on a suitable surface with backrest (8)
AR91.10- P- 1020MCU 2.1 Unclip sidebag plug (1) from seat heater plug (2) On vehicles with code (S17) Seat heaters (FFO)
2.2 Unclip sidebag plug (1) from bracket at seat console (7) On vehicles without code (S17) Seat heater (FFO)
3 Expose sidebag wiring harness from brackets (3, 5)
4 Unclip seat belt buckle plug (4) from bracket at seat console (7)
5 Expose seat belt buckle wiring harness (13) from brackets (3)
6 Expose heated seat wiring harness and disconnect heated cushion connector (6) On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable tie (arrow)
8 Place front passenger seat on its rails
9 Unclip belt tension sensor plug (15) and put to one side
Unclip belt tension
Shown on code (S17) Seat heaters (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3682 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Seat Cushion Cover Components - Shown On Code (S17) Seat Heaters (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3683 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A 1 Remove driver seat
AR91.10- P- 1010MCU 2 Detach terminal strip (3) of seat cushion cover (1) in front and side area of seat
Fig 2: Identifying Seat Cushion Cover Components - Shown On Code (S17) Seat Heaters (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
con ole (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3684 · Applies to: 450, 451, 452, 454
3 Place driver seat on a suitable surface on its side
4 Unclip plug (7) of wiring harness for seat heater (10) at seat console (2) On vehicles with code (S17) Seat heaters (FFO)
5 Unlock catch hook (12) and detach plug (7) from plug (11) On vehicles with code (S17) Seat heaters (FFO)
6 Unclip wiring harness for seat heater (10) from brackets (8) and detach connector of left heated seat cushion or right heated seat cushion On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable ties (9) and expose seat heater (10) On vehicles with code (S17) Seat heaters (FFO)
8 Position extraction hook (6) at side on terminal strip (5) Fig 3 9 Pull the extraction hook (6) towards the arrow, release the terminal strip (5) from the seat console (2) and completely expose it Fig 3 10 Route terminal strip (5) of seat cushion cover (1) forwards between the seat cushion (4) and backrest
Place driver seat
on it rail¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3685 · Applies to: 450, 451, 452, 454
11 on it rail
12 Remove seat cushion (4) with seat cushion cover (1) from the seat console (2) On vehicles with code (S17) Seat heaters (FFO) the seat heater wiring harness (10) also has to be routed when removing the seat cushion (4) with the seat cushion cover (1).
13 Fold seat cushion cover (1) in rear area as far forward as possible until the first Hog rings (15) are accessible Ensure that the seat cushion cover (1) is not torn and thus damaged, as it otherwise must be replaced.
14 Remove hog rings (15) using suitable side cutting pliers Fold seat cushion cover (1) forward piece by piece and remove exposed Hog rings (15). A total of 16 Hog rings (15) are installed in the marked areas (arrows D). Installation: Use new hog rings (15) (arrow B). Place hog ring (15) into padding clip pliers and hook into the eyes of the respective staple rail (13), then hook into wire of seat cushion (4) and press padding clip pliers together until hog ring (15) is fully closed (arrow C).Align seams (14) of seat cushion cover (1) and position in the cutouts in the seat cushion (4).
Fig 4 15 Remove seat cushion cover (1)
16 Install in the reverse order
Fig 3: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3687 · Applies to: 450, 451, 452, 454
Fig 2: Identifying Seat Cushion Cover Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Seat Cushion Cover Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of injury caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3688 · Applies to: 450, 451, 452, 454
backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A 1 Remove front passenger seat and carefully place on a suitable surface with backrest (8)
AR91.10- P- 1020MCU 2.1 Unclip sidebag plug (1) from seat heater plug (2) On vehicles with code (S17) Seat heaters (FFO)
2.2 Unclip sidebag connector (1) from bracket on supporting seat frame (7) On vehicles without code (S17) Seat heater (FFO)
3 Expose sidebag wiring harness from brackets (3, 5)
4 Unclip seat belt buckle connector (4) from bracket on supporting seat frame (7)
5 Expose seat belt buckle wiring harness (13) from brackets (3)
6 Expose wiring harness for seat heater and disconnect heated cushion connector (6) On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable tie (arrow)
8 Place front passenger seat on guide rails
9 Unclip belt tension sensor plug (15) and put to one side
10 Unclip belt tension sensor retaining plate (14) in rear area and remove
11 Fold backrest (8) forward
Installation: Position backrest (8) on
Remove bolts (9) of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3689 · Applies to: 450, 451, 452, 454
12 Remove bolts (9) of backrest (8) supporting seat frame (7) and turn bolts (9, 11) all the way in. Tighten bolts (11) starting from the front. Move backrest (8) to its rearmost position and lock in place. Tighten bolts (9) starting from the rear. While doing so, press the backrest (8) backwards.
*BA91.10- P-1002- 01P 13 Lift backrest (8) in vicinity of seat belt buckle (12) and lead seat belt buckle wiring harness (13) out of supporting seat frame (7) Installation: Ensure that grommet (10) is seated correctly.
14 Remove bolts (11) from backrest (8) and remove backrest (8)
15 Place supporting seat frame (7) on seat cushion cover (18) and detach terminal strip (16) of seat cushion cover (18) in rear area of supporting seat frame (7)
16 Detach terminal strip (17) of seat cushion cover (18) in side and front area of supporting seat frame (7) Installation: The terminal strip (17) must audibly engage.
17 Place supporting seat frame (7) on guide rails
18 Start by folding down seat cushion cover (18) in rear area and then on sides and front until hog rings of side staple strips are accessible (arrows A) Ensure that the seat cushion cover (18) is not torn and thus damaged, as it otherwise must be replaced.
19 Remove hog rings of side staple strips using suitable side cutting pliers (arrows A). Next, fold back seat cushion cover (18) in front area until hog rings of center staple strip are accessible and remove them with the side cutting pliers (arrows B) Remove all hog rings as otherwise the seat cushion (19) or the seat cushion cover (18) can be damaged. Installation: Use new hog rings. Insert hog ring into the padding clip pliers and hook into the eyelet of the staple strips, then hook into the wire of the seat cushion (19) and push padding clip pliers together. Align all seams (20) of seat cushion cover (18) and position in the cutouts in the seat cushion (19).
Figure Remove all hog rings as otherwise the seat
Continue folding back seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3690 · Applies to: 450, 451, 452, 454
20 Continue folding back seat cushion cover (18) until hog rings of rear staple strip are accessible and remove them with the side cutting pliers (arrows C) cushion (19) or the seat cushion cover (18) can be damaged. Installation: Use new hog rings. Insert hog ring into the padding clip pliers and hook into the eyelet of the staple strips, then hook into the wire of the seat cushion (19) and push padding clip pliers together.
Figure 21 Remove seat cushion cover (18) Further dismantling the supporting seat frame (7) is not permissible.
22 Install in the reverse order
FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE/INSTALL FRONT SEAT BACKREST FRAME - AR91.10-P- 3331MCU > MODEL 451.3 /4 Shown on left front seat Fig 4: Identifying Padding Clip Pliers (454 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on right front seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3691 · Applies to: 450, 451, 452, 454
Shown on right front seat Fig 1: Identifying Front Seat Backrest Frame Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front Seat Backrest Frame Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3692 · Applies to: 450, 451, 452, 454
7.5.10 Removal/installation of center armrest mounting added Steps 11 and 12 Removing
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1.1 Remove driver seat When removing backrest frame (2) from driver seat. AR91.10- P- 1010MCU Fig 3: Identifying Backrest Frame, Retaining Plate, Clip & Belt Tension Sensor Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove passenger seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3693 · Applies to: 450, 451, 452, 454
1.2 Remove passenger seat When removing backre t frame (2) from front passenger seat. AR91 10 P- 1020MCU 2 Remove bolt (5), place seat belt buckle (1) with wiring harness for seat belt buckle (4) to one side and detach grommet (6) from backrest frame (2)
3 Remove foam part for backrest
AR91.10- P- 1120MCU 4 Fold backrest frame (2) forward
5 Unclip belt tension sensor connector (B48/3x1) from the retaining plate (10) When removing backrest frame (2) from front passenger seat.
6 Unclip clip (11) Only if the clip (11) has been installed and when the backrest frame (2) is being removed from the front passenger seat.
7 Remove retaining plate (10)
8 Remove bolts (3) of backrest frame (2)
9 Remove backrest frame (2)
10 Remove fuse (9) When replacing the backrest frame (2).
11 Remove armrest support For vehicles with code (I50) Armrest or with retrofitted armrest
Install
12 Install support for armrest For vehicles with code (I50) Armrest or with retrofitted armrest
13 Clip retainer (9) to backrest frame (2) When replacing the backrest frame (2).
14 Position backrest frame (2) on seat console and screw in bolts (3) up to contact surface
15 Screw in bolts (3) opposite the seat belt buckle (1), starting from the front. Move backrest frame (2) to its rearmost position and lock in place. Screw in bolts (3) in vicinity of seat belt buckle (1), starting from the rear. While doing so, press the backrest frame (2) backwards. *BA91.10- P-1002- 01P 16 Fit retaining plate (10) to backrest frame (2)
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3695 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A 1 Remove driver seat and carefully place on a suitable surface with backrest (6)
AR91.10- P- 1010MCU 2 Unclip plug (1) on seat-cushion frame (4) The number of connectors (1) depends on the vehicle equipment.
Fig 1: Identifying Seat Cushion Frame Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3697 · Applies to: 450, 451, 452, 454
Risk of injury caused Fig 1: Identifying Seat Cushion Frame Components (Shown On Code (S17) Seat Heaters (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Seat Cushion Frame Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
by backrest suddenly¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3698 · Applies to: 450, 451, 452, 454
folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A 1 Remove front passenger seat and carefully place on a suitable surface with backrest (8)
AR91.10- P- 1020MCU 2.1 Unclip head/thorax airbag connector (1) on seat heater connector (2) On vehicles with code (S17) Seat heaters (FFO)
2.2 Unclip head/thorax airbag connector (1) from bracket on seat- cushion frame (7) On vehicles without code (S17) Seat heater (FFO)
3 Expose sidebag wiring harness from brackets (3, 5)
4 Unclip seat belt buckle (4) from bracket on seat-cushion frame (7)
5 Expose seat belt buckle wiring harness (13) from brackets (3)
6 Expose wiring harness for seat heater and disconnect heated cushion connector (6) On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable tie (arrow)
8 Place front passenger seat on guide rails
9 Unclip belt tension sensor plug (15) and put to one side
Unclip belt tension sensor retaining plate
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3700 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V 1 Insert assembly wedge (3) between seat frame (2) and handle (1), pry off handle (1) from adjusting shaft of backrest adjustment and remove The handle (1) is destroyed during removal.Pay attention to installation position of handle (1).
Fig 2 2 Remove spring clip (4) from adjusting shaft of backrest adjustment using suitable pliers Replace spring clip (4).Pay attention to installation position of spring clip (4).
Install
3 Clip spring clip (4) into catch hooks (5) at handle (1) corresponding to its locking direction
4 Position new handle (1) on adjusting shaft of backrest adjustment and clip in The handle (1) can only be installed when the spring clip (4) is inserted correctly. The lever of the handle (1) must run downwards (arrow) parallel to the seat frame (2).
Fig 1: Identifying Handle, Seat Frame, Mounting Wedge, Spring Clip And Catch Hook Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Perform function test of backrest¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3701 · Applies to: 450, 451, 452, 454
5 Perform function test of backrest adjustment
TESTING & REPAIR > MAKE CUTS FOR BELT GUIDE AT COVER OF FRONT SEAT BACKREST - AR91.10-P-8656-01MCC > 1. Feel for carrier (4) of belt guide in top section of seat and draw a reference point (2) onto the cover (1) corresponding to the corner (arrow A) of the carrier (4). 2. Feel for carrier (4) of belt guide in top section of seat and draw a reference point (3) onto the cover (1) corresponding to the corner (arrow B) of the carrier (4). 3. Draw a cut (5) 5 mm above the reference point (2) with a length of 15 mm in the upward direction. The cut (5) must be drawn directly behind the carrier (4). 4. Draw a 25 mm long cut (6) in the downward direction starting from the reference point (3). The cut (6) must be drawn directly behind the carrier (4). Fig 2: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Making Cuts For Belt Guide At Cover Of Front Seat Backrest Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on code (S17) Seat heaters (FFO)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3703 · Applies to: 450, 451, 452, 454
MODIFICATION NOTES 7.5.10 Remove armrest added Operation step 4 Fig 2: Identifying Backrest Cover, Foam Rubber And Hog Ring Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Backrest Cover, Foam Rubber, Plastic Rails And Seam Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3704 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V 1 Remove belt guide Installation: When replacing the backrest cover (1), cuts must be made for the belt guide.See: ↓ AR91.45- P- 0500MCC
Make cuts for belt guide at cover of front seat backrest AR91.10- P-8656- 01MCC 2.1 Remove driver seat When removing backrest cover (1) from driver seat. AR91.10- P- 1010MCU 2.2 Remove passenger seat When removing backrest cover (1) from front passenger seat. AR91.10- P- 1020MCU 3 Remove sidebag unit
AR91.60- P- 0695MCU 4 Remove center armrest For vehicles with code (I50) Armrest or with retrofitted center armrest AR91.27- P- 1000MCC 5 Set seat backrest to vertical position
6 Remove hog rings (5) using suitable side cutting pliers Fold up backrest cover (1) piece by piece and remove exposed hog rings (5). A total of 18 hog rings (5) are installed in the marked areas (arrows D). Installation: Use new hog rings (5) (arrow B). Place hog ring (5) into padding clip pliers, hook padding clip pliers into eyelet on plastic rail (6), then hook onto wire of foam part (4) and press together until the hog ring (5) is completely closed (arrow C).Align seams (7) of backrest cover (1) and position in cutouts in foam section (4).
Padding clip pliers Figure 7 Take backrest cover (1) up and out
8 Install in the
reverse order¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3705 · Applies to: 450, 451, 452, 454
TESTING & REPAIR > REMOVE/INSTALL FRONT SEAT CENTER ARMREST - AR91.27-P- 1000MCC > MODEL 451.3 /4 as of 31.8.10 with CODE (I50) Armrest MODEL 451.3 /4 Retrofitted center armrest Removing
1 Fold armrest (1) upward
2 Pry out catch spring (2) with a suitable screwdriver from trim ring (3) and then pull out
Fig 4: Identifying Padding Clip Pliers (454 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Armrest Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3708 · Applies to: 450, 451, 452, 454
Risk of injury caused Fig 1: Identifying Heated Cushion On Front Seat Cushion Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Front Seat Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
by backrest suddenly¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3709 · Applies to: 450, 451, 452, 454
folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A The front passenger seat console (7) must not be dismantled.
1 Remove front passenger seat and carefully place on a suitable surface with backrest (8)
AR91.10- P- 1020MCU 2.1 Unclip sidebag plug (1) from seat heater plug (2) On vehicles with code (S17) Seat heaters (FFO)
2.2 Unclip sidebag plug (1) from bracket at seat console (7) On vehicles without code (S17) Seat heater (FFO)
3 Expose sidebag wiring harness from brackets (3, 5)
4 Unclip seat belt buckle plug (4) from bracket at seat console (7)
5 Expose seat belt buckle wiring harness (13) from brackets (3)
6 Expose wiring harness for seat heater and disconnect heated cushion connector (6) On vehicles with code (S17) Seat heaters (FFO)
7 Remove cable tie (arrow)
8 Place front passenger seat on its rails
9 Unclip belt tension sensor plug (15) and put to one side
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3711 · Applies to: 450, 451, 452, 454
1 Remove foam section (1) from front seat backrest The foam section (1) and the left seat heated cushion (R13/1) or the right seat heated cushion (R13/3) cannot be reused and must be replaced. AR91.10- P- 1120MCU Install
2 Align left seat heated cushion (R13/1) or right seat heated cushion (R13/3), as illustrated, on foam section (1) The cutouts (arrows B) on the left heated seat cushion (R13/1) or right heated seat cushion (R13/3) must be over the attachment points (arrows A) of the backrest cover.
3 Pull off adhesive strips (2) one by one and glue left seat heated cushion (R13/1) or right seat heated cushion (R13/3) to foam section (1) starting from above If the left seat heated cushion (R13/1) or right seat heated cushion (R13/3) is not fully inserted into the recesses, this can lead to the proper assembly of the backrest cover no longer being possible. The left seat heated cushion (R13/1) or right seat heated cushion (R13/3) must be inserted into recesses of foam section (1) in area of fastening points (arrows A).
4 Install foam section (1) of front seat backrest
AR91.10- P- 1120MCU TESTING & REPAIR > REMOVE/INSTALL HEATED SEATS CONTROL UNIT - AR91.30-P- 0030MCU > MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO) Fig 1: Identifying Foam Part & Adhesive Strips On Left & Right Seat Heated Cushion Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
As of 31.8.10, shown at left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3713 · Applies to: 450, 451, 452, 454
Remove/install
Risk of injury caused by release of spring in the automatic belt retractor. Never disassemble automatic belt retractors. AS91.00- Z-0002- 01A Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Fig 1: Identifying Seat Belt With Emergency Tensioning Retractor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Seat Belt With Emergency Tensioning Retractor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on performing repair, body work¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3714 · Applies to: 450, 451, 452, 454
and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Remove paneling on B-pillar Model 451.3 AR68.30- P- 4700MCU
Model 451.4 AR68.30- P- 4700MCV 3 Disconnect left emergency tensioning retractor squib connector (R12/1x1) or right emergency tensioning retractor squib connector (R12/2x1) and unclip wiring harness (3) from bracket (arrow) up to 30.8.10
4 Detach belt force limiter electrical connector (6) from driver belt force limiter (R12/27) As of 31.8.10
5 Detach reel tensioner squib electrical connector (7) from driver reel tensioner squib (R12/32) or front passenger reel tensioner squib (R12/33) As of 31.8.10
6 Remove bolt (5) from seat belt guide bracket of seat belt (4) Installation: The seat belt guide bracket of the seat belt (4) must be movable when the bolt (5) is screwed on tight.
*BA91.40- P-1002- 01G 7 Remove bolt (2) and remove automatic belt retractor (1) of seat belt (4) upwards Installation: Check automatic belt retractor (1) is correctly seated in guides and slide down.
*BA91.40- P-1004- 01G If the automatic belt retractor
work on airbag or¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3716 · Applies to: 450, 451, 452, 454
emergency tensioning retractor units. facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. Z-0001- 01A Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V 1 Move seat to front-most position and fold toward front
2 Turn lock (arrow) in lock (3) of seat belt (4) through 90° clockwise and detach seat belt (4) from belt anchor fitting tensioner (1) Installation: Check lock (3) is correctly seated in mounting (2) and check for correct installation position of the seat belt (4).
3 Unclip and remove cover (5)
4 Detach driver anchor fitting tensioner connector (R12/37x1) from driver anchor fitting tensioner squib (R12/37)
5 Remove bolt (6) and remove belt anchor fitting tensioner (1) *BA91.40- P-1005- 01G
Installation: Check belt anchor fitting tensioner (1) is correctly seated in body cutout.If the belt anchor fitting tensioner (1) is replaced, the defective belt anchor fitting tensioner (1) has to be disposed of correctly.See: ↓
Notes on disposing of airbag and emergency OS91.00-
tensioning retractor units¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3717 · Applies to: 450, 451, 452, 454
P-0001- 01A 6 Install in the reverse order
7 Check supplemental restraint system using STAR DIAGNOSIS When replacing the belt anchor fitting tensioner (1). AD00.00- P-2000- 04MCC SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1005-01G Bolt to belt anchor fitting tensioner Nm 35 TESTING & REPAIR > REMOVE SEAT BELT BUCKLE - AR91.40-P-1515-01MCU > 1. Fold backrest of seat forwards. 2. Place seat with backrest onto a suitable base. 3. Unclip plug (4) of seat belt buckle wiring harness (3) from seat. 4. Detach seat belt buckle wiring harness (3) from brackets (2) and expose. 5. Remove bolt (7) at belt buckle (5). 6. Remove bolts (6) and raise seat console slightly off the backrest frame (1). Fig 1: Identifying Seat Belt Buckle Components
7. Expose seat belt buckle wiring harness (3) in the direction of the seat belt buckle (5).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3718 · Applies to: 450, 451, 452, 454
- Pull grommet (8) of wiring harness for seat belt buckle (3) out of backrest frame (1).
- Remove bolt (7) and remove seat belt buckle (5) with seat belt buckle wiring harness (3). TESTING & REPAIR > INSTALL SEAT BELT BUCKLE - AR91.40-P-1515-02MCU > FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1003-01G Screw on seat belt buckle Nm 30
- Mount seat belt buckle (6) using bolt (5) onto backrest frame (1) and screw in bolt (5) up to the contact surface.
- Raise seat console slightly off the backrest frame (1) and route the wiring harness for the seat belt buckle (4) to the holders (9). Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The edge guard (3) must be positioned such that the wiring harness for the seat belt buckle (4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3719 · Applies to: 450, 451, 452, 454
cannot suffer any chafe damage. The wiring harness for the seat belt buckle (4) must be routed in front of the holder (10). 3. Insert grommet (7) of wiring harness for the seat belt buckle (4) into the opening (arrow). 4. Align seat console to the backrest frame (1) and screw in bolts (2) up to the contact surface. 5. Insert seat belt buckle wiring harness (4) into brackets (9). 6. Clip plug (8) of seat belt buckle wiring harness (4) to seat console. 7. Place seat onto guide rails and move backrest frame (1) to rearmost position, then lock in place. 8. Tighten bolt (5) of seat belt buckle (6) to the specified tightening torque. 9. Starting from the rear, tighten the bolts (2) in the area of the seat belt buckle (6) to the specified tightening torque. While doing so, press the backrest frame (1) backwards. TESTING & REPAIR > REMOVE/INSTALL SEAT BELT BUCKLE (FRONT SEAT) - AR91.40- P-1515MCU > MODEL 451.3 /4 Fig 1: Identifying Seat Belt Buckle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3720 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V 1.1 Remove driver seat When removing seat belt buckle (1) from driver seat. AR91.10- P- 1010MCU 1.2 Remove passenger seat When removing seat belt buckle (1) from front passenger seat. AR91.10- P- 1020MCU 2 Expose seat belt buckle wiring harness (4), remove bolt (3) and remove seat belt buckle (1) from backrest frame (2)
AR91.40- P-1515- 01MCU Install
3 Install belt buckle (1)
AR91.40- P-1515- 02MCU
*BA91.10- P-1002- 01P
*BA91.40- P-1003- 01G 4.1 Install driver seat When installing seat belt buckle (1) on driver seat. AR91.10- P- 1010MCU 4.2 Install front passenger seat When installing seat belt buckle (1) on front passenger seat. AR91.10- P- 1020MCU Fig 1: Identifying Seat Belt Buckle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
means of a screwdriver (5) by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3722 · Applies to: 450, 451, 452, 454
pressing downward on carrier (3) and fold belt guide (1) outward in direction of arrow (arrow C) 5 Remove screwdriver (5), release belt guide (1) from lower guide (arrow B) of carrier (3) and remove
Install
6 Insert belt guide (1) into lower guide (arrow B) of carrier (3)
7 Press belt guide (1) in direction of arrow (arrow D) Belt guide (1) must latch audibly in spring lock (4). 8 Thread seat belt (2) into belt guide (1)
9 Move seat back to its default position
TESTING & REPAIR > REMOVE/INSTALL HEATED SEATS CONTROL UNIT - AR91.30-P- 0030MCU > MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO)
Remove/install 1 Adjust driver seat to the rear 2 Pull front HS [SIH] control unit (N25/5) out of its bracket Fig 1: Identifying Front HS (SIH) Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
retractor units.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3725 · Applies to: 450, 451, 452, 454
units, disconnect the power supply. Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A If the driver airbag unit (1) is deployed the complete steering wheel (2) must always be replaced
1 Remove steering wheel (2) and place onto a suitable base For safety reasons, the steering wheel (2) must not be placed onto the driver airbag unit (1) or onto the fanfare horns and airbag clock spring contact (A54).A suitable base would be, e.g. the packaging (4) of a new steering wheel (2). AR46.10- P- 0100MCC 2 Remove coverings for steering wheel spokes
AR46.10- P- 0105MCC 3 Undo screws (3) on driver airbag unit (1) The screws (3) remain on the steering wheel (2).
*BA91.60- P-1005- 01C 4 Remove driver airbag unit (1) from steering wheel (2) until the electrical connectors (5, 6, 7) are accessible Installation: Before positioning the driver airbag unit (1) onto the steering wheel (2), make sure that the springs are correctly seated (arrows).There are three springs (arrows on the steering wheel (2).
5 Detach the electrical connector (lilac) (5), electrical connector (yellow) (6) and the electrical connectors (7) and place the driver airbag unit (1) to one side If driver airbag unit (1) is being replaced, the defective driver airbag unit (1) must be disposed of properly.Refer to: ↓
Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001- 01A 6 Install in the reverse order
7 Check supplemental restraint system using STAR DIAGNOSIS Only when replacing the driver airbag unit (1).
Connect STAR DIAGNOSIS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3726 · Applies to: 450, 451, 452, 454
and read out fault memory
AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1005- 01C Bolt, airbag to steering wheel Nm 4 4 TESTING & REPAIR > REMOVE/INSTALL PASSENGER AIRBAG UNIT - AR91.60-P- 0680MCU > MODEL 451.3 /4
Remove/install
Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Fig 1: Identifying Passenger Airbag Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Legal requirements on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3727 · Applies to: 450, 451, 452, 454
handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Remove trim on passenger-side
AR68.10- P- 1502MCU 3 Detach electrical connector (yellow) (2) and electrical connector (green) (3) on the front passenger airbag unit (1)
4 Remove screws (4) from passenger airbag (1) *BA91.60- P-1001- 01C 5 Unscrew nuts (5) from front passenger airbag (1) and remove front passenger airbag (1) downward. No more bolted connections may be opened. Do not disassemble front passenger airbag (1), otherwise it must be replaced.
*BA91.60- P-1004- 01C
Installation: Observe tightening sequence (A to D) of nuts (5).If the front passenger airbag unit (1) is being replaced, the faulty front passenger airbag unit (1) must be properly disposed of.Refer to: ↓
Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001- 01A 6 Install in the reverse order
7 Check supplemental restraint system using STAR DIAGNOSIS When installing new front passenger airbag unit (1).
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1001- Bolt of front passenger airbag unit to Nm 10 10
Notes on avoiding¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3729 · Applies to: 450, 451, 452, 454
damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A
The windowbag unit (1) cannot be removed without destroying it and therefore it has to be replaced.
1 Remove side roof frame paneling
AR68.30- P- 4480MCU 2 Remove paneling on A-pillar.
AR68.30- P- 4050MCU 3 Remove bolts (2) *BA91.60- P-1009- 01C 4 Pull check strap (5) as far as possible out of the A-pillar and cut check strap (5) as close as possible to the end piece using cutter The cut off end piece of the check strap (5) remains in the A-pillar. Installation: Route check strap (5) uniformly, starting from the windowbag device (1), so that the white color strips on the check strap (5) face towards the vehicle interior.Insert end piece of check strap (5) into opening of A-pillar and secure end piece by placing diagonally into A-pillar.
5 Remove bracket (3) from roof frame Installation: Check bracket (3) is correctly seated in roof frame.
6 Unscrew bolts (6) and pull out trim for B-pillar far enough to enable the bolt (4) to be removed Installation: Check that the B-pillar trim is correctly seated in the windowbag unit (1) area.
7 Unscrew bolt (4) Secure bolt (4) against falling down.
*BA91.60- P-1009- 01C 8 Detach electrical connector (7) from left windowbag squib (R12/16) or right windowbag
squib (R12/17)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3730 · Applies to: 450, 451, 452, 454
9 Remove bolts (arrows) of windowbag unit (1) and remove windowbag unit (1) downwards The windowbag unit (1) must not be disassembled, as it will then have to be replaced.
*BA91.60- P-1010- 01C
Installation: If a new windowbag unit (1) is being installed, the defective windowbag unit (1) must be properly disposed of.See: ↓
Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001- 01A 10 Install in the reverse order
11 Check supplemental restraint system using STAR DIAGNOSIS When replacing windowbag unit (1). AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 BA91.60-P-1009-01C Screw, windowbag unit to roof frame Nm 3 BA91.60-P-1010-01C Bolt, windowbag inflator Nm 8 TESTING & REPAIR > REMOVE/INSTALL FRONT SEAT SIDEBAG UNIT - AR91.60-P- 0695MCU > MODEL 451.3 /4
Fig 1: Identifying Backrest Upholstery, Closing Strip And Rail¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3731 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Closing Strip, Puller Hook, Side Closing Strip And Side Rail Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3732 · Applies to: 450, 451, 452, 454
Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00- Z-0005- 01V Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM Legal requirements on handling and storing airbags and emergency tensioning retractor units
AH91.00- P-0004- 01A 1.1 Remove driver seat When removing the sidebag unit (11) on the driver seat AR91.10- P- 1010MCU Fig 3: Identifying Front Seat Sidebag Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove passenger seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3733 · Applies to: 450, 451, 452, 454
1.2 Remove passenger seat When removing the sidebag unit (11) on the front passenger seat AR91.10- P- 1020MCU 2 Expose rear closing strip (2) at the sides (arrows A)
3 Unhook closing strip (2) by turning on rail (3) Installation: Insert closing strip (2) into rail (3) starting from the right.The position of the closing strip (2) to the rail (3) is marked.
4 Route extraction hook (4) behind backrest cover (1) in marked area (arrow B) and insert into side closing strip (5) Figure 5 Expose the lower section of the side closing strip (5) by pulling extraction hook (4) in direction of arrow Figure 6 Unhook side closing strip (5) by turning on side rail (6)
7 Route lower section of backrest cover (1) forward between seat cushion and backrest Ensure that the seat cover is not damaged by the rail (3), as it otherwise must be replaced.
8 Fold up backrest cover (1) in front area Ensure that the backrest cover (1) is not torn and thus damaged, as it otherwise must be replaced.
9 Fold over backrest
10 Fold over backrest cover (1) in rear area until sidebag unit (11) is accessible
11 Remove cable ties in area of white markings (7) Installation: Fasten cable ties on white markings (7) on sidebag unit wiring harness (8) or seat heater wiring harness.Pay attention to installation position of cable ties.
12 Unscrew nuts (9) of sidebag unit (11) Installation: Replace self-locking nuts (9). Before tightening nuts (9), ensure that electrical connector (10) is positioned in opening of backrest frame, as otherwise sidebag unit (11) or electrical connector (10) may be damaged.
*BA91.60- P-1007- 01C Remove sidebag unit (11)
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3735 · Applies to: 450, 451, 452, 454
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM 1 Disconnect ground line of battery
AR54.10- P- 0003MCC 2 Remove left and right side paneling in trunk
AR68.30- P- 4800MCU 3 Detach electrical connector (1) on the driver head/thoraxbag sensor (A53) or the front passenger head/thoraxbag sensor (A54)
4 Unscrew bolt (2) and remove driver head/thoraxbag sensor (A53) or front passenger head/thoraxbag sensor (A54) Installation: If the bolt (2) cannot be tightened to the prescribed tightening torque, it must be replaced by a bolt listed in the parts ordering notes table (oversize repair bolt).
*BA91.60- P-1006- 01C 5 Install in the reverse order
6 Check supplemental restraint system using STAR When replacing the driver head/thoraxbag sensor (A53) or the front passenger
Fig 1: Identifying Sidebag Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3738 · Applies to: 450, 451, 452, 454
Remove/install
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units
AH91.00- P-0002- 01SM 1 Remove door paneling
AR72.18- P- 1000MCC 2 Disconnect ground line of battery
AR54.10- P- 0003MCC 3 Feel along the marked area (A) for the driver door pressure sensor (B48/7) or front passenger pressure sensor (B48/8) and carefully cut inner door foil (1) to a length of approx. 10 cm When cutting the inner door foil (1) the electrical components and lines behind it may be damaged. Installation: Seal inner door foil (1) using adhesive tape (4).
Adhesive tape *BR00.45- Z-1071- Fig 1: Identifying Sensor For Sidebag/Windowbag Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Expose driver door pressure sensor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3739 · Applies to: 450, 451, 452, 454
02A 4 Expose driver door pressure sensor (B48/7) or front passenger door pressure sensor (B48/8)
5 Disconnect electrical connector (2) from driver door pressure sensor (B48/7) or passenger door pressure sensor (B48/8)
6 Remove bolts (3) and remove driver door pressure sensor (B48/7) or front passenger door pressure sensor (B48/8)
7 Install in the reverse order
8 Check supplemental restraint system using STAR DIAGNOSIS When replacing the driver door pressure sensor (B48/7) or the front passenger door pressure sensor (B48/8). AD00.00- P-2000- 04MCC REPAIR MATERIALS Number Designation Order number BR00.45-Z-1071-02A Adhesive tape roll, gray Tesa tape, 50 meters 0.3X50, 236 mm A 001 989 17 85 TESTING & REPAIR > REMOVE/INSTALL FRONTAL ACCELERATION SENSOR - AR91.60- P-0750MCU > MODEL 451.3 /4
Remove/install
1 Disconnect ground line of battery
AR54.10- P- 0003MCC Fig 1: Identifying Frontal Acceleration Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove front CBS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3740 · Applies to: 450, 451, 452, 454
2 Remove front CBS
AR88.00- P- 1010MCC 3 Undo bolt (3) on driver-side frontal acceleration sensor (B48/1) or on the passenger-side frontal acceleration sensor (B48/2) Replace self-locking bolt (3). Counterhold the driver-side frontal acceleration sensor (B48/1) or the passenger-side frontal acceleration sensor (B48/2) at the rear.
*BA91.60- P-1008- 01C 4 Remove driver-side frontal acceleration sensor (B48/1) or the passenger-side frontal acceleration sensor (B48/2) from the CMS front (1) and detach the electrical connector (4) Installation: The guide (2) must be inserted into the CMS front (1).
5 Install in the reverse order
6 Check supplemental restraint system using STAR DIAGNOSIS When replacing the driver-side frontal acceleration sensor (B48/1) or passenger-side frontal acceleration sensor (B48/2)
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1008- 01C Torx screw, frontal acceleration sensor to CMS front Nm 8 8 SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY PERFORMING TESTING OR REPAIR WORK ON AIRBAG OR EMERGENCY TENSIONING RETRACTOR UNITS. - AS91.00-Z-0001-01A > Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. Risk of injury caused by flying objects if an airbag or emergency tensioning retractor unit is triggered accidentally or if an airbag unit is stored with its deployment side face down. When scrapping airbags or emergency tensioning retractor units by means of controlled ignition, a danger is also present if an insufficient safe distance is kept or when opening with cutting torches or other cutting tools, or due to smelting or if parts that have not yet ignited end up in a blaze or a smoldering fire at landfills. Safety instructions/precautions
Always store removed airbag units with the deployment side facing up.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3741 · Applies to: 450, 451, 452, 454
- Acquisition, transportation, storage, testing and assembly work should only be performed or
- supervised by properly trained personnel.
- Install airbag units or seat belt emergency tensioning retractors immediately after taking them from the
- storage room.
- Airbags units and seat belt emergency tensioning retractors must be protected from flying sparks,
- open flames and temperatures of > 100°C.
- Do not transport airbags and emergency tensioning retractors in the passenger compartment, but
- rather stow them securely in the load compartment of the vehicle in their original replacement part
- packaging so as to prevent any slippage.
- Do not let airbag units and emergency tensioning retractors come into contact with grease, oil or
- cleaning agents.
- Perform system tests using approved testing equipment only and only when the units are properly
- installed and the vehicle is unoccupied.
- Before the initial hookup of the battery or an external power supply, the ignition must be switched on
- and the vehicle unoccupied.
- Airbag units and emergency tensioning retractors that have dropped from a height of more than 0.5 m
- must be replaced.
-
The airbag units and emergency tensioning retractors must be disposed of in their original packaging through the MeRSy (Renz) disposal channel in a professional and environmentally acceptable manner. In all countries except national regulations governing proper disposal must be complied with. A safe distance of at least 10 meters must be maintained when scrapping airbag units and emergency tensioning retractors with controlled triggering. The following steps must be taken before starting any bodywork or aftermarket installations, work on airbag units or emergency tensioning retractors, or work on components connected to airbag units or emergency tensioning retractors or work that involves the electric circuits of the airbag units or emergency tensioning retractors (e.g. removal of the steering wheel): Withdraw ignition key. Disconnect any external power sources (e.g. battery chargers). Disconnect control unit connector prior to performing any work in the interior and prior to any welding work. On vehicles with Keyless Go (KG) Ensure that no circuit is on. SAFETY PRECAUTIONS > RISK OF INJURY. INJURY MAY RESULT WHEN THE TENSION IN THE SPRING IN THE AUTOMATIC BELT RETRACTOR IS RELEASED. - AS91.00-Z-0002- 01A > Never disassemble automatic belt retractors.
Risk of injury¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3742 · Applies to: 450, 451, 452, 454 · AR: AS88.00-Z-9999ZZ, BA91.00-Z-9999CZ
Disassembling an automatic belt retractor may cause the sudden release of spring tension and result in injuries. Safety guidelines/precautions Never disassemble automatic belt retractors! SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY BACKREST SUDDENLY FOLDING FORWARD IF RELEASE LEVER IS ACCIDENTALLY OPERATED DURING INSPECTION AND REPAIR WORK - AS91.00-Z-0005-01V > When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. Risk of injury When working near a backrest, particularly if the backrest cushion has been removed, injuries may result if the backrest latch mechanism is accidentally released allowing the backrest to suddenly fold forward. Safety precautions/instructions If the work situation allows, fold backrest forward in a controlled manner prior to working on a front seat which has its backrest cushion removed. Keep body parts clear of the backrest travel range. Do not accidentally operate the backrest release lever. SAFETY PRECAUTIONS > SAFETY INFORMATION: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - AS88.00-Z-9999ZZ > MODEL all Risk of injury caused by pinching and crushing when opening and closing engine hood MODEL 949 AS88.40-Z- 0001-01A Risk of injury caused by tearing of the cutting wire MODEL all AS88.00-Z- 0001-01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: SEATS, BUNKS, RESTRAINT SYSTEMS - BA91.00-Z-9999CZ > MODEL all
Airbag MODEL 454.0 BA91.60-P-1000- 01D
Airbag MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA91.60-P-1000- 01C
Bench seat MODEL 454.0 BA91.22-P-1000- 01A
Child seats MODEL 452.3 /4, 451.3 /4 BA91.20-P-1000- 01C
Front seats¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3743 · Applies to: 450, 451, 452, 454
MODEL 451.3 /4 BA91.10-P-1000- 01P
Front seats MODEL 454.0 BA91.10-P-1000- 01J
Front seats MODEL 450.3 /4, 452.3 /4 BA91.10-P-1000- 01G
Seat belts/emergency tensioning retractors MODEL 454.0 BA91.40-P-1000- 01J
Seat belts/emergency tensioning retractors MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA91.40-P-1000- 01G TORQUE SPECIFICATIONS > FRONT SEATS - BA91.10-P-1000-01P > Model 451 FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1001-01P Bolt, seat to floor panel Nm 35 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 BA91.10-P-1003-01P Nut, backrest frame side piece to backrest frame Nm 20 TORQUE SPECIFICATIONS > CHILD SEATS - BA91.20-P-1000-01C > Model 451, 452 MODIFICATION NOTES 1.4.08 Value modified: Retaining rail, quick attachment to front passenger seat Model 451.3/4 CHILD SEATS Number Designation Model 451.3/4 Model 452.3/4 BA91.20-P-1001- 01C Retaining rail, quick attachment to front passenger seat Nm 25 25 BA91.20-P-1002- 01C Bolt, child seat anchorage to body Nm 22 - TORQUE SPECIFICATIONS > SEAT BELTS/EMERGENCY TENSIONING RETRACTORS - BA91.40-P-1000-01G > Model 450, 451, 452 MODIFICATION NOTES 14.2.07 Screw on belt end fitting Model 451.3/4
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3744 · Applies to: 450, 451, 452, 454
Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA91.40-P-1001- 01G Screw on belt end fitting Nm 30 35 30 BA91.40-P-1002- 01G Bolt to upper seat belt guide bracket Nm 30 30 30 BA91.40-P-1003- 01G Bolt on seat belt buckle Nm 30 30 30 BA91.40-P-1004- 01G Automatic belt retractor bolt Nm 30 30 30 BA91.40-P-1005- 01G Screw/bolt at belt end fitting tensioner Nm - 35 - TORQUE SPECIFICATIONS > AIRBAG - BA91.60-P-1000-01C > Model 450, 451, 452 MODIFICATION NOTES 25.8.08 Value changed: Screw/bolt, release unit to instrument panel carrier Model 451.3/4 AIRBAG Number Designation Model 450.3/4 Model 451.3 Model 451.4 BA91.60-P- 1001-01C Bolt of front passenger airbag unit to dashboard mounting Nm 8 10 10 BA91.60-P- 1002-01C Bolt, release unit to dashboard carrier Nm 8 10 10 BA91.60-P- 1003-01C Screw for sidebag to seat backrest Nm 6 - - BA91.60-P- 1004-01C Nut, front passenger airbag unit to dashboard Nm - 2 2 BA91.60-P- 1005-01C Bolt, airbag to steering wheel Nm - 4 4 BA91.60-P- 1006-01C Bolt, sensor for head airbag/thoraxbag to body Nm - 3 3 BA91.60-P- 1007-01C Nut, sidebag to backrest Nm - 10 10 BA91.60-P- 1008-01C Torx screw, frontal acceleration sensor to CMS front Nm - 8 8 BA91.60-P- 1009-01C Screw, windowbag unit to roof frame Nm - 3 -
BA91.60-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3745 · Applies to: 450, 451, 452, 454
1010-01C Bolt, windowbag inflator Nm - 8 - BA91.60-P- 1011-01C Nut, bracket to kneebag Nm - 5 5 BA91.60-P- 1012-01C Screw/bolt, kneebag bracket to crossmember Nm - 4 4 AIRBAG Number Designation Model 452.3/4 BA91.60-P-1001-01C Bolt of front passenger airbag unit to dashboard mounting Nm 14 BA91.60-P-1002-01C Bolt, release unit to dashboard carrier Nm 9 BA91.60-P-1003-01C Screw for sidebag to seat backrest Nm 6 BA91.60-P-1004-01C Nut, front passenger airbag unit to dashboard Nm - BA91.60-P-1005-01C Bolt, airbag to steering wheel Nm - BA91.60-P-1006-01C Bolt, sensor for head airbag/thoraxbag to body Nm - BA91.60-P-1007-01C Nut, sidebag to backrest Nm - BA91.60-P-1008-01C Torx screw, frontal acceleration sensor to CMS front Nm - BA91.60-P-1009-01C Screw, windowbag unit to roof frame Nm - BA91.60-P-1010-01C Bolt, windowbag inflator Nm - BA91.60-P-1011-01C Nut, bracket to kneebag Nm - BA91.60-P-1012-01C Screw/bolt, kneebag bracket to crossmember Nm - BASIC KNOWLEDGE > SEAT HEATER (SIH) LOCATION OF COMPONENTS - GF91.30-P- 0003-02MCU >
Operating keys and switches¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3747 · Applies to: 450, 451, 452, 454
Left seat heater switch Right seat heater switch Function requirements: Circuit 15 On No overvoltage or undervoltage Switch on seat heater (2nd stage) The 2nd stage of the seat heater is activated by a one-time actuation of the heated seat switch. At the same time, the heated seats control unit measures the interior temperature (once only) using an integrated temperature sensor. The heated seats control unit energizes the respective heated cushion in heat-up mode at maximum output. The duration of the actuation in heat-up mode depends on the measured interior temperature. Then the heated cushion is actuated in continuous heating mode at 50 % of the maximum output. Switch on seat heater (1st stage) The 1st stage of the seat heater is activated by actuating the heated seat switch twice. At the same time, the heated seats control unit measures the interior temperature (once only) using an integrated temperature sensor. The heated seats control unit energizes the respective heated cushion in heat-up mode at reduced output. The duration of the actuation in heat-up mode depends on the measured interior temperature. Then the heated cushion is actuated in continuous heating mode at 15 % of the maximum output. Because of the lower maximum output at level 1, the heated cushion is actuated for a longer period in heat-up mode compared to level 2. Switch over seat heater The heating level can be changed during the following operating conditions by pressing the heated seat switch: Heat-up mode Continuous heating mode The change is from level 2 to level 1 or from level 1 to level 2 via seat heater "Off" Changing the heating level during heat-up mode If the heated seat switch is pressed during heat-up mode the heated cushion is actuated by the heated seats control unit with the maximum heat output for the selected heating level. After the expiration of the heat-up period that was calculated before the heating level was changed, further actuation takes place in continuous heating mode using the selected heating level. The timer control is not interrupted when the heating level is changed.
Function requirements¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3751 · Applies to: 450, 451, 452, 454
Circuit 15 On Function The supplemental restraint system serves passive occupant safety. The following events can be recorded and distinguished: Head-on collision Rear end collision Side-on collision Roll-over Impact detection Fig 1: Supplemental Restraint System (SRS) Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The restraint systems control unit records the acceleration values using an internal sensor. The following¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3752 · Applies to: 450, 451, 452, 454
sensors are also read in: Driver head/thoraxbag sensor Front passenger head/thoraxbag sensor Driver-side frontal acceleration sensor Passenger-side frontal acceleration sensor Depending on the severity and nature of the impact, the following restraint equipment may be activated: Driver airbag unit Front passenger airbag unit Driver head/thoraxbag Front passenger head/thoraxbag Left emergency tensioning retractor Right emergency tensioning retractor The emergency tensioning retractors are not activated for seat belts that are not being worn. This is monitored by the restraint systems control unit via the signals from the seat belt buckle restraint systems switches. The occupancy of the front passenger seat is also evaluated in order to assess the situation in the vehicle interior. This is done by determining the weight on the front passenger seat by means of a pressure measurement from the seat occupied recognition pressure sensor in a seat mat filled with silicone. The force that is introduced via the seat belt is measured by the belt tension sensor so that weight classification corrections can be made if necessary. These two measured values are used to calculate a weight classification for the weight on the seat by the weight sensing system (WSS) control unit, which is then transmitted via CAN-B to the instrument cluster, which acts as a gateway and relays the data to the restraint systems control unit via CAN. The following conditions are defined depending on the weight classification: Seat unoccupied: the front passenger airbag unit, the front passenger head/thoraxbag and the right emergency tensioning retractor unit are shut off Seat occupied: Light weight (e.g. child seat) and belt applied: the front passenger airbag unit, the front passenger sidebag unit and the right emergency tensioning retractor unit are shut off Person detected: required restraint equipment enabled If the restraint equipment is switched off at the front passenger side, the automatic child seat recognition airbag OFF indicator lamp illuminates. Actuation takes place via the restraint systems control unit. Frontal impact
The restraint systems control unit evaluates the data from the frontal acceleration sensors and the internal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3753 · Applies to: 450, 451, 452, 454
sensor in the event of a frontal impact. Depending on the severity of the impact and the situation in the vehicle interior, the following squibs for the respective restraint systems can be triggered: Driver airbag ignition squib 1 Driver airbag ignition squib 2 Front passenger airbag squib 1 Passenger airbag squib 2 Left emergency tensioning retractor squib Right emergency tensioning retractor squib Rear end collision The restraint systems control unit evaluates the data from the internal sensor in the event of a rear end collision. Depending on the severity of the impact and the situation in the vehicle interior, the following squibs for the respective restraint systems can be triggered: Left emergency tensioning retractor squib Right emergency tensioning retractor squib Side-on collision The restraint systems control unit evaluates information from the following components in order to detect a side-on collision: Sensor integrated into the restraint systems control unit Driver head/thoraxbag sensor Front passenger head/thoraxbag sensor Depending on the severity of the impact and the situation in the vehicle interior, the following squibs for the respective restraint systems can be triggered: Driver head/thoraxbag squib Front passenger head/thoraxbag squib Left emergency tensioning retractor squib Right emergency tensioning retractor squib Rollover along the longitudinal vehicle axis The restraint systems control unit evaluates information from the following components in order to detect a rollover: Sensor integrated into the restraint systems control unit Driver head/thoraxbag sensor
Front passenger head/thoraxbag sensor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3754 · Applies to: 450, 451, 452, 454
Depending on the severity of the impact and the situation in the vehicle interior, the following squibs for the respective restraint systems can be triggered: Left emergency tensioning retractor squib Right emergency tensioning retractor squib Driver head/thoraxbag squib Front passenger head/thoraxbag squib Capacitor The supplemental restraint system is equipped with a capacitor in the restraint systems control unit. If the battery is disconnected, then the voltage supply is assured for at least 150 ms. System monitoring When the ignition is switched on, the airbag indicator and warning lamp illuminates in the instrument cluster for approximately 4 s and goes off if the restraint systems control unit self-test runs successfully. If a fault occurs during the cyclic self-tests, the airbag warning lamp is permanently actuated. As well as triggering the restraint equipment, the following interventions are controlled by the restraint systems control unit: Automatic engine shutoff Automatic emergency opening of the central locking Activation of hazard warning lamp function Switch on the interior illumination Automatic engine shutoff In the event of an impact the engine can be automatically shut off. The restraint systems control unit transmits the crash signal via CAN to the ME-SFI [ME] control unit, which shuts off the engine and interrupts the fuel supply via the fuel pump with fuel level sensor (M3/3). Automatic emergency opening of the central locking In the event of an impact the doors are automatically unlocked. The restraint systems control unit transmits the crash signal to the SAM control unit via CAN. This actuates the following components to unlock the doors: Right door CL motor (M14/5) Left front door central locking motor (M14/6) Activation of hazard warning lamp function In the event of an impact the hazard warning function is automatically activated. The restraint systems control unit transmits the crash signal via CAN to the SAM control unit, which actuates the hazard warning flasher. Switching on the interior illumination
General¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3758 · Applies to: 450, 451, 452, 454
The restraint systems control unit controls the supplemental restraint system and is a subscriber on the Controller Area Network (data bus/CAN bus) (CAN). If an accident occurs, the restraint systems control unit specifically deploys the restraint units. This includes the airbag units and the emergency tensioning retractor units. The restraint systems control unit has self-monitoring and fault monitoring features. Frontal, side-on and rear-end collisions and a rollover along the longitudinal vehicle axis are detected and differentiated. Scope of tasks Self-test and continuous monitoring of supplemental restraint system Storage of faults that have occurred Fault output via the diagnosis communication System readiness indication via CAN to the instrument cluster (A1) Power supply Driver head/thoraxbag sensor (A53) Front passenger head/thoraxbag sensor (A54) Driver-side frontal acceleration sensor (B48/1) Passenger-side frontal acceleration sensor (B48/2) Accident detection and ignition time determination Restraint equipment triggering Capacitor for the event of a battery disconnection in the event of a collision Evaluation of the sensor integrated in the restraint systems control unit Seat belt reminder warning request Evaluation of front passenger seat occupied recognition Direct entries Tml. 15 Tml. 31 Driver head/thoraxbag sensor Front passenger head/thoraxbag sensor Driver-side frontal acceleration sensor Passenger-side frontal acceleration sensor Driver side seat belt buckle restraint systems switch (S68/3) Front passenger-side seat belt buckle restraint systems switch (S68/4) Direct outputs
Task¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3762 · Applies to: 450, 451, 452, 454
The WSS control unit determines the weight on the front passenger seat. This is determined via a pressure measurement in a gel mat filled with silicone. The pressure measurement is performed by the pressure sensor of the seat occupied recognition (B48/4). The tractive force at the belt is transmitted via the belt tension sensor (B48/3) to the WSS control unit. The WSS control unit uses the pressure and belt tension to calculate the corresponding weight class and forwards this to the instrument cluster (A1) via the Controller Area Network bus class B (interior) (CAN-B). Discrete inputs Circuit 30 Circuit 31 Belt tension sensor Seat occupied recognition pressure sensor Discrete outputs Power supply from: Belt tension sensor Pressure sensor of seat occupied recognition BASIC KNOWLEDGE > HEAD/THORAXBAG, COMPONENT DESCRIPTION - GF91.60-P- 4100MCU > MODEL 451.3 /4 Location The head/thoraxbag units are located in the outboard side of the driver and front passenger seat backrests. Fig 1: Locating Weight Sensing System (WSS) Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
B48/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3767 · Applies to: 450, 451, 452, 454
Driver-side frontal acceleration sensor 12L B48/2 Passenger-side frontal acceleration sensor 8L B48/3 Belt tension sensor 41L B48/3x1 Belt tension sensor connector
B48/4 Seat occupied recognition pressure sensor 43L B48/4x1 Seat occupied recognition pressure sensor connector
E16 Automatic child seat recognition airbag OFF indicator lamp 6L N10/10 SAM control unit 3L N10/10f18 Fuse 18 4L N110 Weight Sensing System (WSS) control unit 42A N110 Weight Sensing System (WSS) control unit 38A N2/7 Restraint systems control module 34A N2/7 Restraint systems control module 28A N2/7 Restraint systems control module 20A N2/7 Restraint systems control module 12A N2/7 Restraint systems control module 4A R12/1 Left emergency tensioning retractor squib 21L R12/13 Driver airbag ignition squib 1 18L R12/14 Driver airbag ignition squib 2 19L R12/1x1 Left emergency tensioning retractor squib connector
R12/2 Right emergency tensioning retractor squib 23L R12/20 Driver head/thoraxbag squib 26L R12/21 Front passenger head/thoraxbag squib 25L R12/2x1 Right emergency tensioning retractor squib connector
R12/4 Front passenger airbag ignition squib 1 15L R12/5 Front passenger airbag ignition squib 2 17L S68/3 Driver-side seat belt buckle restraint systems switch 29L S68/4 Passenger-side seat belt buckle restraint systems switch 31L W26 Ground (transmission tunnel) 2G W7 Ground (right wheelhousing in trunk) 40L X28/6 Driver head/thoraxbag connector 26G X28/7 Front passenger head/thoraxbag connector 24G
X28/8¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3768 · Applies to: 450, 451, 452, 454
Driver seat ETR [GUS] connector (2-pin) 28G X28/9 Passenger seat ETR [GUS] connector (2-pin) 30G X55/4 Front passenger seat contacting strip 37G Z3/17 Circuit 15 (fused) connector sleeve 39L Z3/17 Circuit 15 (fused) connector sleeve 31E Z3/17 Circuit 15 (fused) connector sleeve 29E Z3/17 Circuit 15 (fused) connector sleeve 4G Z37/2 CAN engine bus (low) connector sleeve 34G Z37/3 CAN engine bus (high) connector sleeve 35G
Fig 1: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3769 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3770 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
OV00.01-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3772 · Applies to: 450, 451, 452, 454
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 plug 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 WIRING DIAGRAMS > WIRING DIAGRAM OF AIRBAG (AB), EMERGENCY TENSIONING RETRACTOR (ETR) - PE91.00-P-2000-97MCV > Code: Designation: Position: A1 Instrument cluster 56L A45 Fanfare horns and airbag clock spring contact 29L A53 Driver head/thoraxbag sensor 23L A54 Passenger head/thoraxbag sensor 17L B3 Driver seat adjustment detection sensor 8L B48/1 Driver-side frontal acceleration sensor 19L B48/2 Passenger-side frontal acceleration sensor 14L B48/3 Belt tension sensor 62L B48/3x1 Belt tension sensor connector
B48/4 Seat occupied recognition pressure sensor 64L B48/4x1 Seat occupied recognition pressure sensor connector
B48/7 Driver door pressure sensor 44L B48/8 Front passenger door pressure sensor 49L E16 Automatic child seat recognition airbag OFF indicator lamp 6L N10/10 SAM control unit 3L N10/10f18 Fuse 18 4L N110 Weight Sensing System (WSS) control unit 63A N110 Weight Sensing System (WSS) control unit 60A
N2/7¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3773 · Applies to: 450, 451, 452, 454
Restraint systems control unit 5A N2/7 Restraint systems control unit 12A N2/7 Restraint systems control unit 20A N2/7 Restraint systems control unit 28A N2/7 Restraint systems control unit 36A N2/7 Restraint systems control unit 45A N2/7 Restraint systems control unit 53A R12/16 Left windowbag squib 9L R12/17 Right windowbag squib 10L R12/20 Driver head/thoraxbag squib 37L R12/21 Front passenger head/thoraxbag squib 35L R12/24 Front passenger kneebag squib 52L R12/25 Driver kneebag squib 51L R12/27 Driver belt force limiter 11L R12/32 Driver reel tensioner squib 32L R12/33 Front passenger reel tensioner squib 33L R12/37 Driver-side anchor fitting tensioner squib 13L R12/37x1 Driver anchor fitting tensioner connector
R12/4 Front passenger airbag squib 1 25L R12/5 Front passenger airbag squib 2 26L S68/3 Driver seat belt buckle restraint systems switch 39L S68/4 Front passenger seat belt buckle restraint systems switch 42L U592 Valid for windowbag 8A W26 Ground (transmission tunnel) 2G W6 Ground (left wheelhouse in luggage compartment) 20K W7 Ground (right wheelhouse in luggage compartment) 61K W7 Ground (right wheelhouse in luggage compartment) 15K W83 Ground (transmission tunnel) 46K X28/10 Driver seat adjustment detection sensor connector 7G X28/6 Driver head/thoraxbag connector 37G X28/7 Front passenger head/thoraxbag connector 35G X28/8 Driver seat ETR [GUS] connector (2-pin) 39G X28/9 Front passenger seat ETR [GUS] connector (2-pin) 41G X35/1 Left door separation point 44G
X35/2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3774 · Applies to: 450, 451, 452, 454
Right door separation point 48G X55/4 Front passenger seat connector block 58G X99/17 Kneebag separation point 51G Z169 Shielding connector sleeve 46C Z20/52 Wire end tracer wire connector sleeve 16J Z20/52 Wire end tracer wire connector sleeve 21J Z20/53 Left tracer wire connector sleeve 21H Z20/53 Left tracer wire connector sleeve 45E Z20/54 Right tracer wire connector sleeve 16H Z20/54 Right tracer wire connector sleeve 48E Z3/17 Circuit 15 (fused) connector sleeve 60K Z3/17 Circuit 15 (fused) connector sleeve 42E Z3/17 Circuit 15 (fused) connector sleeve 39E Z3/17 Circuit 15 (fused) connector sleeve 4G Z37/2 CAN engine bus (low) connector sleeve 55G Z37/3 CAN engine bus (high) connector sleeve 56G
Fig 1: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (1 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3775 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (2 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3776 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (3 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3777 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 4: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (4 Of 5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3778 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > LEGEND OF ELECTRICAL FUNCTION DIAGRAM FOR AIRBAG (AB),¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3779 · Applies to: 450, 451, 452, 454
EMERGENCY TENSIONING RETRACTOR (ETR) - PE91.00-P-2050-60MCU > MODEL 451 Code Designation Coordinates A1 Instrument cluster 21G A1e9 Seat belt warning lamp 21D A1e15 Airbag indicator and warning lamp 21E A45 Fanfare horns and airbag clock spring contact 11J A53 Driver head/thoraxbag sensor 3B A54 Front passenger head/thoraxbag sensor 8B B48/1 Driver-side frontal acceleration sensor 2B B48/2 Passenger-side frontal acceleration sensor 7B B48/3 Belt tension sensor 16J B48/4 Seat occupied recognition pressure sensor 16J E16 Automatic child seat recognition airbag OFF indicator lamp 9G N2/7 Restraint systems control unit 10F N3/10 ME-SFI [ME] control unit 17D N10/10 SAM control unit 2G N110 Weight Sensing System (WSS) control unit 18J R12/1 Left emergency tensioning retractor squib 10G R12/2 Right emergency tensioning retractor squib 10H R12/4 Front passenger airbag squib 1 10H R12/5 Passenger airbag squib 2 10H Fig 5: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (5 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR AIRBAG (AB),¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3781 · Applies to: 450, 451, 452, 454
EMERGENCY TENSIONING RETRACTOR (ETR) - PE91.00-P-2050-99MCU > Code: Designation: Position: A1 Instrument cluster 21 G A1e15 Airbag indicator and warning lamp 21 E A1e9 Seat belt reminder lamp 21 E A45 Fanfare horns and airbag clock spring contact 11 J A53 Driver head/thorax sensor 3 C A54 Front passenger head/thorax sensor 8 C B48/1 Driver-side frontal acceleration sensor 2 B B48/2 Passenger-side frontal acceleration sensor 7 B B48/3 Belt tension sensor 16 J B48/4 Seat occupied recognition pressure sensor 16 K E16 Automatic child seat recognition airbag OFF indicator lamp 9 H N10/10 SAM control unit 2 G N110 Weight Sensing System (WSS) control unit 18 J N2/7 Restraint systems control module 9 F N3/10 ME-SFI [ME] control module 17 D R12/1 Left emergency tensioning retractor squib 9 H R12/13 Driver airbag ignition squib 1 13 J R12/14 Driver airbag ignition squib 2 13 J R12/2 Right emergency tensioning retractor squib 9 H R12/20 Driver head/thoraxbag squib 9 J R12/21 Front passenger head/thoraxbag squib 9 J R12/4 Front passenger airbag ignition squib 1 9 H R12/5 Front passenger airbag ignition squib 2 9 H S68/3 Driver-side seat belt buckle restraint systems switch 10 E S68/4 Passenger-side seat belt buckle restraint systems switch 10 E X11/4 Data link connector 12 C
Fig 1: Airbag (AB), Emergency Tensioning Retractor (ETR) Electrical Function Diagram (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3782 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > WIRING DIAGRAM OF SEAT HEATER (SIH) - PE91.30-P-2000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3784 · Applies to: 450, 451, 452, 454
97MCU > Code: Designation: Position: N10/10 SAM control unit 4L N10/10f12 Fuse 12 6L N10/10f20 Fuse 20 3L N10/10f44 Fuse 44 (slot R9) 2L N25/5 Front HS [SIH] control unit 12A N25/5 Front HS [SIH] control unit 4A R13/1 Left seat heated cushion 11L R13/3 Right seat heated cushion 14L S6/1 Cockpit switch group 8L S6/1s3 Left seat heater switch
S6/1s4 Right seat heater switch
W10 Ground (battery) 8E W14 Left floor interior compartment ground 12E W7 Ground (right wheelhouse in luggage compartment) 14E W9 Ground (left front, at lamp unit) 5E X28/4 Driver seat heated cushion connector 11H X28/5 Front passenger seat heated cushion connector 13H Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve 3E
SPECIAL TOOLS > SPECIAL TOOLS: SMART: SEATS, BUNKS, RESTRAINT SYSTEMS -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3785 · Applies to: 450, 451, 452, 454 · AR: WS91.00-Z-9999CZ
WS91.00-Z-9999CZ > MODEL all 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K Fig 1: Seat Heater (SIH) - Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Screwdriver bit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3786 · Applies to: 450, 451, 452, 454
126 589 00 10 00 Screwdriver bit FG 46/91/14/32/ Set B WS46.00-P-0033B 129 589 00 21 00 126-pin socket box FG 00/42/54/91 / Set B WS54.00-P-0008B 211 589 00 32 00 Plates FG 91/Set B WS91.00-P-0034B 450 589 07 99 00 Assembly tool set FG 68/91/Set B WS91.00-P-0031B 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P-0012K 454 589 01 37 00 Pliers FG 91/Set B WS91.00-P-0039B 454 589 02 37 00 Pliers FG 91/Set B WS91.00-P-0040B 454 589 03 37 00 Padding clip pliers FG 91/Set B WS91.00-P-0043B SPECIAL TOOLS > 450 589 07 99 00 ASSEMBLY TOOL SET - WS91.00-P-0031B > FG 68/91/Set B MODEL 450, 451, 452, 454 Use: Model 450; 451; 452 Assembly tool set for seat repair. Model 454 Pulling hook from assembly tool set for removal of air outlets from instrument panel. NOTE: Set consists of three individual tools smart no. 001 0475 V001 0000 00.
SPECIAL TOOLS > 211 589 00 32 00 PLATES - WS91.00-P-0034B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3787 · Applies to: 450, 451, 452, 454
FG 91/Set B MODEL 199, 240 as of 1.8.06 MODEL 164, 203, 209, 211, 216, 219, 221, 230, 251 with CODE (494) USA version MODEL 451 with CODE (494) USA version MODEL 451 with CODE (L27) Canada Use: Plates for checking the weight sensing system in the front passenger seat. SPECIAL TOOLS > 454 589 03 37 00 PADDING CLIP PLIERS - WS91.00-P-0043B > FG 91/Set B Fig 1: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Plates (211 589 00 32 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451, 454¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3788 · Applies to: 450, 451, 452, 454
Use: Pliers for installing padding clips when replacing the seat cover. Fig 1: Identifying Padding Clip Pliers (454 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Expose spot welds on front bottom side wall paneling (1.1) and cut out (areas B, C and D).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3791 · Applies to: 450, 451, 452, 454
- Remove damaged front bottom side wall paneling (1.1). TESTING & REPAIR > PARTIALLY PREPARE CONNECTING POINTS FOR SIDE WALL PANELING ON BODY. - AR63.10-P-0115-02MCO > All operation steps are shown on the front bottom side wall paneling as an example. Adapt repair sections according to damage profile.
- Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Side Wall Paneling Spot Welds And Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PARTIALLY PREPARE SIDE WALL PANELING FOR INSTALLATION¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3792 · Applies to: 450, 451, 452, 454
- AR63.10-P-0115-03MCO > All operation steps are shown on the front bottom side wall paneling as an example. Adapt repair sections according to damage profile.
- Scribe cut on side wall paneling (1) and separate (area A). Fig 1: Identifying Side Wall Paneling Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill holes for plug welding on front bottom side wall paneling (1.1) (area D).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3793 · Applies to: 450, 451, 452, 454
Transfer dimensions of holes for plug welding from vehicle. 3. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > PARTIALLY INSTALL SIDE WALL PANELING AND WELD IN. - AR63.10-P-0115-04MCO > Fig 1: Identifying Side Wall Paneling Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Drill Holes For Plug Welding On Front Bottom Side Wall Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
All operations steps are shown on the front bottom front bottom side wall paneling (1.1) as an example.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3794 · Applies to: 450, 451, 452, 454
Adapt repair sections according to damage profile. Front bottom side wall paneling (1.1) only if spot used welder has the required capacity, if not, corresponding areas 1. Fit front bottom side wall paneling (1.1) and fasten with vise grip pliers. 2. Front bottom side wall paneling (1.1) (areas C and D). 3. Front bottom side wall paneling (1.1) (areas A and B). 4. Front bottom side wall paneling (1.1) (area E). 5. Grind all weld joints down flat if required. 6. Clean all other welds with wire brush. 7. Restore surface on front bottom side wall paneling (1.1) and smooth (area E). TESTING & REPAIR > PARTIALLY REPLACE SIDE WALL PANELING - AR63.10-P- 0115MCO > MODEL 451.4 Fig 1: Identifying Side Wall Paneling Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3795 · Applies to: 450, 451, 452, 454
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 Side Wall Paneling And Cuts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3796 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 (1) Fit cuts (A to C) according to damage profile AR63.10-P-0115- 01MCO 4 Prepare connecting points for side wall paneling (1) on body
AR63.10-P-0115- 02MCO
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A
Prepare ide wall¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3797 · Applies to: 450, 451, 452, 454
5 Prepare ide wall paneling (1) for installation
AR63 10 P 0115 03MCO
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
6 Install side wall paneling (1) and weld in
AR63.10-P-0115- 04MCO 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 GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- Zinc dust paint suitable for spot welding A 000 986 34 42
TESTING & REPAIR > CUT AWAY REAR WHEELHOUSE LINER ASSEMBLY - AR63.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3798 · Applies to: 450, 451, 452, 454
07A TESTING & REPAIR > CUT AWAY REAR WHEELHOUSE LINER ASSEMBLY - AR63.10-P- 0661-01MCC > Shown on model 451.3 1. Expose spot welds on rear wheelhouse (1) and cut out (areas A, B and C). 2. Heat rear wheelhouse (1) with hot air gun (area A). Area A is bonded. 3. Remove damaged rear wheelhouse (1). TESTING & REPAIR > PREPARE COMPLETE REAR WHEELHOUSE LINER ASSEMBLY FOR INSTALLATION - AR63.10-P-0661-02MCC > Shown on model 451.3 1. Drill holes for plug welding on rear wheelhouse (1) (area A). Transfer dimensions of hole for plug welding from vehicle. Fig 1: Identifying Rear Wheelhouse Cutting And Heating Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind rear wheelhouse (1) down to bare metal in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3799 · Applies to: 450, 451, 452, 454
Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications of 2-component adhesive for drying and processing time. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR > INSTALL WHEELHOUSE LINER ASSEMBLY AT REAR AND WELD IN - AR63.10-P-0661-03MCC > Fig 1: Identifying Plug Welding Holes & Grinding Area On Rear Wheelhouse Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3800 · Applies to: 450, 451, 452, 454
- Apply adhesive to mating surfaces in crosshatched areas. 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.
- Fit rear wheelhouse (1) together with B-pillar reinforcement (2) and fasten with vise grip pliers.
- Rear wheelhouse (1) (areas A and B). Position resistance spot welds in area A at precise position of resistance spot welds made at factory to ensure minimum required strength for weld joints.
- Rear wheelhouse (1) (area C).
- Grind all spot welds down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR > PREPARE CONNECTING POINTS FOR REAR WHEELHOUSE ON BODY - AR63.10-P-0661-04MCC >
- Grind mating surfaces down to bare metal in 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding Fig 1: Identifying Wheelhouse Adhesive And Welding Application Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3802 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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
AH91.00-P-0002-01SM Fig 1: Identifying Rear Wheel Well Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
adhe ive¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3805 · Applies to: 450, 451, 452, 454
02A adhe ive 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 > INSTALL B-PILLAR REINFORCEMENT - AR63.10-P-0696-05MCO > 1. Apply 2-component adhesive material in 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. Observe manufacturer's specifications of 2- component adhesive for drying and processing time. Fig 1: Identifying B-Pillar Reinforcement Adhesive Material Application Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Fit B-pillar reinforcement (1) and fasten with vise grip pliers.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3806 · Applies to: 450, 451, 452, 454
- B-pillar reinforcement (1) (areas B, C, D, E and G ). If the side wall is installed later, it is necessary to position the resistance spot welds in areas (D and E) exactly on the points set here, because otherwise the weld joint could be faulty. Areas (A and F) are when installing side wall.
- B-pillar reinforcement (1) (areas G, H, J, K, L and M).
- Grind all spot welds down flat if required.
- Clean all other welds with wire brush. TESTING & REPAIR > SEPARATE WHEEL WELL LOCKING LUG - AR63.20-P-0013-01MCC
- Expose spot welds on wheel well locking lug (1) and cut out (area A).
- Remove damaged wheel well locking lug (1). 1 Fig 2: Identifying B-Pillar Reinforcement Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE WHEEL WELL LOCKING LUG FOR INSTALLATION -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3807 · Applies to: 450, 451, 452, 454
AR63.20-P-0013-02MCC > Fig 1: Identifying Wheel Well Locking Lug Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Drill holes for plug welding on wheel well locking lug (1) (area C).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3808 · Applies to: 450, 451, 452, 454
- Grind mating surfaces on body down to bare metal in shaded areas (area A). Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint.
- Grind connecting flange on wheel well locking lug (1) down to bare metal in shaded areas (area B). Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > INSTALL WHEEL WELL LOCKING LUG AND WELD IN - AR63.20-P- 0013-03MCC >
- Fit wheel well locking lug (1) with side wall paneling (2) and fasten wheel well locking lug (1) with clamping pliers. When fitting observe correct distances.
- Remove side wall paneling (2).
- Wheel well locking lug (1) (area A).
- Wheel well locking lug (1) (area B).
- Grind all spot welds down flat, if required
- Clean all other spot welds with wire brush. Fig 1: Identifying Wheel Well Locking Lug Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3810 · Applies to: 450, 451, 452, 454
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 Wheel Well Locking Lug Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3811 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 separate side wall paneling Model 451.3 AR63.10-P- 0115MCC
Model 451.4 AR63.10-P- 0115MCO 4 Remove wheel well
AR63.20-P-0013-
pecification 6069 20¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3813 · Applies to: 450, 451, 452, 454
01A pecification 6069 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 > SEPARATE SIDE WALL REINFORCEMENT - AR63.20-P-0860- 01MCC > Shown on model 451.3 1. Expose spot welds on side wall reinforcement (1) and cut out (areas A, B, C, D and E). 2. Remove damaged side wall reinforcement (1). TESTING & REPAIR > PREPARE CONNECTING POINTS FOR SIDE WALL REINFORCEMENT ON BODY - AR63.20-P-0860-02MCC > Shown on model 451.3 1. Grind mating surfaces down to bare metal on one side (areas F, G and H). 2. Grind mating surfaces in remaining shaded areas illustrated down to bare metal on both sides and coat insides of spot welding flange with zinc dust paint. Fig 1: Identifying Side Wall Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE SIDE WALL REINFORCEMENT FOR INSTALLATION -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3814 · Applies to: 450, 451, 452, 454
AR63.20-P-0860-03MCC > 1. Drill holes for plug welding on side wall reinforcement (1) (areas K, L and M). Fig 1: Identifying Side Wall Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind connecting flange on side wall reinforcement (1) down to bare metal on both sides and coat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3815 · Applies to: 450, 451, 452, 454
insides of spot welding flange with zinc dust paint (areas I and J). 3. Grind connecting flange down to bare metal in remaining shaded areas on one side. TESTING & REPAIR > INSTALL SIDE WALL REINFORCEMENT - AR63.20-P-0860-04MCC > Fig 1: Identifying Drill Holes For Plug Welding On Side Wall Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Side Wall Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3817 · Applies to: 450, 451, 452, 454
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 Side Wall Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3818 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Model 451.3 AR63.10-P- 0115MCC
Model 451.4 AR63.10-P- 0115MCO 4 Separate A-pillar outer Model 451.4 AR63.20-P-
ection¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3819 · Applies to: 450, 451, 452, 454
1102MCO 5 Separate side wall reinforcement (1)
AR63.20-P-0860- 01MCC 6 Prepare connecting points for side wall reinforcement (1) on body
AR63.20-P-0860- 02MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 7 Prepare side wall reinforcement (1) for installation
AR63.20-P-0860- 03MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
8 Install side wall reinforcement (1)
AR63.20-P-0860- 04MCC 9 Install A-pillar outer section Model 451.4 AR63.20-P- 1102MCO 10 Partially install side wall paneling Model 451.3 AR63.10-P- 0115MCC
Model 451.4 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
Tero on protective wa¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3820 · Applies to: 450, 451, 452, 454
*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-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 > PARTIALLY SEPARATE SIDE WALL REINFORCEMENT - AR63.20- P-0861-01MCC > Shown on model 451.3 1. Scribe cuts on side wall reinforcement according to damage profile and separate (areas F and G). Fig 1: Identifying Side Wall Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Expose spot welds on side wall reinforcement section (1.1 to 1.3) according to damage profile and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3821 · Applies to: 450, 451, 452, 454
cut out (areas A, A , B, C, D and E). 3. Remove damaged side wall reinforcement section (1.1 to 1.3). TESTING & REPAIR > PARTIALLY PREPARE CONNECTING POINTS ON SIDE WALL REINFORCEMENT ON BODY - AR63.20-P-0861-02MCC > Shown on model 451.3 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 > PARTIALLY PREPARE SIDE WALL REINFORCEMENT FOR INSTALLATION - AR63.20-P-0861-03MCC > 1. Scribe cuts on side wall reinforcement according to damage profile and separate (areas N and O). 2. Drill holes for plug welding on side wall reinforcement section (1.1 to 1.3) according to damage profile (areas K, L and M). Transfer dimensions of holes for plug welding from vehicle. 1 Fig 1: Identifying Side Wall Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Grind mating surfaces on side wall reinforcement section (1.1 to 1.3) in cross-hatched areas down¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3822 · Applies to: 450, 451, 452, 454
to bare metal according to damage profile. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Side Wall Reinforcement Cutting Areas And Holes For Plug Welding Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Side Wall Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PARTIALLY INSTALL SIDE WALL REINFORCEMENT - AR63.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3823 · Applies to: 450, 451, 452, 454
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 > 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. 3824 · Applies to: 450, 451, 452, 454
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 General information on
AH60.00-P-0003- Fig 1: Identifying Side Wall Reinforcement With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
riveting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3825 · Applies to: 450, 451, 452, 454
01MCC Notes on replacing body parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Model 451.3 AR63.10-P- 0115MCC
Model 451.4 AR63.10-P- 0115MCO 4 Separate A-pillar outer section Model 451.4 AR63.20-P- 1102MCO 5 Partially separate side wall reinforcement (1)
AR63.20-P-0861- 01MCC
Prepare connecting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3826 · Applies to: 450, 451, 452, 454
6 Prepare connecting points for side wall reinforcement (1) on body
AR63.20-P-0861- 02MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 7 Prepare side wall reinforcement (1) for installation
AR63.20-P-0861- 03MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
8 Install side wall reinforcement (1)
AR63.20-P-0861- 04MCC 9 Install A-pillar outer section Model 451.4 AR63.20-P- 1102MCO 10 Partially install side wall paneling Model 451.3 AR63.10-P- 0115MCC
Model 451.4 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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3827 · Applies to: 450, 451, 452, 454
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 > SEPARATE A-PILLAR OUTER SECTION - AR63.20-P-1102-01MCO > 1. Expose spot welds on bottom A-pillar outer paneling (1) and cut out (areas A, B, C, and D). 2. Remove damaged bottom A-pillar outer paneling (1). TESTING & REPAIR > PREPARE A-PILLAR OUTER SECTION FOR INSTALLATION - Fig 1: Identifying A-Pillar Outer Paneling With Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
AR63.20-P-1102-02MCO >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3828 · Applies to: 450, 451, 452, 454
- Drill holes for plug welding on bottom A-pillar outer paneling (1) (area A). Transfer dimensions of holes for plug welding from vehicle.
- Grind connection flange on bottom A-pillar outer paneling (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. TESTING & REPAIR > INSTALL A-PILLAR OUTER SECTION - AR63.20-P-1102-03MCO >
- Fit bottom A-pillar outer paneling (1) and fasten with vise grip pliers.
- Bottom A-pillar outer paneling (1) (areas A and B).
- Bottom A-pillar outer paneling (1) (areas C and D).
- Grind all spot welds down flat if required.
- Clean all other welds with wire brush. Fig 1: Identifying Grinding Areas And Drill Holes For Plug Welding On Bottom A-Pillar Outer Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE CONNECTION POINTS FOR A-PILLAR OUTER SECTION¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3829 · Applies to: 450, 451, 452, 454
ON BODY - AR63.20-P-1102-06MCO > 1. Sand mating surfaces down to bare metal in the cross-hatched areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying A-Pillar Outer Paneling With Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL A-PILLAR OUTER SECTION - AR63.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3830 · Applies to: 450, 451, 452, 454
1102MCO > MODEL 451.4 Fig 1: Identifying A-Pillar Outer Section Sanding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3831 · Applies to: 450, 451, 452, 454
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 A-Pillar Outer Bottom Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3832 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Remove A-pillar outer bottom section (1)
AR63.20-P-1102- 01MCO 4 Prepare connecting points on body
AR63.20-P-1102- 06MCO
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 5 Prepare A-pillar outer bottom section (1) for installation
AR63.20-P-1102- 02MCO
TESTING & REPAIR > REMOVE UPPER A-PILLAR OUTER PANELING - AR63.20-P-1105-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3834 · Applies to: 450, 451, 452, 454
01MCO > 1. Expose spot welds on upper A-pillar outer paneling (1) and cut out (areas A, B, C, D and E). 2. Remove damaged upper A-pillar outer paneling (1). TESTING & REPAIR > PREPARE UPPER A-PILLAR OUTER PANELING FOR INSTALLATION. - AR63.20-P-1105-02MCO > Fig 1: Identifying Upper A-Pillar Outer Paneling Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Upper A-Pillar Outer Paneling Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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. 3835 · Applies to: 450, 451, 452, 454
Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. 2. Drill holes for plug welding on upper A-pillar outer paneling (1) (areas F, G, H and J). Transfer dimensions of holes for plug welding from vehicle. 3. Grind connection flange on upper A-pillar outer paneling (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. TESTING & REPAIR > INSTALL UPPER A-PILLAR OUTER PANELING - AR63.20-P-1105- 03MCO > Fig 2: Identifying Drill Holes For Plug Welding On Upper A-Pillar Outer Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit upper A-pillar outer paneling (1) and fasten with vise grip pliers.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3836 · Applies to: 450, 451, 452, 454
- Upper A-pillar outer paneling (1) (areas K, M, P and Q).
- Upper A-pillar outer paneling (1) (areas L, N, O and R).
- Grind all spot welds down flat if required.
- Clean all other welds with wire brush. TESTING & REPAIR > REPLACE UPPER A-PILLAR OUTER PANELING - AR63.20-P- 1105MCO > MODEL 451.4 Fig 1: Identifying Upper A-Pillar Outer Paneling Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3837 · Applies to: 450, 451, 452, 454
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 Upper A-Pillar Outer Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3838 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Remove upper A-pillar outer paneling (1)
AR63.20-P-1105- 01MCO 4 Prepare connecting points on body and upper A-pillar outer paneling (1)
AR63.20-P-1105- 02MCO
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
5 Install upper A-pillar outer
AR63.20-P-1105-
1. Expose spot welds on upper A-pillar reinforcement (1) and cut out (areas A, B, C, D, E and F).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3840 · Applies to: 450, 451, 452, 454
- Remove damaged upper A-pillar reinforcement (1). TESTING & REPAIR > PREPARE CONNECTING POINTS FOR UPPER A-PILLAR REINFORCEMENT ON BODY - AR63.20-P-1113-02MCO > Fig 1: Identifying Upper A-Pillar Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Upper A-Pillar Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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. 3841 · Applies to: 450, 451, 452, 454
Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > PREPARE UPPER A-PILLAR REINFORCEMENT FOR INSTALLATION - AR63.20-P-1113-03MCO > 1. Drill holes for plug welding on upper A-pillar reinforcement (1) (area A). 2. Grind upper A-pillar reinforcement (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. TESTING & REPAIR > INSTALL UPPER A-PILLAR REINFORCEMENT AND WELD IN - AR63.20-P-1113-04MCO > Fig 1: Identifying Upper A-Pillar Reinforcement Welding And Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit upper A-pillar reinforcement (1) and fix in place using vise grip pliers.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3842 · Applies to: 450, 451, 452, 454
- Upper A-pillar reinforcement (1) (areas A, B, C, D, E and F).
- Grind weld joints down flat, if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR > REPLACE UPPER A-PILLAR REINFORCEMENT - AR63.20-P- 1113MCO > MODEL 451.4 Fig 1: Identifying Upper A-Pillar Reinforcement Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3843 · Applies to: 450, 451, 452, 454
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 General information on
AH60.00-P-0003- Fig 1: Identifying Upper A-Pillar Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
riveting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3844 · Applies to: 450, 451, 452, 454
01MCC Notes on replacing body parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Sanding disk Cutting disks Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Remove lower A-pillar outer section
AR63.20-P- 1102MCO 6 Remove upper A-pillar outer paneling
AR63.20-P- 1105MCO 7 Remove lower A-pillar reinforcement
AR63.20-P- 1114MCO
Remove roof paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3845 · Applies to: 450, 451, 452, 454
8 Remove roof paneling
AR65.10-P- 5702MCO 9 Remove upper A-pillar reinforcement (1)
AR63.20-P-1113- 01MCO 10 Prepare connecting points for upper A-pillar reinforcement (1) on body
AR63.20-P-1113- 02MCO
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 11 Prepare upper A-pillar reinforcement (1) for installation
AR63.20-P-1113- 03MCO
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
12 Install upper A-pillar reinforcement (1)
AR63.20-P-1113- 04MCO 13 Install roof paneling
AR65.10-P- 5702MCO 14 Install lower A-pillar reinforcement
AR63.20-P- 1114MCO 15 Install upper A-pillar outer paneling
AR63.20-P- 1105MCO 16 Install lower outer A-pillar
AR63.20-P- 1102MCO 17 Install side wall reinforcement
AR63.20-P- 0862MCC 18 Install side wall paneling
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
2. Expose spot welds on lower A-pillar reinforcement (1) and cut out (area J).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3847 · Applies to: 450, 451, 452, 454
- Remove damaged lower A-pillar reinforcement (1). Fig 1: Identifying Lower A-Pillar Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE CONNECTING POINTS ON LOWER A-PILLAR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3848 · Applies to: 450, 451, 452, 454
REINFORCEMENT ON BODY - AR63.20-P-1114-02MCO > Fig 2: Identifying Lower A-Pillar Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
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. 3849 · Applies to: 450, 451, 452, 454
Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > PREPARE LOWER A-PILLAR REINFORCEMENT FOR INSTALLATION - AR63.20-P-1114-03MCO > 1. Drill holes for plug welding on lower A-pillar reinforcement (1) (areas A, B, C and D). Transfer dimensions of holes for plug welding from vehicle. 2. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Lower A-Pillar Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL LOWER A-PILLAR REINFORCEMENT AND WELD IN -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3850 · Applies to: 450, 451, 452, 454
AR63.20-P-1114-04MCO > 1. Fit lower A-pillar reinforcement (1) and fix in place using vise grip pliers. 2. Lower A-pillar reinforcement (1) (areas F, G, H and K). Position resistance spot welds at precise position of resistance spot welds made at factory in area F to ensure minimum required strength for weld joints. Fig 1: Identifying Drill Holes For Plug Welding & Grinding Areas On Lower A-Pillar Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Lower A-pillar reinforcement (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3851 · Applies to: 450, 451, 452, 454
(areas A, B, C, D and E). 4. Grind weld joints down flat if required. 5. Clean all other weld joints with wire brush. TESTING & REPAIR > REPLACE LOWER A-PILLAR REINFORCEMENT - AR63.20-P- 1114MCO > MODEL 451.4 Fig 1: Identifying Lower A-Pillar Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3852 · Applies to: 450, 451, 452, 454
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 General information on
AH60.00-P-0003- Fig 1: Identifying Bottom A-Pillar Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
riveting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3853 · Applies to: 450, 451, 452, 454
01MCC Notes on replacing body parts
AH60.00-P-0027- 01FF General information on repairs to body
AH60.00-P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Sanding disk Cutting disks Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 lower outer A- pillar
AR63.20-P- 1102MCO 6 Remove upper A-pillar outer paneling
AR63.20-P- 1105MCO 7 Remove lower A-pillar reinforcement (1)
AR63.20-P-1114- 01MCO 8 Prepare connecting points
AR63.20-P-1114-
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3855 · Applies to: 450, 451, 452, 454
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 GmbH Arabellastrasse 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 > SEPARATE B-PILLAR REINFORCEMENT - AR63.20-P-1351-01MCO
- Expose spot welds on B-pillar reinforcement (1) and cut out (areas A, B, B1, C, D, E, F, G and H).
- Heat B-pillar reinforcement (1) with hot air gun (area D). Area (D) is bonded.
- Remove damaged B-pillar reinforcement (1). TESTING & REPAIR > PREPARE CONNECTION POINTS ON B-PILLAR REINFORCEMENT ON BODY - AR63.20-P-1351-02MCO > Fig 1: Identifying B-Pillar Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Sand mating surfaces down to bare metal in the cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3856 · Applies to: 450, 451, 452, 454
Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2- component adhesive may be adversely affected. Sand spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR > PREPARE CONNECTION POINTS ON B-PILLAR REINFORCEMENT - AR63.20-P-1351-03MCO > 1. Drill holes for plug welding on B-pillar reinforcement (1) (areas A, B, C, D, E, F and G). Transfer dimensions of holes for plug welding from vehicle. Fig 1: Identifying B-Pillar Reinforcement Sanding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind B-pillar reinforcement (1) down to bare metal in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3857 · Applies to: 450, 451, 452, 454
Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2- component adhesive may be adversely affected. Sand spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications of 2-component adhesive for drying and processing time. Coat inside of spot weld flanges not bonded with zinc dust paint. Fig 1: Identifying Drill Holes For Plug Welding On B-Pillar Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3859 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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
AH91.00-P-0002-01SM Fig 1: Identifying B-Pillar Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
All operations steps are shown on model 451.3 as an example.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3862 · Applies to: 450, 451, 452, 454
- Expose spot welds on B-pillar internal component (1) and cut out (areas A, B and F).
- Heat B-pillar internal component (1) with hot air gun (area A). Area A is bonded.
- Expose spot welds on B-pillar internal component (1) and cut out (area D). Fig 1: Identifying B-Pillar Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying B-Pillar Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Expose spot welds on B-pillar internal component (1) and cut out (area C and E).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3863 · Applies to: 450, 451, 452, 454
Only for model 451.3 5. Remove damaged B-pillar internal component (1). TESTING & REPAIR > PREPARE CONNECTING POINTS FOR B-PILLAR INTERNAL COMPONENT ON BODY. - AR63.20-P-1355-02MCC > 1. Grind mating surfaces down to bare metal in the crosshatched 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. Fig 3: Identifying B-Pillar Internal Component With Cutting 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. 3864 · Applies to: 450, 451, 452, 454
- Grind mating surfaces down to bare metal in the crosshatched 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. Only for model 451.3 Fig 1: View Of B-Pillar Internal Component With Grinding Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE B-PILLAR INTERNAL COMPONENT FOR INSTALLATION¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3865 · Applies to: 450, 451, 452, 454
- AR63.20-P-1355-03MCC > Fig 2: Identifying B-Pillar Internal Component With Grinding Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3866 · Applies to: 450, 451, 452, 454
- Grind B-pillar internal component (1) down to bare metal in cross-hatched areas (areas A and B only on model 451.3). Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Refer to manufacturer specifications for adhesive curing and application times. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR > INSTALL B-PILLAR INTERNAL COMPONENT AND WELD IN - AR63.20-P-1355-04MCC > All operations steps are shown on model 451.3 as an example.
- Fit B-pillar internal component (1) and fasten with vise grip pliers.
- Drill holes for plug welding on B-pillar internal component (1) through one sheet metal thickness (area A).
- Remove B-pillar inner section (1) Fig 1: Identifying B-Pillar Internal Component With Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Apply 2-component adhesive material in crosshatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3867 · Applies to: 450, 451, 452, 454
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. Fig 1: Fitting B-Pillar Internal Component Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. B-pillar internal component (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3868 · Applies to: 450, 451, 452, 454
(areas B, C, D and F). 6. B-pillar internal component (1) (area E). 7. B-pillar internal component (1) (areas G and H). Fig 2: Identifying Adhesive Material Application Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying B-Pillar Internal Component With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Only for model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3869 · Applies to: 450, 451, 452, 454
- Grind all spot welds down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR > REMOVE/INSTALL B-PILLAR INNER SECTION - AR63.20-P- 1355MCC > MODEL 451.3/4 Illustrated on model 451.3 Fig 4: Identifying B-Pillar Internal Component With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3870 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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
AH91.00-P-0002-01SM Fig 1: Identifying B-Pillar Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BR00.45-Z-1092-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3873 · Applies to: 450, 451, 452, 454
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 > REMOVE SIDE LONGITUDINAL MEMBER REINFORCEMENT - AR63.30-P-0816-01MCC > Shown on model 451.3 1. Expose spot welds on side longitudinal member reinforcement (1) and cut out (areas C, D, E, F, G and H). 2. Remove damaged side longitudinal member reinforcement (1). TESTING & REPAIR > PREPARE SIDE LONGITUDINAL MEMBER REINFORCEMENT FOR INSTALLATION - AR63.30-P-0816-02MCC > 1. Drill holes for plug welding on side longitudinal member reinforcement (1) (area C). Transfer dimensions of holes for plug welding from vehicle. Fig 1: Identifying Longitudinal Member Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind connection flange on side longitudinal member reinforcement (1) down to bare metal in cross-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3874 · Applies to: 450, 451, 452, 454
hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR > INSTALL SIDE LONGITUDINAL MEMBER REINFORCEMENT - AR63.30-P-0816-03MCC > Fig 1: Identifying Side Longitudinal Member Reinforcement With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Position resistance spot welds at precise position of resistance spot welds made at factory to ensure¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3875 · Applies to: 450, 451, 452, 454
minimum required strength for weld joints. (areas C, E and G). 1. Fit side longitudinal member reinforcement (1) and fasten with vise grip pliers. 2. Side longitudinal member reinforcement (1) (areas C, D, E, F, G and H). 3. Side longitudinal member reinforcement (1) (area J). 4. Grind all spot welds down flat if required. 5. Clean all other weld joints with wire brush. TESTING & REPAIR > PREPARE CONNECTION POINTS ON SIDE LONGITUDINAL MEMBER REINFORCEMENT ON BODY. - AR63.30-P-0816-04MCC > 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Side Longitudinal Member Reinforcement With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3877 · Applies to: 450, 451, 452, 454
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 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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, Ø 6 mm
Electrode miller¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3878 · Applies to: 450, 451, 452, 454
Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com 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 Remove side wall paneling section In case of model 451.3 AR63.10-P- 0115MCC
On model 451.4 AR63.10-P- 0115MCO 4 Remove side wall reinforcement section
AR63.20-P- 0862MCC 5 Remove B-pillar reinforcement In case of model 451.3 AR63.20-P- 1351MCC
On model 451.4 AR63.20-P- 1351MCO 6 Remove rear lamp insert In case of model 451.3 AR64.20-P- 1061MCC
On model 451.4 AR64.20-P- 1061MCO 7 Remove rear wheelhouse
AR63.10-P- 0661MCC 8 Remove lower A-pillar reinforcement In case of model 451.3 AR63.20-P- 1114MCC
On model 451.4 AR63.20-P- 1114MCO 9 Remove side longitudinal member reinforcement (1)
AR63.30-P-0816- 01MCC 10 Prepare connection points on side longitudinal member reinforcement (1) on body
AR63.30-P-0816- 04MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 11 Prepare side longitudinal
AR63.30-P-0816-
member reinforcement (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3879 · Applies to: 450, 451, 452, 454
for installation 02MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
12 Install side longitudinal member reinforcement (1) and weld in
AR63.30-P-0816- 03MCC 13 Install lower A-pillar reinforcement In case of model 451.3 AR63.20-P- 1114MCC
On model 451.4 AR63.20-P- 1114MCO 14 Install rear wheelhouse
AR63.10-P- 0661MCC 15 Install rear lamp insert In case of model 451.3 AR64.20-P- 1061MCC
On model 451.4 AR64.20-P- 1061MCO 16 Install B-pillar reinforcement In case of model 451.3 AR63.20-P- 1351MCC
On model 451.4 AR63.20-P- 1351MCO 17 Install side wall paneling reinforcement section
AR63.20-P- 0862MCC 18 Install side wall paneling section In case of 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
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3881 · Applies to: 450, 451, 452, 454
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
AH91.00-P-0002- Fig 1: Identifying Side Longitudinal Member Reinforcement With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
repair, body work and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3882 · Applies to: 450, 451, 452, 454
welding on vehicles with airbags and ETR units 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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, Ø 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Remove side wall paneling section In case of model 451.3 AR63.10-P- 0115MCC
On model 451.4 AR63.10-P- 0115MCO 4 Remove side wall reinforcement section
AR63.20-P- 0862MCC
remove B-pillar¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3883 · Applies to: 450, 451, 452, 454
5 remove B-pillar reinforcement In case of model 451.3 AR63.20-P- 1351MCC
On model 451.4 AR63.20-P- 1351MCO 6 Remove rear lamp insert In case of model 451.3 AR64.20-P- 1061MCC
On model 451.4 AR64.20-P- 1061MCO 7 Remove rear wheelhouse
AR63.10-P- 0661MCC 8 Remove lower A-pillar reinforcement In case of model 451.3 AR63.20-P- 1114MCC
On model 451.4 AR63.20-P- 1114MCO 9 Remove side longitudinal member reinforcement section (1)
AR63.30-P-0818- 01MCC 10 Prepare connection points for side longitudinal member reinforcement section (1) on body
AR63.30-P-0818- 04MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 11 Prepare side longitudinal member reinforcement section (1) for installation
AR63.30-P-0818- 02MCC
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
12 Install side longitudinal member reinforcement section (1) and weld in
AR63.30-P-0818- 03MCC 13 Install lower A-pillar reinforcement In case of model 451.3 AR63.20-P- 1114MCC
On model 451.4 AR63.20-P- 1114MCO 14 Install rear wheelhouse
AR63.10-P- 0661MCC 15 Install rear lamp insert In case of model 451.3 AR64.20-P- 1061MCC
On model 451.4 AR64.20-P- 1061MCO 16 Install B-pillar In case of model 451.3 AR63.20-P-
reinforcement¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3884 · Applies to: 450, 451, 452, 454
1351MCC
On model 451.4 AR63.20-P- 1351MCO 17 Install side wall reinforcement section
AR63.20-P- 0862MCC 18 Install side wall paneling section In case of 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
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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3885 · Applies to: 450, 451, 452, 454
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 > PARTIALLY REMOVE OUTER LONGITUDINAL MEMBER INNER SHELL ON ENTRANCE - AR63.30-P-1143-01MCC > Shown on model 451.3 All steps are shown as an example on the rear section of the longitudinal member inner shell (1). Adapt repair sections according to damage profile. 1. Scribe cut on longitudinal member inner shell (1) and cut (area A). 2. Expose spot welds on longitudinal member inner shell (1) and cut out (areas B, C, D and E). 3. Pry out lug (arrow). 4. Heat connecting flange with hot air blower (area C). Area B is bonded. 5. Remove damaged inner shell longitudinal member (1) TESTING & REPAIR > PARTIALLY PREPARE LONGITUDINAL MEMBER INNER SHELL ON ENTRANCE - AR63.30-P-1143-02MCC > Fig 1: Identifying Outer Longitudinal Member Inner Shell With Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
All steps are shown as an example on the rear section of the longitudinal member inner shell (1.1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3886 · Applies to: 450, 451, 452, 454
Adapt repair sections according to damage profile. 1. Scribe cut on longitudinal member inner shell (1) and cut (area A). Transfer dimension for cut from vehicle. 2. Grind rear section on longitudinal member inner shell (1.1) down to bare metal in 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 > PARTIALLY INSTALL LONGITUDINAL MEMBER INNER SHELL ON ENTRANCE - AR63.30-P-1143-03MCC > Fig 1: Identifying Longitudinal Member Inner Shell With Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Longitudinal Member Inner Shell Adhesive Application 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. 3887 · Applies to: 450, 451, 452, 454
All steps are shown as an example on the rear section of the longitudinal member inner shell. Adapt repair sections according to damage profile. 1. Apply 2-component adhesive to mating surfaces in 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. Observe the manufacturer's specifications for the curing and processing time of the adhesive. 2. Fit longitudinal member inner shell (1) and fix in place using vise grip pliers. Shown on model 451.3 3. Longitudinal member inner shell (1) on rear entry (areas C, D and E). 4. Position lug (arrow). 5. Longitudinal member inner shell (1) on rear entry (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 > PARTIALLY PREPARE CONNECTING POINTS FOR LONGITUDINAL MEMBER INNER SHELL ON ENTRY ON BODY - AR63.30-P-1143-04MCC > Fig 2: Fitting Longitudinal Member Inner Shell Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3889 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00-P-0008- 01MCC Measures for preventing damage to vehicles or components when performing electric welding work
AH00.00-P-0005-01FF Fig 1: Identifying Longitudinal Member Inner Shell On Entry Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
removed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3892 · Applies to: 450, 451, 452, 454
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 > REMOVE LONGITUDINAL MEMBER INNER SHELL ON ENTRY - AR63.30-P-1164-01MCC > Shown on model 451.3 1. Expose spot welds on longitudinal member inner shell on entry (1) and cut out (areas A, B, C, D, E, F, G, H and J). Fig 1: Identifying Longitudinal Member Inner Shell With Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Pry out lugs (arrows) on longitudinal member inner shell on entry (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3893 · Applies to: 450, 451, 452, 454
- Heat connecting flange with hot air blower (areas A, B and C). Areas A, B and C are bonded.
- Remove damaged longitudinal member inner shell on entry (1).
- Remove drill shavings using wet/dry vacuum cleaner TESTING & REPAIR > PREPARE LONGITUDINAL MEMBER INNER SHELL ON ENTRY - AR63.30-P-1164-02MCC >
- Grind longitudinal member inner shell on entry (1) down to bare metal in cross-hatched areas. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint. Observe pretreatment of bonding surfaces, otherwise, adhesive force of 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 > INSTALL LONGITUDINAL MEMBER INNER SHELL ON ENTRY - AR63.30-P-1164-03MCC > Fig 1: Identifying Longitudinal Member Inner Shell Grinding 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. 3894 · Applies to: 450, 451, 452, 454
- Apply 2-component adhesive mating surfaces in 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. Observe manufacturer's specifications for drying and processing time of adhesive. Fig 1: Identifying Longitudinal Member Inner Shell Adhesive Mating Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3895 · Applies to: 450, 451, 452, 454
- Fit longitudinal member inner shell on entry (1) and fix in place using vise grip pliers.
- Longitudinal member inner shell on entry (1) (areas A, B, C, D, E, F and G).
- Position lugs (arrows) on longitudinal member inner shell on entry (1).
- Longitudinal member inner shell on entry (1) (area H).
- Grind spot welds down flat, is required.
- Clean all other weld joints with wire brush. TESTING & REPAIR > PREPARE CONNECTING POINTS FOR LONGITUDINAL MEMBER INNER SHELL ON ENTRY ON BODY - AR63.30-P-1164-04MCC > Fig 2: Identifying Longitudinal Member Inner Shell Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3897 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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
AH91.00-P-0002-01SM Fig 1: Identifying Longitudinal Member Inner Shell On Entry Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3900 · Applies to: 450, 451, 452, 454
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 > REMOVE CENTER MAIN FLOOR PANEL REINFORCEMENT - AR63.40-P-1110-01MCC > Shown on model 451.4 1. Expose spot welds on center main floor panel reinforcement (1) and cut out (areas A, B, C, D, E, F, G, H, J and K). 2. Remove damaged center main floor panel reinforcement (1). Fig 1: Identifying Center Main Floor Panel Reinforcement Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE CENTER MAIN FLOOR PANEL REINFORCEMENT -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3901 · Applies to: 450, 451, 452, 454
AR63.40-P-1110-02MCC > 1. Drill holes for plug welding on center main floor panel reinforcement (1) (areas A and B). 2. Grind center main floor panel reinforcement (1) down to bare metal in cross-hatched areas. TESTING & REPAIR > PREPARE CONNECTION POINTS ON CENTER MAIN FLOOR PANEL REINFORCEMENT ON BODY - AR63.40-P-1110-03MCC > Shown on model 451.3 1. Sand connection surfaces down to bare metal in the cross-hatched areas. Fig 1: Identifying Drilling Holes For Plug Welding On Center Main Floor Panel Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL CENTER MAIN FLOOR PANEL REINFORCEMENT -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3902 · Applies to: 450, 451, 452, 454
AR63.40-P-1110-04MCC > Fig 1: Identifying Center Main Floor Panel Reinforcement Sanding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit center main floor panel reinforcement (1) and fasten.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3903 · Applies to: 450, 451, 452, 454
- Drill Ø 6.5 mm rivet holes (areas A, B, C, D, E, F, G and K).
- Remove center main floor panel reinforcement (1).
- Deburr rivet holes on center main floor panel reinforcement (1) and body on both sides. Fig 1: Identifying Center Main Floor Panel Reinforcement Rivet Holes Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Center Main Floor Panel Reinforcement Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of injury caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3905 · Applies to: 450, 451, 452, 454
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 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 fire-resistant weld protection blanket to prevent damage from flying sparks.
3 Remove center main floor panel reinforcement (1)
AR63.40-P-1110- 01MCC 4 Prepare connecting points on center main floor panel reinforcement (1) on body.
AR63.40-P-1110- 03MCC 5 Prepare center main floor panel reinforcement (1) for installation
AR63.40-P-1110- 02MCC Install
6 Install center main floor panel reinforcement (1) and weld in
AR63.40-P-1110- 04MCC
Rivet *BR00.45-Z-1001-13A
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3907 · Applies to: 450, 451, 452, 454
- Scribe separation line on front main floor panel (1) and cut (area A).
- Expose spot welds on front main floor panel (1) and cut out (area B).
- Heat connecting flange with hot air blower (area C). Area B is bonded.
- Remove damaged section (1.1)
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PARTIALLY REMOVE MAIN FLOOR PANEL - AR63.40-P-1180- 24MCD > Fig 1: Identifying Front Main Floor Panel 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. 3908 · Applies to: 450, 451, 452, 454
- Scribe separation line on rear main floor panel (1) and cut (area A).
- Expose spot welds on rear main floor panel (1) and cut out (areas B, C and D).
- Remove damaged section (1.1)
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR > PARTIALLY PREPARE CONNECTING POINTS FOR MAIN FLOOR PANEL ON BODY - AR63.40-P-1180-25MCC >
- 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, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Fig 1: Identifying Rear Main Floor Panel Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PARTIALLY PREPARE CONNECTING POINTS FOR MAIN FLOOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3909 · Applies to: 450, 451, 452, 454
PANEL ON BODY - AR63.40-P-1180-25MCD > Shown on model 451.3 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Main Floor Panel Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PARTIALLY PREPARE MAIN FLOOR PANEL FOR INSTALLATION. -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3910 · Applies to: 450, 451, 452, 454
AR63.40-P-1180-26MCC > 1. Scribe separation line on front main floor panel (1) and cut (area A). Fig 1: Identifying Main Floor Panel Grinding Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Main Floor Panel With Cutting Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Transfer dimension for cut A from vehicle.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3911 · Applies to: 450, 451, 452, 454
- Grind mating surfaces on section (1.1) down to bare metal in 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. TESTING & REPAIR > PARTIALLY PREPARE MAIN FLOOR PANEL FOR INSTALLATION. - AR63.40-P-1180-26MCD >
- Scribe separation line on rear main floor panel (1) and cut (area A). Transfer dimension for cut A from vehicle.
- Drill hole for plug welding on section (1.1) (area B). Transfer dimension from vehicle.
- Grind mating surfaces on section (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. TESTING & REPAIR > PARTIALLY INSTALL MAIN FLOOR PANEL - AR63.40-P-1180- 27MCC >
- 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. Fig 1: Identifying Rear Main Floor Panel With Cutting Sections Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Fit main floor panel (1), front longitudinal member (2) and longitudinal member console (3) with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3912 · Applies to: 450, 451, 452, 454
straightening tools and fit in place using vise grip pliers and C-clamps. Observe set-up plans. 3. Tack weld main floor panel (1) (area B). 4. Main floor panel (1) (area A). 5. Main floor panel (1) (area B). Weld in intervals; minimizes heat distortion. Fig 1: Identifying Main Floor Panel Adhesive Application Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Grind all weld joints down flat if required.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3913 · Applies to: 450, 451, 452, 454
- Clean all other weld joints with wire brush.
- Remove front longitudinal member (2) and longitudinal member console (3), if required. TESTING & REPAIR > PARTIALLY INSTALL MAIN FLOOR PANEL - AR63.40-P-1180- 27MCD > Fig 2: Identifying Main Floor Panel With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3915 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00-P-0008- 01MCC Measures for preventing damage to vehicles or components when performing
AH00.00-P-0005-01FF Fig 1: Identifying Front Main Floor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3919 · Applies to: 450, 451, 452, 454
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 Rear Main Floor Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3920 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Inert gas welder Weld protection blanket http://gotis.aftersales.mercedes- benz.com
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof weld protection blanket 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 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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3921 · Applies to: 450, 451, 452, 454
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 console on lower 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 center main floor panel reinforcement
AR63.40-P- 1110MCC 13 Partially remove crossmember below front seat
AR63.40-P- 1189MCC 14 Remove center 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 (1)
AR63.40-P-1180- 24MCD 17 Partially prepare connecting points for rear main floor panel (1) on body.
AR63.40-P-1180- 25MCD
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 18 Partially prepare rear main floor panel (1) for installation
AR63.40-P-1180- 26MCD
Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install
19 Install section of rear main floor panel (1)
AR63.40-P-1180- 27MCD 20 Partially install front main floor panel
AR63.40-P- 1180MCC 21 Instal center console
AR63.40-P-
below front seat.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3922 · Applies to: 450, 451, 452, 454
1192MCC 22 Partially install crossmember below front seat
AR63.40-P- 1189MCC 23 Install center main floor panel reinforcement
AR63.40-P- 1110MCC 24 Install front longitudinal member
AR62.20-P- 1242MCC 25 Partially install longitudinal member inner shell on entrance
AR63.30-P- 1143MCC 26 Install console on lower front longitudinal member
AR62.20-P- 1265MCC 27 Install longitudinal member locking lug
AR62.20-P- 1267MCC 28 Partially install side longitudinal member reinforcement
AR63.30-P- 0818MCC 29 Install outer console below front seat
AR63.40-P- 1192MCD 30 Install tank support. According to damage profile:
Left tank support AR61.10-P- 5708MCD
Right tank support AR61.10-P- 5708MCC 31 Install accelerator pedal console
AR63.40-P- 1300MCC 32 Partially install side wall reinforcement
AR63.20-P- 0862MCC 33 Install lower A-pillar reinforcement On model 451.3 AR63.20-P- 1114MCC
On model 451.4 AR63.20-P- 1114MCO 34 Install lower outer A-pillar On model 451.4 AR63.20-P- 1102MCO 35 Partially install side wall paneling On model 451.3 AR63.10-P- 0115MCC
On model 451.4 AR63.10-P- 0115MCO 36 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
Prime area to be repaired¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3923 · Applies to: 450, 451, 452, 454
37 Prime area to be repaired using primer filler
38 Supply standard seam seals with body sealant
AR97.10-P- 4000MCC
Sealant BR00.45-Z-1003- 01A 39 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 40 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00-P-9408- 02MCC 41 Apply additional cavity preservation
AR97.20-P- 1500FF
Teroson protective wax *BR00.45-Z-1008- 05A 42 Reinstall all detachable parts removed
AUXILIARY 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 > PARTIALLY REMOVE CROSSMEMBER BELOW FRONT SEAT - AR63.40-P-1189-01MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3924 · Applies to: 450, 451, 452, 454
- Scribe cut on crossmember below front seat (1) and cut (area A).
- Expose spot welds on crossmember below front seat (1) and cut out (areas B, C, D and D ).
- Expose spot welds on crossmember below front seat (1) and drill out with Ø 6.5 mm bit (area D).
- Heat connecting flange with hot air blower (area C). Area C is bonded.
- Remove damaged section from crossmember below front seat (1).
- Remove drill shavings using wet/dry vacuum cleaner TESTING & REPAIR > PARTIALLY PREPARE CROSSMEMBER BELOW FRONT SEAT FOR INSTALLATION - AR63.40-P-1189-02MCC >
- Scribe cut on crossmember below front seat (1) and cut (area A). Transfer dimension for cut from vehicle 1 2 Fig 1: Identifying Spot Welds On Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind section (1.1) of crossmember below front seat (1) down to bare metal in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3925 · Applies to: 450, 451, 452, 454
Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces, otherwise the adhesive force of the 2-component adhesive starts to decrease. TESTING & REPAIR > PARTIALLY INSTALL CROSSMEMBER BELOW FRONT SEAT - AR63.40-P-1189-03MCC > 1. Fit section of crossmember below front seat (1.1) and fix in place using clamping pliers and C- clamps. 2. Drill Ø 6.5 mm rivet holes (areas A and B). Complete remaining welding and riveted joints and rivet holes together with longitudinal member inner shell. Fig 1: Identifying Crossmember Below Front Seat With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Remove section from crossmember below front seat (1.1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3926 · Applies to: 450, 451, 452, 454
- Deburr rivet holes on section of crossmember below front seat (1.1) and body on both sides.
- Apply 2-component adhesive to mating surfaces in 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. Apply adhesive bead in area of longitudinal member only after installing longitudinal member inner shell. If applicable, slightly pry open connecting flange (arrows). Observe manufacturer's specifications for drying and processing time for 2-component adhesive. Fig 1: Identifying Crossmember Below Front Seat With Rivet Holes Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Fit section of crossmember below front seat (1.1) and fix in place using manual temporary¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3927 · Applies to: 450, 451, 452, 454
fasteners, clamping pliers and C-clamps. 7. Section of crossmember below front seat (1.1) (area D). 8. Rivet section of crossmember below front seat (1.1) using Polygrip flat round head rivet, 6.4 x 14 (areas A and B). Complete riveted joints in area C only after installing longitudinal member inner shell on entry. Fig 2: Identifying Adhesive Application Areas On Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PARTIALLY PREPARE CONNECTING POINTS FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3928 · Applies to: 450, 451, 452, 454
CROSSMEMBER BELOW FRONT SEAT ON BODY - AR63.40-P-1189-04MCC > 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces, otherwise the adhesive force of the 2-component adhesive starts to decrease. If applicable, slightly pry open sheet metal lug (arrows) to grind down. Fig 3: Identifying Riveting Section Of Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3930 · Applies to: 450, 451, 452, 454
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 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
AH91.00-P-0002-01SM Fig 1: Identifying Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3934 · Applies to: 450, 451, 452, 454
The left longitudinal member inner shell can be removed or installed. The steps are shown with left longitudinal member inner shell installed. 1. Expose spot welds on crossmember below front seat (1) and cut out (areas A, B , B , B , B , C and D). 2. Expose spot welds on crossmember below front seat (1) and drill with Ø 6.5 mm bit (area B). 3. Heat connecting flange with hot air blower (areas B , C and D). Areas B , C and D are bonded. 4. Remove damaged crossmember below front seat (1). 5. Remove drill shavings using wet/dry vacuum cleaner TESTING & REPAIR > PREPARE CROSSMEMBER BELOW FRONT SEAT - AR63.40-P- 1190-02MCC > 1. Grind crossmember below front seat (1) down to bare metal in cross-hatched areas. Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces, otherwise the adhesive force of the 2-component adhesive starts to decrease. TESTING & REPAIR > INSTALL CROSSMEMBER BELOW FRONT SEAT - AR63.40-P-1190- 03MCC > The left longitudinal member inner shell can be removed or installed. The steps are shown with left longitudinal member inner shell installed. 1 2 3 4 5 5 Fig 1: Identifying Grinding Surfaces On Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit crossmember below front seat (1) and fix in place using clamping pliers and C-clamps.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3935 · Applies to: 450, 451, 452, 454
- Drill Ø 6.5 mm rivet holes (areas A, B and C). The remaining welds and riveted joints are completed later.
- Remove crossmember below front seat (1).
- Deburr rivet holes on crossmember below front seat (1) and body on both sides.
- Apply 2-component adhesive to mating surfaces in cross-hatched areas. Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces. Otherwise, the adhesive force of the 2-component adhesive starts to decrease. Fig 1: Identifying Crossmember Below Front Seat Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Fit crossmember below front seat (1) and fix in place using manual temporary fasteners, clamping¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3936 · Applies to: 450, 451, 452, 454
pliers and C-clamps. 7. Rivet crossmember below front seat (1) using Polygrip flat round head rivet, 6.4 x 14 (areas A, B and C). Fig 2: Identifying Crossmember Below Front Adhesive Application Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE MATING SURFACES ON VEHICLE FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3937 · Applies to: 450, 451, 452, 454
CROSSMEMBER BELOW LEFT FRONT SEAT - AR63.40-P-1190-04MCC > 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces. Otherwise the adhesive force of the 2-component adhesive starts to decrease. Fig 3: Identifying Crossmember Below Front Seat Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REPLACE CROSSMEMBER BELOW FRONT SEAT - AR63.40-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3938 · Applies to: 450, 451, 452, 454
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.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3939 · Applies to: 450, 451, 452, 454
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 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.
The repair method using riveting described here can
Fig 1: Identifying Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BR00.45-Z-1001-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3942 · Applies to: 450, 451, 452, 454
02A 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- 13A Blind rivet 6.4 x 14 A 003 990 35 97 TESTING & REPAIR > 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 Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air AS00.00-Z- 0007-01A Fig 1: Identifying Crossmember Below Front Seat With Support Stand, Wooden Wedge And Fixing Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
caused by welding in¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3943 · Applies to: 450, 451, 452, 454
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. extractor system. 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 Notes on replacing body parts
AH60.00-P- 0027-01FF General information on repairs to body
AH60.00-P- 0001-01FF The following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Weld protection blanket http://gotis.aftersales.mercedes- benz.com
Remove detachable¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3944 · Applies to: 450, 451, 452, 454
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 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 upper 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
AR63.40-P- 1180MCD
Scribe cutting line on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3945 · Applies to: 450, 451, 452, 454
17 Scribe cutting line on crossmember below front seat (1) and cut (area A) Support body with suitable jack stand (3) and wooden wedge (4) and secure with fastening aid (5) against tilting. Use tensioning strap (5) as fastening aid.
18 Remove damaged crossmember section below front seat (1.1)
19 Scribe cutting line on new crossmember below front (2) and cut (area C)
20 Remove section of new crossmember below front seat (2.1)
21 Grind mating surfaces on body and on section of new crossmember below front seat (2.1) down to bare metal in cross-hatched areas.
Install
22 Fix in place section of new crossmember below front seat (2.1), rear main floor panel, front main floor panel, front longitudinal member, longitudinal member mounting console and longitudinal member inner shell with straightening tool and fasten using vise grip pliers and C-clamps. Observe set-up plans.
Setup planshttp://gotis.aftersales.mercedes- benz.com
23 Tack weld section of new crossmember below front seat (2.1) from bottom (arrow B).
24 Remove rear main floor panel, front main floor panel, front longitudinal member, longitudinal member mounting console and
longitudinal member¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3946 · Applies to: 450, 451, 452, 454
inner shell. 25 Section of new crossmember below front seat (2.1) (area B)
26 Grind all weld joints down flat if required.
27 Clean all other weld joints using a shank brush
28 Clean weld joints and sheet metal flange using a shank brush and clean repair areas.
29 Partially install rear main floor panel
AR63.40-P- 1180MCD 30 Partially install front main floor panel
AR63.40-P- 1180MCC 31 Install center mounting console below front seat
AR63.40-P- 1192MCC 32 Partially install crossmember below upper front seat
AR63.40-P- 1189MCC 33 Install center main floor panel reinforcement
AR63.40-P- 1110MCC 34 Install front longitudinal member
AR62.20-P- 1242MCC 35 Partially install longitudinal member inner shell on entrance
AR63.30-P- 1143MCC 36 Install mounting console on bottom front longitudinal member
AR62.20-P- 1265MCC 37 Install longitudinal member locking lug
AR62.20-P- 1267MCC 38 Partially install side longitudinal member reinforcement
AR63.30-P- 0818MCC 39 Partially install side wall reinforcement
AR63.20-P- 0862MCC 40 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. 3947 · Applies to: 450, 451, 452, 454
AR63.20-P- 1114MCO 41 Install lower outer A- pillar On model 451.4 AR63.20-P- 1102MCO 42 Partially install side wall paneling On model 451.3 AR63.10-P- 0115MCC
On model 451.4 AR63.10-P- 0115MCO 43 Prime area to be repaired using primer filler
44 Supply standard seam seals with body sealant
AR97.10-P- 4000MCC
Sealant BR00.45-Z- 1003-01A 45 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z- 1001-05A 46 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00-P- 9408-02MCC 47 Apply additional cavity preservation
AR97.20-P- 1500FF
Teroson protective wax *BR00.45-Z- 1008-05A 48 Reinstall all detachable parts removed
AUXILIARY 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 > REMOVE CONSOLE BELOW FRONT SEAT - AR63.40-P-1192-
01MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3948 · Applies to: 450, 451, 452, 454
- Expose spot welds on console below front seat (1) and cut out (areas A and B).
- Remove damaged console below front seat (1). TESTING & REPAIR > REMOVE CONSOLE BELOW FRONT SEAT - AR63.40-P-1192- 01MCD >
- Expose spot welds on console below front seat (1) and cut out (areas A and B).
- Remove damaged console below front seat (1). TESTING & REPAIR > PREPARE CONSOLE BELOW FRONT SEAT - AR63.40-P-1192- Fig 1: Identifying Console Below Front Seat Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Console Below Front Seat Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
02MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3949 · Applies to: 450, 451, 452, 454
- Drill holes for plug welding on console below front seat (1) (areas A and B).
- Grind console below front seat (1) down to bare metal in cross-hatched areas. TESTING & REPAIR > PREPARE CONSOLE BELOW FRONT SEAT - AR63.40-P-1192- 02MCD >
- Drill holes for plug welding on console below front seat (1) (areas A and B).
- Grind console below front seat (1) down to bare metal in cross-hatched areas. TESTING & REPAIR > PREPARE CONNECTION POINTS ON CONSOLE BELOW FRONT SEAT ON BODY - AR63.40-P-1192-03MCC >
- Sand connection surfaces down to bare metal in the cross-hatched areas. Fig 1: Preparing Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Preparing Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE CONNECTION POINTS ON CONSOLE BELOW FRONT¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3950 · Applies to: 450, 451, 452, 454
SEAT ON BODY - AR63.40-P-1192-03MCD > 1. Sand connection surfaces down to bare metal in the cross-hatched areas. TESTING & REPAIR > INSTALL CONSOLE BELOW FRONT SEAT - AR63.40-P-1192- 04MCD > Fig 1: Identifying Connection Surfaces On Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Connection Surfaces On Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit console below front seat (1) together with seat frame and fasten with mounting bolts.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3951 · Applies to: 450, 451, 452, 454
- Drill Ø 6.5 mm rivet holes on console below front seat (1) (areas A and B).
- Remove console below front seat (1), seat frame and mounting bolts.
- Deburr rivet holes on console below front seat (1) and body on both sides.
- Fit console below front seat (1) and fasten with manual temporary fasteners.
- Console below front seat (1) (areas C and D).
- Rivet console below front seat (1) with 6.4 x 14 Polygrip flat/round head rivet (areas A and B).
- Grind all weld joints down flat if required. Fig 1: Identifying Console Below Front Seat With Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Console Below Front Seat Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Measures for preventing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3953 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Inert gas welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com
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 Remove console below front seat (1)
AR63.40-P-1192- 01MCC 4 Prepare connection points on console below front seat (1) on body
AR63.40-P-1192- 03MCC 5 Prepare console below front seat (1) for installation
AR63.40-P-1192- 02MCC Install
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3955 · Applies to: 450, 451, 452, 454
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 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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic)
Fig 1: Identifying Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Wet/dry vacuum cleaner¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3956 · Applies to: 450, 451, 452, 454
Inert gas welder Tarp (fire-resistant) Pneumatic-hydraulic blind rivet tool http://gotis.aftersales.mercedes- benz.com 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 Remove console below front seat (1)
AR63.40-P-1192- 01MCD 4 Prepare connection points on console below front seat (1) on body
AR63.40-P-1192- 03MCD 5 Prepare console below front seat (1) for installation
AR63.40-P-1192- 02MCD Install
6 Install console below front seat (1) and weld in
AR63.40-P-1192- 04MCD 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
TESTING & REPAIR > REPLACE CONSOLE FOR ACCELERATOR PEDAL - AR63.40-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3962 · Applies to: 450, 451, 452, 454
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 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 following workshop equipment and tools are required for repair Shank brush Hart metal ball cutter Grinding disk
Fig 1: Replacing Accelerator Pedal Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Cartridge gun¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3963 · Applies to: 450, 451, 452, 454
Drill (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Tarp (fire-resistant) http://gotis.aftersales.mercedes- benz.com 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 Expose spot welds on accelerator pedal console (1) and cut out (areas A and B)
4 Remove damaged accelerator pedal console (1)
5 Grind mating surfaces on body down to bare metal in cross-hatched areas
6 Drill holes for plug welding on new accelerator pedal console (1) (areas E and F)
7 Remove protective paint from welding areas on new accelerator pedal console (1) and grind connecting flange down to bare metal in cross- hatched areas
Install
8 Fit accelerator pedal console (1) and fasten. When fitting observe correct distances.
9 Accelerator pedal console (1) (areas C and D)
10 Level spot welds and clean with wire brush Clean (areas C and D) and repair areas.
Prime area to be repaired¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3964 · Applies to: 450, 451, 452, 454
11 Prime area to be repaired using primer filler
12 Supply standard seam seals with body sealant
AR97.10-P- 4000MCC
Sealant BR00.45-Z-1003- 01A 13 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 14 Paint area repaired and adjacent surfaces
Notes 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-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 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: SIDE WALL - BA63.00-Z- 9999CZ > MODEL all Rear fender MODEL 450.3 /4 BA63.50-P-1000-01A Rear fender MODEL 451.3/4 BA63.50-P-1000-01B TORQUE SPECIFICATIONS > REAR FENDER - BA63.50-P-1000-01B > Model 451
REINFORCEMENT IN RIGHT REAR FENDER¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3965 · Applies to: 450, 451, 452, 454 · AR: WS63.00-Z-9999CZ
Number Designation Model 451.3/4 BA63.50-P-1001- 01B Bolt, reinforcement in right rear fender Nm 15 SPECIAL TOOLS > SPECIAL TOOLS: SMART: SIDE WALL - WS63.00-Z-9999CZ > MODEL all 129 589 01 98 00 Welding bead catcher Group 00/63/77/Set K WS77.00-P- 0010K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P- 0027K 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P- 0107K
1. Drill holes for plug weldings on side wall paneling (1) (areas A and B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3968 · Applies to: 450, 451, 452, 454
Transfer dimensions of holes for plug welding from vehicle. 2. Drill holes for plug welding on side wall paneling (1) (areas C, D and E). Fig 1: Identifying Drill Holes Areas For Plug Weldings On Side Wall Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Drill Holes Areas For Plug Weldings On Side Wall Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Transfer dimensions of holes for plug welding from vehicle.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3969 · Applies to: 450, 451, 452, 454
- Grind connecting flange on side wall paneling (1) down to bare metal in shaded areas on both sides and coat insides of spot welding flange with zinc dust paint. Fig 3: Identifying Side Wall Paneling Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Grind connecting flange on side wall paneling (1) down to bare metal in shaded areas on both sides¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3970 · Applies to: 450, 451, 452, 454
and coat insides of spot welding flange with zinc dust paint. 5. Grind connecting flange on side wall paneling (1) down to bare metal in shaded areas on both sides and coat insides of spot welding flange with zinc dust paint. Fig 4: Identifying Grinding Areas Of Connecting Flange On Side Wall Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS OF SIDE WALL¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3971 · Applies to: 450, 451, 452, 454
PANELING ON BODY - AR63.10-P-0110-03MCC > Fig 5: Identifying Grinding Areas Of Connecting Flange On Side Wall Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Grind mating surfaces down to bare metal on one side (areas A and C).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3972 · Applies to: 450, 451, 452, 454
- Grind mating surfaces in remaining shaded areas illustrated down to bare metal on both sides and coat insides of spot welding flange with zinc dust paint.
- Grind mating surfaces down to bare metal on one side (areas D, E and F). Fig 1: Identifying Side Wall Paneling Grinding Surface Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Grinding Areas (D, E And F) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Grind mating surfaces in remaining shaded areas illustrated down to bare metal on both sides and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3973 · Applies to: 450, 451, 452, 454
coat insides of spot welding flange with zinc dust paint. 5. Grind mating surfaces down to bare metal in on one side (areas G and H). 6. Grind mating surfaces in remaining shaded areas illustrated down to bare metal on both sides and coat insides of spot welding flange with zinc dust paint. TESTING & REPAIR INDEX > REMOVE SIDE WALL PANELING - AR63.10-P-0110-05MCC > Fig 3: Identifying Grinding Areas (G And H) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Expose spot welds on side wall paneling (1) and cut out (areas A, B and C).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3974 · Applies to: 450, 451, 452, 454
- Expose spot welds on side wall paneling (1) and cut out (areas D and E). Fig 1: Identifying Side Wall Paneling Spot Welding Areas (A, B And C) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Expose spot welds on side wall paneling (1) and cut out (areas B , F and G).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3975 · Applies to: 450, 451, 452, 454
- Remove damaged side wall paneling (1) 1 Fig 2: Identifying Side Wall Paneling Spot Welding Areas (D And E) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > INSTALL SIDE WALL PANELING - AR63.10-P-0110-06MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3976 · Applies to: 450, 451, 452, 454
Fig 3: Identifying Spot Welding Areas On Side Wall Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Side Wall Paneling Spot Welding Areas (A, B And D) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Side wall paneling (1) only¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3977 · Applies to: 450, 451, 452, 454
if the used spot welder has the required capacity. If this is not the case, the corresponding areas . 1. Fit side wall paneling (1) and fasten with vise grip pliers. 2. Side wall paneling (1) (areas A, B and D). 3. Side wall paneling (1) (areas E and H). 4. Side wall paneling (1) (areas F, G and N). 5. Side wall paneling (1) (areas L and M). 6. Side wall paneling (1) (area K). Fig 2: Identifying Side Wall Paneling Spot Welding Areas (E, F, G, H And N) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
7. Side wall paneling (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3978 · Applies to: 450, 451, 452, 454
(area C). 8. Grind all spot welds down flat if required 9. Clean all other weld joints with wire brush Fig 3: Identifying Side Wall Paneling Spot Welding Areas (K, L And M) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > REMOVE/INSTALL SIDE WALL PANELING - AR63.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3979 · Applies to: 450, 451, 452, 454
0110MCC > MODEL 451.3 Fig 4: Identifying Side Wall Paneling Spot Welding Areas (C) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3980 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Side Wall Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3981 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant)
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 Remove side wall paneling (1)
AR63.10- P-0110- 05MCC 4 Prepare connecting points for side wall paneling (1) on body
AR63.10- P-0110- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 5 Prepare side wall paneling (1) for installation
AR63.10- P-0110- 01MCC *BR00.45-
Zinc du t paint uitable for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3982 · Applies to: 450, 451, 452, 454
spot welding Z 1001 07A Install
6 Install side wall paneling (1)
AR63.10- P-0110- 06MCC 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 BR00.45- Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42
TESTING & REPAIR INDEX > PARTIALLY SEPARATE SIDE WALL PANELING - AR63.10-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3983 · Applies to: 450, 451, 452, 454
0115-01MCC > All operation steps are shown as an example on the rear upper side wall paneling (1). Adapt repair sections according to damage profile. 1. Scribe cut on rear upper side wall paneling (1) and cut (areas A and B). 2. Expose spot welds on rear upper side wall paneling (1) and cut out (areas C, D, E and F). 3. Remove damaged rear upper side wall paneling (1). TESTING & REPAIR INDEX > PARTIALLY PREPARE CONNECTING POINTS FOR SIDE WALL PANELING ON BODY - AR63.10-P-0115-02MCC > All operation steps are shown as an example on the rear upper side wall paneling. Adapt repair sections according to damage profile. 1. Sand mating surfaces down to bare metal in the cross-hatched areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Rear Upper Side Wall Paneling Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PARTIALLY PREPARE SIDE WALL PANELING FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3984 · Applies to: 450, 451, 452, 454
INSTALLATION - AR63.10-P-0115-03MCC > All operation steps are shown as an example on the rear upper side wall paneling. Adapt repair sections according to damage profile. 1. Scribe cut on side wall paneling (1) and cut (areas E and G). Fig 1: Identifying Rear Upper Side Wall Panel Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying Side Wall Paneling With Cutting Areas¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3985 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Side Wall Paneling Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Drill holes for plug weldings on rear upper side wall paneling (1.1) (area K).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3986 · Applies to: 450, 451, 452, 454
Transfer dimensions of holes for plug welding from vehicle. 3. Sand mating surfaces down to bare metal in the cross-hatched areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR INDEX > PARTIALLY INSTALL SIDE WALL PANELING AND WELD IN. - AR63.10-P-0115-04MCC > All operation steps are shown as an example on the rear upper side wall paneling (1). Adapt repair sections according to damage profile. The rear upper side wall paneling (1) only , if the used spot welder has the required capacity. If this is not the case, the corresponding areas . 1. Fit rear upper side wall paneling (1) and fasten with vise grip pliers 2. Rear upper side wall paneling (1) (areas J and K). 3. Rear upper side wall paneling (1) (area H). 4. Rear upper side wall paneling (1) (areas L and M). 5. Grind all weld joints down flat if required. Fig 1: Identifying Rear Upper Side Wall Paneling Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Clean all other weld joints with wire brush¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3987 · Applies to: 450, 451, 452, 454
- Restore surface on rear upper side wall paneling (1) and smooth (areas L and M). TESTING & REPAIR INDEX > PARTIALLY REPLACE SIDE WALL PANELING - AR63.10-P- 0115MCC > 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 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 Side Wall Paneling With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on riveting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3988 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant)
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 (1) Adapt cuts (A to H) according to damage profile AR63.10- P-0115- 01MCC 4 Prepare connecting points for side wall paneling (1) on body
AR63.10- P-0115- 02MCC
Zinc dust paint suitable for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3989 · Applies to: 450, 451, 452, 454
spot welding *BR00 45 Z-1001- 07A 5 Prepare side wall paneling (1) for installation
AR63.10- P-0115- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
6 Install side wall paneling (1) and weld in
AR63.10- P-0115- 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- Underfloor protection 800 ml A 001 986 46 10
BR00.45-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3990 · Applies to: 450, 451, 452, 454
05A 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 > CUT AWAY REAR WHEELHOUSE LINER ASSEMBLY - AR63.10-P-0661-01MCC > Shown on model 451.3 1. Expose spot welds on rear wheelhouse (1) and cut out (areas A, B and C). 2. Heat rear wheelhouse (1) with hot air gun (area A). Area A is bonded. 3. Remove damaged rear wheelhouse (1). TESTING & REPAIR INDEX > PREPARE COMPLETE REAR WHEELHOUSE LINER ASSEMBLY FOR INSTALLATION - AR63.10-P-0661-02MCC > Shown on model 451.3 Fig 1: Identifying Rear Wheelhouse Cutting And Heating Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Drill holes for plug welding on rear wheelhouse (1) (area A).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3991 · Applies to: 450, 451, 452, 454
Transfer dimensions of hole for plug welding from vehicle. 2. Grind rear wheelhouse (1) down to bare metal in 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications of 2-component adhesive for drying and processing time. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR INDEX > INSTALL WHEELHOUSE LINER ASSEMBLY AT REAR AND WELD IN - AR63.10-P-0661-03MCC > Fig 1: Identifying Plug Welding Holes On Rear Wheelhouse Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3992 · Applies to: 450, 451, 452, 454
- Apply adhesive to mating surfaces in crosshatched areas. 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.
- Fit rear wheelhouse (1) together with B-pillar reinforcement (2) and fasten with vise grip pliers.
- Rear wheelhouse (1) (areas A and B). Position resistance spot welds in area A at precise position of resistance spot welds made at factory to ensure minimum required strength for weld joints.
- Rear wheelhouse (1) (area C).
- Grind all spot welds down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS FOR REAR WHEELHOUSE ON BODY - AR63.10-P-0661-04MCC >
- Grind mating surfaces down to bare metal in 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding Fig 1: Identifying Wheelhouse Adhesive And Welding Application Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3994 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00- P-0008- Fig 1: Identifying Rear Wheel Well Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
01MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3995 · Applies to: 450, 451, 452, 454
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 *BR00.45-
Zinc du t paint uitable for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3996 · Applies to: 450, 451, 452, 454
spot welding 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 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-0661- 03MCC
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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3997 · Applies to: 450, 451, 452, 454
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- 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 > INSTALL B-PILLAR REINFORCEMENT - AR63.10-P-0696- 05MCC > 1. Apply 2-component adhesive to mating surfaces in 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. Observe manufacturer's specifications of 2- component adhesive for drying and processing time.
Fig 1: Identifying B-Pillar Reinforcement Adhesive Applying Areas¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3998 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying B-Pillar Reinforcement Spot Welding Applying Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Fit B-pillar reinforcement (1) and fasten with vise grip pliers.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3999 · Applies to: 450, 451, 452, 454
- B-pillar reinforcement (1) (areas B, C, D and E). If the side wall is installed later, it is necessary to position the resistance spot welds in areas D and E exactly on the points set here, because otherwise the weld joint could be faulty. Areas A and F are only when installing the side wall.
- B-pillar reinforcement (1) (areas G, H, J, K, L and M).
- Grind all spot welds down flat if required
- Clean all other weld joints with wire brush TESTING & REPAIR INDEX > SEPARATE WHEEL WELL LOCKING LUG - AR63.20-P-0013- 01MCC >
- Expose spot welds on wheel well locking lug (1) and cut out (area A).
- Remove damaged wheel well locking lug (1). TESTING & REPAIR INDEX > PREPARE WHEEL WELL LOCKING LUG FOR INSTALLATION - AR63.20-P-0013-02MCC > Fig 1: Identifying Wheel Well Locking Lug Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Drill holes for plug welding on wheel well locking lug (1) (area C).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4000 · Applies to: 450, 451, 452, 454
- Grind mating surfaces on body down to bare metal in shaded areas (area A). Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint.
- Grind connecting flange on wheel well locking lug (1) down to bare metal in shaded areas (area B). Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR INDEX > INSTALL WHEEL WELL LOCKING LUG AND WELD IN - AR63.20-P-0013-03MCC >
- Fit wheel well locking lug (1) with side wall paneling (2) and fasten wheel well locking lug (1) with clamping pliers. When fitting observe correct distances.
- Remove side wall paneling (2).
- Wheel well locking lug (1) (area A).
- Wheel well locking lug (1) (area B).
- Grind all spot welds down flat, if required
- Clean all other spot welds with wire brush. Fig 1: Identifying Wheel Well Locking Lug Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > REPLACE WHEEL WELL LOCKING LUG - AR63.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4001 · Applies to: 450, 451, 452, 454
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.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4002 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Wheel Well Locking Lug Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4003 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant)
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 separate side wall paneling Model 451.3 AR63.10- P- 0115MCC
Model 451.4 AR63.10- P- 0115MCO 4 Remove wheel well locking lug (1)
AR63.20- P-0013- 01MCC AR63.20-
Prepare wheel well locking lug (1) and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4004 · Applies to: 450, 451, 452, 454
5 Prepare wheel well locking lug (1) and mating surfaces on body for installation
P-0013- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
6 Fit wheel well locking lug (1) and weld in
AR63.20- P-0013- 03MCC 7 Partially install side wall paneling and weld in Model 451.3 AR63.10- P- 0115MCC
Model 451.4 AR63.10- P- 0115MCO 8 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
9 Prime area to be repaired using primer filler
10 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant BR00.45- Z-1003- 01A 11 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 12 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 13 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 14 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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4005 · Applies to: 450, 451, 452, 454
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 > SEPARATE SIDE WALL REINFORCEMENT - AR63.20-P- 0860-01MCC > Shown on model 451.3 1. Expose spot welds on side wall reinforcement (1) and cut out (areas A, B, C, D and E). 2. Remove damaged side wall reinforcement (1). TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS FOR SIDE WALL REINFORCEMENT ON BODY - AR63.20-P-0860-02MCC > Shown on model 451.3 1. Grind mating surfaces down to bare metal on one side (areas F, G and H). 2. Grind mating surfaces in remaining shaded areas illustrated down to bare metal on both sides and coat insides of spot welding flange with zinc dust paint. Fig 1: Identifying Side Wall Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > REPLACE SIDE WALL REINFORCEMENT - AR63.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4006 · Applies to: 450, 451, 452, 454
0860MCC > MODEL 451.3/ 4 Shown on model 451.3 Fig 1: Identifying Side Wall Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4007 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Side Wall Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4008 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant)
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 Model 451.3 AR63.10- P- 0115MCC
Model 451.4 AR63.10- P- 0115MCO 4 Separate A-pillar outer section Model 451.4 AR63.20- P- 1102MCO AR63.20-
Separate side wall reinforcement (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4009 · Applies to: 450, 451, 452, 454
5 Separate side wall reinforcement (1)
P-0860- 01MCC 6 Prepare connecting points for side wall reinforcement (1) on body
AR63.20- P-0860- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 7 Prepare side wall reinforcement (1) for installation
AR63.20- P-0860- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
8 Install side wall reinforcement (1)
AR63.20- P-0860- 04MCC 9 Install A-pillar outer section Model 451.4 AR63.20- P- 1102MCO 10 Partially install side wall paneling Model 451.3 AR63.10- P- 0115MCC
Model 451.4 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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4010 · Applies to: 450, 451, 452, 454
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-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 > PARTIALLY SEPARATE SIDE WALL REINFORCEMENT - AR63.20-P-0861-01MCC > Shown on model 451.3 Fig 1: Identifying Side Wall Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Scribe cuts on side wall reinforcement according to damage profile and separate (areas F and G).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4011 · Applies to: 450, 451, 452, 454
- Expose spot welds on side wall reinforcement section (1.1 to 1.3) according to damage profile and cut out (areas A, A , B, C, D and E).
- Remove damaged side wall reinforcement section (1.1 to 1.3). TESTING & REPAIR INDEX > PARTIALLY PREPARE CONNECTING POINTS ON SIDE WALL REINFORCEMENT ON BODY - AR63.20-P-0861-02MCC > Shown on model 451.3
- 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 > PARTIALLY PREPARE SIDE WALL REINFORCEMENT FOR INSTALLATION - AR63.20-P-0861-03MCC >
- Scribe cuts on side wall reinforcement according to damage profile and separate (areas N and O).
- Drill holes for plug welding on side wall reinforcement section (1.1 to 1.3) according to damage profile (areas K, L and M). Transfer dimensions of holes for plug welding from vehicle. 1 Fig 1: Identifying Side Wall Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Grind mating surfaces on side wall reinforcement section (1.1 to 1.3) in cross-hatched areas down¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4012 · Applies to: 450, 451, 452, 454
to bare metal according to damage profile. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Side Wall Reinforcement Cutting Areas And Holes For Plug Welding Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Side Wall Reinforcement Grinding 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. 4014 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF AH60.00- Fig 1: Identifying Side Wall Reinforcement With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4015 · Applies to: 450, 451, 452, 454
P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, dia. 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant)
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 Model 451.3 AR63.10- P- 0115MCC
Model 451.4 AR63.10- P- 0115MCO 4 Separate A-pillar outer section Model 451.4 AR63.20- P- 1102MCO 5 Partially separate side wall reinforcement (1)
AR63.20- P-0861- 01MCC
Prepare connecting points for side wall¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4016 · Applies to: 450, 451, 452, 454
6 Prepare connecting points for side wall reinforcement (1) on body
AR63.20- P-0861- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 7 Prepare side wall reinforcement (1) for installation
AR63.20- P-0861- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
8 Install side wall reinforcement (1)
AR63.20- P-0861- 04MCC 9 Install A-pillar outer section Model 451.4 AR63.20- P- 1102MCO 10 Partially install side wall paneling Model 451.3 AR63.10- P- 0115MCC
Model 451.4 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 *BR00.45-
Teroson protective wax¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4017 · Applies to: 450, 451, 452, 454
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-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 > REMOVE A-PILLAR INNER SECTION. - AR63.20-P-1104- 01MCC > Shown on model 451.3 1. Expose spot welds am A-pillar inner section (1) and cut out (areas A, B, C, D and E). Fig 1: Identifying A-Pillar Inner Section Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Remove damaged A-pillar inner section (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4018 · Applies to: 450, 451, 452, 454
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR INDEX > PREPARE A-PILLAR INNER SECTION FOR INSTALLATION - AR63.20-P-1104-03MCC >
- Drill holes for plug welding on A-pillar inner section (1) (areas A, B, C and D).
- Grind connecting flange 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. TESTING & REPAIR INDEX > INSTALL A-PILLAR INNER SECTION - AR63.20-P-1104- 04MCC > Fig 1: Identifying Drilling Holes For Plug Welding On A-Pillar Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4020 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying A-Pillar Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4021 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Inert gas welder Spot welder Weld protection blanket
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof weld protection blanket 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 Remove front wheel well locking lug
AR63.20- P- 0013MCC 5 Partially remove side wall reinforcement
AR63.20- P- 0862MCC 6 Remove A-pillar outer section On model 451.4 AR63.20- P- 1102MCO
Remove upper A-pillar outer paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4022 · Applies to: 450, 451, 452, 454
7 Remove upper A-pillar outer paneling On model 451.4 AR63.20- P- 1105MCO 8 Remove upper A-pillar reinforcement On model 451.3 AR63.20- P- 1113MCC
On model 451.4 AR63.20- P- 1113MCO 9 Remove lower A-pillar reinforcement On model 451.3 AR63.20- P- 1114MCC
On model 451.4 AR63.20- P- 1114MCO 10 Partially remove side longitudinal member reinforcement
AR63.30- P- 0818MCC 11 Partially remove outer longitudinal member inner shell on entrance
AR63.30- P- 1143MCC 12 Remove A-pillar inner section (1)
AR63.20- P-1104- 01MCC 13 Prepare mating surfaces on vehicle for A- pillar inner section (1)
AR63.20- P-1104- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 14 Prepare A-pillar inner section (1) for installation
AR63.20- P-1104- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
15 Install A-pillar inner section (1)
AR63.20- P-1104- 04MCC 16 Partially install longitudinal member inner shell on entrance
AR63.30- P- 1143MCC 17 Partially install side longitudinal member
AR63.30- P-
reinforcement¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4023 · Applies to: 450, 451, 452, 454
0818MCC 18 Install lower A-pillar reinforcement On model 451.3 AR63.20- P- 1114MCC
On model 451.4 AR63.20- P- 1114MCO 19 Install upper A-pillar reinforcement On model 451.3 AR63.20- P- 1113MCC
On model 451.4 AR63.20- P- 1113MCO 20 Install upper A-pillar outer paneling On model 451.4 AR63.20- P- 1105MCO 21 Install A-pillar outer section On model 451.4 AR63.20- P- 1102MCO 22 Partially install side wall reinforcement
AR63.20- P- 0862MCC 23 Install front wheel well locking lug
AR63.20- P- 0013MCC 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 29 Paint area repaired and adjacent surfaces
Notes on paintwork repairs¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4024 · Applies to: 450, 451, 452, 454
AH98.00- P-9408- 02MCC 30 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 31 Reinstall all detachable parts removed
AUXILIARY 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 INDEX > REMOVE UPPER A-PILLAR REINFORCEMENT - AR63.20-P- 1113-01MCC >
1. Expose spot welds on A-pillar reinforcement (1) and cut out (areas A, B, C, D and E).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4025 · Applies to: 450, 451, 452, 454
- Remove damaged A-pillar reinforcement (1). TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS FOR UPPER A-PILLAR REINFORCEMENT ON BODY - AR63.20-P-1113-02MCC >
- Sand mating surfaces down to bare metal in the cross-hatched areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying A-Pillar Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE UPPER A-PILLAR REINFORCEMENT FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4026 · Applies to: 450, 451, 452, 454
INSTALLATION - AR63.20-P-1113-03MCC > 1. Drill holes for plug welding on A-pillar reinforcement (1) (areas F, G and H). Transfer dimensions of holes for plug welding from vehicle. 2. Grind connecting flange on A-pillar reinforcement (1) down to bare metal in shaded areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Upper A-Pillar Reinforcement Sanding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > INSTALL UPPER A-PILLAR REINFORCEMENT AND WELD¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4027 · Applies to: 450, 451, 452, 454
IN. - AR63.20-P-1113-04MCC > Fig 1: Identifying Upper A-Pillar Reinforcement Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit A-pillar reinforcement (1) and fasten with vise grip pliers.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4028 · Applies to: 450, 451, 452, 454
- A-pillar reinforcement (1) (areas M, N and O). Areas K and L are when installing the side wall paneling.
- Grind all spot welds down flat if required
- Clean all other weld joints with wire brush TESTING & REPAIR INDEX > REPLACE UPPER A-PILLAR REINFORCEMENT - AR63.20- P-1113MCC > MODEL 451.3 Fig 1: Identifying Upper A-Pillar Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4029 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Upper A-Pillar Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4030 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant)
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- 0115MCC 4 Separate upper A-pillar reinforcement (1)
AR63.20- P-1113- 01MCC 5 Prepare connecting points for upper A- pillar reinforcement (1) on body
AR63.20- P-1113- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A
Prepare upper A-pillar reinforcement (1) for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4031 · Applies to: 450, 451, 452, 454
6 Prepare upper A-pillar reinforcement (1) for installation
AR63.20- P-1113- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
7 Install upper A-pillar reinforcement (1) and weld in
AR63.20- P-1113- 04MCC 8 Partially install side wall paneling
AR63.10- P- 0115MCC 9 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
10 Prime area to be repaired using primer filler
11 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant BR00.45- Z-1003- 01A 12 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 13 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 14 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 15 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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4032 · Applies to: 450, 451, 452, 454
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 > REMOVE LOWER A-PILLAR REINFORCEMENT - AR63.20-P- 1114-01MCC > 1. Expose spot welds on lower A-pillar reinforcement (1) and cut out (areas A, B, C, D, E and F). 2. Remove damaged lower A-pillar reinforcement (1). TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS ON LOWER A-PILLAR REINFORCEMENT ON BODY. - AR63.20-P-1114-02MCC > 1. Grind connecting flange down to bare metal in shaded areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Lower A-Pillar Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE LOWER A-PILLAR REINFORCEMENT FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4033 · Applies to: 450, 451, 452, 454
INSTALLATION - AR63.20-P-1114-03MCC > 1. Grind connecting flange on lower A-pillar reinforcement (1) down to bare metal in shaded areas. Sand spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Lower A-Pillar Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > INSTALL LOWER A-PILLAR REINFORCEMENT AND WELD¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4034 · Applies to: 450, 451, 452, 454
IN. - AR63.20-P-1114-04MCC > 1. Fit lower A-pillar reinforcement (1) and fasten with vise grip pliers. 2. Lower A-pillar reinforcement (1) (areas E and F). Areas C and D are together with the side wall. 3. Lower A-pillar reinforcement (1) (areas A and B). Fig 1: Identifying Lower A-Pillar Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Grind all spot welds down flat if required¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4035 · Applies to: 450, 451, 452, 454
- Clean all other weld joints with wire brush TESTING & REPAIR INDEX > REPLACE LOWER A-PILLAR REINFORCEMENT - AR63.20- P-1114MCC > MODEL 451.3 Fig 1: Identifying A-Pillar Reinforcement Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4036 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Bottom A-Pillar Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4037 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Hart metal ball cutter Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant)
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fire-resistant tarp to avoid damage from flying sparks.
3 Partially remove side wall paneling
AR63.10- P- 0115MCC 4 Separate lower A-pillar reinforcement (1)
AR63.20- P-1114- 01MCC 5 Prepare connecting points for lower A-pillar reinforcement (1) on body
AR63.20- P-1114- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001-
Prepare lower A-pillar reinforcement (1) for¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4038 · Applies to: 450, 451, 452, 454
07A 6 Prepare lower A-pillar reinforcement (1) for installation
AR63.20- P-1114- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
7 Install lower A-pillar reinforcement (1) and weld in
AR63.20- P-1114- 04MCC 8 Partially install side wall paneling
AR63.10- P- 0115MCC 9 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
10 Prime area to be repaired using primer filler
11 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant BR00.45- Z-1003- 01A 12 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 13 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 14 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 15 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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4039 · Applies to: 450, 451, 452, 454
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 > SEPARATE B-PILLAR REINFORCEMENT - AR63.20-P-1351- 01MCC > 1. Expose spot welds on B-pillar reinforcement (1) and cut out (areas A, B, C, D, E, F, G and H). 2. Heat B-pillar reinforcement (1) with hot air gun (area D). Area (D) is bonded. 3. Remove damaged B-pillar reinforcement (1). TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS ON B-PILLAR REINFORCEMENT ON BODY - AR63.20-P-1351-02MCC > 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, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding Fig 1: Identifying B-Pillar Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4040 · Applies to: 450, 451, 452, 454
inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR INDEX > REPLACE B-PILLAR REINFORCEMENT - AR63.20-P- 1351MCC > MODEL 451.3 Fig 1: Identifying B-Pillar Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4041 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00- P-0008- Fig 1: Identifying B-Pillar Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
01MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4042 · Applies to: 450, 451, 452, 454
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- 0115MCC 4 Partially remove side wall reinforcement
AR63.20- P- 0862MCC 5 Remove rear lamp insert
AR64.20- P- 1061MCC 6 Separate B-pillar reinforcement (1)
AR63.20- P-1351- 01MCC 7 Prepare connecting points on B-pillar reinforcement (1) on body
AR63.20- P-1351- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 8 Prepare B-pillar reinforcement (1) for installation
AR63.20- P-1351- 03MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
9 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 AR63.10- P-0696-
corrosion protection, it is¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4043 · Applies to: 450, 451, 452, 454
necessary to apply a seam sealant. 05MCC
Adhesive *BR00.45- Z-1092- 02A 10 Install rear lamp insert
AR64.20- P- 1061MCC 11 Partially install side wall reinforcement
AR63.20- P- 0862MCC 12 Partially install side wall paneling
AR63.10- P- 0115MCC 13 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
14 Prime area to be repaired using primer filler
15 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant BR00.45- Z-1003- 01A 16 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 17 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 18 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 19 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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4044 · Applies to: 450, 451, 452, 454
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 > REMOVE B-PILLAR INTERNAL COMPONENT - AR63.20-P- 1355-01MCC > All operations steps are shown on model 451.3 as an example. 1. Expose spot welds on B-pillar internal component (1) and cut out (areas A, B and F). 2. Heat B-pillar internal component (1) with hot air gun (area A). Area A is bonded. Fig 1: Identifying B-Pillar Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Expose spot welds on B-pillar internal component (1) and cut out (area D).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4045 · Applies to: 450, 451, 452, 454
- Expose spot welds on B-pillar internal component (1) and cut out (area C and E). Only for model 451.3
- Remove damaged B-pillar internal component (1). TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS FOR B-PILLAR INTERNAL COMPONENT ON BODY. - AR63.20-P-1355-02MCC > Fig 2: Identifying B-Pillar Internal Component With Cutting Areas (A) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying B-Pillar Internal Component With Cutting Areas (C And E) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Grind mating surfaces down to bare metal in the crosshatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4046 · Applies to: 450, 451, 452, 454
Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. Shown on model 451.3 2. Grind mating surfaces down to bare metal in the crosshatched 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. Coat inside of spot weld flanges not bonded with zinc dust paint. Only for model 451.3 Fig 1: Identifying B-Pillar Internal Component With Grinding Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE B-PILLAR INTERNAL COMPONENT FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4047 · Applies to: 450, 451, 452, 454
INSTALLATION - AR63.20-P-1355-03MCC > Fig 2: Identifying B-Pillar Internal Component With Grinding Surfaces - Shown On Model 451.3 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4048 · Applies to: 450, 451, 452, 454
- Grind B-pillar internal component (1) down to bare metal in cross-hatched areas (areas A and B only on model 451.3). Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Refer to manufacturer specifications for adhesive curing and application times. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR INDEX > INSTALL B-PILLAR INTERNAL COMPONENT AND WELD IN
- AR63.20-P-1355-04MCC > All operations steps are shown on model 451.3 as an example.
- Fit B-pillar internal component (1) and fasten with vise grip pliers.
- Drill holes for plug welding on B-pillar internal component (1) through one sheet metal thickness (area A).
- Remove B-pillar inner section (1) Fig 1: Identifying B-Pillar Internal Component With Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Apply 2-component adhesive material in crosshatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4049 · Applies to: 450, 451, 452, 454
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. Fig 1: Identifying B-Pillar Internal Component With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. B-pillar internal component (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4050 · Applies to: 450, 451, 452, 454
(areas B, C, D and F). 6. B-pillar internal component (1) (area E). 7. B-pillar internal component (1) (areas G and H). Fig 2: Identifying Adhesive Material Application Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying B-Pillar Internal Component With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Only for model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4051 · Applies to: 450, 451, 452, 454
- Grind all spot welds down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR INDEX > REMOVE/INSTALL B-PILLAR INNER SECTION - AR63.20-P- 1355MCC > MODEL 451.3 /4 Illustrated on model 451.3 Fig 4: Identifying B-Pillar Internal Component With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4052 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00- P-0008- Fig 1: Identifying B-Pillar Inner Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
01MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4053 · Applies to: 450, 451, 452, 454
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
AR63.20- P-1355-
section (1) on body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4054 · Applies to: 450, 451, 452, 454
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 required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR63.20- P-1355- 04MCC
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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4055 · Applies to: 450, 451, 452, 454
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 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 > REMOVE SIDE LONGITUDINAL MEMBER REINFORCEMENT - AR63.30-P-0816-01MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4056 · Applies to: 450, 451, 452, 454
- Expose spot welds on side longitudinal member reinforcement (1) and cut out (areas C, D, E, F, G and H).
- Remove damaged side longitudinal member reinforcement (1). TESTING & REPAIR INDEX > PREPARE SIDE LONGITUDINAL MEMBER REINFORCEMENT FOR INSTALLATION - AR63.30-P-0816-02MCC >
- Drill holes for plug welding on side longitudinal member reinforcement (1) (area C). Transfer dimensions of holes for plug welding from vehicle.
- Grind connection flange on side longitudinal member reinforcement (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. Fig 1: Identifying Longitudinal Member Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > INSTALL SIDE LONGITUDINAL MEMBER REINFORCEMENT¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4057 · Applies to: 450, 451, 452, 454
- AR63.30-P-0816-03MCC > Fig 1: Identifying Side Longitudinal Member Reinforcement With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Position resistance spot welds at precise position of resistance spot welds made at factory to ensure¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4058 · Applies to: 450, 451, 452, 454
minimum required strength for weld joints. (areas C, E and G). 1. Fit side longitudinal member reinforcement (1) and fasten with vise grip pliers. 2. Side longitudinal member reinforcement (1) (areas C, D, E, F, G and H). 3. Side longitudinal member reinforcement (1) (area J). 4. Grind all spot welds down flat if required. 5. Clean all other weld joints with wire brush. TESTING & REPAIR INDEX > PREPARE CONNECTION POINTS ON SIDE LONGITUDINAL MEMBER REINFORCEMENT ON BODY. - AR63.30-P-0816-04MCC > 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Side Longitudinal Member Reinforcement With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4060 · Applies to: 450, 451, 452, 454
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 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 following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, Ø 6 mm Electrode miller
Vise grip pliers¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4061 · Applies to: 450, 451, 452, 454
Inert gas welder Spot welder Tarp (fire-resistant) 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 Remove side wall paneling section In case of model 451.3 AR63.10- P- 0115MCC
On model 451.4 AR63.10- P- 0115MCO 4 Remove side wall reinforcement section
AR63.20- P- 0862MCC 5 Remove B-pillar reinforcement In case of model 451.3 AR63.20- P- 1351MCC
On model 451.4 AR63.20- P- 1351MCO 6 Remove rear lamp insert In case of model 451.3 AR64.20- P- 1061MCC
On model 451.4 AR64.20- P- 1061MCO 7 Remove rear wheelhouse
AR63.10- P- 0661MCC 8 Remove lower A-pillar reinforcement In case of model 451.3 AR63.20- P- 1114MCC
On model 451.4 AR63.20- P- 1114MCO 9 Remove side longitudinal member reinforcement (1)
AR63.30- P-0816- 01MCC Prepare connection points on side AR63.30-
longitudinal member reinforcement (1) on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4062 · Applies to: 450, 451, 452, 454
10 longitudinal member reinforcement (1) on body
P-0816- 04MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 11 Prepare side longitudinal member reinforcement (1) for installation
AR63.30- P-0816- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
12 Install side longitudinal member reinforcement (1) and weld in
AR63.30- P-0816- 03MCC 13 Install lower A-pillar reinforcement In case of model 451.3 AR63.20- P- 1114MCC
On model 451.4 AR63.20- P- 1114MCO 14 Install rear wheelhouse
AR63.10- P- 0661MCC 15 Install rear lamp insert In case of model 451.3 AR64.20- P- 1061MCC
On model 451.4 AR64.20- P- 1061MCO 16 Install B-pillar reinforcement In case of model 451.3 AR63.20- P- 1351MCC
On model 451.4 AR63.20- P- 1351MCO 17 Install side wall paneling reinforcement section
AR63.20- P- 0862MCC 18 Install side wall paneling section In case of model 451.3 AR63.10- P- 0115MCC
On model 451.4 AR63.10- P- 0115MCO
Clean welds and sheet metal flange with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4063 · Applies to: 450, 451, 452, 454
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
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 INDEX > REMOVE SIDE LONGITUDINAL MEMBER REINFORCEMENT SECTION - AR63.30-P-0818-01MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4064 · Applies to: 450, 451, 452, 454
1.1 Scribe cut on side longitudinal member reinforcement and cut (area A). If rear area of longitudinal member is damaged. 1.2 Scribe cut on side longitudinal member reinforcement and cut (area B). If front area of longitudinal member is damaged. 2.1 Expose spot welds on rear section of side longitudinal member reinforcement (1.2) and cut out (areas E, F, G, and H). If rear area of longitudinal member is damaged. 2.2 Expose spot welds on front section of side longitudinal member reinforcement (1.1)and cut out (areas C, D, E and F). If front area of longitudinal member is damaged 3.1 Remove damaged front section from side longitudinal member reinforcement (1.1). If front area of longitudinal member is damaged 3.2 Remove damaged rear section from side longitudinal member reinforcement (1.2). If rear area of longitudinal member is damaged. TESTING & REPAIR INDEX > PREPARE SIDE LONGITUDINAL MEMBER REINFORCEMENT SECTION FOR INSTALLATION - AR63.30-P-0818-02MCC > 1. Scribe cuts on side longitudinal member reinforcement (1) according to damage profile and cut Fig 1: Identifying Side Longitudinal Member Reinforcement With Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(areas A or B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4065 · Applies to: 450, 451, 452, 454
- Drill holes for plug welding on longitudinal member reinforcement (1) in area C (only if rear area is damaged). Transfer dimensions of holes for plug welding from vehicle.
- Grind side longitudinal member reinforcement (1) down to bare metal in cross-hatched areas according to damage profile. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR INDEX > INSTALL SIDE LONGITUDINAL MEMBER REINFORCEMENT SECTION - AR63.30-P-0818-03MCC > Fig 1: Identifying Side Longitudinal Member Reinforcement With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Position resistance spot welds at precise position of resistance spot welds made at factory to ensure¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4066 · Applies to: 450, 451, 452, 454
minimum required strength for weld joints. (areas C, E and G). 1 Fit front section of side longitudinal member reinforcement (1.1) or rear section of side longitudinal member reinforcement (1.2) and fasten with vise grip pliers. 2.1 Front section on side longitudinal member reinforcement (1.1) (areas C, D, E and F). If front area is damaged. 2.2 Rear section on side longitudinal member reinforcement (1.2) (areas E, F, G and H). If rear area is damaged. 3.1 Front section on side longitudinal member reinforcement (1.1) (area B). If front area is damaged. 3.2 Rear section on side longitudinal member reinforcement (1.2) (area A). If rear area is damaged. 4 Rear section on side longitudinal member reinforcement (1.2) (area J). If rear area is damaged. 5 Grind all welds down flat, if required. 6 Clean all other welds with wire brush. TESTING & REPAIR INDEX > PREPARE CONNECTION POINTS FOR SIDE Fig 1: Identifying Side Longitudinal Member Reinforcement With 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. 4068 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Fig 1: Identifying Side Longitudinal Member Reinforcement With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on replacing body parts¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4069 · Applies to: 450, 451, 452, 454
AH60.00- P-0027- 01FF General information on repairs to body
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Hole punching pliers, Ø 6 mm Electrode miller Vise grip pliers Inert gas welder Spot welder Tarp (fire-resistant)
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 Remove side wall paneling section In case of model 451.3 AR63.10- P- 0115MCC
On model 451.4 AR63.10- P- 0115MCO 4 Remove side wall reinforcement section
AR63.20- P- 0862MCC 5 remove B-pillar reinforcement In case of model 451.3 AR63.20- P-
1351MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4070 · Applies to: 450, 451, 452, 454
On model 451.4 AR63.20- P- 1351MCO 6 Remove rear lamp insert In case of model 451.3 AR64.20- P- 1061MCC
On model 451.4 AR64.20- P- 1061MCO 7 Remove rear wheelhouse
AR63.10- P- 0661MCC 8 Remove lower A-pillar reinforcement In case of model 451.3 AR63.20- P- 1114MCC
On model 451.4 AR63.20- P- 1114MCO 9 Remove side longitudinal member reinforcement section (1)
AR63.30- P-0818- 01MCC 10 Prepare connection points for side longitudinal member reinforcement section (1) on body
AR63.30- P-0818- 04MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 11 Prepare side longitudinal member reinforcement section (1) for installation
AR63.30- P-0818- 02MCC
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
12 Install side longitudinal member reinforcement section (1) and weld in
AR63.30- P-0818- 03MCC 13 Install lower A-pillar reinforcement In case of model 451.3 AR63.20- P- 1114MCC
On model 451.4 AR63.20- P- 1114MCO AR63.10-
Install rear wheelhouse¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4071 · Applies to: 450, 451, 452, 454
14 Install rear wheelhouse
P- 0661MCC 15 Install rear lamp insert In case of model 451.3 AR64.20- P- 1061MCC
On model 451.4 AR64.20- P- 1061MCO 16 Install B-pillar reinforcement In case of model 451.3 AR63.20- P- 1351MCC
On model 451.4 AR63.20- P- 1351MCO 17 Install side wall reinforcement section
AR63.20- P- 0862MCC 18 Install side wall paneling section In case of 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
Reinstall all detachable parts removed¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4072 · Applies to: 450, 451, 452, 454
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 INDEX > PARTIALLY REMOVE OUTER LONGITUDINAL MEMBER INNER SHELL ON ENTRANCE - AR63.30-P-1143-01MCC > Shown on model 451.3 All steps are shown as an example on the rear section of the longitudinal member inner shell (1). Adapt repair sections according to damage profile. 1. Scribe cut on longitudinal member inner shell (1) and cut (area A). 2. Expose spot welds on longitudinal member inner shell (1) and cut out (areas B, C, D and E). 3. Pry out lug (arrow). 4. Heat connecting flange with hot air blower (area C). Area B is bonded. 5. Remove damaged inner shell longitudinal member (1) Fig 1: Identifying Outer Longitudinal Member Inner Shell With Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PARTIALLY PREPARE LONGITUDINAL MEMBER INNER¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4073 · Applies to: 450, 451, 452, 454
SHELL ON ENTRANCE - AR63.30-P-1143-02MCC > All steps are shown as an example on the rear section of the longitudinal member inner shell (1.1). Adapt repair sections according to damage profile. 1. Scribe cut on longitudinal member inner shell (1) and cut (area A). Transfer dimension for cut from vehicle. 2. Grind rear section on longitudinal member inner shell (1.1) down to bare metal in 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 > PARTIALLY INSTALL LONGITUDINAL MEMBER INNER SHELL ON ENTRANCE - AR63.30-P-1143-03MCC > Fig 1: Identifying Longitudinal Member Inner Shell With Grinding 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. 4074 · Applies to: 450, 451, 452, 454
All steps are shown as an example on the rear section of the longitudinal member inner shell. Adapt repair sections according to damage profile. 1. Apply 2-component adhesive to mating surfaces in 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. Observe the manufacturer's specifications for the curing and processing time of the adhesive. 2. Fit longitudinal member inner shell (1) and fix in place using vise grip pliers. Shown on model 451.3 3. Longitudinal member inner shell (1) on rear entry (areas C, D and E). 4. Position lug (arrow). Fig 1: Identifying Longitudinal Member Inner Shell Adhesive Applying Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Longitudinal Member Inner Shell With Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4076 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00- P-0008- 01MCC 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
AH91.00- P-0002- Fig 1: Identifying Longitudinal Member Inner Shell On Entry Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
units¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4077 · Applies to: 450, 451, 452, 454
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
AR63.30- P-1143-
shell on entry (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4078 · Applies to: 450, 451, 452, 454
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
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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4079 · Applies to: 450, 451, 452, 454
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
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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4080 · Applies to: 450, 451, 452, 454
Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR INDEX > REMOVE LONGITUDINAL MEMBER INNER SHELL ON ENTRY - AR63.30-P-1164-01MCC > Shown on model 451.3 1. Expose spot welds on longitudinal member inner shell on entry (1) and cut out (areas A, B, C, D, E, F, G, H and J). 2. Pry out lugs (arrows) on longitudinal member inner shell on entry (1). 3. Heat connecting flange with hot air blower (areas A, B and C). Areas A, B and C are bonded. 4. Remove damaged longitudinal member inner shell on entry (1). 5. Remove drill shavings using wet/dry vacuum cleaner TESTING & REPAIR INDEX > PREPARE LONGITUDINAL MEMBER INNER SHELL ON ENTRY - AR63.30-P-1164-02MCC > 1. Grind longitudinal member inner shell on entry (1) down to bare metal in cross-hatched areas. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint. Observe pretreatment of bonding surfaces, otherwise, adhesive force of 2-component adhesive starts to decrease. Fig 1: Identifying Longitudinal Member Inner Shell With Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Grind spot weld flanges down to bare metal on both sides. Coat inside of spot weld flanges not¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4081 · Applies to: 450, 451, 452, 454
bonded with zinc dust paint. TESTING & REPAIR INDEX > INSTALL LONGITUDINAL MEMBER INNER SHELL ON ENTRY - AR63.30-P-1164-03MCC > Fig 1: Identifying Longitudinal Member Inner Shell Grinding 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. 4082 · Applies to: 450, 451, 452, 454
- Apply 2-component adhesive mating surfaces in 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. Observe manufacturer's specifications for drying and processing time of adhesive. Fig 1: Identifying Longitudinal Member Inner Shell Adhesive Mating Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4083 · Applies to: 450, 451, 452, 454
- Fit longitudinal member inner shell on entry (1) and fix in place using vise grip pliers.
- Longitudinal member inner shell on entry (1) (areas A, B, C, D, E, F and G).
- Position lugs (arrows) on longitudinal member inner shell on entry (1).
- Longitudinal member inner shell on entry (1) (area H).
- Grind spot welds down flat, is required.
- Clean all other weld joints with wire brush. TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS FOR LONGITUDINAL MEMBER INNER SHELL ON ENTRY ON BODY - AR63.30-P-1164-04MCC > Fig 2: Identifying Longitudinal Member Inner Shell Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4085 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00- P-0008- Fig 1: Identifying Longitudinal Member Inner Shell On Entry Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
01MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4086 · Applies to: 450, 451, 452, 454
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
AR63.30- P-1164-
entry (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4087 · Applies to: 450, 451, 452, 454
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
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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4088 · Applies to: 450, 451, 452, 454
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
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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4089 · Applies to: 450, 451, 452, 454
Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR INDEX > REMOVE CENTER MAIN FLOOR PANEL REINFORCEMENT - AR63.40-P-1110-01MCC > Shown on model 451.4 1. Expose spot welds on center main floor panel reinforcement (1) and cut out (areas A, B, C, D, E, F, G, H, J and K). 2. Remove damaged center main floor panel reinforcement (1). TESTING & REPAIR INDEX > PREPARE CENTER MAIN FLOOR PANEL REINFORCEMENT - AR63.40-P-1110-02MCC > 1. Drill holes for plug welding on center main floor panel reinforcement (1) (areas A and B). 2. Grind center main floor panel reinforcement (1) down to bare metal in cross-hatched areas. Fig 1: Identifying Center Main Floor Panel Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE CONNECTION POINTS ON CENTER MAIN¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4090 · Applies to: 450, 451, 452, 454
FLOOR PANEL REINFORCEMENT ON BODY - AR63.40-P-1110-03MCC > Shown on model 451.3 1. Sand connection surfaces down to bare metal in the cross-hatched areas. Fig 1: Identifying Drilling Holes For Plug Welding On Center Main Floor Panel Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > INSTALL CENTER MAIN FLOOR PANEL REINFORCEMENT -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4091 · Applies to: 450, 451, 452, 454
AR63.40-P-1110-04MCC > Fig 1: Identifying Center Main Floor Panel Reinforcement Sanding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit center main floor panel reinforcement (1) and fasten.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4092 · Applies to: 450, 451, 452, 454
- Drill Ø 6.5 mm rivet holes (areas A, B, C, D, E, F, G and K).
- Remove center main floor panel reinforcement (1).
- Deburr rivet holes on center main floor panel reinforcement (1) and body on both sides. Fig 1: Identifying Center Main Floor Panel Reinforcement Rivet Holes Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Center Main Floor Panel Reinforcement Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
body parts on sharp vehicle parts¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4094 · Applies to: 450, 451, 452, 454
near sharp and non- deburred vehicle parts. Deburr repair panels. 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 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
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 Remove center main floor panel reinforcement (1)
AR63.40- P-1110- 01MCC 4 Prepare connecting points on center main floor panel reinforcement (1) on body.
AR63.40- P-1110- 03MCC 5 Prepare center main floor panel reinforcement (1) for installation
AR63.40- P-1110- 02MCC Install
6 Install center main floor panel reinforcement (1) and weld in
AR63.40- P-1110- 04MCC
Rivet *BR00.45- Z-1001- 13A
Clean welds and sheet metal flange with wire¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4095 · Applies to: 450, 451, 452, 454
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 MunichGermanyTel. +49-899268-0Fax +49- 899101978www.Loctite.de BR00.45- Z-1001- 13A Blind rivet 6.4 x 14 A 003 990 35 97 TESTING & REPAIR INDEX > PARTIALLY REMOVE MAIN FLOOR PANEL - AR63.40-P- 1180-24MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4096 · Applies to: 450, 451, 452, 454
- Scribe separation line on front main floor panel (1) and cut (area A).
- Expose spot welds on front main floor panel (1) and cut out (area B).
- Heat connecting flange with hot air blower (area C). Area B is bonded.
- Remove damaged section (1.1)
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR INDEX > PARTIALLY REMOVE MAIN FLOOR PANEL - AR63.40-P- 1180-24MCD > Fig 1: Identifying Front Main Floor Panel 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. 4097 · Applies to: 450, 451, 452, 454
- Scribe separation line on rear main floor panel (1) and cut (area A).
- Expose spot welds on rear main floor panel (1) and cut out (areas B, C and D).
- Remove damaged section (1.1)
- Remove drilling shavings with wet/dry vacuum cleaner. TESTING & REPAIR INDEX > PARTIALLY PREPARE CONNECTING POINTS FOR MAIN FLOOR PANEL ON BODY - AR63.40-P-1180-25MCC >
- 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, otherwise adhesion of the 2-component adhesive may be adversely affected. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. Fig 1: Identifying Rear Main Floor Panel Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PARTIALLY PREPARE CONNECTING POINTS FOR MAIN¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4098 · Applies to: 450, 451, 452, 454
FLOOR PANEL ON BODY - AR63.40-P-1180-25MCD > Shown on model 451.3 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Fig 1: Identifying Main Floor Panel Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PARTIALLY PREPARE MAIN FLOOR PANEL FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4099 · Applies to: 450, 451, 452, 454
INSTALLATION. - AR63.40-P-1180-26MCC > 1. Scribe separation line on front main floor panel (1) and cut (area A). Fig 1: Identifying Main Floor Panel Grinding Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Main Floor Panel With Cutting Section Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Transfer dimension for cut A from vehicle.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4100 · Applies to: 450, 451, 452, 454
- Grind mating surfaces on section (1.1) down to bare metal in 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. Grind spot weld flanges down to bare metal on both sides. Observe pretreatment of bonding surfaces. TESTING & REPAIR INDEX > PARTIALLY PREPARE MAIN FLOOR PANEL FOR INSTALLATION. - AR63.40-P-1180-26MCD >
- Scribe separation line on rear main floor panel (1) and cut (area A). Transfer dimension for cut A from vehicle.
- Drill hole for plug welding on section (1.1) (area B). Transfer dimension from vehicle.
- Grind mating surfaces on section (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. TESTING & REPAIR INDEX > PARTIALLY INSTALL MAIN FLOOR PANEL - AR63.40-P- 1180-27MCC >
- 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. Fig 1: Identifying Rear Main Floor Panel With Cutting Sections Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Fit main floor panel (1), front longitudinal member (2) and longitudinal member console (3) with¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4101 · Applies to: 450, 451, 452, 454
straightening tools and fit in place using vise grip pliers and C-clamps. Observe set-up plans. 3. Tack weld main floor panel (1) (area B). 4. Main floor panel (1) (area A). 5. Main floor panel (1) (area B). Weld in intervals; minimizes heat distortion. Fig 1: Identifying Main Floor Panel Adhesive Applying Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Grind all weld joints down flat if required.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4102 · Applies to: 450, 451, 452, 454
- Clean all other weld joints with wire brush.
- Remove front longitudinal member (2) and longitudinal member console (3), if required. TESTING & REPAIR INDEX > PARTIALLY INSTALL MAIN FLOOR PANEL - AR63.40-P- 1180-27MCD > Fig 2: Identifying Main Floor Panel With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4104 · Applies to: 450, 451, 452, 454
30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Pretreatment of bonding surfaces
AH60.00- P-0008- 01MCC 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
AH91.00- P-0002- Fig 1: Identifying Front Main Floor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
units¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4105 · Applies to: 450, 451, 452, 454
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 AR62.20-
Remove front longitudinal member¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4106 · Applies to: 450, 451, 452, 454
11 Remove front longitudinal member
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 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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4107 · Applies to: 450, 451, 452, 454
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 29 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 30 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 31 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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4108 · Applies to: 450, 451, 452, 454
Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunichGermanyTel. +49-899268-0Fax +49- 899101978www.Loctite.de TESTING & REPAIR INDEX > PARTIALLY REPLACE MAIN FLOOR PANEL - AR63.40-P- 1180MCD > MODEL 451.3 /4 Rear main floor panel 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 Measures for preventing damage to vehicles or components when performing
AH00.00- P-0005- Fig 1: Identifying Rear Main Floor Panel Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
electric welding work¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4109 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Electrode miller Vise grip pliers Spot welder Inert gas welder Weld protection blanket
1 Remove detachable parts in the repair area
2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof weld protection blanket to avoid damage from flying sparks.
3 Partially remove side wall paneling On model 451.3 AR63.10- P-
0115MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4110 · Applies to: 450, 451, 452, 454
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 console on lower 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 center main floor panel reinforcement
AR63.40- P- 1110MCC 13 Partially remove crossmember below front seat
AR63.40- P- 1189MCC 14 Remove center 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 (1)
AR63.40- P-1180-
24MCD¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4111 · Applies to: 450, 451, 452, 454
17 Partially prepare connecting points for rear main floor panel (1) on body.
AR63.40- P-1180- 25MCD
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A 18 Partially prepare rear main floor panel (1) for installation
AR63.40- P-1180- 26MCD
Zinc dust paint suitable for spot welding *BR00.45- Z-1001- 07A Install
19 Install section of rear main floor panel (1)
AR63.40- P-1180- 27MCD 20 Partially install front main floor panel
AR63.40- P- 1180MCC 21 Instal center console below front seat.
AR63.40- P- 1192MCC 22 Partially install crossmember below front seat
AR63.40- P- 1189MCC 23 Install center main floor panel reinforcement
AR63.40- P- 1110MCC 24 Install front longitudinal member
AR62.20- P- 1242MCC 25 Partially install longitudinal member inner shell on entrance
AR63.30- P- 1143MCC 26 Install console on lower front longitudinal member
AR62.20- P- 1265MCC 27 Install longitudinal member locking lug
AR62.20- P- 1267MCC 28 Partially install side longitudinal member reinforcement
AR63.30- P- 0818MCC
Install outer console below front seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4112 · Applies to: 450, 451, 452, 454
29 Install outer console below front seat
AR63.40- P- 1192MCD 30 Install tank support. According to damage profile:
Left tank support AR61.10- P- 5708MCD
Right tank support AR61.10- P- 5708MCC 31 Install accelerator pedal console
AR63.40- P- 1300MCC 32 Partially install side wall reinforcement
AR63.20- P- 0862MCC 33 Install lower A-pillar reinforcement On model 451.3 AR63.20- P- 1114MCC
On model 451.4 AR63.20- P- 1114MCO 34 Install lower outer A-pillar On model 451.4 AR63.20- P- 1102MCO 35 Partially install side wall paneling On model 451.3 AR63.10- P- 0115MCC
On model 451.4 AR63.10- P- 0115MCO 36 Clean welds and sheet metal flange with wire brush and clean areas to be repaired
37 Prime area to be repaired using primer filler
38 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant BR00.45- Z-1003- 01A 39 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A
Paint area repaired and adjacent surfaces¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4113 · Applies to: 450, 451, 452, 454
40 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 41 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 42 Reinstall all detachable parts removed
AUXILIARY 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 INDEX > PARTIALLY REMOVE CROSSMEMBER BELOW FRONT SEAT - AR63.40-P-1189-01MCC >
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4114 · Applies to: 450, 451, 452, 454
- Scribe cut on crossmember below front seat (1) and cut (area A).
- Expose spot welds on crossmember below front seat (1) and cut out (areas B, C, D and D ).
- Expose spot welds on crossmember below front seat (1) and drill out with Ø 6.5 mm bit (area D).
- Heat connecting flange with hot air blower (area C). Area C is bonded.
- Remove damaged section from crossmember below front seat (1).
- Remove drill shavings using wet/dry vacuum cleaner TESTING & REPAIR INDEX > PARTIALLY PREPARE CROSSMEMBER BELOW FRONT SEAT FOR INSTALLATION - AR63.40-P-1189-02MCC >
- Scribe cut on crossmember below front seat (1) and cut (area A). Transfer dimension for cut from vehicle 1 2 Fig 1: Identifying Spot Welding Areas On Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Grind section (1.1) of crossmember below front seat (1) down to bare metal in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4115 · Applies to: 450, 451, 452, 454
Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces, otherwise the adhesive force of the 2-component adhesive starts to decrease. TESTING & REPAIR INDEX > PARTIALLY INSTALL CROSSMEMBER BELOW FRONT SEAT - AR63.40-P-1189-03MCC > 1. Fit section of crossmember below front seat (1.1) and fix in place using clamping pliers and C- clamps. 2. Drill Ø 6.5 mm rivet holes (areas A and B). Complete remaining welding and riveted joints and rivet holes together with longitudinal member inner shell. Fig 1: Identifying Crossmember Below Front Seat With Cutting Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Remove section from crossmember below front seat (1.1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4116 · Applies to: 450, 451, 452, 454
- Deburr rivet holes on section of crossmember below front seat (1.1) and body on both sides.
- Apply 2-component adhesive to mating surfaces in 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. Apply adhesive bead in area of longitudinal member only after installing longitudinal member inner shell. If applicable, slightly pry open connecting flange (arrows). Observe manufacturer's specifications for drying and processing time for 2-component adhesive. Fig 1: Identifying Crossmember Below Front Seat With Rivet Holes Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Fit section of crossmember below front seat (1.1) and fix in place using manual temporary¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4117 · Applies to: 450, 451, 452, 454
fasteners, clamping pliers and C-clamps. 7. Section of crossmember below front seat (1.1) (area D). 8. Rivet section of crossmember below front seat (1.1) using Polygrip flat round head rivet, 6.4 x 14 (areas A and B). Complete riveted joints in area C only after installing longitudinal member inner shell on entry. Fig 2: Identifying Adhesive Applying Areas On Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PARTIALLY PREPARE CONNECTING POINTS FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4118 · Applies to: 450, 451, 452, 454
CROSSMEMBER BELOW FRONT SEAT ON BODY - AR63.40-P-1189-04MCC > 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces, otherwise the adhesive force of the 2-component adhesive starts to decrease. If applicable, slightly pry open sheet metal lug (arrows) to grind down. Fig 3: Identifying Rivet Section Of Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4120 · Applies to: 450, 451, 452, 454
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 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 Pretreatment of bonding surfaces
AH60.00- P-0008- Fig 1: Identifying Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
01MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4121 · Applies to: 450, 451, 452, 454
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
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
Remove B-pillar inner section¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4122 · Applies to: 450, 451, 452, 454
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 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 AR64.20-
Install rear lamp insert¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4123 · Applies to: 450, 451, 452, 454
18 Install rear lamp insert On model 451.3 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 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-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4124 · Applies to: 450, 451, 452, 454
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- 13A Blind rivet 6.4 x 14 A 003 990 35 97 TESTING & REPAIR INDEX > REMOVE CROSSMEMBER BELOW FRONT SEAT - AR63.40- P-1190-01MCC > Shown on model 451.3 The left longitudinal member inner shell can be removed or installed. The steps are shown with left longitudinal member inner shell installed. 1. Expose spot welds on crossmember below front seat (1) and cut out (areas A, B , B , B , B , C and D). 2. Expose spot welds on crossmember below front seat (1) and drill with Ø 6.5 mm bit (area B). 3. Heat connecting flange with hot air blower (areas B , C and D). Areas B , C and D are bonded. 1 2 3 4 5 5 Fig 1: Identifying Spot Welding Areas On Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. Remove damaged crossmember below front seat (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4125 · Applies to: 450, 451, 452, 454
- Remove drill shavings using wet/dry vacuum cleaner TESTING & REPAIR INDEX > PREPARE CROSSMEMBER BELOW FRONT SEAT - AR63.40-P-1190-02MCC >
- Grind crossmember below front seat (1) down to bare metal in cross-hatched areas. Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces, otherwise the adhesive force of the 2-component adhesive starts to decrease. TESTING & REPAIR INDEX > INSTALL CROSSMEMBER BELOW FRONT SEAT - AR63.40- P-1190-03MCC > The left longitudinal member inner shell can be removed or installed. The steps are shown with left longitudinal member inner shell installed.
- Fit crossmember below front seat (1) and fix in place using clamping pliers and C-clamps.
- Drill Ø 6.5 mm rivet holes (areas A, B and C). The remaining welds and riveted joints are completed later. Fig 1: Identifying Grinding Surfaces On Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Remove crossmember below front seat (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4126 · Applies to: 450, 451, 452, 454
- Deburr rivet holes on crossmember below front seat (1) and body on both sides.
- Apply 2-component adhesive to mating surfaces in cross-hatched areas. Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces. Otherwise, the adhesive force of the 2-component adhesive starts to decrease. Fig 1: Identifying Crossmember Below Front Seat Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. Fit crossmember below front seat (1) and fix in place using manual temporary fasteners, clamping¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4127 · Applies to: 450, 451, 452, 454
pliers and C-clamps. 7. Rivet crossmember below front seat (1) using Polygrip flat round head rivet, 6.4 x 14 (areas A, B and C). Fig 2: Identifying Crossmember Below Front Adhesive Applying Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE MATING SURFACES ON VEHICLE FOR¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4128 · Applies to: 450, 451, 452, 454
CROSSMEMBER BELOW LEFT FRONT SEAT - AR63.40-P-1190-04MCC > 1. Grind mating surfaces down to bare metal in the cross-hatched areas. Thoroughly clean all bonding surfaces. Observe pretreatment of bonding surfaces. Otherwise the adhesive force of the 2-component adhesive starts to decrease. Fig 3: Identifying Crossmember Below Front Seat Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4130 · Applies to: 450, 451, 452, 454
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 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 Pneumatic/hydraulic blind rivet tool
Fig 1: Identifying Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
listed above.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4131 · Applies to: 450, 451, 452, 454
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 Remove crossmember below front seat (1)
AR63.40- P-1190- 01MCC Prepare connecting points for AR63.40-
crossmember below front seat¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4132 · Applies to: 450, 451, 452, 454
11 crossmember below front seat (1) on body
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 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 AR63.10-
On model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4133 · Applies to: 450, 451, 452, 454
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- 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-
Measures for preventing damage to¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4135 · Applies to: 450, 451, 452, 454
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 Notes on replacing body parts
AH60.00- P-0027- 01FF General information on repairs to body
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Sanding disks Cutting discs Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Body saw (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Weld protection blanket
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 AR63.20-
Remove lower A-pillar outer section¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4136 · Applies to: 450, 451, 452, 454
4 Remove lower A-pillar outer section On model 451.4 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 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 upper 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
AR63.40- P- 1180MCD 17 Scribe cutting line on crossmember below front seat (1) and cut (area A) Support body with suitable jack stand (3) and wooden wedge (4) and secure with fastening aid (5) against tilting. Use tensioning strap
(5) as fastening aid.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4137 · Applies to: 450, 451, 452, 454
18 Remove damaged crossmember section below front seat (1.1)
19 Scribe cutting line on new crossmember below front (2) and cut (area C)
20 Remove section of new crossmember below front seat (2.1)
21 Grind mating surfaces on body and on section of new crossmember below front seat (2.1) down to bare metal in cross- hatched areas.
Install
22 Fix in place section of new crossmember below front seat (2.1), rear main floor panel, front main floor panel, front longitudinal member, longitudinal member mounting console and longitudinal member inner shell with straightening tool and fasten using vise grip pliers and C-clamps. Observe set-up plans.
Setup plans
23 Tack weld section of new crossmember below front seat (2.1) from bottom (arrow B).
24 Remove rear main floor panel, front main floor panel, front longitudinal member, longitudinal member mounting console and longitudinal member inner shell.
25 Section of new crossmember below front seat (2.1) (area B)
26 Grind all weld joints down flat if required.
27 Clean all other weld joints using a shank brush
28 Clean weld joints and sheet metal flange using a shank brush and clean repair areas.
29 Partially install rear main floor panel
AR63.40- P- 1180MCD 30 Partially install front main floor panel
AR63.40- P- 1180MCC 31 Install center mounting console below front seat
AR63.40- P-
1192MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4138 · Applies to: 450, 451, 452, 454
32 Partially install crossmember below upper front seat
AR63.40- P- 1189MCC 33 Install center main floor panel reinforcement
AR63.40- P- 1110MCC 34 Install front longitudinal member
AR62.20- P- 1242MCC 35 Partially install longitudinal member inner shell on entrance
AR63.30- P- 1143MCC 36 Install mounting console on bottom front longitudinal member
AR62.20- P- 1265MCC 37 Install longitudinal member locking lug
AR62.20- P- 1267MCC 38 Partially install side longitudinal member reinforcement
AR63.30- P- 0818MCC 39 Partially install side wall reinforcement
AR63.20- P- 0862MCC 40 Install lower A-pillar reinforcement On model 451.3 AR63.20- P- 1114MCC
On model 451.4 AR63.20- P- 1114MCO 41 Install lower outer A-pillar On model 451.4 AR63.20- P- 1102MCO 42 Partially install side wall paneling On model 451.3 AR63.10- P- 0115MCC
On model 451.4 AR63.10- P- 0115MCO 43 Prime area to be repaired using primer filler
44 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC *BR00.45-
Sealant¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4139 · Applies to: 450, 451, 452, 454
Z-1003- 01A 45 Supplement standard underbody protection with permanent underbody sealant Underfloor protection *BR00.45- Z-1001- 05A 46 Paint area repaired and adjacent surfaces
Notes on paintwork repairs
AH98.00- P-9408- 02MCC 47 Apply additional cavity preservation
AR97.20- P-1500FF
Teroson protective wax *BR00.45- Z-1008- 05A 48 Reinstall all detachable parts removed
AUXILIARY 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 > REMOVE CONSOLE BELOW FRONT SEAT - AR63.40-P- 1192-01MCC >
1. Expose spot welds on console below front seat (1) and cut out (areas A and B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4140 · Applies to: 450, 451, 452, 454
- Remove damaged console below front seat (1). TESTING & REPAIR INDEX > REMOVE CONSOLE BELOW FRONT SEAT - AR63.40-P- 1192-01MCD >
- Expose spot welds on console below front seat (1) and cut out (areas A and B).
- Remove damaged console below front seat (1). TESTING & REPAIR INDEX > PREPARE CONSOLE BELOW FRONT SEAT - AR63.40-P- 1192-02MCC > Fig 1: Identifying Console Below Front Seat Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Console Below Front Seat Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Drill holes for plug welding on console below front seat (1) (areas A and B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4141 · Applies to: 450, 451, 452, 454
- Grind console below front seat (1) down to bare metal in cross-hatched areas. TESTING & REPAIR INDEX > PREPARE CONSOLE BELOW FRONT SEAT - AR63.40-P- 1192-02MCD >
- Drill holes for plug welding on console below front seat (1) (areas A and B).
- Grind console below front seat (1) down to bare metal in cross-hatched areas. TESTING & REPAIR INDEX > PREPARE CONNECTION POINTS ON CONSOLE BELOW FRONT SEAT ON BODY - AR63.40-P-1192-03MCC >
- Sand connection surfaces down to bare metal in the cross-hatched areas. Fig 1: Identifying Drilling Holes For Plug Welding On Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Drilling Holes For Plug Welding On Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE CONNECTION POINTS ON CONSOLE BELOW¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4142 · Applies to: 450, 451, 452, 454
FRONT SEAT ON BODY - AR63.40-P-1192-03MCD > 1. Sand connection surfaces down to bare metal in the cross-hatched areas. TESTING & REPAIR INDEX > INSTALL CONSOLE BELOW FRONT SEAT - AR63.40-P- 1192-04MCC > Fig 1: Identifying Connection Surfaces On Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Connection Surfaces On Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit console below front seat (1) together with seat frame and fasten with mounting bolts.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4143 · Applies to: 450, 451, 452, 454
- Fasten console below front seat (1) with a number of tack welds.
- Remove seat frame and mounting bolts.
- Console below front seat (1) (areas A and B).
- Grind all weld joints down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR INDEX > INSTALL CONSOLE BELOW FRONT SEAT - AR63.40-P- 1192-04MCD > Fig 1: Identifying Console Below Front Seat Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Console Below Front Seat With Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Fit console below front seat (1) together with seat frame and fasten with mounting bolts.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4144 · Applies to: 450, 451, 452, 454
- Drill Ø 6.5 mm rivet holes on console below front seat (1) (areas A and B).
- Remove console below front seat (1), seat frame and mounting bolts.
- Deburr rivet holes on console below front seat (1) and body on both sides.
- Fit console below front seat (1) and fasten with manual temporary fasteners.
- Console below front seat (1) (areas C and D).
- Rivet console below front seat (1) with 6.4 x 14 Polygrip flat/round head rivet (areas A and B).
- Grind all weld joints down flat if required.
- Clean all other weld joints with wire brush. TESTING & REPAIR INDEX > REPLACE CONSOLE BELOW FRONT SEAT - AR63.40-P- 1192MCC > MODEL 451.3 /4 Center console below front seat Shown on model 451.3 Fig 2: Identifying Console Below Front Seat Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4145 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4146 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Inert gas welder Tarp (fire-resistant)
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 Remove console below front seat (1)
AR63.40- P-1192- 01MCC 4 Prepare connection points on console below front seat (1) on body
AR63.40- P-1192- 03MCC 5 Prepare console below front seat (1) for installation
AR63.40- P-1192- 02MCC Install
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
Supplement standard underbody protection¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4147 · Applies to: 450, 451, 452, 454
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 CONSOLE BELOW FRONT SEAT - AR63.40-P- 1192MCD > MODEL 451.3 /4 Outer console below front seat Shown on model 451.3
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4148 · Applies to: 450, 451, 452, 454
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 General information on riveting
AH60.00- P-0003- 01MCC Notes on replacing body parts
AH60.00- P-0027- 01FF Fig 1: Identifying Console Below Front Seat - Shown On Model 451.3 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
General information on repairs to body¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4149 · Applies to: 450, 451, 452, 454
AH60.00- P-0001- 01FF The following workshop equipment and tools are required for repair: Shank brush Grinding disk Cartridge gun Drill (electric/pneumatic) Angle grinder (electric/pneumatic) Wet/dry vacuum cleaner Inert gas welder Tarp (fire-resistant) Pneumatic- hydraulic blind rivet tool
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 Remove console below front seat (1)
AR63.40- P-1192- 01MCD 4 Prepare connection points on console below front seat (1) on body
AR63.40- P-1192- 03MCD 5 Prepare console below front seat (1) for installation
AR63.40- P-1192- 02MCD Install
6 Install console below front seat (1) and weld in
AR63.40- P-1192- 04MCD 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
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4151 · Applies to: 450, 451, 452, 454
MODIFICATION NOTES 30.1.09 Information on alternative repair method added (structural bonding eliminated) 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 Fig 1: Identifying Crossmember Mounting Console On Rear Floor Assembly With Wooden Wedge And Rear Main Floor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on performing repair, body work and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4152 · Applies to: 450, 451, 452, 454
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 longitudinal member¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4153 · Applies to: 450, 451, 452, 454
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¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4154 · Applies to: 450, 451, 452, 454
necessary to apply a seam sealant.
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
Install longitudinal member locking lug¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4155 · Applies to: 450, 451, 452, 454
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 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 *BR00.45-
Teroson protective wax¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4156 · Applies to: 450, 451, 452, 454
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 > REMOVE BATTERY COMPARTMENT - AR63.40-P-1196- 01MCC > Fig 1: Identifying Battery Compartment Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4157 · Applies to: 450, 451, 452, 454
- Expose spot welds on battery recess (1) and drill with 6.5 mm dia. bit (areas A, B, C and D).
- Heat connecting flange with hot air gun (areas A, B, C and D). Areas A, B, C and D are bonded.
- Remove damaged right battery recess (1).
- Remove drill shavings using wet/dry vacuum cleaner TESTING & REPAIR INDEX > PREPARE BATTERY COMPARTMENT FOR INSTALLATION - AR63.40-P-1196-02MCC > Shown on model 451.4
- Grind mating surfaces on battery recess (1) down to bare metal in 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. Observe manufacturer's specifications of 2- component adhesive for drying and processing time. TESTING & REPAIR INDEX > INSTALL BATTERY COMPARTMENT - AR63.40-P-1196- Fig 1: Identifying Mating Surfaces On Battery Recess - Shown On Model 451.4 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
03MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4158 · Applies to: 450, 451, 452, 454
- Fit battery recess (1) and fasten. Fasten battery recess (1) on underbody with manual hydraulic floor jack.
- Drill dia. 6.5 mm rivet holes (areas A, B, C and D).
- Remove battery recess (1)
- Deburr rivet holes on battery recess (1) and body on both sides. Fig 1: Identifying Battery Recess Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Apply 2-component glue to mating surfaces in crosshatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4159 · Applies to: 450, 451, 452, 454
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 battery recess (1) and fasten with manual temporary fasteners. 7. Rivet battery recess (1) Polygrip flat/round head rivet, dia. 6.4 x 14 (areas A, B, C and D). Fig 2: Identifying Glue Applying Areas On Mating Surfaces Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS ON BATTERY BOX ON¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4160 · Applies to: 450, 451, 452, 454
BODY - AR63.40-P-1196-04MCC > Shown on model 451.4 Fig 3: Identifying Battery Recess Rivet Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Grinding Surfaces Of Battery Box Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Pretreatment of bonding¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4162 · Applies to: 450, 451, 452, 454
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
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 Remove battery recess (1)
AR63.40- P-1196- 01MCC 4 Prepare connecting points on battery recess (1) on body
AR63.40- P-1196- 04MCC 5 Prepare battery recess (1) for installation
AR63.40- P-1196- 02MCC Install
6 Install battery recess (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-1196- 03MCC
Adhesive *BR00.45- Z-1092- 02A
Rivet *BR00.45- Z-1001-
Clean welds and sheet metal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4163 · Applies to: 450, 451, 452, 454
13A 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-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- Blind rivet 6.4 x 14 A 003 990 35 97
General information on riveting¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4165 · Applies to: 450, 451, 452, 454
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 following workshop equipment and tools are required for repair Shank brush Hart metal ball cutter Grinding disk Cartridge gun Drill (electric/pneumatic) Wet/dry vacuum cleaner Vise grip pliers Inert gas welder Tarp (fire-resistant)
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 Expose spot welds on accelerator pedal console (1) and cut out (areas A and B)
4 Remove damaged accelerator pedal console (1)
5 Grind mating surfaces on body down to bare metal in cross-hatched areas
6 Drill holes for plug welding on new accelerator pedal console (1) (areas E and F)
7 Remove protective paint from welding areas on new accelerator pedal console (1) and grind connecting flange down to bare metal in cross-hatched areas
Install
Fit accelerator pedal console (1) and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4166 · Applies to: 450, 451, 452, 454
8 Fit accelerator pedal console (1) and fasten. When fitting observe correct distances.
9 Accelerator pedal console (1) (areas C and D)
10 Level spot welds and clean with wire brush Clean (areas C and D) and repair areas.
11 Prime area to be repaired using primer filler
12 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC
Sealant BR00.45- Z-1003- 01A 13 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 14 Paint area repaired and adjacent surfaces
Notes 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-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 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: SIDE WALL - BA63.00-Z- 9999CZ > MODEL all
Rear fender¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4167 · Applies to: 450, 451, 452, 454 · AR: WS63.00-Z-9999CZ
MODEL 450.3 /4 BA63.50-P-1000-01A Rear fender MODEL 451.3 /4 BA63.50-P-1000-01B TORQUE SPECIFICATIONS > REAR FENDER - BA63.50-P-1000-01B > Model 451 REINFORCEMENT IN RIGHT REAR FENDER Number Designation Model 451.3/4 BA63.50-P-1001-01B Bolt, reinforcement in right rear fender Nm 15 SPECIAL TOOLS > SPECIAL TOOLS: SMART: SIDE WALL - WS63.00-Z-9999CZ > MODEL all 129 589 01 98 00 Welding bead catcher Group 00/63/77/Set K WS77.00-P-0010K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P-0027K 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K
Shown on right side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4172 · Applies to: 450, 451, 452, 454
Shown on left side of vehicle Fig 1: Identifying Folding Top Components (1 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Folding Top Components (2 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Slide soft top (1) with rear sliding¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4175 · Applies to: 450, 451, 452, 454
14 Slide soft top (1) with rear sliding rails (14) into guides (13) on roof cassette. Push sliding rail (14) into center channel of guides (13); erroneous positioning can lead to damage on the soft top system.
Aid of helper required.
15 Slide soft top (1) with center sliding rails (15) into guides (13) on roof cassette. Push sliding rail (15) into inner channel of guides (13); erroneous positioning can lead to damage on the soft top system.
Aid of helper required.
16 Hook sliding plates (11) into drive cable (12). Aid of helper required.
17 Align sliding plates (11) as shown and carefully pull into guides (13) on roof cassette by actuating power soft top switch. Pull sliding plates (11) into outer and center channel of guides (13); erroneous positioning can lead to damage on the soft top system.
Aid of 2 helpers required.
18 Pull tensioning straps (10) into roof cassette and clamping plates (8). The tensioning straps (10) should not be twisted.
19 Align tensioning straps (10) and clamping plates (8) according to marking and tighten bolts (9).
20 Install side supports (7).
21 Close soft top (1).
22 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).
23 Open soft top (1) approx. 10 cm.
24 Align tension cable retaining plates (5) and tighten bolts (6). Ensure that creases are not present in the soft top covering (1).
Shown on left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4179 · Applies to: 450, 451, 452, 454
Remove/install
Notes on soft tops
AH77.30- P-0001- 01MCO 1 Remove roof cassette locks (3).
AR77.30- P- 1110MCU 2 Remove electric soft top motor (M12/6)
AR77.39- P- 4000MCU 3 Cut cable tie (6)
Guide electric wiring harness (4) out Installation: Ensure that electric Fig 2: Identifying Soft Top Roof Cassette Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Soft Top Roof Cassette & Screws Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4182 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Soft Top Main Bearing Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Soft Top Main Bearing Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on soft tops¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4183 · Applies to: 450, 451, 452, 454
AH77.30-P- 0001- 01MCO 1 Open rear soft top (1) and unscrew bolt (3) on retaining clip (2).
2 Remove left soft top drive (M12/7)
AR77.39-P- 4010MCU 3 Remove electric wiring harness (6) from main bearing (5).
AR77.39-P- 1010MCU 4 Mark position of fastening points on main bearing (5) with suitable marker (broken lines).
5 Remove bolts (7) Installation: Helper required to position roof cassette.
6 Unscrew bolts (8) and remove main bearing (5).
7 Install in the reverse order
8 Remove marks (broken lines) with suitable cleaning agent.
9 Adjust retaining clip (2) on rear soft top (1).
AR77.30-P- 1151- 01MCO 10 Perform a function test
TESTING & REPAIR > REMOVE/INSTALL SOFT TOP MAIN BEARING - AR77.30-P- 1108MCV > MODEL 451.4 Right main bearing
Fig 1: Identifying Soft Top Main Bearing Components (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4184 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Soft Top Main Bearing Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4185 · Applies to: 450, 451, 452, 454
Notes on soft tops
AH77.30- P-0001- 01MCO 1 Open rear soft top (1) and unscrew bolt (3) on retaining clip (2).
2 Remove right soft top drive (M12/8)
AR77.39- P- 4010MCU 3 Guide soft top connector (X23/7) out of B-pillar, disconnect and remove cable tie (8)
4 Disconnect electrical connector (7)
5 Mark position of fastening points on main bearing (5) with suitable marker (broken lines).
6 Remove bolts (6) Installation: Helper required to position roof cassette.
7 Unscrew bolts (9) and remove main bearing (5).
8 Remove electric wiring harness (13) from steering wheel (10).
Fig 3: Identifying Soft Top Main Bearing Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove retainer (11) from retaining¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4186 · Applies to: 450, 451, 452, 454
9 Remove retainer (11) from retaining bolts of right rear soft top microswitch (S84/39) using suitable tool and remove right rear soft top microswitch (S84/39) Do not damage retaining bolts, otherwise it is necessary to replace the electric wiring harness (13).
10 Remove retaining clip (12) from main bearing (5) and remove electric wiring harness (13) Installation: Route electric wiring harness (13) to prevent it from being damaged by chafing and pinching, otherwise electric wiring harness (13) must be replaced.
11 Install in the reverse order
12 Remove marks (broken lines) with suitable cleaning agent.
13 Adjust retaining clip (2) on rear soft top (1).
AR77.30- P-1151- 01MCO 14 Perform a function test
TESTING & REPAIR > REMOVE/INSTALL SOFT TOP ROOF CASSETTE - AR77.30-P- 1109MCU > MODEL 451.4 Removing
Notes on soft tops
AH77.30-P-0001- 01MCO Fig 1: Identifying Soft Top Roof Cassette Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL SOFT TOP ROOF CASSETTE PLUG - AR77.30-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4188 · Applies to: 450, 451, 452, 454
P-1110MCU > MODEL 451.4 Shown on left side of vehicle Shown on right side of vehicle Fig 1: Identifying Soft Top Roof Cassette Plug Components (Shown On Left Side Of Vehicle) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Identifying Soft Top Roof Cassette Plug Components - Shown On Right Side Of Vehicle (1 Of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4189 · Applies to: 450, 451, 452, 454
4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Soft Top Roof Cassette Plug Components - Shown On Right Side Of Vehicle (2 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4190 · Applies to: 450, 451, 452, 454
Notes on soft tops
AH77.30- P-0001- 01MCO 1 Remove soft top drive cable
AR77.30- P- 1104MCU Fig 4: Identifying Soft Top Roof Cassette Plug Components - Shown On Right Side Of Vehicle (3 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Soft Top Roof Cassette Plug Components - Shown On Right Side Of Vehicle (4 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove roof cassette seals (4).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4191 · Applies to: 450, 451, 452, 454
2 Remove roof cassette seals (4).
AR77.30- P- 1109MCU 3 Unscrew bolts (5) on left and right side of soft top (2).
4 Unscrew bolts (3, 6)
5 Unhook rear soft top (2) from roof cassette (8) and fold toward rear.
6 Unscrew bolts (9, 10)
7 Remove roof cassette plugs (7) from roof cassette (8) and unscrew bolts (11).
8 Separate guide tube (1) and roof cassette plugs (7).
9 Remove retainers (12) from retaining bolts on left roof cassette microswitch (S84/38) and right roof cassette microswitch (S84/40) with suitable tool Do not damage retaining bolts, otherwise it is necessary to replace the electric wiring harness.
10 Lift spring (13) on left roof cassette microswitch (S84/38) out of cutout in roof cassette plug (7) with suitable tool and remove left roof cassette microswitch (S84/38) Do not bend or damage spring (13) on left roof cassette microswitch (S84/38).This can lead to malfunction and damage to the soft top.
11 Lift spring (13) on right roof cassette microswitch (S84/40) out of cutout in roof cassette plug (7) with suitable tool and remove right roof cassette microswitch (S84/40) Do not bend or damage spring (13) on right roof cassette microswitch (S84/40). This can lead to malfunction and damage to the soft top.
12 Unscrew bolts (16) and bolt (19) from roof cassette plug (7) and carrier plate (17).
13 Unscrew bolt (18) at rear of roof cassette plug (7).
14 Remove carrier plate (17) from roof cassette plug (7). Do not bend or damage spring (13) on soft top microswitch (S84/37).This can lead to malfunction and damage to the soft top.
15 Open catch hook (14) and remove soft top microswitch (S84/37) Do not damage retaining bolts at rear of soft top microswitch (S84/37), otherwise it is necessary to replace the electric wiring harness.
16 Check position of nuts (15) in roof cassette (8), correct if necessary.
17 Install in the reverse order
Perform a function test¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4192 · Applies to: 450, 451, 452, 454
18 Perform a function test
TESTING & REPAIR > REMOVE/INSTALL GUIDE TUBE FOR DRIVE CABLE - AR77.30-P- 1112MCU > MODEL 451.4 Shown on left side of vehicle Fig 1: Identifying Guide Tube For Drive Cable 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. 4195 · Applies to: 450, 451, 452, 454
Fig 3: Identifying Rear Soft Top Components (3 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Rear Soft Top Components (4 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Notes on soft tops¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4196 · Applies to: 450, 451, 452, 454
AH77.30- P-0001- 01MCO 1 Remove roof cassette seals
AR77.30- P- 1109MCU 2 Remove bolts (3)
3 Unscrew bolts (2, 16)
4 Unhook rear soft top (1) from roof cassette on left and right and fold toward rear, guide electrical lines through
5 Unscrew bolts (4)
6 Disconnect electrical connectors (5)
7 Pull retaining tab of water pocket (6) out of frame (7) on rear window (13).
8 Pull retaining tab (15) of rear soft top (1) out of frame (7) on rear window (13).
9 Fold up retaining clip (10), unscrew bolts (8) and pull seal (9) out of retaining clip (10).
10 Unhook rear soft top (1) from retaining clip (10) from outside toward inside and remove.
11 Remove clips (11) remaining in retaining clip (10) using suitable tool. Installation: Install clips (11) on hooking lug (12) on rear soft top (1).
12 Fold down rear window (13) and retaining clip (10).
13 Remove clips (14) remaining in rear window (13) of frame (7) with suitable tool. Installation: Install clips (14) on retaining tab (15) on rear soft top (1).
14 Install in the reverse order
15 Close rear soft top (1) and check for creases; if applicable, adjust retaining clip (10) of rear soft top (1).
AR77.30- P-1151- 01MCO 16 Perform a function test
TESTING & REPAIR > ADJUST REAR SOFT TOP RETAINING CLIP - AR77.30-P-1151- 01MCO > 1. Open rear soft top (1). 2. Loosen bolts (2), nuts (4) and retaining clip (3) on main bearing (5). 3. Close rear soft top (1).
4. Pull rear soft top (1) on retaining clip toward rear (arrows).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4197 · Applies to: 450, 451, 452, 454
- Check gap between rear soft top (1) and B-pillar (7). The distance (A) should be the same at top and bottom, the covering of the rear soft top (1) should make contact with the seal on the rear window (6). Fig 1: Identifying Rear Soft Top, Bolts, Nuts And Retaining Clip On Main Bearing Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
6. When rear soft top (1) is closed, tighten bolt (2) and nuts (4) on main bearing (5).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4198 · Applies to: 450, 451, 452, 454
- Open and close rear soft top (1). The retaining clip (3) should close easily, the covering of the rear soft top (1) should be seated tautly and without creases. Fig 2: Pulling Rear Soft Top Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL REAR SOFT TOP RETAINING CLIP - AR77.30-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4199 · Applies to: 450, 451, 452, 454
1151MCO > MODEL 451.4 Fig 3: Identifying Rear Soft Top, Bolts, Nuts And Retaining Clip On Main Bearing Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4200 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Rear Soft Top Retaining Clip Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Soft Top Retaining Clip Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4202 · Applies to: 450, 451, 452, 454
Notes for soft tops
AH77.30-P- 0001-01MCO 1 Remove paneling from rear pillar.
AR68.30-P- 4505MCO 2 Remove bolts (3)
Fig 1: Identifying Rear Soft Top, Retaining Clamp, Bolt And Nut Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Soft Top, Retaining Clamp, Lock Washer And Locking Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4204 · Applies to: 450, 451, 452, 454
Notes on soft tops
AH77.30-P-0001- 01MCO 1 Open soft top and rear soft top Open soft top and rear soft top until side wall seal (1) is exposed.
2 Remove side supports.
3 Remove side wall seal (1) starting at marked area (arrow A).
Install
4 First insert guide of side wall seal (1) into cutout (arrow B) on B-pillar (2), then press side wall seal (1) manually onto body flange and drive down with plastic mallet, if necessary Insert side wall seal (1) as close as possible in the radii, otherwise leakage can occur.The right and left side wall seal (1) should make contact at the center of the rear end panel without gap (arrow A).The lip of the side wall seal (1) must contact the body without any contortions.
5 Install side supports
6 Close folding top and rear soft top
Fig 1: Identifying Side Wall Seal And B-Pillar Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4207 · Applies to: 450, 451, 452, 454
Notes for soft tops
AH77.30-P-0001- 01MCO 1 Open soft top so that retaining tabs (2, 3, 5) on headliner (1) can be removed from roof edge and roof cassette without tension. When removing retaining tabs (2, 3, 5) on headliner (1), open soft top slightly, otherwise headliner (1) can be damaged by overstretching.
2 Loosen retaining tabs (2) on roof edge and pull out of gap on roof edge. Use plastic wedge when loosening retaining tabs (2).
3 Loosen retaining tabs (3) on left and right front roof edge, then pull headliner (1) out of gap of roof edge, from outside toward center Use plastic wedge when loosening retaining tabs (3).
4 Loosen retaining tab (5) on left and right roof cassette, then pull headliner (1) out of gap of roof cassette, from outside toward center. Use plastic wedge when loosening retaining tab (5).
5 Close soft top
6 Remove mounting strips (6) from soft top bows (7). Loosen mounting strips (6) on left and right, then pull headliner (1) out of gap of soft top bow (7), from outside toward center.
Fig 2: Identifying Headliner Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove remaining¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4208 · Applies to: 450, 451, 452, 454
7 Remove remaining retaining clamps (4) from gap on roof edge and gap on roof cassette.
Install
8 Attach retaining clamps (4) on retaining tabs (2, 3, 5).
9 Open soft top so that retaining tab (5) on headliner (1) can be installed on roof cassette.
10 Insert retaining tab (5) on headliner (1) at center into gap on roof cassette and press in with uniform pressure from left and right, starting at center.
11 Close soft top
12 Insert mounting strips (6) into soft top bows (7) starting at rear and press in from left and right, starting at center, with uniform pressure. Aid of helper required.Counterhold soft top from outside.
13 Position mounting strips (6) on headliner (1) in center of roof bows (7). Prevent formation of creases.
14 Turn front edge of headliner (1) 90° upward, insert retaining tab (3) in center into gap of roof edge and press in with uniform pressure toward left and right, starting at center.
15 Insert retaining tabs (2) into gap on roof edge and press in with uniform pressure.
16 Check headliner (1). Check headliner (1) for formation of creases and position mounting strips (6) in center, if necessary.Open soft top, check headliner (1) for tension and position mounting strips (6) in center, if necessary.Close soft top and observe chafing spots of
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4211 · Applies to: 450, 451, 452, 454
Notes on soft tops
AH77.30-P-0001- Fig 1: Identifying Side Support Seal Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Side Support Seal Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4216 · Applies to: 450, 451, 452, 454
Notes for soft tops AH77.30-P-0001- 01MCO 1 Open soft top until bolt (2) on centering aid (1) is accessible.
2 Unscrew bolt (2) and remove centering aid (1).
3 Install in the reverse order
4 Check soft top for proper function, close soft top.
TESTING & REPAIR > REMOVE/INSTALL ROOF CASSETTE SPOILER - AR77.33-P- 2030MCU > MODEL 451.4 Fig 1: Identifying Centering Aid & Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on left side of vehicle¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4220 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Rear Soft Top Window Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Soft Top Window Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on removed rear soft top¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4221 · Applies to: 450, 451, 452, 454
Remove/install
Notes for soft tops
AH77.30-P-0001- 01MCO 1 Separate electrical connectors (2)
2 Remove bolts (4)
3 Pull retaining tab of water pocket (3) out of frame
Fig 3: Identifying Rear Soft Top Window Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Retaining Tab, Rear Soft Top And Clamps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
(5) on rear window (1).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4222 · Applies to: 450, 451, 452, 454
4 Pull retaining tab (6) of rear soft top (7) out of frame (5) on rear window (1).
5 Remove clips (12) remaining in frame (5) with suitable plastic wedge. Installation: Install clips (12) on retaining lug (6) on rear soft top (7).
6 Fold up retaining clip (10), unscrew bolts (9) and pull seal (8) out of retaining clip (10).
7 Unhook rear soft top (7) from retaining clip (10) from outside toward inside and fold up.
8 Remove clips (10) remaining in retaining clips (11) with suitable plastic wedge. Installation: Attach clips (11) on hooking lug on rear soft top (7).
9 Unscrew bolts (14), remove rear window (1). Aid of helper required.
10 Pull seal (13) out of frame (5) on rear window (1). When replacing rear window (1).
Installation: The ends of the seal (13) should make contact with one another at the bottom at the center of the frame (5).
11 Install in the reverse order
12 Perform a function test
TESTING & REPAIR > REMOVE, INSTALL REAR SOFT TOP WINDOW SEAL - AR77.35-P- 1001MCO > 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. 4223 · Applies to: 450, 451, 452, 454
Fig 1: Identifying Rear Soft Top Window Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Soft Top Window Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on removed rear soft top¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4224 · Applies to: 450, 451, 452, 454
Remove/install
Notes for soft tops
AH77.30-P-0001- 01MCO 1 Separate electrical connectors (2)
2 Remove bolts (4)
3 Pull retaining tab of water pocket (3) out of frame (5) on rear window (1).
Fig 3: Identifying Rear Soft Top Window Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Retaining Tab, Rear Soft Top And Clamps Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Pull retaining tab (6) of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4225 · Applies to: 450, 451, 452, 454
4 Pull retaining tab (6) of rear soft top (7) out of frame (5) on rear window (1).
5 Remove clips (12) remaining in frame (5) with suitable plastic wedge. Installation: Install clips (12) on retaining lug (6) on rear soft top (7).
6 Fold up retaining clip (10), unscrew bolts (9) and pull seal (8) out of retaining clip (10).
7 Unhook rear soft top (7) from retaining clip (10) from outside toward inside and fold up.
8 Remove clips (10) remaining in retaining clips (11) with suitable plastic wedge. Installation: Attach clips (11) on hooking lug on rear soft top (7).
9 Pull seal (13) out of frame (5) on rear window (1). Installation: The ends of the seal (13) should make contact with one another at bottom at the center of the frame (5).
10 Install in the reverse order
11 Perform a function test
TESTING & REPAIR > REMOVE/INSTALL POWER SOFT TOP SWITCH - AR77.39-P- 1000MCU > MODEL 451.4 Fig 1: Identifying Electrical Connector, Selector Lever Position Indicator And Power Soft Top Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4227 · Applies to: 450, 451, 452, 454
Notes on soft tops
AH77.30-P-0001- Fig 2: Identifying Left Rear Soft Top Drive Wiring Harness Components (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Left Rear Soft Top Drive Wiring Harness Components (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
S84/41¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4235 · Applies to: 450, 451, 452, 454
Left rear soft top microswitch 28L S9/1 Stop lamp switch 12L U101 Valid up to 02/2009 5E U102 Valid as of 03/2009 3E W10 Ground (battery) 38E W6 Ground (left wheelhouse in luggage compartment) 19E W9 Ground (left front, at lamp unit) 2G X23/7 Soft top connector 30G X23/7 Soft top connector 15G Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve 37E Z40 Stop lamp signal connector sleeve 12H Z54/16 Soft top control "open" connector sleeve 32E Z54/16 Soft top control "open" connector sleeve 17E Z54/16 Soft top control "open" connector sleeve 7H Z54/17 Soft top control "closed" connector sleeve 33E Z54/17 Soft top control "closed" connector sleeve 18E Z54/17 Soft top control "closed" connector sleeve 9H Z6/16 Soft top ground connector sleeve 25L Z6/16 Soft top ground connector sleeve 35H Z6/16 Soft top ground connector sleeve 19L Z6/16 Soft top ground connector sleeve 13H Z7/59 Tml. 30 connector sleeve 4F
Fig 1: Electric Soft Top - Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4236 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Electric Soft Top - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4237 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Operation¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4240 · Applies to: 450, 451, 452, 454
Open/close soft top The soft top is opened automatically to the end position by momentarily pressing the soft top actuation switch in the opening direction (arrow 1). The soft top is opened manually by pressing and holding down the soft top actuation switch in the opening direction (arrow 1). If the opening request is terminated before the rear end position is reached, the soft top stops in the current position. The soft top is closed by pressing and holding down the soft top actuation switch in the closing direction (arrow 2). If the closing request is terminated before the front end position is reached, the soft top stops in the current position. Open/close rear soft top When the soft top is opened completely and the soft top actuation switch is reactuated in the opening direction (arrow 1), the rear soft top is opened. If the opening request is terminated before the end position is reached and below a vehicle speed of 5 km/h, the rear soft top stops in the current position. The rear soft top is opened until the end position is reached at a vehicle speed above 5 km/h. The rear soft top is closed by actuating the soft top actuation switch in the closing direction (arrow 2). If the closing request is terminated before the end position is reached and below a vehicle speed of 5 km/h, the rear soft top stops in the current position. The rear soft top is opened until the end position is reached at a vehicle speed above 5 km/h. WIRING DIAGRAMS > ELECTRIC WIRING DIAGRAM FOR ELECTRIC SOFT TOP - PE77.39- P-2200MCU > MODEL 451 Electric wiring diagram for electric soft top PE77.39-P-2200-97MCU Use of wiring diagrams OV00.01-P-1901-03MCC Fig 1: Locating Power Soft Top Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
0031K¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4242 · Applies to: 450, 451, 452, 454
450 589 08 37 00 Pliers Group 77/Set B WS77.00-P- 0030B 452 589 01 09 00 Wrench socket SW 15 FG 77/Set K WS77.00-P- 0034K 452 589 01 15 00 Drift FG 77/Set K WS77.00-P- 0037K 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P- 0107K 452 589 02 23 00 Soft top template Group 77/Set K WS77.00-P- 0048K 452 589 02 99 00 Wiring harness repair kit FG 00/54/77/83/ Set B WS00.00-P- 0243B
BA61.25-P-1003-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4244 · Applies to: 450, 451, 452, 454
01B Bolt, console to underbody Nm 26 Shown on removed diagonal struts 1. Unscrew bolts (2) and remove bracket (1) from underfloor. Note the installation position of the bracket (1). 2. Install in the reverse order. TESTING & REPAIR > UNFASTEN/FASTEN DIAGONAL STRUTS - AR61.10-P-5138-02MCU
UNDERBODY FRAME Number Designation Model 451.4 except 451.491 BA61.25-P-1002- 01B Bolt, diagonal strut to underbody Nm 65 Fig 1: Identifying Bracket With Mounting Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4247 · Applies to: 450, 451, 452, 454
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 below. Pneumatic/hydraulic blind rivet toolgotis://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 Expose spot welds on diagonal strut console (1) and cut out (areas A, B and C)
4 Remove damaged diagonal strut console (1)
Install
5 Fit new diagonal strut console (1) with diagonal strut and fix in place When fitting, observe correct distances.
6 Drill Ø 6.5 mm rivet holes (areas D, E and F)
7 Remove new diagonal strut console (1) and diagonal strut
8 Debur rivet holes on diagonal strut console (1) and body on both sides
9 Fit new diagonal strut console (1)
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4252 · Applies to: 450, 451, 452, 454
- Expose spot welds on right tank support (1) and drill with 6.5 mm dia. bit (area A).
- Heat connecting flange with hot air gun (area A). Area A is bonded.
- Remove damaged right tank support (1).
- Remove drill shavings using wet/dry vacuum cleaner TESTING & REPAIR > REMOVE TANK SUPPORT - AR61.10-P-5708-01MCD > Shown on model 451.3
- Expose spot welds on left tank support (1) and drill out with Ø 6.5 mm from top (areas A and B).
- Remove damaged left tank support (1).
- Remove drill shavings using wet/dry vacuum cleaner TESTING & REPAIR > PREPARE CONNECTING POINTS FOR TANK SUPPORT ON BODY.
- AR61.10-P-5708-02MCC > Fig 1: Identifying Left Tank Support & Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4253 · Applies to: 450, 451, 452, 454
- Grind mating surfaces down to bare metal in the crosshatched 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. Observe manufacturer's specifications of 2- component adhesive for drying and processing time. TESTING & REPAIR > PREPARE TANK SUPPORT FOR INSTALLATION. - AR61.10-P-5708- 03MCC >
- Grind right tank support (1) down to bare metal in 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. Observe manufacturer's specifications of 2- component adhesive for drying and processing time. Fig 1: Identifying Tank Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL TANK SUPPORT - AR61.10-P-5708-04MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4254 · Applies to: 450, 451, 452, 454
Shown on model 451.3 1. Fit tank support (1) together with tank and fasten with tank mounting bolts. 2. Drill 6.5 mm dia. rivet holes (area A). 3. Remove tank support (1) and tank. 4. Deburr rivet holes on tank support (1) and body on both sides. Fig 1: Identifying Grinding Area On Right Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Right Tank Support & Drilling Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5. Apply 2-component glue to mating surfaces in cross-hatched areas.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4255 · Applies to: 450, 451, 452, 454
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 tank support (1) and fasten with manual temporary fasteners. 7. Rivet tank support (1) with Polygrip flat/round head rivet, dia. 6.4x14 (areas A). TESTING & REPAIR > INSTALL TANK SUPPORT - AR61.10-P-5708-04MCD > Fig 2: Identifying Glue Application Area On Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Rivet Area On Fuel Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4256 · Applies to: 450, 451, 452, 454
- Fit left tank support (1) together with tank and fasten with mounting bolts.
- Drill Ø 6.5 mm rivet holes from top (areas A and B).
- Remove left tank support (1) and tank.
- Deburr rivet holes on left tank support (1) and body on both sides. Shown on model 451.3
- Fit left tank support (1) and fasten with manual temporary fasteners.
- Rivet left tank support (1) from top with 6.4 x 14 Polygrip flat/round head rivet (areas A and B). Fig 1: Identifying Drill Area On Left Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rivet Area On Left Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4260 · Applies to: 450, 451, 452, 454
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 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.
Fig 1: Locating Left Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
899268 0Fa +49¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4262 · Applies to: 450, 451, 452, 454
899101978www.Loctite.de BR00.45-Z-1001- 13A Blind rivet 6.4x14 A 003 990 35 97 TESTING & REPAIR > REPLACE THREAD FOR INTEGRAL CARRIER MOUNT - AR61.10-P- 6200MCU > MODEL 451.3/4 Removing
Notes on thread repairs
AH00.00-P-0008- 01MCC The following tools are required for repair Drill (electric/pneumatic) Wet/dry vacuum cleaner http://gotis.aftersales.mercedes- benz.com
1 Remove rear drive module
AR01.00-P- 3060MCU
Replace
2 Drill out damaged thread in crossmember (1) Hold spiral bit (2) vertical to hole to prevent damaging remaining thread See Fig 1.
Fig 1: Replacing Thread For Integral Carrier Mount Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Thread insert repair kit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4263 · Applies to: 450, 451, 452, 454
*450589019900 3 Countersink hole in crossmember (1) with seat cutter (3) See Fig 1.
Thread insert repair kit *450589019900 4 Recut thread down to bottom of hole with thread tap (4) See Fig 1.
Thread tap set *450589009900
Thread insert repair kit *450589019900 5 Remove drilling shavings with wet/dry vacuum cleaner.
6 Attach threaded socket (5) to lubricated thread former (6) and screw into hole See Fig 1.Use threaded bushing (5) with a length of 16.3 mm.If the threaded bushing (5) is flush with the crossmember (1), increased force is required for turning until the inner thread is formed and pressed into the basic threadThe thread former (6) can be turned more easily when pressing is finished.
Thread tap set *450589009900
Thread insert repair kit *450589019900 Install
7 Install rear drive module
AR01.00-P- 3060MCU Fig 2: Identifying Thread Tap Set (450 589 00 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4266 · Applies to: 450, 451, 452, 454
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
The repair method using riveting described here can be replaced by plug welding if required. Adapt preparatory work
Fig 1: Identifying Mounting Console For Bulkhead On Floor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
pre ervation¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4268 · Applies to: 450, 451, 452, 454 · AR: BA61.00-Z-9999CZ
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-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- 13A Blind rivet 6.4 x 14 A 003 990 35 97 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: SUBSTRUCTURE - BA61.00-Z-9999CZ > MODEL all Substructure frame MODEL 450.4 BA61.25-P-1000-01C Underbody frame MODEL 450.3 /4, 451.4 BA61.25-P-1000-01A Underbody frame MODEL 450.4, 451.4 BA61.25-P-1000-01B TORQUE SPECIFICATIONS > UNDERBODY FRAME - BA61.25-P-1000-01A > Model 450, 451.4 BULKHEAD ON UNDERBODY Number Designation Model 450.3/4 Model 451.4 BA61.25-P-1001- 01A Bolt for bulkhead on underbody Nm 23 26 TORQUE SPECIFICATIONS > UNDERBODY FRAME - BA61.25-P-1000-01B > Model 450, 451 UNDERBODY FRAME Number Designation Model 450.4 Model 451.4 except 451.491 Model 451.491 BA61.25-P- Bolt, cross strut to substructure Nm 70 - -
1001 01B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4269 · Applies to: 450, 451, 452, 454 · AR: WS61.00-Z-9999CZ
BA61.25-P- 1002-01B Bolt, diagonal strut to underbody Nm - 65 65 BA61.25-P- 1003-01B Bolt, console to underbody Nm - 26 26 BA61.25-P- 1004-01B Bolt, diagonal strut to high- voltage battery Nm - - 65 SPECIAL TOOLS > SPECIAL TOOLS: SMART: SUBSTRUCTURE - WS61.00-Z-9999CZ > MODEL all 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B 452 589 01 31 00 Adapter FG 61/Set K WS61.00-P-0003K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P-0012K
When replacing body panels, observe the following measures:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4271 · Applies to: 450, 451, 452, 454
Check number and position of present spot welds, complete missing spot welds. Compare spot welds on new part with old part. Use resistance spot welding method to create multiple-layer sheet metal connections, if the spot welder has the appropriate welding capacity (weldable sheet metal thickness and number of layers). If this it not the case, pre-drill corresponding spot welds, countersink and plug weld. TESTING & REPAIR > REMOVE TANK SUPPORT - AR61.10-P-5708-01MCD > Shown on model 451.3 1. Expose spot welds on left tank support (1) and drill out with Ø 6.5 mm from top (areas A and B). 2. Remove damaged left tank support (1). 3. Remove drill shavings using wet/dry vacuum cleaner GENERAL INFORMATION > NOTES ON REPLACING BODY PARTS - AH60.00-P-0027-01FF
Model 451.3/4, 454.0 When replacing body panels, observe the following measures: Check number and position of present spot welds, complete missing spot welds. Compare spot welds on new part with old part. Use resistance spot welding method to create multiple-layer sheet metal connections, if the spot welder has the appropriate welding capacity (weldable sheet metal thickness and number of layers). Fig 1: Identifying Left Tank Support (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
If this it not the case, pre-drill corresponding spot welds, countersink and plug weld.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4272 · Applies to: 450, 451, 452, 454
TESTING & REPAIR > PREPARE TANK SUPPORT FOR INSTALLATION. - AR61.10-P-5708- 03MCC > 1. Grind right tank support (1) down to bare metal in 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. Observe manufacturer's specifications of 2- component adhesive for drying and processing time. TESTING & REPAIR > INSTALL TANK SUPPORT - AR61.10-P-5708-04MCC > Fig 1: Identifying Grinding Area On Right Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown on model 451.3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4273 · Applies to: 450, 451, 452, 454
- Fit tank support (1) together with tank and fasten with tank mounting bolts.
- Drill 6.5 mm dia. rivet holes (area A).
- Remove tank support (1) and tank.
- Deburr rivet holes on tank support (1) and body on both sides.
- Apply 2-component glue to mating surfaces in 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. Observe manufacturer's specifications for drying and Fig 1: Identifying Rivet Area On Tank Support (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Glue Application Area On Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
processing time of adhesive.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4274 · Applies to: 450, 451, 452, 454
- Fit tank support (1) and fasten with manual temporary fasteners.
- Rivet tank support (1) with Polygrip flat/round head rivet, dia. 6.4x14 (areas A). TESTING & REPAIR > INSTALL TANK SUPPORT - AR61.10-P-5708-04MCD > Shown on model 451.3
- Fit left tank support (1) together with tank and fasten with mounting bolts.
- Drill Ø 6.5 mm rivet holes from top (areas A and B).
- Remove left tank support (1) and tank. Fig 3: Identifying Rivet Area On Fuel Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Drill Area On Left Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4276 · Applies to: 450, 451, 452, 454
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 body
AH60.00- P-0001- 01FF Fig 1: Identifying Right Tank Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Generally conventional tools¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4277 · Applies to: 450, 451, 452, 454
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 Remove right tank support (1)
AR61.10- P-5708- 01MCC 4 Prepare connecting points on right tank support (1) on body
AR61.10- P-5708- 02MCC 5 Prepare right tank support (1) for installation
AR61.10- P-5708- 03MCC Install
6 Install right tank console (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. AR61.10- P-5708- 04MCC Adhesive BR00.45- Z-1092- 02A Rivet BR00.45- Z-1001- 13A 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-
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4279 · Applies to: 450, 451, 452, 454
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 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.
Fig 1: Identifying Left Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove detachable parts in the repair¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4280 · Applies to: 450, 451, 452, 454
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 Remove left tank support (1)
AR61.10- P-5708- 01MCD Install
4 Install left tank support (1)
AR61.10- P-5708- 04MCD Rivet *BR00.45- Z-1001- 13A 5 Clean sheet metal flange with wire brush and clean areas to repaired
6 Prime area to be repaired using primer filler
7 Supply standard seam seals with body sealant
AR97.10- P- 4000MCC Sealant BR00.45- Z-1003- 01A 8 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 9 Paint area repaired and adjacent surfaces
Notes on paintwork repairs AH98.00- P-9408- 02MCC 10 Apply additional cavity preservation
AR97.20- P-1500FF Teroson protective wax *BR00.45- Z-1008- 05A 11 Reinstall all detachable parts removed
REPAIR MATERIALS Number Designation Order number BR00.45- Z-1003- Sealant, white, 310 ml, DB supply specification A 001 989 63 20
BR00.45-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4281 · Applies to: 450, 451, 452, 454 · AR: BA61.00-Z-9999CZ, WS61.00-Z-9999CZ
01A 6069 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 MunichGermanyTel. +49-899268-0Fax +49- 899101978www.Loctite.de BR00.45- Z-1001- 13A Blind rivet 6.4x14 A 003 990 35 97 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: SUBSTRUCTURE - BA61.00-Z-9999CZ > MODEL all
Substructure frame MODEL 450.4 BA61.25-P-1000-01C
Underbody frame MODEL 450.3 /4, 451.4 BA61.25-P-1000-01A
Underbody frame MODEL 450.4, 451.4 BA61.25-P-1000-01B SPECIAL TOOLS > SPECIAL TOOLS: SMART: SUBSTRUCTURE - WS61.00-Z-9999CZ > MODEL all 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B 452 589 01 31 00 Adapter FG 61/Set K WS61.00-P-0003K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P-0012K
GENERAL INFORMATION > NOTES ON STONE IMPACT REPAIR ON LAMINATED GLASS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4282 · Applies to: 450, 451, 452, 454
WINDOWS - AH67.10-P-0002-01MCC > Model 450.3/4 except 450.418, 451.3/4, 452.3/4, 454.0 Stone mark repair is only permitted in areas outside the long-range field of vision (2). The long-range field of vision (2) is 29 cm wide and is centered around the center point of the steering wheel on the windshield. The long-range field of vision (2) is limited at the top and bottom by the windshield wiper field (1). The damage profiles shown here (stone marks on the windshield) can be repaired economically and satisfactorily using the stone mark repair method. A repair set approved by DaimlerChrysler is required for this purpose. PS laminated glass window repair system http://gotis.aftersales.daimlerchrysler.com Fig 1: Identifying Windshield Wiper Field And Long Range Field Of Vision Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Before repairing damage point, please be sure to always observe the following information:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4283 · Applies to: 450, 451, 452, 454
A workplace without UV radiation should be available, otherwise it can result in paint adhesion problems of the filler resin or finish resin. The windshield temperature must be between 10°C and 25°C to repair the stone marks; if applicable, heat or cool down windshield with suitable methods. Otherwise it can result in paint adhesion problems of the filler resin or finish resin. Only damage on the outside window surface may be repaired. Damages to the inside of the windshield or to the plastic laminate are not permitted. Ensure that moisture has not penetrated into the damaged point (seal damage point immediately after damage using adhesive tape and repair it as soon as possible). The diameter of the chip should not exceeded 5 mm. Any radial cracks extending from the damage point should not exceed 50 mm. They should not end at the rubber window seal and never reach to the outer edge of the window. This repair method can be used only when the damaged point is outside the driver's long-range field of vision. After repair, a spot of approx. 2 mm in diameter can still be seen. GENERAL INFORMATION > NOTES ON REMOVAL/INSTALLATION OF WINDSHIELD - AH67.10-P-1000-01MCE > Model 451.3/4 Adhesive kit for isopropanol cleaner Fig 2: View Of Windshield Damage Profiles Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Adhesive kit with heptane cleaner¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4284 · Applies to: 450, 451, 452, 454
Use individual components as described in table below. Deviation is not permissible, otherwise adhesive force of bonded connection is not ensured. Fig 1: Identifying Adhesive Kit Components For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Adhesive Kit Components With Heptane Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Allow corresponding primer to flash off for at least 10 minutes, however, for max. 15 minutes.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4285 · Applies to: 450, 451, 452, 454
The crank window in the driver door must be opened during the curing time to prevent the component glued in from being pressed out by the air when the doors are closed. Avoid to open and close doors. Designation Note Use Adhesive cartridge (4) Hot application: Short processing time Durability is achieved after approx. 2 h measured from the time the component is installed. The rated accident strength is achieved only after approx. 8 h. The adhesive cartridge (4) is heated in cartridge heater. Adhesive material for: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Plastic primer (5) Apply with wool wiper (13). Allow primer to flash off for at least 10 - 15 minutes, otherwise the adhesive force of the bonded joint starts to decrease. Primer for: Full roof (with code (E23) Full roof (FFO)) Primer stick (6) PC primer Allow primer to flash off for at least 10 - 15 minutes, otherwise the adhesive force of the bonded joint starts to decrease. Primer for: Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Body flange Heptane cleaner 3350 (7) Apply with cloth (9). Cleaner for primer surface: Full roof (with code (E23) Full roof (FFO)) Cleaning cloth (8) Cleaning cloth containing isopropanol and cleaning drying cloth Cleaner for primer surface: Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Body flange Cloth (9) Color blue-green For applying:
Heptane cleaner 3350 (7)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4286 · Applies to: 450, 451, 452, 454
Spacer (10)
Spacer (10) for: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Cutting wire (11) Cut out with cutting wire (11) and the two handles included in the window removal kit. To cut out: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Application nozzle (12) Nozzle tips are already cut to size. Application of adhesive material in combination with adhesive cartridge (4) Wool wiper (13)
Applying plastic primer (5) GENERAL INFORMATION > NOTES ON REMOVAL/INSTALLATION OF WINDOWS - AH67.10-P-1000-02SM > Model 450.3/4 except 450.418, 451.3/4 Work on glass panes The use of 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. When working on the glued vehicle windows wear sturdy gloves and eye protection to prevent injuries from cutting and splinters. Bonded points are parts of the unibody construction. Always perform work on bonded windows with particular care. Following fire damage, check adhesive seams and replace if required because the adhesive can be damaged by high heat. Repair of glass panes Repair of windshields is permissible under the following conditions: It is only permissible to repair damage to the outer surface of the windshield. The inner surface and plastic foil should not be damaged in any form.
TESTING & REPAIR > PREPARE WINDOW FOR INSTALLATION - AR67.10-P-1000-03MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4288 · Applies to: 450, 451, 452, 454
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. 2.1 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 adhesion problems. When reinstalling removed window. 2.2 Clean gluing area on window with cleaning rag (8) from repair kit. When installing a new window. 3.1 Repair damaged primer layer on window with primer stick (6) from repair kit. When reinstalling removed window. Allow primer to flash off for at least 10 - 15 minutes. Fig 1: Identifying Adhesive Kit Components For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3.2 Coat gluing area on window with primer stick (6) included in repair kit (max. 20 mm).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4289 · Applies to: 450, 451, 452, 454
When installing a new window. Allow primer to flash off for at least 10 - 15 minutes. Windshields are generally delivered with a viewing window on the bottom left. If the viewing window is not required, coat this area on the inside of the window with primer stick (6). TESTING & REPAIR > ALIGN WINDSHIELD IN BODY OPENING - AR67.10-P-1000-04MCC > 1. Lay windshield (1) down on spacers on body flange, align windshield (1) at top and center at side. Cup suction tool http://gotis.aftersales.mercedes-benz.com Aid of helper required. 2. Attach suitable strips of adhesive tape (arrows) and cut at upper edge on windshield (1). 3. Remove windshield (1) from body flange Cup suction tool http://gotis.aftersales.mercedes-benz.com Aid of helper required. TESTING & REPAIR > APPLY ADHESIVE MATERIAL - AR67.10-P-1000-08MCC > Fig 1: Locating Strips Of Adhesive Tape On Windshield Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4290 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1041-02B TS adhesive (with isopropanol cleaner) A 451 989 00 71 Install windshield (3) on body flange within 2 minutes after applying adhesive material, to prevent adhesion problems of the adhesive material. The curing time is approx. 2 h measured from the time the windshield (3) is installed. The rated accident strength is achieved only after approx. 8 h. Fig 1: Identifying Intermediate Piece (000 589 86 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Guiding Nozzle On Windshield Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Guide nozzle (2) along bonding surface on windshield (3) or along residual adhesive material on¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4291 · Applies to: 450, 451, 452, 454
body flange and uniformly apply adhesive material in shape of a bead with a height (b) of approx. 12 mm and a width of approx. 8 mm. Cartridge gun gotis://K 67.0 02.0 Completely press out adhesive material not required immediately following application (disposal). TESTING & REPAIR > ELECTRIC WIRING DIAGRAM FOR HEATED REAR WINDOW - PE67.29-P-2000-97MCU > Code: Designation: Position: N10/10 SAM control unit 11A N10/10 SAM control unit 4A N10/10f28 Fuse 28 7A N10/10f28 Fuse 28 3A N23 Heater/AC operating unit 13L N23s1 Rear window defroster switch
R1 Heated rear window 8L R1 Heated rear window 3L U23 Valid for cabriolet 6A U606 Valid for all except convertibles 1A W6 Ground (left wheelhousing in trunk) 10H W6 Ground (left wheelhousing in trunk) 5H X18/19 Trunk lid connector 2E X23/7 Soft top connector 8E Fig 3: Identifying Dimension Of Adhesive Bead On Windshield Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
X23/7¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4292 · Applies to: 450, 451, 452, 454
Soft top connector 6E Z6/16 Soft top ground connector sleeve 8H Z6/20 Trunk lid ground connector sleeve 3H TESTING & REPAIR > CUT OUT WINDOWS WITH ROLL OUT - AR67.10-P-1000-11MCC > REPAIR MATERIALS Number Designation Order number BR00.45-Z-1041-02B TS adhesive (with isopropanol cleaner) A 451 989 00 71 Fig 1: Heated Rear Window - Electric Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
"Roll out" window removal tool gotis://K 67.0 - 01.0¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4293 · Applies to: 450, 451, 452, 454
Scope of supply: Work is shown on windshield. 1. Mask off puncture point at position (A) (arrow) from outside with suitable textile adhesive tape and punch from vehicle interior through adhesive seam of window (18) with awl (2). 2. Cut cutting wire to correct length. The length of the cutting wire should be approx. 4 times the diagonal of the window. Fig 1: Identifying Window Removal Tools Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Insert ends of cutting wire (17) through eye of awl (2) and bend over in direction of arrow.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4294 · Applies to: 450, 451, 452, 454
- Cover areas adjacent to puncture point in vehicle interior with appropriate interior protection and pull cutting wire (17) approx. 70 cm into passenger compartment using awl (2).
- Bend cutting wire (17) straight and remove awl (2).
- Moisten sealing lip on window (18) with soapy water. On windows (18) with sealing lip to facilitate inserting cutting wire (17).
- Route the remaining outer wire loop between windshield (18) and body flange counterclockwise while pulling the excess cutting wire (17) into the inside of the vehicle. Ensure that cutting wire (17) is located below windshield (18) at all four corner points. Fig 2: Masking Off Puncture Point Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Inserting Cutting Wire Through Eye Of Awl Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Insert guide needles (5) into adhesive seam at bottom edge of window (18).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4295 · Applies to: 450, 451, 452, 454
Only if cutting wire (17) is not attached below window (18). Ensures that cutting wire (17) makes contact to adhesive seam when tensioning. 9. Install windlass (15) on opposite side of window (18) diagonal of puncture point. 10. Insert end of cutting wire (17) into coil of windlass (15) with the shorter end toward the windlass (15). Fig 4: Inserting Cutting Wire Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Guide Needles And Cutting Wire Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Position reversible ratchet (3) on windlass (15) and tension cutting wire (17). Then check from¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4296 · Applies to: 450, 451, 452, 454
outside whether the cutting wire (17) makes contact to the adhesive seam on the window all-round. The coil of the windlass (15) can only be turned in one direction, therefore it is necessary to ensure that the cutting wire (17) is located in the guide groove (20) of the windlass (15). 12. Insert suitable interior protection (10) between cutting wire (17) and inner paneling. Use parabolic chisel (1) at points not easy to reach. Fig 6: Installing Windlass Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
13. Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4297 · Applies to: 450, 451, 452, 454
- Remove reversible ratchet, parabolic chisel and interior protection and turn windlass (15) to next position. To move windlass (15), release locking knob (19) while retaining under tension the cutting wire (17) of the coil.
- Install reversible ratchet, parabolic chisel and appropriate interior protection. Fig 7: Positioning Reversible Ratchet On Windlass Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Cutting Out Window Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
grea e to prevent a¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4301 · Applies to: 450, 451, 452, 454
decrease in the gluing force when installing window.Wet/dry vacuum cleaner gotis://P_00.12_06.0
TS adhesive (with isopropanol cleaner) *BR00.45-Z-1041-02B 10 Align windshield (1) in the body opening Aid of helper required.Cup suction tool gotis://K_67.0_03.0 AR67.10-P-1000- 04MCC 11 Prepare windshield (1) for glazing The gluing area on the windshield (1) should be absolutely free of dust and grease to prevent adhesion problems of the adhesive material. AR67.10-P-1000- 03MCC
TS adhesive (with isopropanol cleaner) *BR00.45-Z-1041-02B 12 Open crank window in driver door The crank window in the driver door must be opened during the curing time to prevent the windshield (1) from being pressed out by the air when the doors are closed.
13 Apply adhesive material Install windshield (1) on body flange within 2 minutes after applying adhesive material, to prevent adhesion problems of the adhesive material. If the paintwork structure on the body flange is renewed, apply adhesive material on body flange for corrosion protection reasons. The curing time is approx. 2 h measured from the time the windshield (1) is installed. The rated accident strength is achieved only after approx. 8 h.Uniformly apply adhesive bead at a height of approx. 12 mm. AR67.10-P-1000- 08MCC
Intermediate pieceCartridge gun gotis://K_67.0_02.0 *000589866300
TS adhesive (with isopropanol cleaner) *BR00.45-Z-1041-02B
BR00.45-Z-1041-02B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4303 · Applies to: 450, 451, 452, 454
TS adhesive (with isopropanol cleaner) A 451 989 00 71 TESTING & REPAIR > PREPARE BODY FLANGE FOR INSTALLATION OF WINDOW - AR67.10-P-1501-01MCC > 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 (2) on the body flange (1) must be absolutely free of dust and grease to prevent paint adhesion problem of the adhesive material when glazing. Cut back remaining adhesive material on body flange (1) max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts with the ambient air which can lead to adhesion problems. Fig 1: Identifying Adhesive Kit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Cut off residual adhesive material on body flange (1) down to a height of approx. 2 mm using¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4304 · Applies to: 450, 451, 452, 454
suitable scraper. Remove adhesive material residues. 2. Clean painted adhesive surface on body flange (1) with cleaning rag from repair kit and rub dry with rag. 3. Repair paint damage at body flange (1) with primer applicator. 4. Apply primer to body flange (1) with primer stick from repair kit in areas where residual adhesive material is missing or damaged. s Allow primer to flash off for at least 10 minutes. 5. Install spacers (10) as shown. 6. Clean working area. Wet/dry vacuum cleaner gotis://P_00.12_06.0 Fig 2: Identifying Gluing Area On Body Flange Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > INSTALL WINDSHIELD - AR67.10-P-1503-01MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4305 · Applies to: 450, 451, 452, 454
Shown on model 451.3 1. Center windshield (1) above body opening and position to coincide with strips of adhesive tape (arrows). Cup suction tool http://gotis.aftersales.mercedes-benz.com Helper required. 2. Position windshield (1) on body flange and press on until it makes contact with spacers. Then fix in place with suitable adhesive tape. The curing time is approx. 2 h measured from the time the windshield (1) is installed. The rated accident strength is achieved only after approx. 8 h. Fig 3: Locating Spacers Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > PREPARE REPAIR FOR WINDSHIELD - AR67.10-P-1600-01MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4306 · Applies to: 450, 451, 452, 454
- Check damaged point for moisture If applicable, heat damaged point with hot air gun and allow to flash off for approx. 10 minutes. Fig 1: Positioning Windshield On Body Flange Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Repair Tools Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2. Clean windshield around damaged point with cleaning agent (12).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4307 · Applies to: 450, 451, 452, 454
- Evaluate damaged point A conical fissure or filling cavity should be present in each damaged point to ensure that the filler resin (8) continues to flow.
- If applicable, crack damaged point to create conical fissure or filling cavity. Use stone impact cracker (5).
- Install inspection mirror (3) on inside of windshield.
- Chamfer edges of damaged point using milling cutter (4). Roughen surfaces and remove grayness from porous surfaces.
- Blow out loose glass particles and wipe out with paper towel. Do not use compressed air when blowing out to prevent enlargement of the damaged point. TESTING & REPAIR > REPAIR WINDSHIELD - AR67.10-P-1600-02MCC > Fig 1: Identifying Windshield Repair Tools (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Place tool holder (1) on windshield so that it is not in the area of the damaged point.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4308 · Applies to: 450, 451, 452, 454
- Press suction cup of tool holder (1) onto windshield with clamping lever (2) in vertical position. To improve adhesion of suction cup moisten with thin layer of adhesion gel (13).
- Arrest tool holder (1) on windshield by moving clamping lever (2) down.
- Screw injector (10) into tool holder (1) until rubber nozzle (10.1) makes slight contact to windshield.
- Mark cracks extending from end of damaged point using suitable pen to check whether cracks have become longer.
- Remove tool holder (1) and position so that rubber nozzle (10.1) of injector (10) is located at center of damaged point.
- Arrest tool holder (1) on windshield by moving clamping lever (2) down. If the cracks extending from the damaged point increase, immediately reduce pressure by Fig 2: Identifying Windshield Repair Tools (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Windshield Repair Tools (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
unscrewing injector (10) from tool holder (1) to prevent the windshield from breaking.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4309 · Applies to: 450, 451, 452, 454
- Screw injector (10) into tool holder (1) until rubber nozzle (10.1) on injector (10) makes contact with windshield all-round. The contact pressure is indicated in the inspection mirror (3) by the edge of the rubber nozzle (10.1) becoming a darker red or deforming edge (10.1). 9.1 Completely unscrew injector piston (10.3), moisten piston thread (10.4) with a drop of filler resin (8) and fill 12 drops of filler resin into the filler opening (10.2). When reusing new injector (10). 9.2 Completely unscrew injector piston (10.3) and fill three to five drops of filler resin into filler opening (10.2) When reusing used injector (10). 10 Provide for sufficient pressure by screwing in injector piston (10.3) (picture B). Observe deformation of rubber nozzle (10.1) of injector (10) to achieve good repair results. The opening is widened (picture B) if sufficient pressure is present. The pressure should not be present more than 90 s. 11 Hold injector (10) to prevent unscrewing from tool holder (1) and provide for vacuum by unscrewing injector piston (10.3) up to the thread end (picture A). Observe deformation of rubber nozzle (10.1) to achieve good repair results. The opening is smaller (picture A) if sufficient vacuum is present. Do not remove injector piston (10.3) beyond end of thread to ensure that vacuum is maintained. The thread end is indicated by a cracking noise when unscrewing. Maintain vacuum at least as long as pressure. The longer the better. 12 Increase contact pressure of injector (10) on windshield by screwing injector (10) into tool holder (1). Observe damaged points coming from cracks to prevent additional damage. 13 Repeat steps 10 to 12 (8 to 12 times). Increase time of pressure 50 % for each repetition. The air is completely removed, when air pockets are no longer visible under vacuum after an additional waiting time. Air not completely removed can be recognized as small black spots. Perfect repair does not have black spots. Otherwise, repeat until air pockets are no longer visible. 14 Check results by holding white background behind. If the repair results are not satisfactory, repeat steps 10 to 14 by maintaining longer pressure and vacuum (2 to 5 minutes) until air pockets are no longer visible. 15 Cut off an approx. 2 to 3 cm strip of curing foil (11) with bow-shaped blade (7). 16 Loosen clamping lever (2) and pivot tool holder (1) to side using injector (10). As long as the filler resin (8) is not yet cured, it is possible to continue work at any time.
17 Slightly wipe out filler resin (8) in damaged point using lint-free cloth.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4310 · Applies to: 450, 451, 452, 454
18 Apply a drop of filler resin (9) at top of damaged point and attach prepared strip of curing foil (11) first at bottom of mark and lay over area of impact. Avoid formation of air pockets. Do not press curing foil (11) down; this could endanger the repair result. If applicable, repeat operation. 19 Remove injector (10) from tool holder (1) and screw in injector piston (10.3) one thread. 20 Store injector (10) in opaque bag to prevent filler resin (8) from curing. Storing filler resin (8) and injector (10) at 4°C to 8°C in a refrigerator prolongs applicability significantly. 21 Position UV curing lamp (6) above area of impact, switch on and allow filler resin (9) to cure for at least 5 minutes. 22 Switch on UV curing lamp (6) and remove. TESTING & REPAIR > FINISH WINDSHIELD REPAIR - AR67.10-P-1600-03MCC > 1. Remove curing foil (11). 2. Scrape off cured finish resin (9) on windshield using bow-shaped blade (7). To achieve good repair results, move bow-shaped blade (7) at an angle of exactly 90° to windshield by weaving crosswise above damaged point. Scraped finish resin (9) is visible as mat or gray surface. Shining resin surfaces are located deeper and not yet sufficiently filled and must be treated with finish resin (9). Fig 1: Identifying Windshield Repair Finishing Tools Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
When inserting or removing the blade for the multicutter, body parts may be cut if the tightening wrench slips¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4312 · Applies to: 450, 451, 452, 454 · AR: AS67.00-Z-9999ZZ
or if the multicutter switches on unintentionally. Injuries to eyes and hands may be caused by flying glass splinters when cutting out bonded windows. Safety instructions/precautions Wear protective gloves. Wear safety glasses when cutting out window glass. Pneumatic multicutter: Always interrupt air supply when inserting or removing multicutter blade. Electric multicutter: Always interrupt power supply when inserting or removing multicutter blade. SAFETY PRECAUTIONS > RISK OF INJURY FROM CUTTING WIRE TEARING OR BECOMING HOT AND FROM SPLINTERS OF GLASS WHEN CUTTING OUT BONDED WINDOWS - AS67.00-Z-0004-01A > Wear protective gloves and eye protection. Injury hazard When cutting out the bonded window with the cutting wire, there is a risk of injuries to eyes and hands as a result of the cutting wire tearing or becoming hot and as a result of glass splinters jumping off. Protective measures/guidelines Wear protective gloves. Wear eye protection when cutting out the window. SAFETY PRECAUTIONS > SAFETY INFORMATION: WINDOWS - AS67.00-Z-9999ZZ > MODEL all Risk of injury caused by slipping when inserting blade in the multicutter and by glass splinters when cutting out bonded windows MODEL all AS67.00-Z-0001- 01A Risk of injury from contusions to hands if window glass is not secured MODEL all AS67.00-Z-0002- 01A Risk of injury from cutting wire tearing or becoming hot and from splinters of glass when cutting out bonded windows MODEL all AS67.00-Z-0004- 01A Risk of injury from pinching or crushing hands and feet when working on windows. MODEL 210, 211, 212, 220, 221, 240, 397, 461,463,613,671,684... AS67.00-Z-0003- 01A
Vehicle with code (I01) Air¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4315 · Applies to: 450, 451, 452, 454
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 Trunk lid ground connector sleeve 3H 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 N10/10f28 Fuse 28 7 A N23 Heater/AC operating unit 13 L
FG67FG 27/Set B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4318 · Applies to: 450, 451, 452, 454
FG67FG 27/Set B MODEL 450, 451, 452 Use: Stone chipping cracker for increasing size of impact hole for repair preparation. NOTE: Smart no.: 001 6322 V000 0000 00 SPECIAL TOOLS > 452 589 00 99 00 GLASS REPAIR BOX - WS67.00-P-0022B > FG 67/Set B MODEL 450, 451, 452 Single part 452 589 00 99 11 Stone chipping cracker FG67FG 27/Set B WS67.00-P-0022-11B Use: Repair of stone chipping in laminated glass. NOTE: Smart no.: 001 5780 V000 0000 00 Fig 1: Identifying Stone Chipping Cracker (452 589 00 99 11) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > SPECIAL TOOLS: SMART: WINDOWS - WS67.00-Z-9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4319 · Applies to: 450, 451, 452, 454 · AR: WS67.00-Z-9999CZ
MODEL all 000 589 86 63 00 Adapter FG 60/67/72/Set K WS60.00-P-0085K 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P-0027K 450 589 08 63 00 Cutting wire FG 65/67/Set B WS67.00-P-0020B 452 589 00 99 00 Glass repair box FG 67/Set B WS67.00-P-0022B 452 589 00 99 11 Stone chipping cracker FG67FG 27/Set B WS67.00-P-0022- 11B 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P-0012K 454 589 01 63 00 Set of cutting blades Group 67/Set B WS67.00-P-0023B 454 589 01 63 01 Cutting blade Group 67/Set B WS67.00-P-0023- 01B 454 589 01 63 02 Cutting blade Group 67/Set B WS67.00-P-0023- 02B 454 589 01 63 03 Cutting blade Group 67/Set B WS67.00-P-0023- 03B 454 589 01 63 04 Cutting blade Group 67/Set B WS67.00-P-0023- 04B 454 589 01 63 05 Cutting blade Group 67/Set B WS67.00-P-0023- 05B Fig 1: Identifying Glass Repair Box (452 589 00 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
454 589 01 63 06 Cutting blade¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4320 · Applies to: 450, 451, 452, 454
Group 67/Set B WS67.00-P-0023- 06B 454 589 01 63 07 Cutting blade Group 67/Set B WS67.00-P-0023- 07B 930 589 00 99 00 Supplemental truck wiring harness repair kit FG 00/14/54/67 / Set B WS00.19-N-0004B 930 589 00 99 07 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N-0004- 13B 930 589 00 99 08 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N-0004- 14B 930 589 00 99 25 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N-0004- 15B 930 589 00 99 26 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N-0004- 16B
GENERAL INFORMATION > NOTES ON STONE IMPACT REPAIR ON LAMINATED GLASS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4321 · Applies to: 450, 451, 452, 454
WINDOWS - AH67.10-P-0002-01MCC > Model 450.3/4 except 450.418, 451.3/4, 452.3/4, 454.0 Stone mark repair is only permitted in areas outside the long-range field of vision (2). The long-range field of vision (2) is 29 cm wide and is centered around the center point of the steering wheel on the windshield. The long-range field of vision (2) is limited at the top and bottom by the windshield wiper field (1). The damage profiles shown here (stone marks on the windshield) can be repaired economically and satisfactorily using the stone mark repair method. A repair set approved by DaimlerChrysler is required for this purpose. PS laminated glass window repair system Fig 1: Identifying Windshield Wiper Field And Long Range Field Of Vision Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Before repairing damage point, please be sure to always observe the following information:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4322 · Applies to: 450, 451, 452, 454
A workplace without UV radiation should be available, otherwise it can result in paint adhesion problems of the filler resin or finish resin. The windshield temperature must be between 10°C and 25°C to repair the stone marks; if applicable, heat or cool down windshield with suitable methods. Otherwise it can result in paint adhesion problems of the filler resin or finish resin. Only damage on the outside window surface may be repaired. Damages to the inside of the windshield or to the plastic laminate are not permitted. Ensure that moisture has not penetrated into the damaged point (seal damage point immediately after damage using adhesive tape and repair it as soon as possible). The diameter of the chip should not exceeded 5 mm. Any radial cracks extending from the damage point should not exceed 50 mm. They should not end at the rubber window seal and never reach to the outer edge of the window. This repair method can be used only when the damaged point is outside the driver's long-range field of vision. After repair, a spot of approx. 2 mm in diameter can still be seen. GENERAL INFORMATION > NOTES ON REMOVAL/INSTALLATION OF WINDSHIELD - AH67.10-P-1000-01MCE > Model 451.3/4 Adhesive kit for isopropanol cleaner Fig 2: Identifying Windshield Damaged Profiles Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Adhesive kit with heptane cleaner¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4323 · Applies to: 450, 451, 452, 454
Use individual components as described in table below. Deviation is not permissible, otherwise adhesive force of bonded connection is not ensured. Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Adhesive Kit With Heptane Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Allow corresponding primer to flash off for at least 10 minutes, however, for max. 15 minutes.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4324 · Applies to: 450, 451, 452, 454
The crank window in the driver door must be opened during the curing time to prevent the component glued in from being pressed out by the air when the doors are closed. Avoid to open and close doors. Designation Note Use Adhesive cartridge (4) Hot application: Short processing time Durability is achieved after approx. 2 h measured from the time the component is installed. The rated accident strength is achieved only after approx. 8 h. The adhesive cartridge (4) is heated in cartridge heater. Adhesive material for: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Plastic primer (5) Apply with wool wiper (13). Allow primer to flash off for at least 10 - 15 minutes, otherwise the adhesive force of the bonded joint starts to decrease. Primer for: Full roof (with code (E23) Full roof (FFO)) Primer stick (6) PC primer Allow primer to flash off for at least 10 - 15 minutes, otherwise the adhesive force of the bonded joint starts to decrease. Primer for: Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Body flange Heptane cleaner 3350 (7) Apply with cloth (9). Cleaner for primer surface: Full roof (with code (E23) Full roof (FFO)) Cleaner for primer surface:
Cleaning¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4325 · Applies to: 450, 451, 452, 454
cloth (8) Cleaning cloth containing isopropanol and cleaning drying cloth Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Body flange Cloth (9) Color blue-green For applying: Heptane cleaner 3350 (7) Spacer (10)
Spacer (10) for: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Cutting wire (11) Cut out with cutting wire (11) and the two handles included in the window removal kit. To cut out: Full roof (with code (E23) Full roof (FFO)) Glass roof (with code (E22) Glass roof (FFO)) Windshield Firewall segment Application nozzle (12) Nozzle tips are already cut to size. Application of adhesive material in combination with adhesive cartridge (4) Wool wiper (13)
Applying plastic primer (5)
adhe ion problem¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4327 · Applies to: 450, 451, 452, 454
When reinstalling removed window. Clean gluing area on window with cleaning rag (8) from repair kit. When installing a new window. 3. Repair damaged primer layer on window with primer stick (6) from repair kit. When reinstalling removed window. Allow primer to flash off for at least 10 - 15 minutes. Coat gluing area on window with primer stick (6) included in repair kit (max. 20 mm). When installing a new window. Allow primer to flash off for at least 10 - 15 minutes. Windshields are generally delivered with a viewing window on the bottom left. If the viewing window is not required, coat this area on the inside of the window with primer stick (6). TESTING & REPAIR INDEX > ALIGN WINDSHIELD IN BODY OPENING - AR67.10-P-1000- 04MCC > 1. Lay windshield (1) down on spacers on body flange, align windshield (1) at top and center at side. Cup suction tool Aid of helper required. 2. Attach suitable strips of adhesive tape (arrows) and cut at upper edge on windshield (1). 3. Remove windshield (1) from body flange Cup suction tool Aid of helper required.
TESTING & REPAIR INDEX > PREPARE WINDOW FOR INSTALLATION - AR67.10-P-1000-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4328 · Applies to: 450, 451, 452, 454
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 Fig 1: Locating Suitable Strips Of Adhesive Tape On Windshield Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The gluing area on the window must be absolutely free of dust and grease, flaws can lead to adhesion¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4329 · Applies to: 450, 451, 452, 454
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 adhesion problems. When reinstalling removed window. Clean gluing area on window with cleaning rag (8) from repair kit. 3. Repair damaged primer layer on window with primer stick (6) from repair kit. When installing a new window. When reinstalling removed window. Allow primer to flash off for at least 10 - 15 minutes. Coat gluing area on window with primer stick (6) included in repair kit (max. 20 mm). When installing a new window. Allow primer to flash off for at least 10 - 15 minutes. Windshields are generally delivered with a viewing window on the bottom left. If the viewing window is not required, coat this area on the inside of the window with primer stick (6). TESTING & REPAIR INDEX > CUT OUT WINDOWS WITH ROLL OUT - AR67.10-P-1000- 11MCC > Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4330 · Applies to: 450, 451, 452, 454
Number Designation Order number BR00.45-Z-1041-02B TS adhesive (with isopropanol cleaner) A 451 989 00 71 "Roll out" window removal tool Scope of supply: Work is shown on windshield. 1. Mask off puncture point at position (A) (arrow) from outside with suitable textile adhesive tape and punch from vehicle interior through adhesive seam of window (18) with awl (2). 2. Cut cutting wire to correct length. The length of the cutting wire should be approx. 4 times the diagonal of the window. Fig 1: Identifying Window Removal Tools Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3. Insert ends of cutting wire (17) through eye of awl (2) and bend over in direction of arrow.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4331 · Applies to: 450, 451, 452, 454
- Cover areas adjacent to puncture point in vehicle interior with appropriate interior protection and pull cutting wire (17) approx. 70 cm into passenger compartment using awl (2).
- Bend cutting wire (17) straight and remove awl (2).
- Moisten sealing lip on window (18) with soapy water. On windows (18) with sealing lip to facilitate inserting cutting wire (17).
- Route the remaining outer wire loop between windshield (18) and body flange counterclockwise while pulling the excess cutting wire (17) into the inside of the vehicle. Ensure that cutting wire (17) is located below windshield (18) at all four corner points. Fig 2: Masking Off Puncture Point Using Textile Adhesive Tape Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Inserting Cutting Wire Through Eye Of Awl Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
8. Insert guide needles (5) into adhesive seam at bottom edge of window (18).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4332 · Applies to: 450, 451, 452, 454
Only if cutting wire (17) is not attached below window (18). Ensures that cutting wire (17) makes contact to adhesive seam when tensioning. 9. Install windlass (15) on opposite side of window (18) diagonal of puncture point. 10. Insert end of cutting wire (17) into coil of windlass (15) with the shorter end toward the windlass (15). Fig 4: Inserting Cutting Wire On Window Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Guide Needles And Cutting Wires Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
11. Position reversible ratchet (3) on windlass (15) and tension cutting wire (17). Then check from¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4333 · Applies to: 450, 451, 452, 454
outside whether the cutting wire (17) makes contact to the adhesive seam on the window all-round. The coil of the windlass (15) can only be turned in one direction, therefore it is necessary to ensure that the cutting wire (17) is located in the guide groove (20) of the windlass (15). 12. Insert suitable interior protection (10) between cutting wire (17) and inner paneling. Use parabolic chisel (1) at points not easy to reach. Fig 6: Identifying Cutting Wire, Windlass And Window Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
13. Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (B).¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4334 · Applies to: 450, 451, 452, 454
- Remove reversible ratchet, parabolic chisel and interior protection and turn windlass (15) to next position. To move windlass (15), release locking knob (19) while retaining under tension the cutting wire (17) of the coil.
- Install reversible ratchet, parabolic chisel and appropriate interior protection. Fig 7: Inserting Interior Protection Between Cutting Wire And Inner Paneling Using Chisel Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Identifying Locking Knob And Tension Cutting Wire Of Coil Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4336 · Applies to: 450, 451, 452, 454
9.7.10 Special tool added Step 6.2 Removing
Risk of injury due to tear or warming up of cutting wire and through glass splinters when cutting out glued windows Wear protective gloves and safety glasses. AS67.00- Z-0004- 01A Notes on removal/installation of windshield
AH67.10- P-1000- 01MCE Notes on removal/installation of windows
AH67.10- P-1000- 02SM 1 Remove maintenance flap
2 Remove wiper arms
AR82.30- P- 6100MCC 3 Remove inside rearview mirror * not for USA AR68.40- P- 0001MCC
- for USA only AR68.40- P- Fig 1: Identifying Windshield (Shown On Model 451.3/4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
0001MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4337 · Applies to: 450, 451, 452, 454
4 Remove rain/light sensor For vehicles with code (V54) Rain/light sensor AR82.30- P- 7800MCC 5 Cover dashboard with suitable protective cover
6.1 Cut out windshield (1) with "Roll out" window removal tool When using "Roll out" window removal tool. Aid of helper required to remove windshield (1) from body flange. Cutting wire is included in TS adhesive."Roll out" window removal toolCup suction tool AR67.10- P-1000- 11MCC
TS adhesive (with isopropanol cleaner) *BR00.45- Z-1041- 02B 6.2 Cut out windshield (1) "Veritrac" window removal tool When using "Veritrac" window removal tool. Mask off body flange, front edge of vehicle roof as well as detachable parts in cutting area using masking tape to prevent damage from cutting wire. Aid of helper required to cut out and remove windshield (1). Cutting wire is included in TS adhesive.
Cutting wireCup suction tool Fig 3
TS adhesive (with isopropanol cleaner) *BR00.45- Z-1041- 02B Checking
7 Check bonding area on body flange for paint chipping Damage from removing windshield (1) can be repaired with approved materials.
Notes on repair paintwork in bonding area of windows and components
AH98.00- P-9408- 07MCC 8.1 Repair paint chipping on body flange with approved materials On paint chips up to approx. 2 cm . Do not apply basic or clear varnish in boding area.
General notes on touch-up applicators and paint spray cans
AH98.00- P-9409- 06SM 8.2 Renew paintwork structure on body flange On paint chips larger than approx. 2 cm . AR98.00- P- 0900MCC 2 2
Install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4338 · Applies to: 450, 451, 452, 454
9 Prepare body flange for installation of window The gluing area on the body flange must be absolutely free of dust and grease to prevent a decrease in the gluing force when installing window.Wet/dry vacuum cleaner AR67.10- P-1501- 01MCC
TS adhesive (with isopropanol cleaner) *BR00.45- Z-1041- 02B 10 Align windshield (1) in the body opening Aid of helper required.Cup suction tool AR67.10- P-1000- 04MCC 11 Prepare windshield (1) for glazing The gluing area on the windshield (1) should be absolutely free of dust and grease to prevent adhesion problems of the adhesive material. AR67.10- P-1000- 03MCC
TS adhesive (with isopropanol cleaner) *BR00.45- Z-1041- 02B 12 Open crank window in driver door The crank window in the driver door must be opened during the curing time to prevent the windshield (1) from being pressed out by the air when the doors are closed.
13 Apply adhesive material Install windshield (1) on body flange within 2 minutes after applying adhesive material, to prevent adhesion problems of the adhesive material. If the paintwork structure on the body flange is renewed, apply adhesive material on body flange for corrosion protection reasons. The curing time is approx. 2 h measured from the time the windshield (1) is installed. The rated accident strength is achieved only after approx. 8 h.Uniformly apply adhesive bead at a height of approx. 12 mm. AR67.10- P-1000- 08MCC
Intermediate pieceCartridge gun Fig 2
TS adhesive (with isopropanol cleaner) *BR00.45- Z-1041- 02B 14 Install windshield (1) Aid of helper required. Fasten windshield (1) with suitable adhesive tape.Cup suction tool AR67.10- P-1503- 01MCC 15 Install rain/light sensor For vehicles with code (V54) Rain/light sensor AR82.30- P- 7800MCC 16 Install rearview mirror unit * not for USA AR68.40- P- 0001MCC
- for USA only AR68.40- P- 0001MCU
Install wiper arms¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4339 · Applies to: 450, 451, 452, 454
17 Install wiper arms
AR82.30- P- 6100MCC 18 Install maintenance flap
19 Clean windshield (1)
20 Connect Star Diagnosis, read out fault memory, initialize rain/light sensor For vehicles with code (V54) Rain/light sensor AD00.00- P-2000- 04MCC REPAIR MATERIALS Number Designation Order number BR00.45-Z-1041-02B TS adhesive (with isopropanol cleaner) A 451 989 00 71 TESTING & REPAIR INDEX > PREPARE BODY FLANGE FOR INSTALLATION OF WINDOW - AR67.10-P-1501-01MCC > Fig 2: Identifying Intermediate Piece (000 589 86 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Cutting Wire (450 589 08 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
REPAIR MATERIALS¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4340 · Applies to: 450, 451, 452, 454
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 (2) on the body flange (1) must be absolutely free of dust and grease to prevent paint adhesion problem of the adhesive material when glazing. Cut back remaining adhesive material on body flange (1) max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts with the ambient air which can lead to adhesion problems. Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Gluing Area On Body Flange Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Cut off residual adhesive material on body flange (1) down to a height of approx. 2 mm using¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4341 · Applies to: 450, 451, 452, 454
suitable scraper. Remove adhesive material residues. 2. Clean painted adhesive surface on body flange (1) with cleaning rag from repair kit and rub dry with rag. 3. Repair paint damage at body flange (1) with primer applicator. 4. Apply primer to body flange (1) with primer stick from repair kit in areas where residual adhesive material is missing or damaged. s Allow primer to flash off for at least 10 minutes. 5. Install spacers (10) as shown in illustration. 6. Clean working area. Wet/dry vacuum cleaner TESTING & REPAIR INDEX > INSTALL WINDSHIELD - AR67.10-P-1503-01MCC > Shown on model 451.3 1. Center windshield (1) above body opening and position to coincide with strips of adhesive tape (arrows). Cup suction tool Helper required. 2. Position windshield (1) on body flange and press on until it makes contact with spacers. Then fix in place with suitable adhesive tape. Fig 3: Identifying Spacers Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The curing time is approx. 2 h measured from the time the windshield (1) is installed. The rated¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4342 · Applies to: 450, 451, 452, 454
accident strength is achieved only after approx. 8 h. TESTING & REPAIR INDEX > PREPARE REPAIR FOR WINDSHIELD - AR67.10-P-1600- 01MCC > Fig 1: Positioning Windshield On Body Flange Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Repair Tools Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Check damaged point for moisture¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4343 · Applies to: 450, 451, 452, 454
If applicable, heat damaged point with hot air gun and allow to flash off for approx. 10 minutes. 2. Clean windshield around damaged point with cleaning agent (12). 3. Evaluate damaged point A conical fissure or filling cavity should be present in each damaged point to ensure that the filler resin (8) continues to flow. 4. If applicable, crack damaged point to create conical fissure or filling cavity. Use stone impact cracker (5). 5. Install inspection mirror (3) on inside of windshield. 6. Chamfer edges of damaged point using milling cutter (4). Roughen surfaces and remove grayness from porous surfaces. 7. Blow out loose glass particles and wipe out with paper towel. Do not use compressed air when blowing out to prevent enlargement of the damaged point. TESTING & REPAIR INDEX > REPAIR WINDSHIELD - AR67.10-P-1600-02MCC > Fig 1: Identifying Windshield Repair Tools (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1. Place tool holder (1) on windshield so that it is not in the area of the damaged point.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4344 · Applies to: 450, 451, 452, 454
- Press suction cup of tool holder (1) onto windshield with clamping lever (2) in vertical position. To improve adhesion of suction cup moisten with thin layer of adhesion gel (13).
- Arrest tool holder (1) on windshield by moving clamping lever (2) down.
- Screw injector (10) into tool holder (1) until rubber nozzle (10.1) makes slight contact to windshield.
- Mark cracks extending from end of damaged point using suitable pen to check whether cracks have become longer.
- Remove tool holder (1) and position so that rubber nozzle (10.1) of injector (10) is located at center of damaged point.
- Arrest tool holder (1) on windshield by moving clamping lever (2) down. If the cracks extending from the damaged point increase, immediately reduce pressure by Fig 2: Identifying Windshield Repair Tools (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Windshield Repair Tools (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
unscrewing injector (10) from tool holder (1) to prevent the windshield from breaking.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4345 · Applies to: 450, 451, 452, 454
- Screw injector (10) into tool holder (1) until rubber nozzle (10.1) on injector (10) makes contact with windshield all-round. The contact pressure is indicated in the inspection mirror (3) by the edge of the rubber nozzle (10.1) becoming a darker red or deforming edge (10.1).
- Completely unscrew injector piston (10.3), moisten piston thread (10.4) with a drop of filler resin (8) and fill 12 drops of filler resin into the filler opening (10.2). When reusing new injector (10).
- Completely unscrew injector piston (10.3) and fill three to five drops of filler resin into filler opening (10.2) When reusing used injector (10).
- Provide for sufficient pressure by screwing in injector piston (10.3) (picture B). Observe deformation of rubber nozzle (10.1) of injector (10) to achieve good repair results. The opening is widened (picture B) if sufficient pressure is present. The pressure should not be present more than 90 s.
- Hold injector (10) to prevent unscrewing from tool holder (1) and provide for vacuum by unscrewing injector piston (10.3) up to the thread end (picture A). Observe deformation of rubber nozzle (10.1) to achieve good repair results. The opening is smaller (picture A) if sufficient vacuum is present. Do not remove injector piston (10.3) beyond end of thread to ensure that vacuum is maintained. The thread end is indicated by a cracking noise when unscrewing. Maintain vacuum at least as long as pressure. The longer the better.
- Increase contact pressure of injector (10) on windshield by screwing injector (10) into tool holder (1). Observe damaged points coming from cracks to prevent additional damage.
- Repeat steps 11 to 13 (8 to 12 times). Increase time of pressure 50% for each repetition. The air is completely removed, when air pockets are no longer visible under vacuum after an additional waiting time. Air not completely removed can be recognized as small black spots. Perfect repair does not have black spots. Otherwise, repeat until air pockets are no longer visible.
- Check results by holding white background behind. If the repair results are not satisfactory, repeat steps 11 to 15 by maintaining longer pressure and vacuum (2 to 5 minutes) until air pockets are no longer visible.
- Cut off an approx. 2 to 3 cm strip of curing foil (11) with bow-shaped blade (7).
- Loosen clamping lever (2) and pivot tool holder (1) to side using injector (10). As long as the filler resin (8) is not yet cured, it is possible to continue work at any time.
18. Slightly wipe out filler resin (8) in damaged point using lint-free cloth.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4346 · Applies to: 450, 451, 452, 454
- Apply a drop of filler resin (9) at top of damaged point and attach prepared strip of curing foil (11) first at bottom of mark and lay over area of impact. Avoid formation of air pockets. Do not press curing foil (11) down; this could endanger the repair result. If applicable, repeat operation.
- Remove injector (10) from tool holder (1) and screw in injector piston (10.3) one thread.
- Store injector (10) in opaque bag to prevent filler resin (8) from curing. Storing filler resin (8) and injector (10) at 4°C to 8°C in a refrigerator prolongs applicability significantly.
- Position UV curing lamp (6) above area of impact, switch on and allow filler resin (9) to cure for at least 5 minutes.
- Switch on UV curing lamp (6) and remove. TESTING & REPAIR INDEX > FINISH WINDSHIELD REPAIR - AR67.10-P-1600-03MCC >
- Remove curing foil (11).
- Scrape off cured finish resin (9) on windshield using bow-shaped blade (7). To achieve good repair results, move bow-shaped blade (7) at an angle of exactly 90° to windshield by weaving crosswise above damaged point. Scraped finish resin (9) is visible as mat or gray surface. Shining resin surfaces are located deeper and not yet sufficiently filled and must be treated with finish resin (9). Fig 1: Identifying Windshield Repair Finishing Tools Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Injuries to eyes and hands may be caused by flying glass splinters when cutting out bonded windows.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4348 · Applies to: 450, 451, 452, 454 · AR: AS67.00-Z-9999ZZ
Safety instructions/precautions Wear protective gloves. Wear safety glasses when cutting out window glass. Pneumatic multicutter: Always interrupt air supply when inserting or removing multicutter blade. Electric multicutter: Always interrupt power supply when inserting or removing multicutter blade. SAFETY PRECAUTIONS > RISK OF INJURY FROM CUTTING WIRE TEARING OR BECOMING HOT AND FROM SPLINTERS OF GLASS WHEN CUTTING OUT BONDED WINDOWS - AS67.00-Z-0004-01A > Wear protective gloves and eye protection. Injury hazard When cutting out the bonded window with the cutting wire, there is a risk of injuries to eyes and hands as a result of the cutting wire tearing or becoming hot and as a result of glass splinters jumping off. Protective measures/guidelines Wear protective gloves. Wear eye protection when cutting out the window. SAFETY PRECAUTIONS > SAFETY INFORMATION: WINDOWS - AS67.00-Z-9999ZZ > MODEL all Risk of injury caused by slipping when inserting blade in the multicutter and by glass splinters when cutting out bonded windows MODEL all AS67.00- Z-0001- 01A Risk of injury from contusions to hands if window glass is not secured MODEL all AS67.00- Z-0002- 01A Risk of injury from cutting wire tearing or becoming hot and from splinters of glass when cutting out bonded windows MODEL all AS67.00- Z-0004- 01A Risk of injury from pinching or crushing hands and feet when working on windows. MODEL 210, 211, 212, 220, 221, 240, 397, 461, 463, 613, 671, 684... AS67.00- Z-0003- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: WINDOWS - BA67.00-Z- 9999CZ > Side Windows Model 452.3
N10/10f28¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4353 · Applies to: 450, 451, 452, 454
Fuse 28 7 A N23 Heater/AC operating unit 13 L N23s1 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 Fig 1: Heated Rear Window Electric Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 452 589 00 99 11 STONE CHIPPING CRACKER - WS67.00-P-0022-11B¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4355 · Applies to: 450, 451, 452, 454
FG67FG 27/Set B MODEL 450, 451, 452 Use: Stone chipping cracker for increasing size of impact hole for repair preparation. NOTE: Smart no.: 001 6322 V000 0000 00 Fig 1: Identifying Cutting Wire (450 589 08 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Stone Chipping Cracker (452 589 00 99 11) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 452 589 00 99 00 GLASS REPAIR BOX - WS67.00-P-0022B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4356 · Applies to: 450, 451, 452, 454 · AR: WS67.00-Z-9999CZ
FG 67/Set B MODEL 450, 451, 452 Single part 452 589 00 99 11 Stone chipping cracker FG67FG 27/Set B WS67.00-P-0022- 11B Use: Repair of stone chipping in laminated glass. NOTE: Smart no.: 001 5780 V000 0000 00 SPECIAL TOOLS > SPECIAL TOOLS: SMART: WINDOWS - WS67.00-Z-9999CZ > MODEL all 000 589 86 63 00 Adapter FG 60/67/72/Set K WS60.00-P-0085K 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P-0027K 450 589 08 63 00 Cutting wire FG 65/67/Set B WS67.00-P-0020B 452 589 00 99 00 Glass repair box FG 67/Set B WS67.00-P-0022B 452 589 00 99 11 Stone chipping cracker FG67FG 27/Set B WS67.00-P-0022-11B Fig 1: Identifying Glass Repair Box (452 589 00 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
452 589 01 21 00 Feeler¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4357 · Applies to: 450, 451, 452, 454
gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P-0107K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P-0012K 454 589 01 63 00 Set of cutting blades Group 67/Set B WS67.00-P-0023B 454 589 01 63 01 Cutting blade Group 67/Set B WS67.00-P-0023-01B 454 589 01 63 02 Cutting blade Group 67/Set B WS67.00-P-0023-02B 454 589 01 63 03 Cutting blade Group 67/Set B WS67.00-P-0023-03B 454 589 01 63 04 Cutting blade Group 67/Set B WS67.00-P-0023-04B 454 589 01 63 05 Cutting blade Group 67/Set B WS67.00-P-0023-05B 454 589 01 63 06 Cutting blade Group 67/Set B WS67.00-P-0023-06B 454 589 01 63 07 Cutting blade Group 67/Set B WS67.00-P-0023-07B 930 589 00 99 00 Supplemental truck wiring harness repair kit FG 00/14/54/67 / Set B WS00.19-N-0004B 930 589 00 99 07 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N-0004-13B 930 589 00 99 08 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N-0004-14B 930 589 00 99 25 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N-0004-15B 930 589 00 99 26 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N-0004-16B
SPECIAL TOOLS > SPECIAL TOOLS: SMART: AUTOMATIC TRANSMISSION - WS27.00-Z-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4358 · Applies to: 450, 451, 452, 454
9999CZ > MODEL all 000 589 34 33 00 Counter stay FG 26/27/Set C WS26.00-P-0114C 168 589 00 14 00 Sleeve FG 26/27 Set C WS26.00-P-0063C 452 589 00 99 11 Stone chipping cracker FG67FG 27/Set B WS67.00-P-0022-11B 454 589 01 14 00 Set of extractor sleeves FG 26/27Satz C WS26.00-P-0123C 454 589 01 21 00 Adjusting the turning angle sensor FG 27/Set B WS27.00-P-0144B 454 589 02 15 00 Drift FG 26/27 Set C WS26.00-P-0124C
SPECIAL TOOLS > SPECIAL TOOLS: SMART: AUTOMATIC TRANSMISSION - WS27.00-Z-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4359 · Applies to: 450, 451, 452, 454
9999CZ > MODEL all 000 589 34 33 00 Counter stay FG 26/27/Set C WS26.00-P-0114C 168 589 00 14 00 Sleeve FG 26/27 Set C WS26.00-P-0063C 452 589 00 99 11 Stone chipping cracker FG67FG 27/Set B WS67.00-P-0022-11B 454 589 01 14 00 Set of extractor sleeves FG 26/27Satz C WS26.00-P-0123C 454 589 01 21 00 Adjusting the turning angle sensor FG 27/Set B WS27.00-P-0144B 454 589 02 15 00 Drift FG 26/27 Set C WS26.00-P-0124C
TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: CLUTCH - AR25.00-Z-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4360 · Applies to: 450, 451, 452, 454 · AR: AR25.20-P-0125MCC, AR25.20-P-0125MCU, AR25.20-P-0180MCC, AR25.20-P-0180MCU, AR25.10-P-0050MCC (+2 more)
9451CA > MODEL 451 Clutch actuator remove/install MODEL 451.3/4 with TRANSMISSION 717.4 AR25.20-P-0125MCC Clutch actuator remove/install MODEL 451.3/4 with ENGINE 132.910 with TRANSMISSION 717.4 AR25.20-P-0125MCU Remove/install central clutch operator MODEL 451.3/4 with ENGINE 132.9, 660.9 with TRANSMISSION 717.4 AR25.20-P-0180MCC Remove/install central clutch operator MODEL 451.3/4 with ENGINE 132.910 with TRANSMISSION 717.4 AR25.20-P-0180MCU Remove/install clutch MODEL 451.3/4 with ENGINE 132.9 with TRANSMISSION 717.4 AR25.10-P-0050MCC Remove/install clutch MODEL 451.3/4 with ENGINE 660.9 with TRANSMISSION 717.4 AR25.10-P-0050MCE Remove/install clutch MODEL 451.3/4 with ENGINE 132.910 with TRANSMISSION 717.4 AR25.10-P-0050MCU TESTING & REPAIR > CHECKING PRESSURE PLATE AND CLUTCH DISK - AR25.10-P- 0050-01MCC > TEST VALUES FOR CLUTCH Number Designation Engine 132.9 Engine 660.9 BE25.10-P-1001- 01E Lining thickness mm 3,1 3,1 BE25.10-P-1002- 01E Max. total wear mm 2.0 2.0 BE25.10-P-1003- 01E Max. lateral runout mm 0.75 0.75 BE25.10-P-1004- 01E Clutch diameter mm 200 200 BE25.10-P-1005- 01E Thickness, uncompressed mm 7.6 to 8.2 7.6 to 8.2 Checking pressure plate 1. Check pressure plate (6) for cracks and scores as well as diaphragm spring (arrow) for breakage
2. Inspect the tabs (arrows) of the diaphragm spring for wear and uniform height.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4361 · Applies to: 450, 451, 452, 454
Checking clutch plate 3. Check the friction linings (1a) of the clutch plate for oil fouling, cracks, chipping and wear. 4. Check the damping springs (1b) for cracks and firm seating. 5. Inspect spline shaft profile (1c) for wear and chippings. It must be possible to slide the clutch plate onto the input shaft of the transmission with a small amount of force. Fig 1: Locating Diaphragm Spring Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Locating Tabs Of Diaphragm Spring Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL CLUTCH - AR25.10-P-0050MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4362 · Applies to: 450, 451, 452, 454 · AR: AR25.10-P-0050MCU
MODEL 451.3/4 with ENGINE 132.910 with TRANSMISSION 717.4 Remove/install
1 Remove transmission
AR26.10-P- 0020MCU 2 Attach retaining
AR03.30-P- 1600-06MCC Fig 3: Identifying Friction Lining Of Clutch Plate, Damping Springs And Spline Shaft Profile Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Clutch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
lock for engine¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4363 · Applies to: 450, 451, 452, 454
*451589014000 3 Remove bolts (3) securing pressure plate (2) Loosen bolts (3) diagonally in each case in steps of 1.5 revolutions. Installation: Tighten bolts (3) diagonally in each case in steps of 1.5 revolutions.
*BA25.10-P- 1003-01C 4 Remove pressure plate (2) and clutch plate (1) Installation: Degrease the pressure plate's (2) friction surface and grind down using coarse abrasive emery cloth. Center the pressure plate (2) and clutch plate (1) using the centering tool (5) as per the manufacturer's operating instructions. Ensure that the clutch disc (1) is correctly positioned.
*000589473100 Checking
5 Check pressure plate (2) and clutch plate (1)
AR25.10-P- 0050-01MCC Max. total wear BE25.10-P- 1002-01E Max. lateral runout BE25.10-P- 1003-01E Clutch diameter BE25.10-P- 1004-01E Thickness, uncompressed BE25.10-P- 1005-01E 6 Check flywheel (4) for wear and damage Replace flywheel (4) in the event of damage or wear. See: ↓
Remove, install a flywheel Installation: Degrease the flywheel's (4) friction surface and grind down using coarse abrasive emery cloth. AR03.30-P- 8002MCU 7 Check central clutch release bearing for noises, rough running, leakage, wear and damage Replace the central clutch release bearing if necessary.See: ↓
Remove/install central clutch operator AR25.20-P- 0180MCU 8 Install in the reverse order
TEST VALUES FOR CLUTCH Number Designation Engine 132.9 BE25.10-P-1001-01E Lining thickness mm 3,1 BE25.10-P-1002-01E Max. total wear mm 2.0
BE25.10-P-1003-01E¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4364 · Applies to: 450, 451, 452, 454 · AR: AR25.20-P-0125MCU
Max. lateral runout mm 0,75 BE25.10-P-1004-01E Clutch diameter mm 200 BE25.10-P-1005-01E Thickness, uncompressed mm 7,6 to 8,2 CLUTCH Number Designation Model 451.3/4 BA25.10-P-1003-01C Bolt, pressure plate to flywheel Nm 20 TESTING & REPAIR > CLUTCH ACTUATOR REMOVE/INSTALL - AR25.20-P-0125MCU > MODEL 451.3/4 with ENGINE 132.910 with TRANSMISSION 717.4 Fig 2: Identifying Centering Tool (000 589 47 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4365 · Applies to: 450, 451, 452, 454
19.3.09 Document revised as per new repair method. The clutch motor can be replaced individually in the event of damage. Removing
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 2 Disconnect electrical connector (2) on clutch motor (M18)
3 Remove bolts (3) and remove clutch actuator (1) from transmission
4 Remove bolts (4) and remove clutch motor (M18) from clutch actuator (1). Only remove clutch motor (M18) in the event of damage.
Install
5 Position clutch motor (M18) in clutch actuator (1) as per picture (arrow B) screw on with bolts (4) Only install clutch motor (M18) in the event of damage.
Fig 1: Identifying Clutch Actuator Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
*BA25 20 P 1004¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4366 · Applies to: 450, 451, 452, 454
01C 6 Position clutch actuator (1) on transmission and fix in place with bolts (3) Do not tighten down the bolts (3).
7 Slide clutch actuator (1) towards the bell housing until the plunger of clutch actuator (1) abuts the release lever of the clutch operator
8 Starting from this position, slide the clutch actuator (1) by a further three graduation lines (arrow A) towards the bell housing and tighten bolts (3) *BA25.20-P-1003- 01C 9 Contact electrical connector (2) on clutch motor (M18)
10 Lower vehicle with vehicle lift
11 Perform commissioning without control unit replacement Observe menu guidance in DAS (DAS).
Connect STAR DIAGNOSIS and read out fault memory AD00.00-P-2000- 04MCC CLUTCH OPERATING MECHANISM Number Designation Model 451.3/4 BA25.20-P-1003-01C Clutch actuator to transmission Nm 10 BA25.20-P-1004-01C Clutch motor to clutch actuator Nm 9 TESTING & REPAIR > REMOVE/INSTALL CENTRAL CLUTCH OPERATOR - AR25.20-P- 0180MCU > MODEL 451.3/4 with ENGINE 132.910 with TRANSMISSION 717.4
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4367 · Applies to: 450, 451, 452, 454
1 Remove transmission
AR26.10- P- 0020MCU 2 Remove bolts (3) *BA25.20- P-1001- 01C 3 Unhook spring (4) on release lever (2) Do not overstretch spring (4) otherwise the correct seat of the release lever (2) can no longer be guaranteed. Installation: Check spring (4), replace if necessary.Pay attention to correct seat of spring (4).
4 Remove central clutch release bearing (1) with release lever (2) and guide sleeve (5) from transmission (6)
5 Pull guide sleeve (5) out of central clutch release bearing (1) Rotate guide sleeve (5) such that the catches on the guide sleeve (5) fit into the cutouts on the central clutch release bearing (1).
6 Carefully push catch hooks (7) together and remove central clutch release bearing (1) from release lever (2) Clean and grease bearing points of release lever (2). Installation: Check central clutch release bearing (1) for noise, rough running, leakage and wear and replace central clutch release bearing (1) if necessary.
Transmission shaft grease *BR00.45- Z-1062- 06A 7 Install in the reverse order
Fig 1: Identifying Central Clutch Operator Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
CLUTCH OPERATING MECHANISM¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4368 · Applies to: 450, 451, 452, 454 · AR: AS25.00-Z-9999ZZ
Number Designation Model 451.3/4 BA25.20-P-1001-01C Bolt, release system to transmission Nm 10 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1062- 06A Lubricating grease, Olista Longtime, DB supply specification 6804.60 A 001 989 36 51 10 SAFETY PRECAUTIONS > SAFETY INFORMATION: CLUTCH - AS25.00-Z-9999ZZ > MODEL all Risk of injury caused by body parts being trapped or crushed when working on the pressurized clutch actuator MODEL 375, 930, 932, 933, 934, 940, 944... AS25.00-Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: CLUTCH - BA25.00-Z- 9999CZ > MODEL all Clutch MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454 BA25.10-P-1000-01C Clutch operation MODEL 454.0 BA25.20-P-1000-01D Clutch operator MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA25.20-P-1000-01C TORQUE SPECIFICATIONS > CLUTCH - BA25.10-P-1000-01C > Model 450, 451, 452, 454 MODIFICATION NOTES 27.4.05 Bolt, clutch module to driver CLUTCH Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 Model 454.0 BA25.10-P- 1001-01C Bolt, clutch module to driver Stage 1 Nm 20 - 20 - Stage 2 ∠° 90 - 90 - Stage 3 ∠° 10 - 10 - BA25.10-P- Bolt, drive plate to Stage Nm 45 45 45 -
1002-01C¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4369 · Applies to: 450, 451, 452, 454 · AR: BE25.00-Z-9999CZ
crankshaft 1 Stage 2 ∠° 90 90 90 - BA25.10-P- 1003-01C Bolt, pressure plate to flywheel Nm - 20 - 19 TORQUE SPECIFICATIONS > CLUTCH OPERATOR - BA25.20-P-1000-01C > Model 450, 451, 452 CLUTCH OPERATING MECHANISM Number Designation Model 450.3 Model 450.4 Model 451.3/4 Model 452.3/4 BA25.20-P- 1001-01C Bolt, release system to transmission Nm 10 10 10 10 BA25.20-P- 1002-01C Clutch actuation to transmission Nm 10 10 - 10 BA25.20-P- 1003-01C Clutch actuator to transmission Nm - - 10 - BA25.20-P- 1004-01C Clutch motor to clutch actuator Nm - - 9 - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: CLUTCH - BE25.00-Z-9999CZ > MODEL all Clutch ENGINE 132.9, 660.9 in MODEL 451.3/4 BE25.10-P-1000-01E TEST & ADJUSTMENT VALUES > CLUTCH - BE25.10-P-1000-01E > Engines 132.9, 660.9 MODIFICATION NOTES 18.12.06 Lining thicknessMax. total wearMax. lateral runout TEST VALUES FOR CLUTCH Number Designation Engine 132.9 Engine 660.9 BE25.10-P-1001- 01E Lining thickness mm 3,1 3,1 BE25.10-P-1002- 01E Max. total wear mm 2.0 2.0 BE25.10-P-1003- 01E Max. lateral runout mm 0,75 0,75 BE25.10-P-1004- Clutch diameter mm 200 200
BE25.10-P-1005-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4370 · Applies to: 450, 451, 452, 454
01E BE25.10-P-1005- 01E Thickness, uncompressed mm 7,6 to 8,2 7,6 to 8,2 SPECIAL TOOLS > 000 589 47 31 00 ALIGNMENT TOOL - WS25.00-P-0003B > FG 25/Set B MODEL 107, 123, 124, 126, 129, 140, 163, 168, 169, 170, 171, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 245.2, 454, 414, 636, 638, 639 MODEL 451 with ENGINE 132 MODIFICATION NOTES 28.5.97 Replacement for 201 589 08 15 00
4.6.08 Replacement for 454 589 00 31 00 centering tool WS25.00-P-0010B Use: Centering tool 15...28 mm dia. for clutch plate to clutch pressure plate.
SPECIAL TOOLS > 454 589 03 15 00 DRIFT - WS25.00-P-0011B > FG 25/26/Set B MODEL 451, 454 Use: Drift for hammering in shaft seals on transmission (on output side). Fig 1: Identifying Alignment Tool (000 589 47 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 451 589 03 31 00 ASSEMBLY TOOL - WS25.00-P-0013B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4371 · Applies to: 450, 451, 452, 454 · AR: WS25.00-Z-9999CZ
FG 25/Set B MODEL 451 Use: Assembly tool for centering of clutch plate relative to clutch pressure plate. SPECIAL TOOLS > SPECIAL TOOLS: SMART: CLUTCH - WS25.00-Z-9999CZ > MODEL all 000 589 47 31 00 Alignment tool FG 25/Set B WS25.00-P- 0003B 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B Fig 1: Identifying Drift (454 589 03 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Assembly Tool (451 589 03 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
450 589 02 09 00 Socket wrench¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4372 · Applies to: 450, 451, 452, 454
bit FG 25/Set B WS25.00-P-0005B 450 589 10 21 00 Spring balance FG 25/Set B WS25.00-P-0006B 450 589 10 63 00 Y-cable FG 25/Set B WS25.00-P-0008B 450 589 11 09 00 Socket FG 25/Set B WS25.00-P-0014B 450 589 12 21 00 Bracket FG 25/Set B WS25.00-P-0007B 451 589 03 31 00 Assembly tool FG 25/Set B WS25.00-P- 0013B 454 589 00 31 00 Alignment tool FG 25/Set B WS25.00-P-0010B 454 589 01 09 00 Socket wrench bit FG 25/Set B WS25.00-P-0009B 454 589 01 91 00 Adapter FG 42/25/26/Set A WS42.00-P-0069A 454 589 03 15 00 Drift FG 25/26/Set B WS25.00-P- 0011B
TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: CLUTCH - AR25.00-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4373 · Applies to: 450, 451, 452, 454 · AR: AR25.20-P-0125MCC, AR25.20-P-0125MCU, AR25.20-P-0180MCC, AR25.20-P-0180MCU, AR25.10-P-0050MCC (+2 more)
Z-9451CA > MODEL 451 Clutch actuator remove/install MODEL 451.3 /4 with TRANSMISSION 717.4 AR25.20-P-0125MCC Clutch actuator remove/install MODEL 451.3 /4 with ENGINE 132.910 with TRANSMISSION 717.4 AR25.20-P-0125MCU Remove/install central clutch operator MODEL 451.3 /4 with ENGINE 132.9, 660.9 with TRANSMISSION 717.4 AR25.20-P-0180MCC Remove/install central clutch operator MODEL 451.3 /4 with ENGINE 132.910 with TRANSMISSION 717.4 AR25.20-P-0180MCU Remove/install clutch MODEL 451.3 /4 with ENGINE 132.9 with TRANSMISSION 717.4 AR25.10-P-0050MCC Remove/install clutch MODEL 451.3 /4 with ENGINE 660.9 with TRANSMISSION 717.4 AR25.10-P-0050MCE Remove/install clutch MODEL 451.3 /4 with ENGINE 132.910 with TRANSMISSION 717.4 AR25.10-P-0050MCU TESTING & REPAIR INDEX > CHECKING PRESSURE PLATE AND CLUTCH DISK - AR25.10-P-0050-01MCC > TEST VALUES FOR CLUTCH Number Designation Engine 132.9 Engine 660.9 BE25.10-P-1001-01E Lining thickness mm 3,1 3,1 BE25.10-P-1002-01E Max. total wear mm 2.0 2.0 BE25.10-P-1003-01E Max. lateral runout mm 0.75 0.75 BE25.10-P-1004-01E Clutch diameter mm 200 200 BE25.10-P-1005-01E Thickness, uncompressed mm 7.6 to 8.2 7.6 to 8.2 Checking pressure plate 1. Check pressure plate (6) for cracks and scores as well as diaphragm spring (arrow) for breakage
2. Inspect the tabs (arrows) of the diaphragm spring for wear and uniform height.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4374 · Applies to: 450, 451, 452, 454
Checking clutch plate 3. Check the friction linings (1a) of the clutch plate for oil fouling, cracks, chipping and wear. 4. Check the damping springs (1b) for cracks and firm seating. 5. Inspect spline shaft profile (1c) for wear and chippings. It must be possible to slide the clutch plate onto the input shaft of the transmission with a small amount of force. Fig 1: Identifying Pressure Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Locating Tabs Of Diaphragm Spring Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR INDEX > REMOVE/INSTALL CLUTCH - AR25.10-P-0050MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4375 · Applies to: 450, 451, 452, 454 · AR: AR25.10-P-0050MCU
MODEL 451.3 /4 with ENGINE 132.910 with TRANSMISSION 717.4 Remove/install
1 Remove transmission
AR26.10- P- 0020MCU AR03.30- P-1600- Fig 3: Identifying Friction Lining Of Clutch Plate, Damping Springs And Spline Shaft Profile Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Clutch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Attach retaining¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4376 · Applies to: 450, 451, 452, 454
2 Attach retaining lock for engine
06MCC Fig 3 3 Remove bolts (3) securing pressure plate (2) Loosen bolts (3) diagonally in each case in steps of 1.5 revolutions. Installation: Tighten bolts (3) diagonally in each case in steps of 1.5 revolutions.
*BA25.10- P-1003- 01C 4 Remove pressure plate (2) and clutch plate (1) Installation: Degrease the pressure plate's (2) friction surface and grind down using coarse abrasive emery cloth. Center the pressure plate (2) and clutch plate (1) using the centering tool (5) as per the manufacturer's operating instructions. Ensure that the clutch disc (1) is correctly positioned.
Fig 2 Checking
5 Check pressure plate (2) and clutch plate (1)
AR25.10- P-0050- 01MCC Max. total wear BE25.10- P-1002- 01E Max. lateral runout BE25.10- P-1003- 01E Clutch diameter BE25.10- P-1004- 01E Thickness, uncompressed BE25.10- P-1005- 01E 6 Check flywheel (4) for wear and damage Replace flywheel (4) in the event of damage or wear. See: ↓
Remove, install a flywheel Installation: Degrease the flywheel's (4) friction surface and grind down using coarse abrasive emery cloth. AR03.30- P- 8002MCU 7 Check central clutch release bearing for noises, rough running, leakage, wear and damage Replace the central clutch release bearing if necessary.See: ↓
Remove/install central clutch operator AR25.20- P- 0180MCU 8 Install in the reverse order
TEST VALUES FOR CLUTCH¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4377 · Applies to: 450, 451, 452, 454
Number Designation Engine 132.9 BE25.10-P-1001-01E Lining thickness mm 3,1 BE25.10-P-1002-01E Max. total wear mm 2.0 BE25.10-P-1003-01E Max. lateral runout mm 0,75 BE25.10-P-1004-01E Clutch diameter mm 200 BE25.10-P-1005-01E Thickness, uncompressed mm 7,6 to 8,2 CLUTCH Number Designation Model 451.3/4 BA25.10-P-1003-01C Bolt, pressure plate to flywheel Nm 20 TESTING & REPAIR INDEX > CLUTCH ACTUATOR REMOVE/INSTALL - AR25.20-P- 0125MCU > MODEL 451.3 /4 with ENGINE 132.910 with TRANSMISSION 717.4 Fig 2: Identifying Centering Tool (000 589 47 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4378 · Applies to: 450, 451, 452, 454
19.3.09 Document revised as per new repair method. The clutch motor can be replaced individually in the event of damage. Removing
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 2 Disconnect electrical connector (2) on clutch motor (M18)
3 Remove bolts (3) and remove clutch actuator (1) from transmission
4 Remove bolts (4) and remove clutch motor (M18) from clutch actuator (1). Only remove clutch motor (M18) in the event of damage.
Install
5 Position clutch motor (M18) in clutch actuator (1) as per picture (arrow B) screw on with bolts (4) Only install clutch motor (M18) in the event of damage.
*BA25.20- P-1004- 01C Position clutch actuator (1) on Do not tighten down the bolts Fig 1: Identifying Clutch Actuator Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
tran mi¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4379 · Applies to: 450, 451, 452, 454 · AR: AR25.20-P-0180MCU
6 tran mi ion and fi in place with bolts (3) (3)
7 Slide clutch actuator (1) towards the bell housing until the plunger of clutch actuator (1) abuts the release lever of the clutch operator
8 Starting from this position, slide the clutch actuator (1) by a further three graduation lines (arrow A) towards the bell housing and tighten bolts (3) *BA25.20- P-1003- 01C 9 Contact electrical connector (2) on clutch motor (M18)
10 Lower vehicle with vehicle lift
11 Perform commissioning without control unit replacement Observe menu guidance in DAS (DAS).
Connect STAR DIAGNOSIS and read out fault memory AD00.00- P-2000- 04MCC CLUTCH OPERATING MECHANISM Number Designation Model 451.3/4 BA25.20-P-1003-01C Clutch actuator to transmission Nm 10 BA25.20-P-1004-01C Clutch motor to clutch actuator Nm 9 TESTING & REPAIR INDEX > REMOVE/INSTALL CENTRAL CLUTCH OPERATOR - AR25.20-P-0180MCU > MODEL 451.3 /4 with ENGINE 132.910 with TRANSMISSION 717.4 Remove/install
Fig 1: Identifying Central Clutch Operator Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove transmission¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4380 · Applies to: 450, 451, 452, 454 · AR: AS25.00-Z-9999ZZ
1 Remove transmission
AR26.10- P- 0020MCU 2 Remove bolts (3) *BA25.20- P-1001- 01C 3 Unhook spring (4) on release lever (2) Do not overstretch spring (4) otherwise the correct seat of the release lever (2) can no longer be guaranteed. Installation: Check spring (4), replace if necessary.Pay attention to correct seat of spring (4).
4 Remove central clutch release bearing (1) with release lever (2) and guide sleeve (5) from transmission (6)
5 Pull guide sleeve (5) out of central clutch release bearing (1) Rotate guide sleeve (5) such that the catches on the guide sleeve (5) fit into the cutouts on the central clutch release bearing (1).
6 Carefully push catch hooks (7) together and remove central clutch release bearing (1) from release lever (2) Clean and grease bearing points of release lever (2). Installation: Check central clutch release bearing (1) for noise, rough running, leakage and wear and replace central clutch release bearing (1) if necessary.
Transmission shaft grease *BR00.45- Z-1062- 06A 7 Install in the reverse order
CLUTCH OPERATING MECHANISM Number Designation Model 451.3/4 BA25.20-P-1001-01C Bolt, release system to transmission Nm 10 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1062- 06A Lubricating grease, Olista Longtime, DB supply specification 6804.60 A 001 989 36 51 10 SAFETY PRECAUTIONS > SAFETY INFORMATION: CLUTCH - AS25.00-Z-9999ZZ > MODEL all Risk of injury caused by body parts being trapped or crushed when working on the MODEL 375, 930, 932, 933, 934, 940, 944...
pressurized clutch actuator¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4381 · Applies to: 450, 451, 452, 454
TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: CLUTCH - BA25.00-Z- 9999CZ > MODEL all Clutch MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454 BA25.10-P-1000-01C Clutch operation MODEL 454.0 BA25.20-P-1000-01D Clutch operator MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA25.20-P-1000-01C TORQUE SPECIFICATIONS > CLUTCH - BA25.10-P-1000-01C > Model 450, 451, 452, 454 MODIFICATION NOTES 27.4.05 Bolt, clutch module to driver CLUTCH Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 Model 454.0 BA25.10-P- 1001-01C Bolt, clutch module to driver Stage 1 Nm 20 - 20 - Stage 2 ∠° 90 - 90 - Stage 3 ∠° 10 - 10 - BA25.10-P- 1002-01C Bolt, drive plate to crankshaft Stage 1 Nm 45 45 45 - Stage 2 ∠° 90 90 90 - BA25.10-P- 1003-01C Bolt, pressure plate to flywheel Nm - 20 - 19 TORQUE SPECIFICATIONS > CLUTCH OPERATOR - BA25.20-P-1000-01C > Model 450, 451, 452 CLUTCH OPERATING MECHANISM Number Designation Model 450.3 Model 450.4 Model 451.3/4 Model 452.3/4 BA25.20-P- 1001-01C Bolt, release system to transmission Nm 10 10 10 10
BA25.20-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4382 · Applies to: 450, 451, 452, 454 · AR: BE25.00-Z-9999CZ
1002-01C Clutch actuation to transmission Nm 10 10 - 10 BA25.20-P- 1003-01C Clutch actuator to transmission Nm - - 10 - BA25.20-P- 1004-01C Clutch motor to clutch actuator Nm - - 9 - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: CLUTCH - BE25.00-Z-9999CZ > MODEL all Clutch ENGINE 132.9, 660.9 in MODEL 451.3 /4 BE25.10-P-1000-01E TEST & ADJUSTMENT VALUES > CLUTCH - BE25.10-P-1000-01E > Engines 132.9, 660.9 MODIFICATION NOTES 18.12.06 Lining thicknessMax. total wearMax. lateral runout TEST VALUES FOR CLUTCH Number Designation Engine 132.9 Engine 660.9 BE25.10-P-1001-01E Lining thickness mm 3,1 3,1 BE25.10-P-1002-01E Max. total wear mm 2.0 2.0 BE25.10-P-1003-01E Max. lateral runout mm 0,75 0,75 BE25.10-P-1004-01E Clutch diameter mm 200 200 BE25.10-P-1005-01E Thickness, uncompressed mm 7,6 to 8,2 7,6 to 8,2 SPECIAL TOOLS > 000 589 47 31 00 ALIGNMENT TOOL - WS25.00-P-0003B > FG 25/Set B MODEL 107, 123, 124, 126, 129, 140, 163, 168, 169, 170, 171, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 245.2, 454, 414, 636, 638, 639 MODEL 451 with ENGINE 132 MODIFICATION NOTES 28.5.97 Replacement for 201 589 08 15 00
4.6.08 Replacement for 454 589 00 31 00 centering tool WS25.00-P-0010B
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4383 · Applies to: 450, 451, 452, 454
Centering tool 15...28 mm dia. for clutch plate to clutch pressure plate.
SPECIAL TOOLS > 454 589 03 15 00 DRIFT - WS25.00-P-0011B > FG 25/26/Set B MODEL 451, 454 Use: Drift for hammering in shaft seals on transmission (on output side). SPECIAL TOOLS > 451 589 03 31 00 ASSEMBLY TOOL - WS25.00-P-0013B > FG 25/Set B MODEL 451 Fig 1: Identifying Alignment Tool (000 589 47 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Drift (454 589 03 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4384 · Applies to: 450, 451, 452, 454 · AR: WS25.00-Z-9999CZ
Assembly tool for centering of clutch plate relative to clutch pressure plate. SPECIAL TOOLS > SPECIAL TOOLS: SMART: CLUTCH - WS25.00-Z-9999CZ > MODEL all 000 589 47 31 00 Alignment tool FG 25/Set B WS25.00-P-0003B 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 450 589 02 09 00 Socket wrench bit FG 25/Set B WS25.00-P-0005B 450 589 10 21 00 Spring balance FG 25/Set B WS25.00-P-0006B 450 589 10 63 00 Y-cable FG 25/Set B WS25.00-P-0008B 450 589 11 09 00 Socket FG 25/Set B WS25.00-P-0014B 450 589 12 21 00 Bracket FG 25/Set B WS25.00-P-0007B 451 589 03 31 00 Assembly tool FG 25/Set B WS25.00-P-0013B 454 589 00 31 00 Alignment tool FG 25/Set B WS25.00-P-0010B 454 589 01 09 00 Socket wrench bit FG 25/Set B WS25.00-P-0009B 454 589 01 91 00 Adapter FG 42/25/26/Set A WS42.00-P-0069A 454 589 03 15 00 Drift FG 25/26/Set B WS25.00-P-0011B Fig 1: Identifying Assembly Tool (451 589 03 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 1: Identifying Transmission Components (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4391 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Transmission Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4392 · Applies to: 450, 451, 452, 454
1 Position selector lever on electronic selector lever module control unit in position "P"
2 Remove interior flap above engine
AR88.40-P- 1100-03MCC 3 Disconnect ground line of battery
AR54.10-P- 0003MCC 4 Remove air filter housing
AR09.10-P- 1150MCU 5 Remove rear axle shafts
AR35.30-P- 0620MCU 6 Remove fender liner from left rear fender
AR88.10-P- 1400MCU 7 Lower vehicle with vehicle lift
8 Unscrew bolt (2) *BA26.10-P- 1001-01D 9 Unhook counter bearing (3) of wire pull of park pawl (4) on transmission (1) and unclip wire pull of park pawl (4) at lever (5)
10 Loosen bolts (6) of bushing of transmission mounting (7) on transmission (1) *BA26.00-P- 1002-01D 11 Unscrew bolts (8) of bracket (9) on cylinder head put down bracket (9) to one side
12 Fasten retaining plate to the upper threaded hole in the cylinder head with one bolt (8) *451589026300 Attach support brace to engine hoist, position Turn back the spindle at the engine hoist so
engine hoist and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4393 · Applies to: 450, 451, 452, 454
13 engine hoist and suspend suitable chain in the retaining plate that it is ensured that it is possible to lower the engine with the transmission (1) by approx. a further 4 cm.
*451589016200
*451589026300
*639589006100 14 Raise vehicle with vehicle lift
15 Detach wiring harness from transmission (1)
AR26.19-P- 0001-05MCU 16 Pull out the plug (10) on the starter (M1)
17 Unscrew nut (11) and remove charge current line (12) from starter (M1) BA15.30-P- 1002-01E 18 Unscrew bolts (13) of carrier for front engine mount (14) from transmission (1) BA22.10-P- 1012-01M 19 Unscrew bolt (15) BA26.10-P- 1001-01D 20 Support transmission (1) with transmission jack and removal fixture and secure with tensioning strap Transmission jackgotis://H_00.10_01.0 450589026200 21 Unscrew bolts (6) of bushing of transmission mounting (7) from transmission (1) Installation: Screw in bolts (6) until they abut.
22 Unscrew bolts (16) on bracket (17) of exhaust system
23 Remove bolts (18) *BA26.10-P- 1001-01D When moving the transmission (1) out and in ensure that no electrical lines and hoses are
Loosen¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4394 · Applies to: 450, 451, 452, 454
24 Loosen transmission (1) from engine and lower damaged. Helper required to guide the transmission (1). Installation: The centering sleeves must seat firmly in the cylinder crankcase, replace centering sleeves if necessary. Grease transmission input shaft lightly.
Olista Longtime 3 E P *BR00.45-Z- 1062-06A 25 Release tensioning strap and remove transmission (1) from transmission jack Aid of 2 helpers required.
*450589026200 26 Unscrew bracket (19) of air filter housing on transmission (1) When replacing the transmission (1).
27 Detach starter (M1) from transmission (1) When replacing the transmission (1).
*BA15.30-P- 1001-01E 28 Detach clutch motor (M18) from transmission (1) When replacing the transmission (1). Installation: Only install clutch motor (M18) after installing the transmission (1). AR25.20-P- 0125MCU 29 Install in the reverse order
30 Perform commissioning without control unit replacement Observe menu guidance in DAS (DAS).
Connect STAR DIAGNOSIS and read out fault memory
AD00.00-P- 2000-04MCC STARTER Number Designation Engine 132.9 BA15.30-P-1001- 01E Bolt, starter to transmission Nm 42 BA15.30-P-1002- 01E Cable on starter circuit 30 Nm 10 ENGINE MOUNTS, ENGINE SUPPORTS
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4395 · Applies to: 450, 451, 452, 454
Designation Engine 132.9 BA22.10-P-1012- 01M Bolt, carrier for front engine mount to transmission Nm 23 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.48 BA26.00-P-1002- 01D Bolt, transmission mount to transmission Nm 80 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.4 in model 451.3/4 BA26.10-P-1001- 01D Bolt, transmission to engine Nm 45 Fig 3: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Support Braces (451 589 01 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4397 · Applies to: 450, 451, 452, 454
1 Remove air filter housing
AR09.10- P- 1150MCU 2 Support transmission using a hand-operated hydraulic floor jack Use a suitable protective underlay in order to avoid damage to the transmission. Manual hydraulic floor jackhttp://gotis.aftersales.mercedes- benz.com
3 Remove bolts (2) for transmission mounting bearing (1) on transmission BA26.00- P-1002- 01D 4 Unscrew bolts (3) of bearing of transmission mounting (1) from frame- type integral support (4) BA26.00- P-1009- 01D 5 Remove bushing of transmission mounting (1) upwards and take out
6 Install in the reverse order
COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.48 BA26.00-P-1002- 01D Bolt, transmission mount to transmission Nm 80 BA26.00-P-1009- Bolt, transmission mount to frame-type Nm 56 Fig 1: Identifying Mount For Transmission Mounting, Frame-Type Integral Support, Bolts And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4401 · Applies to: 450, 451, 452, 454
Notes on avoiding damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Turn off ignition
2 Remove driver seat (1)
AR91.10- P- 1010MCU 3 Reposition floor covering under the driver seat (1) in the rear area until the automated manual transmission control unit (N15/6) is accessible When repositioning the floor covering ensure that this is not damaged due to breaking or cracking.
4 Separate electrical connectors (2) on the automated manual transmission control unit (N15/6)
5 Unscrew nuts (3) on automated manual transmission control unit (N15/6) and put ground line (4) to one side Replace self-locking nuts (3).
6 Remove automated manual transmission control unit (N15/6)
7 Install in the reverse order
8 Flash the automated manual transmission control unit (N15/6) When replacing the automated manual transmission control unit (N15/6). AR54.21- P- 0012MCU TESTING & REPAIR > REMOVE/INSTALL RADIAL SHAFT SEALING RINGS ON AXLE Fig 1: Locating Automated Manual Transmission Control Unit, Electric Connectors And Ground Cable Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4410 · Applies to: 450, 451, 452, 454
1 Pull off shift lever knob (1) carefully in direction of arrow Do not operate shift lever knob for automatic function (2) while pulling off, otherwise the contact spring (3) or automatic function microswitch (4) will be damaged.
2 Unhook contact spring (3) on automatic function microswitch (4)
Checking
3 Check contact spring (3) for damage Replace contact spring (3) if damaged.
4 Check attachment point (arrow) on left and right of automatic function microswitch (4) See magnified section A.If the attachment point (arrow) on left or right on automatic function microswitch (4) is damaged, the electronic selector lever module control unit is damaged (N15/5). See: ↓Remove/install shift module
Model 450.3/4 AR26.60- P- 0630SM
Model 451.3/4 AR26.60- P- 0630MCC Install in the reverse Fig 2: Identifying Electronic Selector Lever Module Control Unit And Automatic Function Microswitch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4412 · Applies to: 450, 451, 452, 454
1 Remove electronic selector lever module control unit (N15/5)
AR26.60- P- 0630MCU 2 Remove cargo area floor cover
AR68.20- P- 4810MCU 3 Remove air filter housing
AR09.10- P- 1150MCU 4 Remove cable ties on cable (1) There are two cable 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 > REMOVE/INSTALL HANDLE AT GEARSHIFT LEVER - AR26.60-P- 6601MCU > TRANSMISSION 717.4 in MODEL 451.3/4 Fig 1: Identifying Electronic Selector Lever Module Control Unit, Cable, Grommet And Relay Lever Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4413 · Applies to: 450, 451, 452, 454
1 Switch on ignition and move transmission into neutral
2 Use an assembly wedge to loosen cover of selector lever (3) from the center console (4) *110589035900 3 Move transmission into park position, switch off ignition and remove transmitter key
4 Raise cover of selector lever (3), grasp sleeve (2) with thumbs and index fingers of both hands and turn approx. 45° counterclockwise Ensure that the electrical connectors of the components located on the cover of the selector lever (3) are not separated The cast seam (arrow) on the sleeve (2) serves as a reference point. In the locked condition of the shift lever knob (1) it is transverse to the vehicle longitudinal axis (picture A) and in the unlocked condition of the shift lever knob (1) it is twisted approx. 45° to the rear (picture B). Installation: Ensure that the
Fig 1: Identifying Shift Lever Knob, Sleeve, Selector Lever Cover And Center Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
shift lever knob (1) is locked¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4414 · Applies to: 450, 451, 452, 454
correctly in the sleeve (2). 5 Detach shift lever knob (1) upwards off the selector lever
6 Install in the reverse order
TESTING & REPAIR > WIRING DIAGRAM OF AUTOMATED MANUAL TRANSMISSION (SEQ) CONTROL UNIT - PE26.19-P-2101-97MCU > Code: Designation: Position: A1 Instrument cluster 21L A2/3 smart Entry radio 36L A2/4 smart Premium radio 37L E3 Left taillamp 16L E3e3 Left backup lamp 16L E4 Right taillamp 18L E4e3 Right backup lamp 18L L2 Transmission RPM sensor 42L M17/3 Transmission motor 1 25L M17/4 Transmission motor 2 29L M18 Clutch motor 33L N10/10 SAM control unit 5L N10/10f10 Fuse 10 4L N10/10f12 Fuse 12 6L N10/10f19 Fuse 19
N10/10f24 Fuse 24 9L Fig 2: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
N10/10f30¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4415 · Applies to: 450, 451, 452, 454
Fuse 30 3L N15/5 Electronic selector lever module control unit 12L N15/6 Automated manual transmission control unit 22A N15/6 Automated manual transmission control unit 29A N15/6 Automated manual transmission control unit 6A N15/6 Automated manual transmission control unit 13A N15/6 Automated manual transmission control unit 37A S16/2 Park pawl switch 40L U1010 Valid for radio with Premium sound system 35K U1011 Valid for radio without Premium sound system 35L U1012 Valid up to 30/08/2010 39E U1013 Valid as of 31/08/2010 38E U865 Valid for Entry radio 35K W10 Ground (battery) 12E W14 Left floor interior compartment ground 8E Z20 Connector sleeve cable end insulation not stripped, placed inside insulated tubing 41G Z3/24 Circuit 15 (fused) connector sleeve, function 7E Z37/2 CAN engine bus (low) connector sleeve 13E Z37/2 CAN engine bus (low) connector sleeve 21G Z37/3 CAN engine bus (high) connector sleeve 14E Z37/3 CAN engine bus (high) connector sleeve 20G Z37/41 CAN databus (high) connector sleeve 19E Z37/42 CAN bus (low) connector sleeve 21E Z37/42 CAN bus (low) connector sleeve 38E Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 6E Z7/24 Circuit 87/1 connector sleeve 2E Z7/35 Circuit 87 M1e connector sleeve 11E Z7/35 Circuit 87 M1e connector sleeve 3E
Fig 1: Automated Manual Transmission (SEQ) Control Unit Wiring Diagram (1 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4416 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Automated Manual Transmission (SEQ) Control Unit Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4417 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TORQUE SPECIFICATIONS > MANUAL TRANSMISSION, GENERAL - BA26.00-P-1000-01D¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4418 · Applies to: 450, 451, 452, 454
Transmission 717 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717 except 717.478 Transmission 717.478 Transmission 717.48 Fig 3: Automated Manual Transmission (SEQ) Control Unit Wiring Diagram (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA26.00-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4419 · Applies to: 450, 451, 452, 454 · AR: BA26.00-Z-9999CZ
1001-01D Bolt, transmission bearing to longitudinal member Nm 35 35 - BA26.00-P- 1002-01D Bolt, transmission mount to transmission Nm 41 43 80 BA26.00-P- 1003-01D Nut, transmission bearing to transmission Nm 41 43 - BA26.00-P- 1004-01D Bolt, lower transmission bearing to front axle carrier Nm 58 58 - BA26.00-P- 1005-01D Bolt, lower transmission bearing to transmission Nm 58 58 - BA26.00-P- 1006-01D Bolt of transmission to engine Nm 48 48 23 BA26.00-P- 1007-01D Bolt, flywheel cover to engine Nm - 23 - BA26.00-P- 1008-01D Bolt, flywheel cover to transmission Nm - 48 - BA26.00-P- 1009-01D Bolt, transmission mount to frame-type integral support Nm - - 56 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: MANUAL TRANSMISSION - BA26.00-Z-9999CZ > MODEL all Cover ENGINE 122.9 in MODEL 454.0 BA26.30-P-1000- 01E Gear module TRANSMISSION 717.4 in MODEL 454 BA26.20-P-1000- 04A Gear set, shafts TRANSMISSION 717.4 in MODEL 454 BA26.50-P-1000- 01E Housing TRANSMISSION 717... BA26.40-P-1000- 01D Manual transmission complete TRANSMISSION 717.4 in MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 BA26.10-P-1000- 01D Manual transmission, general ENGINE 780.009 in MODEL 451.391/491 BA26.00-P-1000- 01E Manual transmission, general TRANSMISSION 717.470 /471 /473 /474 /475 /478 /48 BA26.00-P-1000- 01D Sensors/senders TRANSMISSION 717.470 /471 /473 /474 /475 BA26.19-P-1000- 01B
Shift mechanism¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4420 · Applies to: 450, 451, 452, 454
MODEL 451.391/491 with ENGINE 780.009 BA26.60-P-1000-01I Shift mechanism TRANSMISSION 717.470 /471 /473 /474 /475 /478 in MODEL 454.0 BA26.60-P-1000- 01E Shift mechanism TRANSMISSION 717... BA26.60-P-1000- 01C TORQUE SPECIFICATIONS > MANUAL TRANSMISSION COMPLETE - BA26.10-P-1000- 01D > Transmission 717 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.4 in model 450.3/4, 452.3/4, 454.0 Transmission 717.4 in model 451.3/4 BA26.10-P-1001- 01D Bolt of transmission to engine Nm 23 45 TORQUE SPECIFICATIONS > HOUSING - BA26.40-P-1000-01D > Transmission 717 MODIFICATION NOTES 3.4.06 Bolt, transmission housing to clutch housing Transmissions 717.407/408 409/476/477 HOUSING Number Designation Transmission 717.407 up to 11.09.00 Transmission 717.407 as of 12.09.00, transmission 717.408/409/ 476/477 BA26.40-P- 1001-01D Screw plug to transmission housing Nm 43 43 BA26.40-P- 1002-01D Temperature sensor to transmission housing Nm 10 - BA26.40-P- 1003-01D Bolt, RPM sensor to transmission housing Nm 10 10 BA26.40-P- 1004-01D Bolt, transmission housing to clutch housing Stage 1 Nm 27 27 Stage 2
Releasing Releasing Stage 3 Nm 25 25 BA26.40-P- 1005-01D Bolt for front section of transmission housing to rear section of transmission housing Nm - -
BA26.40-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4421 · Applies to: 450, 451, 452, 454
1006-01D Bolt, bearing cap to front section of transmission housing Nm - - BA26.40-P- 1007-01D Bolt, reverse gear shaft to transmission housing Nm - - BA26.40-P- 1008-01D Bolt, selector drum lock to transmission housing Nm - - HOUSING Number Designation Transmission 717.470/471/473/478 Transmission 717.474/475 BA26.40-P- 1001-01D Screw plug to transmission housing Nm 43 43 BA26.40-P- 1002-01D Temperature sensor to transmission housing Nm - - BA26.40-P- 1003-01D Bolt, RPM sensor to transmission housing Nm - 10 BA26.40-P- 1004-01D Bolt, transmission housing to clutch housing Stage 1 Nm - - Stage 2
-¶
Stage 3 Nm - - BA26.40-P- 1005-01D Bolt for front section of transmission housing to rear section of transmission housing Nm 15 15 BA26.40-P- 1006-01D Bolt, bearing cap to front section of transmission housing Nm 8 8 BA26.40-P- 1007-01D Bolt, reverse gear shaft to transmission housing Nm - - BA26.40-P- 1008-01D Bolt, selector drum lock to transmission housing Nm - - HOUSING Number Designation Transmission 717.480/481/482/483/484 BA26.40-P- 1001-01D Screw plug to transmission housing Nm 43 BA26.40-P- 1002-01D Temperature sensor to transmission housing Nm - BA26.40-P- 1003-01D Bolt, RPM sensor to transmission housing Nm 10 BA26.40-P- 1004-01D Bolt, transmission housing to clutch housing Stage 1 Nm - Stage 2
-
Stage 3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4422 · Applies to: 450, 451, 452, 454 · AR: BF26.00-Z-9999CZ
Nm¶
BA26.40-P- 1005-01D Bolt for front section of transmission housing to rear section of transmission housing Nm 15 BA26.40-P- 1006-01D Bolt, bearing cap to front section of transmission housing Nm 8 BA26.40-P- 1007-01D Bolt, reverse gear shaft to transmission housing Nm 15 BA26.40-P- 1008-01D Bolt, selector drum lock to transmission housing Nm 25 TORQUE SPECIFICATIONS > SHIFT MECHANISM - BA26.60-P-1000-01C > Transmission 717.4 SHIFT MECHANISM Number Designation Transmission 717.4 in Model 450, 452 Transmission 717.4 in model 451 BA26.60-P- 1001-01C Bolt, shift module to body Nm 12 12 BA26.60-P- 1002-01C Bolt, electric motor to transmission housing Nm 11 - BA26.60-P- 1003-01C Bolt, angle of rotation sensor to transmission housing Nm 10 - BA26.60-P- 1004-01C Shift roller locking system to transmission housing Nm 25 - BA26.60-P- 1005-01C Bolt, carrier to transmission housing Nm 8,4 - BA26.60-P- 1006-01C Bolt, shift actuator to transmission Nm 10 20 CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: MANUAL TRANSMISSION - BF26.00-Z-9999CZ > MODEL all Complete transmission TRANSMISSION 717.470 /471 /473 /474 /475 /478 in MODEL 454.0 BF26.10-P-1000- 01E Complete transmission MODEL 451.391/491 BF26.10-P-1000- 01H Complete transmission TRANSMISSION 717.407 /408 /409 /476 /477 BF26.10-P-1000- 01D BASIC KNOWLEDGE > AUTOMATED MANUAL TRANSMISSION SHIFT LEVER POSITIONS - GF26.00-P-0003-01MCU >
Shift diagram¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4423 · Applies to: 450, 451, 452, 454
Possible positions: The mechanical park pawl is engaged in the park position, the display "P" appears in the multifunction display (A1p13) of the instrument cluster (A1). The transmitter key can only be removed from the ignition/starter switch (S2/1) in this position. Reverse gear is engaged in the reverse position, the display "R" appears in the multifunction display. No gear is engaged in the neutral position, the vehicle can be pushed or towed away. The display "N" appears in the multifunction display. Automatic mode is active in drive mode, engaging the respective gear is initiated by the automated manual transmission control unit (N15/6). The display "D" appears in the multifunction display. In the manual shift positions the gears are changed manually a gear is upshifted by operating the selector lever towards "+", a gear is downshifted by operating the selector lever towards "-". The respective engaged gear and if necessary a gearshift recommendation appears in the multifunction display. BASIC KNOWLEDGE > AUTOMATED MANUAL TRANSMISSION SHIFT LEVER POSITIONS, FORCE DISTRIBUTION COURSE - GF26.00-P-0003-03MCC > Neutral (N position) In the transmission's N position none of the shift collars are engaged with an idler gear. Fig 1: Identifying Automated Manual Transmission Shift Lever Positions Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1st gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4424 · Applies to: 450, 451, 452, 454
The power flows from the input shaft via the fixed gear of 1st gear (1) to the idler gear of 1st gear (2). The shift fork 1/3 (a) slides the internal toothing of the shift collar 1/3 (3) into the idler gear of 1st gear (2). The torque of the idler gear of 1st gear (2) is now passed on to the main shaft (4) and from there to the differential (5). 2nd gear The power flows from the input shaft via the fixed gear of 2nd gear (6) to the idler gear of 2nd gear (7). The Fig 1: Power Flow Diagram (Neutral) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Power Flow Diagram (1st Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
shift fork 2/4 (c) slides the internal toothing of the shift collar 2/4 (8) into the idler gear of 2nd gear (7). The¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4425 · Applies to: 450, 451, 452, 454
rotation of the idler gear of 2nd gear (7) is now passed on to the main shaft (4) and from there to the differential (5). 3rd gear The power flows from the input shaft via the fixed gear of 3rd gear (9) to the idler gear of 3rd gear (10). The shift fork 1/3 (a) slides the internal toothing of the shift collar 1/3 (3) into the idler gear of 3rd gear (10). The rotation of the idler gear of 3rd gear (10) is now passed on to the main shaft (4) and from there to the differential (5). Fig 3: Power Flow Diagram (2nd Gear Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4th gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4426 · Applies to: 450, 451, 452, 454
The power flows from the input shaft via the fixed gear of 4th gear (11) to the idler gear of 4th gear (12). The shift fork 2/4 (c) slides the internal toothing of shift collar 2/4 (8) into the idler gear of 4th gear (12). The rotation of the idler gear of 4th gear (12) is now passed on to the main shaft (4) and from there to the differential (5). Fig 4: Power Flow Diagram (3rd Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Power Flow Diagram (4th Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5th gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4427 · Applies to: 450, 451, 452, 454
The power flows from the input shaft via the fixed gear of 5th gear (13) to the idler gear of 5th gear (14). The shift fork 5 (b) slides the internal toothing of shift collar 5 (15) into the idler gear of 5th gear (13). The rotation of the idler gear of 5th gear (13) is now passed on via the fixed gear of 5th gear (14) to the main shaft (4) and from there to the differential (5). Reverse gear The power flows from the input shaft via the fixed gear of reverse gear (16) the sliding gear of reverse gear (17) to the reverse gear (18). The shift fork R (d) slides the sliding gear of reverse gear (17) into the external toothing of reverse gear (18). The rotation of the reverse gear (18) is now passed on to the main shaft (4) and from there to the differential (5). Fig 6: Power Flow Diagram (5th Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > AUTOMATED MANUAL TRANSMISSION SHIFT LEVER¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4428 · Applies to: 450, 451, 452, 454
POSITIONS, SHIFT POSITIONS - GF26.00-P-0003-04MCC > Neutral (N) and reverse gear (R) Fig 7: Power Flow Diagram (Reverse Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Adjustment Of Selector Drum And Deflection Of Sliding Block Mass (Neutral And Reverse Gears) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Neutral position¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4429 · Applies to: 450, 451, 452, 454
The sliding blocks in the grooves of the selector drum are in the neutral position. No gear is engaged. Reverse gear The selector drum 2/4, R rotates through 120° downwards. This deflects the upper sliding block by 22.5 mm to the left. The sliding gear of reverse gear engages in the external toothing of the shift collar 1/3 The sliding blocks in the selector drum 1/3, 5 are in the neutral position. Shift position of 1st gear (1) and 2nd gear (2) 1st gear The selector drum 1/3, 5 rotates downwards by 40°. This displaces the upper sliding block by 7.5 mm to the left. The shift collar 1/3 is slid into the idler gear of first gear. The sliding blocks in the selector drum 2/4, R are in the neutral position. 2nd gear When changing from 1st gear to 2nd gear both selector drums are twisted upwards by 40°. This in turn displaces the lower sliding block for the selector drum 2/4, R by 7.5 mm to the left. The shift collar 2/4 is slid into the idler gear of second gear. The sliding blocks of the selector drums 1/3, 5 are in the neutral position. Shift position of 3rd gear (3) and 4th gear (4) Fig 2: Identifying Adjustment Of Selector Drum And Deflection Of Sliding Block Mass (1st And 2nd Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3rd gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4430 · Applies to: 450, 451, 452, 454
When changing from 2nd gear to 3rd gear both selector drums are twisted upwards by 40°. The upper sliding block in the selector drum 1/3, 5 is displaced to the right by 7.5 mm. It presses the shift collar 1/3 into the idler gear of third gear. The other sliding blocks are in the neutral position. 4th gear When changing from 3rd gear to 4th gear both selector drums are twisted upwards by 40°. The lower sliding block in the selector drum 2/4, R is displaced to the right by 7.5 mm. It presses the shift collar 2/4 into the idler gear of fourth gear. The other sliding blocks are in the neutral position. Shift position of 5th. Gang (5) Fig 3: Identifying Adjustment Of Selector Drum And Deflection Of Sliding Block Mass (3rd And 4th Gears) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5th gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4431 · Applies to: 450, 451, 452, 454
When changing from 4th gear to 5th gear both selector drums are twisted upwards 1/3 5 by 40°. The lower sliding block in the selector drum 1/3, 5 is displaced to the left by 7.5 mm. It presses the shift collar 5 into the idler gear of 5th gear. The selector drum 2/4, R is twisted downwards by 40°. The sliding blocks of the selector drum 2/4, R are in the neutral position. BASIC KNOWLEDGE > AUTOMATED MANUAL TRANSMISSION (AUTOMATED MANUAL TRANSMISSION) SHIFT PROCESS - GF26.00-P-0003-05MCC > Fig 4: Identifying Adjustment Of Selector Drum And Deflection Of Sliding Block Mass (5th Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown with code (I75) leather sport steering wheel incl. steering wheel rocker switch system¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4433 · Applies to: 450, 451, 452, 454
Function The automated manual transmission is based on a "standard" manual transmission. The shift operations are carried out by 2 selector drums which are adjusted by gear motor 1 and gear motor 2. The current position is recorded by integrated incremental sensors. The necessary clutch engagements are carried out by the clutch motor. Operation takes place via the electronic selector lever module control unit or via the steering wheel gear shifter (with code (I75) Leather sport steering wheel incl. steering wheel rocker switch system). The complete control of the shift processes and clutch engagements takes place by the automated manual transmission control unit. The currently engaged gear stage as well as the gearshift recommendation are displayed in the multifunction display (A1p13) of the instrument cluster. The following shift programs are possible: Fig 1: Automated Manual Transmission Shift Lever Positions Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Manual shift mode¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4434 · Applies to: 450, 451, 452, 454
The selector lever is located in the "±" plane. The gears must be selected manually. Automatic mode The selector lever is in the "D" plane. The gears are shifted automatically. Engine start Move the selector lever into position "P" and actuate the foot brake and Circuit 15 On Then first the automated manual transmission control unit issues a start enable and the engine can be started with the transmitter key. Starting off To start off the vehicle the selector lever must be in shift plane "D" or "±": Operate service brake, Operate the shift lock button on the selector lever and move the selector lever into "D" or "±" Release service brake The vehicle moves off. "1" or "D" in displayed in the multifunction display depending on the shift mode selected. Manual shift mode The driver determines the gear change in manual shift mode. Selector lever forwards "+": Upshift one gear Selector lever rearwards "-": Downshift one gear On vehicles with code (I75) Leather sport steering wheel incl. steering wheel rocker switch system the gears can also be changed via the steering wheel gear shifter: Steering wheel gear shifter PLUS: Upshift one gear Steering wheel gear shifter MINUS: downshift one gear A manual downshift is only performed if it does not lead to overevving the engine. The respective engaged gear stage is indicated in the multifunction display. If for a driving style for an optimized fuel consumption another gear stage than the one which is engaged would be more meaningful, a gear shift recommendation from the automated manual transmission control unit appears in the multifunction display: Arrow up: Shift up one gear Arrow down: Shift down one gear Forced upshift/downshift
Automatic shift operations also take place in manual shift mode:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4435 · Applies to: 450, 451, 452, 454
Forced upshift just before reaching the maximum speed of the engine Forced downshift when approaching the idle speed of the engine Shift down for kickdown Engage first gear when vehicle is at a standstill Automatic mode In automatic mode the automated manual transmission control unit determines the gear change. The shift operations run automatically (performance-map dependent) corresponding to the current load (accelerator pedal position) and vehicle speed. The following points are taken into account for the shift operations: Upshifts and downshifts are not triggered at the same operating point in order to avoid repeated shifting between two gears in the critical limits. When downshifting multiple gearshifts (e.g. from 5 to 3) are also conducted. Backup Operate foot brake Move selector lever into position "R" Release foot brake The vehicle moves off. "R" is displayed in the multifunction display. The shift lock button on the selector lever must be operated for engaging reverse gear. Kickdown function In order to trigger an automatic downshift via the kickdown function, the accelerator pedal must be fully depressed (overcoming the over-center preload). The following processes can be triggered based on a performance map: Downshift by one to three gears After this automatic upshift just before reaching the maximum speed of the engine The kickdown function is possible in manual shift mode and in automatic mode. Crawl function The crawl function enables the vehicle to be driven slowly, e.g. when parking or in a traffic jam. Function requirements: Forward or reverse gear engaged Accelerator pedal not actuated (engine in neutral) Function When the service brake is released the clutch is operated in slip or in the closed range. The vehicle then
moves at a slower speed. The function is terminated by operating the service brake, parking brake,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4436 · Applies to: 450, 451, 452, 454
accelerator pedal or on gradients above 5 %. Parking the vehicle The following items must be taken into account for safely parking the vehicle: Apply service brake Move selector lever to position "P" Operate parking brake Switch off engine and remove transmitter key Release service brake If the selector lever is in position "P" the vehicle is secured to prevent it from rolling away by a mechanical park pawl. The park pawl is engaged by the electronic selector lever module control unit via a cable to the transmission The status of the park pawl is recorded by the park pawl switch and is passed on to the automated manual transmission control unit. No gear is engaged when the engine is switched off in selector lever position "N". The vehicle can be pushed or towed away. Removal of the transmitter key is only possible in selector lever position "P". Transmission temperature The oil temperature influences the viscosity of the transmission oil and thus the shift operation process. As the transmission control takes into account the oil temperature for the actuation of the actuator motors, a consistent shift quality is achieved. The temperature of the transmission is computed. The speed of the shafts and the transmitted torque is drawn on to calculate the friction, which is converted in the transmission into heat. The cooling due to the airstream is determined from the ambient temperature and the vehicle speed and the transmission temperature is established by means of a performance map. Following an extended immobilization period the ambient temperature is adopted for the transmission temperature. Error reactions The processes in the transmission are monitored by means of the actuation signals and the sensor signals. If events occur in the process which deviate from the normal sequence, these are stored in the automated manual transmission control unit. Stored events can be erased again if they do not occur any more on several trips in sequence. There are three fault classes: Fault without impairment of driving mode Faults which slightly impair driving mode Faults which severely impair driving mode Fault without impairment of driving mode Fault is stored but no effects on driving are noticeable. No warning message is output in the multifunction display. Such event recordings serve solely analysis of causes.
Faults which slightly impair driving mode¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4437 · Applies to: 450, 451, 452, 454
In the event of basic faults a warning message is output in the multifunction display. The trip is only slightly impaired, the restrictions are often not noticed by the driver. Thus, e.g. overlaps and gear steps are no longer executed. The duration of the shift operations is extended. Faults which severely impair driving mode In the event of serious faults a warning message is likewise output in the multifunction display. The transmission changes into limp-home mode. The following reactions are possible: No further gearshifts are performed, the gear engaged is retained. Only reverse gear and 1st gear are actuated after stopping and restarting, engine performance and engine speed are limited. No further gear is engaged after stopping and restarting. Initializing The initialization must be performed using STAR DIAGNOSIS after the following activities: Removal of transmission Removal of one or both transmission motors Replacement of automated manual transmission control unit A transmission teach-in process takes place after the power supply is discontinued. In the process the incremental counter reading of the selector drum system of sensors is readjusted. For this purpose the selector drums are moved into their end positions when the clutch is open. Clutch actuation For each shift operation a clutch process is carried out by the automated manual transmission control unit. The automated manual transmission control unit actuates the clutch motor directly for this. The load is evaluated in the automated manual transmission control unit in order to avoid overloading the clutch. If the threshold value is exceeded the clutch starts to pulse in order to draw the driver's attention to an overload. The clutch is opened in the event of further overload. For wear adaptation the drag point and the transmission characteristics of the clutch are continuously adapted by the automated manual transmission control unit.
Automated manual transmission shift lever positions
GF26.00-P-0003- 01MCU
Automated manual transmission shift lever positions, force distribution course
GF26.00-P-0003- 03MCC
Automated manual transmission shift lever positions, shift positions
GF26.00-P-0003- 04MCC
Automated manual transmission (Automated Manual Transmission) shift process
GF26.00-P-0003- 05MCC
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4441 · Applies to: 450, 451, 452, 454
The electronic selector lever module control unit is located in the center console. Task The electronic selector lever module control unit records the driver's shift requirements. The following selector lever positions are possible Park position "P" Reverse gear "R" Neutral "N" Transmission mode "D" (automatic mode) Manual shift mode "±" If the selector lever is in "R" the left backup lamp (E3e3) and right backup lamp (E4e3) is actuated directly by the electronic selector lever module control unit. If the selector lever is moved out of the transmission mode to the left in the "±" plane, manual shift mode is active. In the process the gears are shifted manually by the driver: "+" one gear is upshifted "-" one gear is downshifted The shift lock button must be operated for the following shift operations: from "P" to "R" from "N" to "R" from "R" to "P" Fig 1: Identifying Electronic Selector Lever Module Control Unit And Shift Lock Button Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4443 · Applies to: 450, 451, 452, 454
The automated manual transmission control unit is located in the passenger compartment under the driver seat. Task The automated manual transmission control unit controls, monitors and coordinates the complete transmission control. For this purpose it exchanges (CAN) data with other control units via the Controller Area Network (data bus/CAN bus). The automated manual transmission control unit controls the following functions: Engage first gear when the vehicle is stationary Gear change Forced upshift just before reaching the maximum speed of the engine Forced downshift when approaching the idle speed of the engine Shift down for kickdown Crawl function Clutch operator Monitoring clutch load Signals from the following components are read in directly by the automated manual transmission control unit: Transmission RPM sensor (L2) Transmission motor 1 (M17/3) Transmission motor 2 (M17/4) Clutch motor (M18) Park pawl switch (S16/2) Fig 1: Locating Automated Manual Transmission Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The following components are actuated directly by the CDI control unit:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4444 · Applies to: 450, 451, 452, 454
Transmission motor 1 Transmission motor 2 Coupling motor Communication via the drive LIN takes place via the CAN: Instrument cluster (A1) ME-SFI [ME] control unit (/)N3/10 Electronic selector lever module control unit (/)N15/5 ESP control unit (N47-5) BASIC KNOWLEDGE > PARK PAWL SWITCH, COMPONENT DESCRIPTION - GF26.19-P- 2100MCU > TRANSMISSION 717.482 in MODEL 451.3/4 Location The park pawl switch is located on the left of the transmission in the direction of travel. Task The park pawl switch monitors the park pawl engaged or released mechanically via the cable and transmits a corresponding signal to the automated manual transmission control unit (N15/6). BASIC KNOWLEDGE > SHIFTING MECHANISM COMPONENT DESCRIPTION - GF26.60-P- Fig 1: Locating Park Pawl Switch And Cable Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
E3e3¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4447 · Applies to: 450, 451, 452, 454
Left backup lamp 22F E4e3 Right backup lamp 22F L2 Transmission RPM sensor 11H M17/3 Transmission motor 1 12D M17/4 Transmission motor 2 12E M18 Coupling motor 10C N3/10 ME-SFI [ME] control unit 15C N10/10 SAM control unit 2D N15/5 Electronic selector lever module control unit 20G N15/6 Automated manual transmission control unit 10F N47-5 ESP control unit 3L S16/2 Park pawl switch 10H S112s1 Steering wheel gear shifter PLUS 20K S112s2 Steering wheel gear shifter MINUS 20K X11/4 Data link connector 6B WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR MANUAL TRANSMISSION - PE26.19-P-2050-99MCU > Code: Designation: Position: A1 Instrument cluster 21 G A1e15 Airbag indicator and warning lamp 21 E A1e9 Seat belt reminder lamp 21 E A45 Fanfare horns and airbag clock spring contact 11 J A53 Driver head/thorax sensor 3 C A54 Front passenger head/thorax sensor 8 C B48/1 Driver-side frontal acceleration sensor 2 B B48/2 Passenger-side frontal acceleration sensor 7 B B48/3 Belt tension sensor 16 J B48/4 Seat occupied recognition pressure sensor 16 K E16 Automatic child seat recognition airbag OFF indicator lamp 9 H N10/10 SAM control unit 2 G N110 Weight Sensing System (WSS) control unit 18 J N2/7 Restraint systems control module 9 F N3/10 ME-SFI [ME] control module 17 D
R12/1¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4448 · Applies to: 450, 451, 452, 454
Left emergency tensioning retractor squib 9 H R12/13 Driver airbag ignition squib 1 13 J R12/14 Driver airbag ignition squib 2 13 J R12/2 Right emergency tensioning retractor squib 9 H R12/20 Driver head/thoraxbag squib 9 J R12/21 Front passenger head/thoraxbag squib 9 J R12/4 Front passenger airbag ignition squib 1 9 H R12/5 Front passenger airbag ignition squib 2 9 H S68/3 Driver-side seat belt buckle restraint systems switch 10 E S68/4 Passenger-side seat belt buckle restraint systems switch 10 E X11/4 Data link connector 12 C Fig 1: Manual Transmission - Electrical Function Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Use:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4451 · Applies to: 450, 451, 452, 454
Pliers for removing/installing snap ring on 2nd gear synchronizer body and drive shaft (on 711.101/11/202, 716.0/1/2/6, 716.0/1/2/6, 717.0/40/41/42/43/44/45/46) or for removing/installing snap rings on drive shaft (711.640/641) or removing/installing snap rings on drive shaft and output shaft (717.48) or for removing/installing retaining rings on main shaft (711.6)
SPECIAL TOOLS > 000 589 60 34 00 CHUCK - WS26.00-P-0006C > FG 26/Set C TRANSMISSION 711.640 /641, 717.45 /46 /4 Use: Clamping pliers for tapered roller bearing at rear of countershaft (on transmission 717.45/46) or when detaching tapered roller bearings of axle differential (transmission 711.640/641) in combination with puller 001 589 50 33 00.
Fig 1: Identifying Pliers (000 589 52 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 001 589 49 33 00 PULLER - WS26.00-P-0011C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4452 · Applies to: 450, 451, 452, 454
FG 26/Set C TRANSMISSION 711.640 /641, 716.5, 717.41 /43 /44 /45 /46, 722.55 /750 /751, 716.508 /509 /513 /514, 717.4 MODIFICATION NOTES 8.6.93 Replacement for: 001 589 47 33 00 Use: Puller for tapered roller bearing inner races (size 4 basic unit) (for 717.41/43/44/45/46, 722.750/751, 716.508/509/513/514) or the tapered roller bearing of the output shaft (for 711.640/641).
SPECIAL TOOLS > 001 589 50 33 00 PULLER - WS26.00-P-0012C > FG 26/Set C Fig 1: Identifying Chuck (000 589 60 34 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Puller (001 589 49 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TRANSMISSION 711.640 /641, 716.5, 717.45 /46 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4453 · Applies to: 450, 451, 452, 454
Further use FG 26/Set C WS26.00-N-0012C
FG 27/Set C WS27.00-P-3116C
FG 28/Set C WS28.00-P-0004C
FG 33/Set C WS33.00-P-0003C
FG 35/Set C WS35.00-P-0010C Use: Puller for taper roller inner races (basic unit size 5) (on 717.45/46) or for detaching taper roller bearings of axle differential (on 711.640/641).
SPECIAL TOOLS > 168 589 00 14 00 SLEEVE - WS26.00-P-0063C > FG 26/27 Set C TRANSMISSION 711.640 /641, 716.5 /508 /509 /513 /514 /6, 722.750 /751 /8, 717.4 Use: Sleeve for pressing in bearing shells and for removing input shaft bearing.
Fig 1: Identifying Puller (001 589 50 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 02 62 00 REMOVAL FIXTURE - WS26.00-P-0090B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4454 · Applies to: 450, 451, 452, 454
FG 26/32/33/31/35/47/83/Set B MODEL 450, 451, 452, 454 Use: For model 450, 451, 452: Removal fixture for removing/installing the transmission. For model 454: Removal fixture for removing/installing the fuel tank, of the front and rear axle, stationary heater and trailer hitch. NOTE: Removal fixture, smart no.: 000 5141 V001 0000 00. Fig 1: Identifying Sleeve (168 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Removal Fixture (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 450 589 04 33 00 PULLER - WS26.00-P-0100B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4455 · Applies to: 450, 451, 452, 454
FG 26/Set B MODEL 450, 451, 452 Use: Extractor for extracting the radial shaft seal of the transmission input shaft. NOTE: ExtractorSmart no.: 0012701 SPECIAL TOOLS > 711 589 13 15 00 DRIFT - WS26.00-P-0105B > FG 26/Set B TRANSMISSION 711.640 /641, 717.4 Use: Drift for installing shaft seal (input side) and for installing bearing shells of output shafts.
Fig 1: Identifying Puller (450 589 04 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 722 589 00 35 00 INSTALLER - WS26.00-P-0112C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4456 · Applies to: 450, 451, 452, 454
FG 26/Set C TRANSMISSION 711.640 /641, 717.4 Further use FG 27/Set C WS27.00-P-0115C Use: Installer for pulling bearing shells into the transmission housing.
SPECIAL TOOLS > 000 589 30 33 00 INTERNAL EXTRACTOR - WS26.00-P-0113C > FG 26/Set C TRANSMISSION 711.640 /641, 716.5, 722.8, 717.4 Further use FG 28/Set C WS28.00-P-0001C Fig 1: Identifying Drift (711 589 13 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Installer (722 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 00¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4457 · Applies to: 450, 451, 452, 454
WS00.00-N-3028Z
FG 33/Set C WS33.00-N-3067C Use: Internal extractor for removing bearing shells of axle differential on transmission housing.
SPECIAL TOOLS > 000 589 34 33 00 COUNTER STAY - WS26.00-P-0114C > FG 26/27/Set C TRANSMISSION 711.640 /641, 716.5, 722.8, 717.4 Further use FG 28/Set C WS28.00-P-0002C
FG 33/Set C WS33.00-N-3066C
FG 35/Set C WS35.00-N-3312C
FG 00 WS00.00-N-3032Z Use: Counter stay for removing bearing shells of axle differential in transmission housing.
Fig 1: Identifying Internal Extractor (000 589 30 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 140 589 03 15 00 DRIFT - WS26.00-P-0119C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4458 · Applies to: 450, 451, 452, 454
FG 26/Set C TRANSMISSION 711.640 /641, 717.4 Further use FG 35/Set C WS35.00-P-0091C Use: Grooved ball bearing from transmission housing.
SPECIAL TOOLS > 454 589 01 14 01 EXTRACTOR SLEEVE - WS26.00-P-0123-01C > FG26/Set C MODEL 451, 454 Use: Fig 1: Identifying Counter Stay (000 589 34 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Drift (140 589 03 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Extractor sleeve for disassembling the shaft seal on the transmission input shaft.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4459 · Applies to: 450, 451, 452, 454
NOTE: Inside diameter of the extractor sleeve is 24.4 mm and is intended for a vehicle with a diesel engine. SPECIAL TOOLS > 454 589 01 14 02 EXTRACTOR SLEEVE - WS26.00-P-0123-02C > FG26/Set C MODEL 451, 454 Use: Extractor sleeve for disassembling the shaft seal on the transmission input shaft. NOTE: Inside diameter of the extractor sleeve is 27.4 mm and is intended for a vehicle with a diesel engine. Fig 1: Identifying Extractor Sleeve (454 589 01 14 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 454 589 01 14 00 SET OF EXTRACTOR SLEEVES - WS26.00-P-0123C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4460 · Applies to: 450, 451, 452, 454
FG 26/27Satz C MODEL 451, 454 Separate part 454 589 01 14 01 Extractor sleeve FG26/Set C WS26.00-P-0123-01C Separate part 454 589 01 14 02 Extractor sleeve FG26/Set C WS26.00-P-0123-02C Use: Set of extractor sleeves for disassembling the shaft seals on the transmission input shafts. SPECIAL TOOLS > 454 589 02 15 00 DRIFT - WS26.00-P-0124C > FG 26/27 Set C Fig 1: Identifying Extractor Sleeve (454 589 01 14 02) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Set Of Extractor Sleeves (454 589 01 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451, 454¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4461 · Applies to: 450, 451, 452, 454
Use: Drift for hammering radial shaft sealing ring into transmission input shaft. SPECIAL TOOLS > SPECIAL TOOLS: SMART: MANUAL TRANSMISSION - WS26.00-Z- 9999CZ > MODEL all 000 589 25 33 00 Internal extractor FG 00/15/26 WS00.00-P-0050Z 000 589 30 33 00 Internal extractor FG 26/Set C WS26.00-P-0113C 000 589 34 33 00 Counter stay FG 26/27/Set C WS26.00-P-0114C 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 000 589 52 37 00 Pliers FG 26/Set C WS26.00-P-0005C 000 589 60 34 00 Chuck FG 26/Set C WS26.00-P-0006C 001 589 49 33 00 Puller FG 26/Set C WS26.00-P-0011C 001 589 50 33 00 Puller FG 26/Set C WS26.00-P-0012C 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 140 589 03 15 00 Drift FG 26/Set C WS26.00-P-0119C 168 589 00 14 00 Sleeve FG 26/27 Set C WS26.00-P-0063C 450 589 00 15 00 Drift FG 26/Set B WS26.00-P-0092B 450 589 00 34 00 Centering sleeve FG 26/Set B WS26.00-P-0122B Fig 1: Identifying Drift (454 589 02 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
450 589 00 91 00 Plug¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4462 · Applies to: 450, 451, 452, 454
FG 26/Set B WS26.00-P-0091B 450 589 01 15 00 Drift FG 26/Set B WS26.00-P-0093B 450 589 01 31 00 Assembly template FG 26/Set C WS26.00-P-0125C 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 450 589 04 33 00 Puller FG 26/Set B WS26.00-P-0100B 450 589 11 63 00 Y-cable FG 26/Set B WS26.00-P-0094B 454 589 01 14 00 Set of extractor sleeves FG 26/27Satz C WS26.00-P-0123C 454 589 01 14 01 Extractor sleeve FG26/Set C WS26.00-P-0123- 01C 454 589 01 14 02 Extractor sleeve FG26/Set C WS26.00-P-0123- 02C 454 589 01 91 00 Adapter FG 42/25/26/Set A WS42.00-P-0069A 454 589 02 15 00 Drift FG 26/27 Set C WS26.00-P-0124C 454 589 03 15 00 Drift FG 25/26/Set B WS25.00-P-0011B 454 589 04 09 00 Set of socket wrench bits FG 22/26/01 Set B WS22.00-P-0007B 602 589 00 33 00 Impact extractor FG 26/33/35/Set B WS33.00-P-0189B 711 589 13 15 00 Drift FG 26/Set B WS26.00-P-0105B 722 589 00 35 00 Installer FG 26/Set C WS26.00-P-0112C
Fig 1: Identifying Transmission Components (1 Of 2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4469 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Transmission Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4470 · Applies to: 450, 451, 452, 454
1 Position selector lever on electronic selector lever module control unit in position "P"
2 Remove interior flap above engine
AR88.40- P-1100- 03MCC 3 Disconnect ground line of battery
AR54.10- P- 0003MCC 4 Remove air filter housing
AR09.10- P- 1150MCU 5 Remove rear axle shafts
AR35.30- P- 0620MCU 6 Remove fender liner from left rear fender
AR88.10- P- 1400MCU 7 Lower vehicle with vehicle lift
8 Unscrew bolt (2) *BA26.10- P-1001- 01D 9 Unhook counter bearing (3) of wire pull of park pawl (4) on transmission (1) and unclip wire pull of park pawl (4) at lever (5)
10 Loosen bolts (6) of bushing of transmission mounting (7) on transmission (1) *BA26.00- P-1002- 01D 11 Unscrew bolts (8) of bracket (9) on cylinder head put down bracket (9) to one side
12 Fasten retaining plate to the upper threaded hole in the cylinder head with Fig 5
one bolt (8)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4471 · Applies to: 450, 451, 452, 454
13 Attach support brace to engine hoist, position engine hoist and suspend suitable chain in the retaining plate Turn back the spindle at the engine hoist so that it is ensured that it is possible to lower the engine with the transmission (1) by approx. a further 4 cm.
Fig 4
Fig 5
Fig 6 14 Raise vehicle with vehicle lift
15 Detach wiring harness from transmission (1)
AR26.19- P-0001- 05MCU 16 Pull out the plug (10) on the starter (M1)
17 Unscrew nut (11) and remove charge current line (12) from starter (M1) BA15.30- P-1002- 01E 18 Unscrew bolts (13) of carrier for front engine mount (14) from transmission (1) BA22.10- P-1012- 01M 19 Unscrew bolt (15) *BA26.10- P-1001- 01D 20 Support transmission (1) with transmission jack and removal fixture and secure with tensioning strap Transmission jack Fig 3 21 Unscrew bolts (6) of bushing of transmission mounting (7) from transmission (1) Installation: Screw in bolts (6) until they abut.
22 Unscrew bolts (16) on bracket (17) of exhaust system
Remove bolts (18)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4472 · Applies to: 450, 451, 452, 454
23 Remove bolts (18) *BA26.10- P-1001- 01D 24 Loosen transmission (1) from engine and lower When moving the transmission (1) out and in ensure that no electrical lines and hoses are damaged. Helper required to guide the transmission (1). Installation: The centering sleeves must seat firmly in the cylinder crankcase, replace centering sleeves if necessary. Grease transmission input shaft lightly.
Olista Longtime 3 E P *BR00.45- Z-1062- 06A 25 Release tensioning strap and remove transmission (1) from transmission jack Aid of 2 helpers required.
Fig 3 26 Unscrew bracket (19) of air filter housing on transmission (1) When replacing the transmission (1).
27 Detach starter (M1) from transmission (1) When replacing the transmission (1).
*BA15.30- P-1001- 01E 28 Detach clutch motor (M18) from transmission (1) When replacing the transmission (1). Installation: Only install clutch motor (M18) after installing the transmission (1). AR25.20- P- 0125MCU 29 Install in the reverse order
30 Perform commissioning without control unit replacement Observe menu guidance in DAS (DAS).
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC STARTER Number Designation Engine 132.9 BA15.30-P-1001-01E Bolt, starter to transmission Nm 42
BA15.30-P-1002-01E¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4473 · Applies to: 450, 451, 452, 454
Cable on starter circuit 30 Nm 10 ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 BA22.10-P-1012-01M Bolt, carrier for front engine mount to transmission Nm 23 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.48 BA26.00-P-1002-01D Bolt, transmission mount to transmission Nm 80 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.4 in model 451.3/4 BA26.10-P-1001-01D Bolt, transmission to engine Nm 45 Fig 3: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Support Braces (451 589 01 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4475 · Applies to: 450, 451, 452, 454
1 Remove air filter housing
AR09.10- P- 1150MCU 2 Support transmission using a hand- operated hydraulic floor jack Use a suitable protective underlay in order to avoid damage to the transmission. Manual hydraulic floor jack
3 Remove bolts (2) for transmission mounting bearing (1) on transmission BA26.00- P-1002- 01D 4 Unscrew bolts (3) of bearing of transmission mounting (1) from frame-type integral support (4) BA26.00- P-1009- 01D 5 Remove bushing of transmission mounting (1) upwards and take out
6 Install in the reverse order
COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.48 BA26.00-P-1002- 01D Bolt, transmission mount to transmission Nm 80 BA26.00-P-1009- 01D Bolt, transmission mount to frame-type integral support Nm 56 TESTING & REPAIR INDEX > REMOVE/INSTALL WIRING HARNESS AT TRANSMISSION - Fig 1: Identifying Mount For Transmission Mounting, Frame-Type Integral Support, Bolts And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4477 · Applies to: 450, 451, 452, 454
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
2 Disconnect electrical connector (1) from transmission rpm sensor (L2)
3 Unscrew bolt (2) and remove transmission rpm sensor (L2)
4 Install in the reverse order
5 Read out fault memory, erase if necessary When replacing the transmission rpm sensor (L2).
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC TESTING & REPAIR INDEX > REMOVE/INSTALL PARK PAWL SWITCH - AR26.19-P- 0050MCU > TRANSMISSION 717.4 in MODEL 451.3 /4 Fig 1: Identifying Transmission RPM Sensor, Electrical Connector And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TRANSMISSION 717.4 in MODEL 451.3 /4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4480 · Applies to: 450, 451, 452, 454
TRANSMISSION 717.4 in MODEL 451.3 /4
Remove/install
1 Use STAR DIAGNOSIS to set shift actuator (1) to neutral Installation: Perform commissioning without control unit replacement. Observe menu guidance in DAS (DAS).When replacing the shift actuator (1) the fault memory must be read out and erased if necessary.
Connect STAR DIAGNOSIS and read out fault memory
AD00.00- P-2000- 04MCC 2 Remove resonance tank
AR09.20- P- 0010MCU 3 Detach electrical connectors (2, 3) on shift actuator (1)
4 Remove bolts (4) Replace screws (4).
*BA26.60- P-1006- 01C 5 Detach shift actuator (1) from transmission and remove Installation: Clean sealing surfaces on the shift actuator (1) and transmission, then apply the sealant in the form of a bead with a height and width of approx. 2.0 ± 0.5 mm.
*BR00.45- Fig 1: Identifying Shift Actuator, Electrical Connectors And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4482 · Applies to: 450, 451, 452, 454
1 Remove floor covering * not for USA AR68.20- P- 2040MCC
- for USA only AR68.20- P- 2040MCU 2 Position selector lever on electronic selector lever module (N15/5) in park position It must be ensured that the selector lever on the electronic selector lever module control unit (N15/5) is in position "P", otherwise the electronic selector lever module control unit (N15/5) might be damaged or its function impaired.
3 Unclip transport security device (9) out of park position on the electronic selector lever module control unit (N15/5) (arrow A) and insert transport security device (9) into the electronic selector lever module control unit (N15/5) (arrow E)
4 Unscrew the bolts (2) on the left and right of the electronic selector lever module control unit (N15/5) Fig 3 Fig 2: Identifying Shift Module Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Disconnect electrical¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4483 · Applies to: 450, 451, 452, 454
5 Disconnect electrical connector from transponder coil (1) and electrical connectors (3)
6 Raise control unit for the electronic selector lever module (N15/5) and disconnect electrical connector (6)
7 Unclip retaining clip (4) and remove
8 Turn bolt (7) of adjusting mechanism on electronic selector lever module control unit (N15/5) clockwise (arrow C) and pull wire (5) out of electronic selector lever module control unit (N15/5)
9 Remove electronic selector lever module control unit (N15/5)
10 Remove transponder coil (L11) When replacing electronic selector lever module control unit (N15/5).
-
not for USA AR80.35- P- 4515MCC
-
for USA only AR80.35- P- 4515MCU 11 Remove ignition/starter switch lock cylinder When replacing electronic selector lever module control unit (N15/5).
-
not for USA AR54.25- P- 1030MCC
-
for USA only AR54.25- P- 1030MCU Install
12 Install ignition/starter switch lock cylinder When replacing electronic selector lever module control unit (N15/5).
-
not for USA AR54.25- P- 1030MCC
-
for USA only AR54.25- P-
1030MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4484 · Applies to: 450, 451, 452, 454
13 Install transponder coil (L11) When replacing electronic selector lever module control unit (N15/5).
-
not for USA AR80.35- P- 4515MCC
-
for USA only AR80.35- P- 4515MCU 14 Hold cable (5) on abutment (8) and press the cable (5) until it abuts in the direction of the arrow (arrow B) This ensures that the relay lever of the park pawl is in position "P" on the transmission.
15 Insert cable (5) into the adjusting mechanism on the electronic selector lever module control unit (N15/5)
16 Position abutment (8) of the cable (5), as shown, and attach and clip in retaining clip (4) The abutment (8) of the cable (5) must be pushed in until it abuts in the electronic selector lever module control unit (N15/5).
17 Position electronic selector lever module control unit (N15/5) and lock the cable (5) by twisting the bolt (7) counterclockwise (arrow D) in the adjusting mechanism on the electronic selector lever module control unit (N15/5) The control unit for the electronic selector lever module (N15/5) must be in its installation position so that the cable (5) is not mounted twisted. The marking on the bolt (7) must be aligned with the marking on the electronic selector lever module control unit (N15/5), only then is the cable (5) locked in the adjusting mechanism on the electronic selector lever module control unit (N15/5).
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
Fig 3
Illustrated on model 450¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4486 · Applies to: 450, 451, 452, 454
Remove/install
1 Pull off shift lever knob (1) carefully in direction of arrow Do not operate shift lever knob for automatic function (2) while pulling off, otherwise the contact spring (3) or automatic function microswitch (4) will be damaged. 2 Unhook contact spring (3) on automatic function microswitch (4)
Checking
Fig 1: Identifying Shift Lever Knob And Shift Lever Knob Automatic Function (Shown On Model 450) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Electronic Selector Lever Module Control Unit And Automatic Function Microswitch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA26.00-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4490 · Applies to: 450, 451, 452, 454 · AR: BA26.00-Z-9999CZ
01D BA26.00- P-1002- 01D Bolt, transmission mount to transmission Nm 41 43 80 BA26.00- P-1003- 01D Nut, transmission bearing to transmission Nm 41 43 - BA26.00- P-1004- 01D Bolt, lower transmission bearing to front axle carrier Nm 58 58 - BA26.00- P-1005- 01D Bolt, lower transmission bearing to transmission Nm 58 58 - BA26.00- P-1006- 01D Bolt of transmission to engine Nm 48 48 23 BA26.00- P-1007- 01D Bolt, flywheel cover to engine Nm - 23 - BA26.00- P-1008- 01D Bolt, flywheel cover to transmission Nm - 48 - BA26.00- P-1009- 01D Bolt, transmission mount to frame-type integral support Nm - - 56 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: MANUAL TRANSMISSION - BA26.00-Z-9999CZ > MODEL all Cover ENGINE 122.9 in MODEL 454.0 BA26.30-P-1000-01E Gear module TRANSMISSION 717.4 in MODEL 454 BA26.20-P-1000-04A Gear set, shafts TRANSMISSION 717.4 in MODEL 454 BA26.50-P-1000-01E Housing TRANSMISSION 717... BA26.40-P-1000-01D Manual transmission complete TRANSMISSION 717.4 in MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 BA26.10-P-1000-01D Manual transmission, general ENGINE 780.009 in MODEL 451.391 /491 BA26.00-P-1000-01E Manual transmission, general TRANSMISSION 717.470 /471 /473 /474 /475 /478 /48 BA26.00-P-1000-01D Sensors/senders TRANSMISSION 717.470 /471 BA26.19-P-1000-01B
Shift mechanism¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4491 · Applies to: 450, 451, 452, 454
/473 /474 /475 Shift mechanism MODEL 451.391 /491 with ENGINE 780.009 BA26.60-P-1000-01I Shift mechanism TRANSMISSION 717.470 /471 /473 /474 /475 /478 in MODEL 454.0 BA26.60-P-1000-01E Shift mechanism TRANSMISSION 717... BA26.60-P-1000-01C TORQUE SPECIFICATIONS > MANUAL TRANSMISSION COMPLETE - BA26.10-P-1000- 01D > Transmission 717 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.4 in model 450.3/4, 452.3/4, 454.0 Transmission 717.4 in model 451.3/4 BA26.10-P- 1001-01D Bolt of transmission to engine Nm 23 45 TORQUE SPECIFICATIONS > HOUSING - BA26.40-P-1000-01D > Transmission 717 MODIFICATION NOTES 3.4.06 Bolt, transmission housing to clutch housing Transmissions 717.407/408 409/476/477 HOUSING Number Designation Transmission 717.407 up to 11.09.00 Transmission 717.407 as of 12.09.00, transmission 717.408/409/ 476/477 BA26.40- P-1001- 01D Screw plug to transmission housing Nm 43 43 BA26.40- P-1002- 01D Temperature sensor to transmission housing Nm 10 - BA26.40- P-1003- 01D Bolt, rpm sensor to transmission housing Nm 10 10 BA26.40- P-1004- 01D Bolt, transmission housing to clutch housing Stage 1 Nm 27 27 Stage 2
Releasing Releasing
Stage¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4492 · Applies to: 450, 451, 452, 454
3 Nm 25 25 BA26.40- P-1005- 01D Bolt for front section of transmission housing to rear section of transmission housing Nm - - BA26.40- P-1006- 01D Bolt, bearing cap to front section of transmission housing Nm - - BA26.40- P-1007- 01D Bolt, reverse gear shaft to transmission housing Nm - - BA26.40- P-1008- 01D Bolt, selector drum lock to transmission housing Nm - - HOUSING Number Designation Transmission 717.470/471/473/478 Transmission 717.474/475 BA26.40- P-1001- 01D Screw plug to transmission housing Nm 43 43 BA26.40- P-1002- 01D Temperature sensor to transmission housing Nm - - BA26.40- P-1003- 01D Bolt, rpm sensor to transmission housing Nm - 10 BA26.40- P-1004- 01D Bolt, transmission housing to clutch housing Stage 1 Nm - - Stage 2
-¶
Stage 3 Nm - - BA26.40- P-1005- 01D Bolt for front section of transmission housing to rear section of transmission housing Nm 15 15 BA26.40- P-1006- 01D Bolt, bearing cap to front section of transmission housing Nm 8 8 BA26.40- P-1007- 01D Bolt, reverse gear shaft to transmission housing Nm - - BA26.40- P-1008- 01D Bolt, selector drum lock to transmission housing Nm - -
HOUSING¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4493 · Applies to: 450, 451, 452, 454
Number Designation Transmission 717.480/481/482/483/484 BA26.40-P- 1001-01D Screw plug to transmission housing Nm 43 BA26.40-P- 1002-01D Temperature sensor to transmission housing Nm - BA26.40-P- 1003-01D Bolt, rpm sensor to transmission housing Nm 10 BA26.40-P- 1004-01D Bolt, transmission housing to clutch housing Stage 1 Nm - Stage 2
- Stage 3 Nm - BA26.40-P- 1005-01D Bolt for front section of transmission housing to rear section of transmission housing Nm 15 BA26.40-P- 1006-01D Bolt, bearing cap to front section of transmission housing Nm 8 BA26.40-P- 1007-01D Bolt, reverse gear shaft to transmission housing Nm 15 BA26.40-P- 1008-01D Bolt, selector drum lock to transmission housing Nm 25 TORQUE SPECIFICATIONS > SHIFT MECHANISM - BA26.60-P-1000-01C > Transmission 717.4 SHIFT MECHANISM Number Designation Transmission 717.4 in Model 450, 452 Transmission 717.4 in model 451 BA26.60-P- 1001-01C Bolt, shift module to body Nm 12 12 BA26.60-P- 1002-01C Bolt, electric motor to transmission housing Nm 11 - BA26.60-P- 1003-01C Bolt, angle of rotation sensor to transmission housing Nm 10 - BA26.60-P- 1004-01C Shift roller locking system to transmission housing Nm 25 - BA26.60-P- 1005-01C Bolt, carrier to transmission housing Nm 8,4 -
BA26.60-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4494 · Applies to: 450, 451, 452, 454 · AR: BF26.00-Z-9999CZ
1006-01C Bolt, shift actuator to transmission Nm 10 20 CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: MANUAL TRANSMISSION - BF26.00-Z-9999CZ > MODEL all Complete transmission TRANSMISSION 717.470 /471 /473 /474 /475 /478 in MODEL 454.0 Complete transmission MODEL 451.391 /491 Complete transmission TRANSMISSION 717.407 /408 /409 /476 /477 BASIC KNOWLEDGE > AUTOMATED MANUAL TRANSMISSION SHIFT LEVER POSITIONS - GF26.00-P-0003-01MCU > Shift diagram Possible positions: The mechanical park pawl is engaged in the park position, the display "P" appears in the multifunction display (A1p13) of the instrument cluster (A1). The transmitter key can only be removed from the ignition/starter switch (S2/1) in this position. Reverse gear is engaged in the reverse position, the display "R" appears in the multifunction display. No gear is engaged in the neutral position, the vehicle can be pushed or towed away. The display "N" appears in the multifunction display. Automatic mode is active in drive mode, engaging the respective gear is initiated by the automated manual transmission control unit (N15/6). The display "D" appears in the multifunction display. In the manual shift positions the gears are changed manually a gear is upshifted by operating the selector lever towards "+", a gear is downshifted by operating the selector lever towards "-". The respective engaged gear and if necessary a gearshift recommendation appears in the multifunction display. Fig 1: Identifying Automated Manual Transmission Shift Lever Positions Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > AUTOMATED MANUAL TRANSMISSION SHIFT LEVER¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4495 · Applies to: 450, 451, 452, 454
POSITIONS, FORCE DISTRIBUTION COURSE - GF26.00-P-0003-03MCC > Neutral (N position) In the transmission's N position none of the shift collars are engaged with an idler gear. 1st gear The power flows from the input shaft via the fixed gear of 1st gear (1) to the idler gear of 1st gear (2). The shift fork 1/3 (a) slides the internal toothing of the shift collar 1/3 (3) into the idler gear of 1st gear (2). The torque of the idler gear of 1st gear (2) is now passed on to the main shaft (4) and from there to the differential (5). Fig 1: Power Flow Diagram (Neutral) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
2nd gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4496 · Applies to: 450, 451, 452, 454
The power flows from the input shaft via the fixed gear of 2nd gear (6) to the idler gear of 2nd gear (7). The shift fork 2/4 (c) slides the internal toothing of the shift collar 2/4 (8) into the idler gear of 2nd gear (7). The rotation of the idler gear of 2nd gear (7) is now passed on to the main shaft (4) and from there to the differential (5). Fig 2: Power Flow Diagram (1st Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Power Flow Diagram (2nd Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3rd gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4497 · Applies to: 450, 451, 452, 454
The power flows from the input shaft via the fixed gear of 3rd gear (9) to the idler gear of 3rd gear (10). The shift fork 1/3 (a) slides the internal toothing of the shift collar 1/3 (3) into the idler gear of 3rd gear (10). The rotation of the idler gear of 3rd gear (10) is now passed on to the main shaft (4) and from there to the differential (5). 4th gear The power flows from the input shaft via the fixed gear of 4th gear (11) to the idler gear of 4th gear (12). The shift fork 2/4 (c) slides the internal toothing of shift collar 2/4 (8) into the idler gear of 4th gear (12). The rotation of the idler gear of 4th gear (12) is now passed on to the main shaft (4) and from there to the differential (5). Fig 4: Power Flow Diagram (3rd Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5th gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4498 · Applies to: 450, 451, 452, 454
The power flows from the input shaft via the fixed gear of 5th gear (13) to the idler gear of 5th gear (14). The shift fork 5 (b) slides the internal toothing of shift collar 5 (15) into the idler gear of 5th gear (13). The rotation of the idler gear of 5th gear (13) is now passed on via the fixed gear of 5th gear (14) to the main shaft (4) and from there to the differential (5). Fig 5: Power Flow Diagram (4th Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Power Flow Diagram (5th Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Reverse gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4499 · Applies to: 450, 451, 452, 454
The power flows from the input shaft via the fixed gear of reverse gear (16) the sliding gear of reverse gear (17) to the reverse gear (18). The shift fork R (d) slides the sliding gear of reverse gear (17) into the external toothing of reverse gear (18). The rotation of the reverse gear (18) is now passed on to the main shaft (4) and from there to the differential (5). BASIC KNOWLEDGE > AUTOMATED MANUAL TRANSMISSION SHIFT LEVER POSITIONS, SHIFT POSITIONS - GF26.00-P-0003-04MCC > Neutral (N) and reverse gear (R) Fig 7: Power Flow Diagram (Reverse Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Neutral position¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4500 · Applies to: 450, 451, 452, 454
The sliding blocks in the grooves of the selector drum are in the neutral position. No gear is engaged. Reverse gear The selector drum 2/4, R rotates through 120° downwards. This deflects the upper sliding block by 22.5 mm to the left. The sliding gear of reverse gear engages in the external toothing of the shift collar 1/3 The sliding blocks in the selector drum 1/3, 5 are in the neutral position. Shift position of 1st gear (1) and 2nd gear (2) Fig 1: Identifying Adjustment Of Selector Drum And Deflection Of Sliding Block Mass (Neutral And Reverse Gears) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
1st gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4501 · Applies to: 450, 451, 452, 454
The selector drum 1/3, 5 rotates downwards by 40°. This displaces the upper sliding block by 7.5 mm to the left. The shift collar 1/3 is slid into the idler gear of first gear. The sliding blocks in the selector drum 2/4, R are in the neutral position. 2nd gear When changing from 1st gear to 2nd gear both selector drums are twisted upwards by 40°. This in turn displaces the lower sliding block for the selector drum 2/4, R by 7.5 mm to the left. The shift collar 2/4 is slid into the idler gear of second gear. The sliding blocks of the selector drums 1/3, 5 are in the neutral position. Shift position of 3rd gear (3) and 4th gear (4) Fig 2: Identifying Adjustment Of Selector Drum And Deflection Of Sliding Block Mass (1st And 2nd Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
3rd gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4502 · Applies to: 450, 451, 452, 454
When changing from 2nd gear to 3rd gear both selector drums are twisted upwards by 40°. The upper sliding block in the selector drum 1/3, 5 is displaced to the right by 7.5 mm. It presses the shift collar 1/3 into the idler gear of third gear. The other sliding blocks are in the neutral position. 4th gear When changing from 3rd gear to 4th gear both selector drums are twisted upwards by 40°. The lower sliding block in the selector drum 2/4, R is displaced to the right by 7.5 mm. It presses the shift collar 2/4 into the idler gear of fourth gear. The other sliding blocks are in the neutral position. Shift position of 5th. Gang (5) Fig 3: Identifying Adjustment Of Selector Drum And Deflection Of Sliding Block Mass (3rd And 4th Gears) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
5th gear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4503 · Applies to: 450, 451, 452, 454
When changing from 4th gear to 5th gear both selector drums are twisted upwards 1/3 5 by 40°. The lower sliding block in the selector drum 1/3, 5 is displaced to the left by 7.5 mm. It presses the shift collar 5 into the idler gear of 5th gear. The selector drum 2/4, R is twisted downwards by 40°. The sliding blocks of the selector drum 2/4, R are in the neutral position. BASIC KNOWLEDGE > AUTOMATED MANUAL TRANSMISSION (AUTOMATED MANUAL TRANSMISSION) SHIFT PROCESS - GF26.00-P-0003-05MCC > Fig 4: Identifying Adjustment Of Selector Drum And Deflection Of Sliding Block Mass (5th Gear) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Shown with code (I75) leather sport steering wheel incl. steering wheel rocker switch system¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4505 · Applies to: 450, 451, 452, 454
Function The automated manual transmission is based on a "standard" manual transmission. The shift operations are carried out by 2 selector drums which are adjusted by gear motor 1 and gear motor 2. The current position is recorded by integrated incremental sensors. The necessary clutch engagements are carried out by the clutch motor. Operation takes place via the electronic selector lever module control unit or via the steering wheel gear shifter (with code (I75) Leather sport steering wheel incl. steering wheel rocker switch system). The complete control of the shift processes and clutch engagements takes place by the automated manual transmission control unit. The currently engaged gear stage as well as the gearshift recommendation are displayed in the multifunction display (A1p13) of the instrument cluster. The following shift programs are possible: Fig 1: Automated Manual Transmission Shift Lever Positions Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Manual shift mode¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4506 · Applies to: 450, 451, 452, 454
The selector lever is located in the "±" plane. The gears must be selected manually. Automatic mode The selector lever is in the "D" plane. The gears are shifted automatically. Engine start Move the selector lever into position "P" and actuate the foot brake and Circuit 15 On Then first the automated manual transmission control unit issues a start enable and the engine can be started with the transmitter key. Starting off To start off the vehicle the selector lever must be in shift plane "D" or "±": Operate service brake, Operate the shift lock button on the selector lever and move the selector lever into "D" or "±" Release service brake The vehicle moves off. "1" or "D" in displayed in the multifunction display depending on the shift mode selected. Manual shift mode The driver determines the gear change in manual shift mode. Selector lever forwards "+": Upshift one gear Selector lever rearwards "-": Downshift one gear On vehicles with code (I75) Leather sport steering wheel incl. steering wheel rocker switch system the gears can also be changed via the steering wheel gear shifter: Steering wheel gear shifter PLUS: Upshift one gear Steering wheel gear shifter MINUS: downshift one gear A manual downshift is only performed if it does not lead to overevving the engine. The respective engaged gear stage is indicated in the multifunction display. If for a driving style for an optimized fuel consumption another gear stage than the one which is engaged would be more meaningful, a gear shift recommendation from the automated manual transmission control unit appears in the multifunction display: Arrow up: Shift up one gear Arrow down: Shift down one gear Forced upshift/downshift
Automatic shift operations also take place in manual shift mode:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4507 · Applies to: 450, 451, 452, 454
Forced upshift just before reaching the maximum speed of the engine Forced downshift when approaching the idle speed of the engine Shift down for kickdown Engage first gear when vehicle is at a standstill Automatic mode In automatic mode the automated manual transmission control unit determines the gear change. The shift operations run automatically (performance-map dependent) corresponding to the current load (accelerator pedal position) and vehicle speed. The following points are taken into account for the shift operations: Upshifts and downshifts are not triggered at the same operating point in order to avoid repeated shifting between two gears in the critical limits. When downshifting multiple gearshifts (e.g. from 5 to 3) are also conducted. Backup Operate foot brake Move selector lever into position "R" Release foot brake The vehicle moves off. "R" is displayed in the multifunction display. The shift lock button on the selector lever must be operated for engaging reverse gear. Kickdown function In order to trigger an automatic downshift via the kickdown function, the accelerator pedal must be fully depressed (overcoming the over-center preload). The following processes can be triggered based on a performance map: Downshift by one to three gears After this automatic upshift just before reaching the maximum speed of the engine The kickdown function is possible in manual shift mode and in automatic mode. Crawl function The crawl function enables the vehicle to be driven slowly, e.g. when parking or in a traffic jam. Function requirements: Forward or reverse gear engaged Accelerator pedal not actuated (engine in neutral) Function When the service brake is released the clutch is operated in slip or in the closed range. The vehicle then
moves at a slower speed. The function is terminated by operating the service brake, parking brake,¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4508 · Applies to: 450, 451, 452, 454
accelerator pedal or on gradients above 5 %. Parking the vehicle The following items must be taken into account for safely parking the vehicle: Apply service brake Move selector lever to position "P" Operate parking brake Switch off engine and remove transmitter key Release service brake If the selector lever is in position "P" the vehicle is secured to prevent it from rolling away by a mechanical park pawl. The park pawl is engaged by the electronic selector lever module control unit via a cable to the transmission The status of the park pawl is recorded by the park pawl switch and is passed on to the automated manual transmission control unit. No gear is engaged when the engine is switched off in selector lever position "N". The vehicle can be pushed or towed away. Removal of the transmitter key is only possible in selector lever position "P". Transmission temperature The oil temperature influences the viscosity of the transmission oil and thus the shift operation process. As the transmission control takes into account the oil temperature for the actuation of the actuator motors, a consistent shift quality is achieved. The temperature of the transmission is computed. The speed of the shafts and the transmitted torque is drawn on to calculate the friction, which is converted in the transmission into heat. The cooling due to the airstream is determined from the ambient temperature and the vehicle speed and the transmission temperature is established by means of a performance map. Following an extended immobilization period the ambient temperature is adopted for the transmission temperature. Error reactions The processes in the transmission are monitored by means of the actuation signals and the sensor signals. If events occur in the process which deviate from the normal sequence, these are stored in the automated manual transmission control unit. Stored events can be erased again if they do not occur any more on several trips in sequence. There are three fault classes: Fault without impairment of driving mode Faults which slightly impair driving mode Faults which severely impair driving mode Fault without impairment of driving mode Fault is stored but no effects on driving are noticeable. No warning message is output in the multifunction display. Such event recordings serve solely analysis of causes.
Faults which slightly impair driving mode¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4509 · Applies to: 450, 451, 452, 454
In the event of basic faults a warning message is output in the multifunction display. The trip is only slightly impaired, the restrictions are often not noticed by the driver. Thus, e.g. overlaps and gear steps are no longer executed. The duration of the shift operations is extended. Faults which severely impair driving mode In the event of serious faults a warning message is likewise output in the multifunction display. The transmission changes into limp-home mode. The following reactions are possible: No further gearshifts are performed, the gear engaged is retained. Only reverse gear and 1st gear are actuated after stopping and restarting, engine performance and engine speed are limited. No further gear is engaged after stopping and restarting. Initializing The initialization must be performed using STAR DIAGNOSIS after the following activities: Removal of transmission Removal of one or both transmission motors Replacement of automated manual transmission control unit A transmission teach-in process takes place after the power supply is discontinued. In the process the incremental counter reading of the selector drum system of sensors is readjusted. For this purpose the selector drums are moved into their end positions when the clutch is open. Clutch actuation For each shift operation a clutch process is carried out by the automated manual transmission control unit. The automated manual transmission control unit actuates the clutch motor directly for this. The load is evaluated in the automated manual transmission control unit in order to avoid overloading the clutch. If the threshold value is exceeded the clutch starts to pulse in order to draw the driver's attention to an overload. The clutch is opened in the event of further overload. For wear adaptation the drag point and the transmission characteristics of the clutch are continuously adapted by the automated manual transmission control unit.
Automated manual transmission shift lever positions
GF26.00-P-0003- 01MCU
Automated manual transmission shift lever positions, force distribution course
GF26.00-P-0003- 03MCC
Automated manual transmission shift lever positions, shift positions
GF26.00-P-0003- 04MCC
Automated manual transmission (Automated Manual Transmission) shift process
GF26.00-P-0003- 05MCC
PE26.19-P-
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4513 · Applies to: 450, 451, 452, 454
The electronic selector lever module control unit is located in the center console. Task The electronic selector lever module control unit records the driver's shift requirements. The following selector lever positions are possible Park position "P" Reverse gear "R" Neutral "N" Transmission mode "D" (automatic mode) Manual shift mode "±" If the selector lever is in "R" the left backup lamp (E3e3) and right backup lamp (E4e3) is actuated directly directly by the electronic selector lever module control unit. If the selector lever is moved out of the transmission mode to the left in the "±" plane, manual shift mode is active. In the process the gears are shifted manually by the driver: "+" one gear is upshifted "-" one gear is downshifted The shift lock button must be operated for the following shift operations: from "P" to "R" from "N" to "R" from "R" to "P" Fig 1: Identifying Electronic Selector Lever Module Control Unit And Shift Lock Button Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Location¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4515 · Applies to: 450, 451, 452, 454
The automated manual transmission control unit is located in the passenger compartment under the driver seat. Task The automated manual transmission control unit controls, monitors and coordinates the complete transmission control. For this purpose it exchanges (CAN) data with other control units via the Controller Area Network (data bus/CAN bus). The automated manual transmission control unit controls the following functions: Engage first gear when the vehicle is stationary Gear change Forced upshift just before reaching the maximum speed of the engine Forced downshift when approaching the idle speed of the engine Shift down for kickdown Crawl function Clutch operator Monitoring clutch load Signals from the following components are read in directly by the automated manual transmission control unit: Transmission rpm sensor (L2) Transmission motor 1 (M17/3) Transmission motor 2 (M17/4) Clutch motor (M18) Park pawl switch (S16/2) Fig 1: Identifying Automated Manual Transmission Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The following components are actuated directly by the CDI control unit:¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4516 · Applies to: 450, 451, 452, 454
Transmission motor 1 Transmission motor 2 Coupling motor Communication via the drive LIN takes place via the CAN: Instrument cluster (A1) ME-SFI [ME] control unit (/)N3/10 Electronic selector lever module control unit (/)N15/5 ESP control unit (N47-5) BASIC KNOWLEDGE > PARK PAWL SWITCH, COMPONENT DESCRIPTION - GF26.19-P- 2100MCU > TRANSMISSION 717.482 in MODEL 451.3 /4 Location The park pawl switch is located on the left of the transmission in the direction of travel. Task The park pawl switch monitors the park pawl engaged or released mechanically via the cable and transmits a corresponding signal to the automated manual transmission control unit (N15/6). BASIC KNOWLEDGE > SHIFTING MECHANISM COMPONENT DESCRIPTION - GF26.60-P- Fig 1: Identifying Park Pawl Switch And Cable Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
A1p13¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4519 · Applies to: 450, 451, 452, 454
Multifunction display 13K A45 Fanfare horns and airbag clock spring contact 18K E3e3 Left backup lamp 22F E4e3 Right backup lamp 22F L2 Transmission rpm sensor 11H M17/3 Transmission motor 1 12D M17/4 Transmission motor 2 12E M18 Coupling motor 10C N3/10 ME-SFI [ME] control unit 15C N10/10 SAM control unit 2D N15/5 Electronic selector lever module control unit 20G N15/6 Automated manual transmission control unit 10F N47-5 ESP control unit 3L S16/2 Park pawl switch 10H S112s1 Steering wheel gear shifter PLUS 20K S112s2 Steering wheel gear shifter MINUS 20K X11/4 Data link connector 6B WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR MANUAL TRANSMISSION - PE26.19-P-2050-99MCU > Code: Designation: Position: A1 Instrument cluster 21 G A1e15 Airbag indicator and warning lamp 21 E A1e9 Seat belt reminder lamp 21 E A45 Fanfare horns and airbag clock spring contact 11 J A53 Driver head/thorax sensor 3 C A54 Front passenger head/thorax sensor 8 C B48/1 Driver-side frontal acceleration sensor 2 B B48/2 Passenger-side frontal acceleration sensor 7 B B48/3 Belt tension sensor 16 J B48/4 Seat occupied recognition pressure sensor 16 K E16 Automatic child seat recognition airbag OFF indicator lamp 9 H N10/10 SAM control unit 2 G N110 Weight Sensing System (WSS) control unit 18 J
N2/7¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4520 · Applies to: 450, 451, 452, 454
Restraint systems control module 9 F N3/10 ME-SFI [ME] control module 17 D R12/1 Left emergency tensioning retractor squib 9 H R12/13 Driver airbag ignition squib 1 13 J R12/14 Driver airbag ignition squib 2 13 J R12/2 Right emergency tensioning retractor squib 9 H R12/20 Driver head/thoraxbag squib 9 J R12/21 Front passenger head/thoraxbag squib 9 J R12/4 Front passenger airbag ignition squib 1 9 H R12/5 Front passenger airbag ignition squib 2 9 H S68/3 Driver-side seat belt buckle restraint systems switch 10 E S68/4 Passenger-side seat belt buckle restraint systems switch 10 E X11/4 Data link connector 12 C Fig 1: Electrical Function Diagram For Manual Transmission (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
PE26.19-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4522 · Applies to: 450, 451, 452, 454
2050-60MCU Legend of electrical function diagram for manual transmission
PE26.19-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- 3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)
GF00.19-P- 3000MCU PE07.00-P- 1100MCU
Further wiring diagrams PE07.00-P- 1100MCU PE26.00-P- 1100MCU
Further wiring diagrams PE26.00-P- 1100MCU PE42.00-P- 1100MCU
Further wiring diagrams PE42.00-P- 1100MCU PE54.00-P- 1100MCU
Further wiring diagrams PE54.00-P- 1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF CAN BUS - PE00.19-P-2150-97MCU > Code: Designation: Position: A1 Instrument cluster 44A A1 Instrument cluster 28A A1 Instrument cluster 52A A1 Instrument cluster 37A A1 Instrument cluster 4A A1 Instrument cluster 20A A1 Instrument cluster 12A B24/15 Yaw rate, lateral and longitudinal acceleration sensor 30L N10/10 SAM control unit 8L
N110¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4523 · Applies to: 450, 451, 452, 454
Weight Sensing System (WSS) control unit 47L N15/5 Electronic selector lever module control unit 23L N15/6 Automated manual transmission control unit 19L N2/7 Restraint systems control unit 43L N23 Heater/AC operating unit 38L N3/10 ME-SFI [ME] control unit 3L N47-5 ESP control unit 34L N49 Steering angle sensor 26L N68 Steering assist control unit 14L N88 TPM [RDK] control unit 54L U1012 Valid up to 30/08/2010 41K U1012 Valid up to 30/08/2010 46K U1013 Valid as of 31/08/2010 41L U1013 Valid as of 31/08/2010 46L U492 Valid for power steering 10D U493 Not valid for power steering 8D U87 Valid for air conditioning 37D X11/4 Data link connector 51L X55/4 Front passenger seat connector block 46G Z37/2 CAN engine bus (low) connector sleeve 55E Z37/2 CAN engine bus (low) connector sleeve 23E Z37/2 CAN engine bus (low) connector sleeve 51E Z37/2 CAN engine bus (low) connector sleeve 43E Z37/2 CAN engine bus (low) connector sleeve 40E Z37/2 CAN engine bus (low) connector sleeve 27E Z37/2 CAN engine bus (low) connector sleeve 34E Z37/3 CAN engine bus (high) connector sleeve 54E Z37/3 CAN engine bus (high) connector sleeve 22E Z37/3 CAN engine bus (high) connector sleeve 50E Z37/3 CAN engine bus (high) connector sleeve 42E Z37/3 CAN engine bus (high) connector sleeve 38E Z37/3 CAN engine bus (high) connector sleeve 26E Z37/3 CAN engine bus (high) connector sleeve 33E Z37/4 Power steering CAN bus connector sleeve (low) 11F
Z37/41¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4524 · Applies to: 450, 451, 452, 454
CAN databus (high) connector sleeve 18E Z37/41 CAN databus (high) connector sleeve 33G Z37/41 CAN databus (high) connector sleeve 30E Z37/42 CAN bus (low) connector sleeve 19E Z37/42 CAN bus (low) connector sleeve 34G Z37/42 CAN bus (low) connector sleeve 31E Z37/5 Power steering CAN bus connector sleeve (high) 10F Fig 1: CAN Bus - Wiring Diagram (1 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: CAN Bus - Wiring Diagram (2 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4525 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: CAN Bus - Wiring Diagram (3 Of 4)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4526 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
OV00.01-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4528 · Applies to: 450, 451, 452, 454
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 plug 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 WIRING DIAGRAMS > WIRING DIAGRAM OF AUTOMATED MANUAL TRANSMISSION (SEQ) CONTROL UNIT - PE26.19-P-2101-97MCU > Code Designation Position A1 Instrument cluster 21L A2/3 smart Entry radio 36L A2/4 smart Premium radio 37L E3 Left taillamp 16L E3e3 Left backup lamp 16L E4 Right taillamp 18L E4e3 Right backup lamp 18L L2 Transmission rpm sensor 42L M17/3 Transmission motor 1 25L M17/4 Transmission motor 2 29L M18 Clutch motor 33L N10/10 SAM control unit 5L N10/10f10 Fuse 10 4L N10/10f12 Fuse 12 6L N10/10f19 Fuse 19
N10/10f24 Fuse 24 9L N10/10f30 Fuse 30 3L
N15/5¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4529 · Applies to: 450, 451, 452, 454
Electronic selector lever module control unit 12l N15/6 Automated manual transmission control unit 22A N15/6 Automated manual transmission control unit 29A N15/6 Automated manual transmission control unit 6A N15/6 Automated manual transmission control unit 13A N15/6 Automated manual transmission controlunit 37A S16/2 Park pawl switch 40L U1010 Valid for radio with Premium sound system 35K U1011 Valid for radio without Premium sound system 35L U1012 Valid up to 30/08/2010 39E U1013 Valid up to 31/08/2010 38E U865 Valid for Entry radio 35K W10 Ground (battery) 12E W14 Left floor interior compartment ground 8E Z20 Connector sleeve cable end insulation not stripped, placed inside insulated tubing 41G Z3/24 Circuit 15 (fused) connector sleeve, function 7E Z37/2 CAN engine bus (low) connector sleeve 13E Z37/2 CAN engine bus (low) connector sleeve 21G Z37/3 CAN engine bus (high) connector sleeve 14E Z37/3 CAN engine bus (high) connector sleeve 20G Z37/41 CAN databus (high) connector sleeve 19E Z37/42 CAN bus (low) connector sleeve 21E Z37/42 CAN bus (low) connector sleeve 38E
ATA [EDW] sensor supply¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4530 · Applies to: 450, 451, 452, 454
Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 6E Z7/24 Circuit 87/1 connector sleeve 2E Z7/35 Circuit 87 M1e connector sleeve 11E Z7/35 Circuit 87 M1e connector sleeve 3E Fig 1: Automated Manual Transmission (SEQ) Control Unit - Wiring Diagram (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 2: Automated Manual Transmission (SEQ) Control Unit - Wiring Diagram (2 Of 3)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4531 · Applies to: 450, 451, 452, 454
Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 000 589 52 37 00 PLIERS - WS26.00-P-0005C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4532 · Applies to: 450, 451, 452, 454
FG 26/Set C TRANSMISSION 711.101 /11 /202 /640 /641 /68, 716.0 /1 /2 /6, 717.0 /40 /41 /42 /43 /44 /45 /46, 711.67, 717.48 Further use FG 27/Set C
FG 46/Set C
FG 47/ Set B Use: Pliers for removing/installing snap ring on 2nd gear synchronizer body and drive shaft (on 711.101/11/202, 716.0/1/2/6, 716.0/1/2/6, 717.0/40/41/42/43/44/45/46) or for removing/installing snap rings on drive shaft (711.640/641) or removing/installing snap rings on drive shaft and output shaft (717.48) Fig 3: Automated Manual Transmission (SEQ) Control Unit - Wiring Diagram (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
or for removing/installing retaining rings on main shaft (711.6)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4533 · Applies to: 450, 451, 452, 454
SPECIAL TOOLS > 000 589 60 34 00 CHUCK - WS26.00-P-0006C > FG 26/Set C TRANSMISSION 711.640 /641, 717.45 /46 /4 Use: Clamping pliers for tapered roller bearing at rear of countershaft (on transmission 717.45/46) or when detaching tapered roller bearings of axle differential (transmission 711.640/641) in combination with puller 001 589 50 33 00.
SPECIAL TOOLS > 001 589 49 33 00 PULLER - WS26.00-P-0011C > FG 26/Set C TRANSMISSION 711.640 /641, 716.5, 717.41 /43 /44 /45 /46, 722.55 /750 /751, 716.508 /509 /513 /514, Fig 1: Identifying Pliers (000 589 52 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Chuck (000 589 60 34 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODIFICATION NOTES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4534 · Applies to: 450, 451, 452, 454
717.4 MODIFICATION NOTES 8.6.93 Replacement for: 001 589 47 33 00 Use: Puller for tapered roller bearing inner races (size 4 basic unit) (for 717.41/43/44/45/46, 722.750/751, 716.508/509/513/514) or the tapered roller bearing of the output shaft (for 711.640/641).
SPECIAL TOOLS > 001 589 50 33 00 PULLER - WS26.00-P-0012C > FG 26/Set C TRANSMISSION 711.640 /641, 716.5, 717.45 /46 /4 Further use FG 26/Set C
FG 27/Set C
FG 28/Set C
FG 33/Set C
FG 35/Set C Use: Puller for taper roller inner races (basic unit size 5) (on 717.45/46) or for detaching taper roller bearings of axle differential (on 711.640/641).
Fig 1: Identifying Puller (001 589 49 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 168 589 00 14 00 SLEEVE - WS26.00-P-0063C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4535 · Applies to: 450, 451, 452, 454
FG 26/27 Set C TRANSMISSION 711.640 /641, 716.5 /508 /509 /513 /514 /6, 722.750 /751 /8, 717.4 Use: Sleeve for pressing in bearing shells and for removing input shaft bearing.
SPECIAL TOOLS > 450 589 02 62 00 REMOVAL FIXTURE - WS26.00-P-0090B > FG 26/32/33/31/35/47/83/Set B MODEL 450, 451, 452, 454 Use: For model 450, 451, 452: Fig 1: Identifying Puller (001 589 50 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Sleeve (168 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Removal fixture for removing/installing the transmission.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4536 · Applies to: 450, 451, 452, 454
For model 454: Removal fixture for removing/installing the fuel tank, of the front and rear axle, stationary heater and trailer hitch. NOTE: Removal fixture, smart no.: 000 5141 V001 0000 00. SPECIAL TOOLS > 450 589 04 33 00 PULLER - WS26.00-P-0100B > FG 26/Set B MODEL 450, 451, 452 Use: Extractor for extracting the radial shaft seal of the transmission input shaft. NOTE: ExtractorSmart no.: 0012701 Fig 1: Identifying Removal Fixture (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 711 589 13 15 00 DRIFT - WS26.00-P-0105B >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4537 · Applies to: 450, 451, 452, 454
FG 26/Set B TRANSMISSION 711.640 /641, 717.4 Use: Drift for installing shaft seal (input side) and for installing bearing shells of output shafts.
SPECIAL TOOLS > 722 589 00 35 00 INSTALLER - WS26.00-P-0112C > FG 26/Set C TRANSMISSION 711.640 /641, 717.4 Further use FG 27/Set C Use: Fig 1: Identifying Puller (450 589 04 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Drift (711 589 13 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Installer for pulling bearing shells into the transmission housing.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4538 · Applies to: 450, 451, 452, 454
SPECIAL TOOLS > 000 589 30 33 00 INTERNAL EXTRACTOR - WS26.00-P-0113C > FG 26/Set C TRANSMISSION 711.640 /641, 716.5, 722.8, 717.4 Further use FG 28/Set C
FG 00
FG 33/Set C Use: Internal extractor for removing bearing shells of axle differential on transmission housing.
SPECIAL TOOLS > 000 589 34 33 00 COUNTER STAY - WS26.00-P-0114C > Fig 1: Identifying Installer (722 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Internal Extractor (000 589 30 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FG 26/27/Set C¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4539 · Applies to: 450, 451, 452, 454
TRANSMISSION 711.640 /641, 716.5, 722.8, 717.4 Further use FG 28/Set C
FG 33/Set C
FG 35/Set C
FG 00 Use: Counter stay for removing bearing shells of axle differential in transmission housing.
SPECIAL TOOLS > 140 589 03 15 00 DRIFT - WS26.00-P-0119C > FG 26/Set C TRANSMISSION 711.640 /641, 717.4 Further use FG 35/Set C Use: Grooved ball bearing from transmission housing.
Fig 1: Identifying Counter Stay (000 589 34 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 454 589 01 14 01 EXTRACTOR SLEEVE - WS26.00-P-0123-01C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4540 · Applies to: 450, 451, 452, 454
FG26/Set C MODEL 451, 454 Use: Extractor sleeve for disassembling the shaft seal on the transmission input shaft. NOTE: Inside diameter of the extractor sleeve is 24.4 mm and is intended for a vehicle with a diesel engine. SPECIAL TOOLS > 454 589 01 14 02 EXTRACTOR SLEEVE - WS26.00-P-0123-02C > FG26/Set C Fig 1: Identifying Drift (140 589 03 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Extractor Sleeve (454 589 01 14 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451, 454¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4541 · Applies to: 450, 451, 452, 454
Use: Extractor sleeve for disassembling the shaft seal on the transmission input shaft. NOTE: Inside diameter of the extractor sleeve is 27.4 mm and is intended for a vehicle with a diesel engine. SPECIAL TOOLS > 454 589 01 14 00 SET OF EXTRACTOR SLEEVES - WS26.00-P-0123C > FG 26/27Satz C MODEL 451, 454 Separate part 454 589 01 14 01 Extractor sleeve FG26/Set C WS26.00-P-0123-01C Separate part 454 589 01 14 02 Extractor sleeve FG26/Set C WS26.00-P-0123-02C Use: Set of extractor sleeves for disassembling the shaft seals on the transmission input shafts. Fig 1: Identifying Extractor Sleeve (454 589 01 14 02) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
SPECIAL TOOLS > 454 589 02 15 00 DRIFT - WS26.00-P-0124C >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4542 · Applies to: 450, 451, 452, 454
FG 26/27 Set C MODEL 451, 454 Use: Drift for hammering radial shaft sealing ring into transmission input shaft. SPECIAL TOOLS > SPECIAL TOOLS: SMART: MANUAL TRANSMISSION - WS26.00-Z- 9999CZ > MODEL all 000 589 25 33 00 Internal extractor FG 00/15/26 WS00.00-P-0050Z 000 589 30 33 00 Internal FG 26/Set C WS26.00-P-0113C Fig 1: Identifying Set Of Extractor Sleeves (454 589 01 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Drift (454 589 02 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
extractor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4543 · Applies to: 450, 451, 452, 454
000 589 34 33 00 Counter stay FG 26/27/Set C WS26.00-P-0114C 000 589 45 33 00 Puller FG 00/ 03/20/26/28/ 33/35/41 WS00.00-N-3036Z 000 589 52 37 00 Pliers FG 26/Set C WS26.00-P-0005C 000 589 60 34 00 Chuck FG 26/Set C WS26.00-P-0006C 001 589 49 33 00 Puller FG 26/Set C WS26.00-P-0011C 001 589 50 33 00 Puller FG 26/Set C WS26.00-P-0012C 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/ 80/82/83/88/91/ Set K WS00.00-P-0274K 140 589 03 15 00 Drift FG 26/Set C WS26.00-P-0119C 168 589 00 14 00 Sleeve FG 26/27 Set C WS26.00-P-0063C 450 589 00 15 00 Drift FG 26/Set B WS26.00-P-0092B 450 589 00 34 00 Centering sleeve FG 26/Set B WS26.00-P-0122B 450 589 00 91 00 Plug FG 26/Set B WS26.00-P-0091B 450 589 01 15 00 Drift FG 26/Set B WS26.00-P-0093B 450 589 01 31 00 Assembly template FG 26/Set C WS26.00-P-0125C 450 589 02 62 00 Removal fixture FG 26/32/33/31/35/47/ 83/Set B WS26.00-P-0090B 450 589 04 33 00 Puller FG 26/Set B WS26.00-P-0100B 450 589 11 63 00 Y-cable FG 26/Set B WS26.00-P-0094B 454 589 01 14 00 Set of extractor sleeves FG 26/27Satz C WS26.00-P-0123C 454 589 01 14 01 Extractor sleeve FG26/Set C WS26.00-P-0123-01C 454 589 01 14 02 Extractor sleeve FG26/Set C WS26.00-P-0123-02C 454 589 01 91 00 Adapter FG 42/25/26/Set A WS42.00-P-0069A 454 589 02 15 00 Drift FG 26/27 Set C WS26.00-P-0124C 454 589 03 15 00 Drift FG 25/26/Set B WS25.00-P-0011B 454 589 04 09 00 Set of socket wrench bits FG 22/26/01 Set B WS22.00-P-0007B 602 589 00 33 00 Impact extractor FG 26/33/35/Set B WS33.00-P-0189B 711 589 13 15 00 Drift FG 26/Set B WS26.00-P-0105B
722 589 00 35 00 Installer¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4544 · Applies to: 450, 451, 452, 454
FG 26/Set C WS26.00-P-0112C
SPECIAL TOOLS > SPECIAL TOOLS: SMART: TRANSFER CASE - WS28.00-Z-9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4545 · Applies to: 450, 451, 452, 454 · AR: WS28.00-Z-9999CZ
MODEL all 000 589 45 33 00 Puller FG 00/03/20/26/28/33/35/41 WS00.00-N-3036Z 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B 001 589 01 16 03 box wrench FG22/09/28/Set B WS22.00-P-0008- 03B 001 589 01 16 09 Box wrench bit FG22/09/28/Set B WS22.00-P-0008- 09B
SPECIAL TOOLS > SPECIAL TOOLS: SMART: TRANSFER CASE - WS28.00-Z-9999CZ >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4546 · Applies to: 450, 451, 452, 454 · AR: WS28.00-Z-9999CZ
MODEL all 000 589 45 33 00 Puller FG 00/03/20/26/28/33/35/41 WS00.00-N-3036Z 000 589 54 37 00 Clamp FG 00/01/07/13/14/ 18/20/22/28/33/46/ 47/82/83/Set B WS00.00-P-0006Z 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B 001 589 01 16 03 box wrench FG22/09/28/Set B WS22.00-P-0008-03B 001 589 01 16 09 Box wrench bit FG22/09/28/Set B WS22.00-P-0008-09B
AIR CONDITIONING >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4547 · Applies to: 450, 451, 452, 454
358314 31 30 HOT IN ON OR START 27 26 12 11 10 9 HOT W/ MAIN RELAY ENERGIZED HOT IN ON OR START 15A 7.5A 29 28 25 24 23 22 21 20 19 18 17 16 15 14 13 8 7 6 5 4 3 2 1 10A HOT AT ALL T MES HOT AT ALL TIMES 58D 15 DG +5V DGM DG SIG CAN L CAN H CAN L CAN H 31 25A 1 N116/1X2 2 C5 11 C3 3 C2 7 3 2 1 2 1 17 X99/4 B4 A4 C3 X99/3 A7 5 6 N116/1X1 8 4 3 A6 X99/3 6 C2 6 4 3 X85/10 1 C6 2 1 14 13 14 13 12 C1 1 2 3 1 4 C1 1 3 2 4 6 5 8 9 10 7 11 2 1 3 5 4 C2 11 12 6 7 8 9 10 4 1 5 3 2 RED/WHT RED/WHT BLK/YEL BRN/WHT BLU RED/GRN RED GRN BLK/YEL BLU BRN/WHT GRN/WHT GRN BRN BLK/GRN WHT BLU GRN/WHT GRN NCA WHT/GRN GRN/WHT GRN/YEL WHT GRY PNK BLU RED ORG WHT/GRN BRN BRN ORG ORG ORG ORG ORG ORG NCA NCA RED/VIO YEL GRN/WHT GRN RED/YEL RED/VIO BRN YEL GRN BLU RED/BLU BRN RED/YEL BRN RED WHT BLK/GRN ORG YEL BLK PNK/YEL BRN/ORG ORG BLU BLU RED GRY WHT GRN RED/WHT GRY/BLU RED/GRY WHT/GRN BRN/ORG GRN PNK BLU RED GRY YEL GRN BLU GRN/WHT ORG/BLU PNK/YEL GRN/WHT GRN BLU GRN/YEL BLK GRN GRY BLK YEL WHT GRY GRN/WHT YEL SAM CONTROL UNIT ELECTR C FUEL PUMP RELAY AUTOMATED MANUAL TRANSMISSON RELAY MAIN RELAY FUSE 19 FUSE 12 FUSE 10 HIGH-VOLTAGE PTC HEATER ELECTR CAL CONNECTOR HIGH-VOLTAGE AC/DC BATTERY CHARGER CONTROL UNIT HIGH-VOLTAGE DISTRIBUTOR CONTROL UNIT ELECTRIC MOTOR CONTROL UNIT COMPUTER DATA L NES SYSTEM COMPUTER DATA LINES SYSTEM INTERIOR L GHTS SYSTEM W10 W10 HEATER BLOWER RELAY FUSE 4 HEATED REAR WINDOW SWITCH AIR CONDITIONING SWITCH AR RECIRCULATION SWITCH INTERIOR TEMPERATURE SENSOR HEATING & AIR CONDIT ONING OPERATING UNIT BLOWER SWITCH STH RADIO REMOTE CONTROL RECEIVER BLOWER MOTOR SERIES RESISTOR GROUP REFRIGERANT COMPRESSOR CONTROL UNIT (EAC) (UNDER LEFT SIDE OF DASH) ( N BATTERY COMPT) (CENTER OF DASH) (IN BATTERY COMPT) Fig 1: Automatic A/C Circuit, W/ Electric Drive (1 of 2)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4548 · Applies to: 450, 451, 452, 454
M M M 358315 31 30 BAT TAX OFF CAN H GN3 GN OUT3 CAN H CAN L SHIELD GN OUT6 27 26 12 11 10 9 HOT AT ALL TIMES 15A SHIELD GND LOG CAN L LOG CAN H VBA TT VBA TT MAIN RELAY COOL FAN1 COOL FAN2 IGN1 PUMP 29 28 25 24 23 22 21 20 19 18 17 16 15 14 13 8 7 6 5 4 3 2 1 CAN H CAN L CAN H CAN L (+) (-) 6 1 2 1 2 4 R23X1 8 2 1 X99/3 B8 B7 X99/3 C2 1 4 3 C1 A8 1 2 2 6 8 4 R6 C1 C2 52 1 2 3 30 29 34 3 20 26 2 15 27 54 28 18 21 5 X85/10 2 2 5 8 6 4 2 5 8 6 4 2 6 9 1 2 16 18 X85/10 4 2 1 3 2 1 5 6 1 2 1 5 2 3 6 RED WHT GRN/BLK RED WHT RED/WHT RED/WHT GRN/BLK BRN/YEL BRN/YEL GRN BLK/YEL BRN WHT BLU NCA NCA WHT/BRN RED GRN RED/YEL BRN BRN BRN RED/GRN BRN RED/YEL WHT BRN BRN YEL BRN RED/GRN YEL RED/GRN BLU/GRN RED WHT BRN NCA WHT/BRN RED/WHT RED/WHT BRN GRN GRN/WHT BRN/WHT BLU BLK/YEL BLU/GRN BRN BLK/GRN WHT/BLU GRN/WHT GRN NCA WHT/GRN GRN/WHT GRN/YEL WHT GRY PNK BLU RED BRN WHT/GRN BRN ORG ORG ORG WHT/GRN GRN NCA GRN/WHT WHT BLU BLK/GRN GRN WHT BRN BRN BRN RED/GRY WHT/GRN RED/GRY BRN BRN BRN RED/GRY BRN RED/GRY YEL BLK PNK/YEL BRN ORG ORG/BLU BLU RED GRY ORG BRN GRN WHT GRN VIO BRN VIO BRN/VIO VIO RED GRY BLU RED BLK PNK/YEL BRN/ORG ORG/BLU GRN/YEL GRN/WHT PNK BLU BLK RED YEL GRY WHT SAM CONTROL UNIT FUSE 41 INSTRUMENT CLUSTER RIGHT ELECTR C DRIVER CONTROL MODULE LEFT ELECTR C DRIVER CONTROL MODULE EVCM ELECTRIC VEHICLE CONTROL UNIT COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM W26 W9 W7 W7 W7 BLOWER MOTOR RELAY 1 BLOWER MOTOR RELAY 2 OUTSDE TEMPERATURE DISPLAY TEMPERATURE SENSOR COOLANT TEMPERATURE WARNING LAMP BLOWER MOTOR H GH-VOLTAGE PTC HEATER REFRIGERANT PRESSURE SENSOR BLEND AIR FLAP ACTUATOR EVAPORATOR TEMPERATURE SENSOR AIR REC RCULATION FLAP ACTUATOR MOTOR ELECTRIC DRIVE & HIGH-VOLTAGE CHARGER COOLANT PUMP RADIATOR FAN MOTOR RELAY INTERIOR AR CONDITION NG EXPANSION VALVE ELECTR C MOTOR COOLING FAN MOTOR BATTERY AIR CONDITIONING EXPANSION VALVE (UNDER LEFT SIDE OF DASH) (LEFT END OF FRONT BUMPER) ( N BATTERY COMPT) (NEAR BASE OF LEFT "A" PLLAR) (LEFT SIDE OF DASH) (ON REFR GERANT LINE) (BEH ND REAR BUMPER) (BEHIND REAR BUMPER) (BEH ND REAR BUMPER) (RIGHT SDE OF DASH) (RIGHT SDE OF DASH) (RIGHT SDE OF DASH) Fig 2: Automatic A/C Circuit, W/ Electric Drive (2 of 2)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4549 · Applies to: 450, 451, 452, 454
M M M M M 358313 HOT IN ON OR START CAN-H CAN-L HOT AT ALL TIMES HOT AT ALL TIMES CAN H CAN L HOT AT ALL TIMES 7.5A 31 CAN L CAN H MSENS 30 TMOT 15A (+) (-) HOT N ON OR START 58D 10A 15 RWH DG +5V DGM DG SIG CAN L CAN H CAN L CAN H 31 25A 14 13 14 13 12 5 C2 40 C8 39 5 8 3 B A C3 11 C1 58 71 78 C2 1 2 80 12 47 C10 7 X26 6 A B 7 2 1 2 16 18 X85/10 4 2 1 C1 1 4 C9 33 3 2 1 5 6 1 2 1 5 2 3 6 X85 10 1 2 3 1 4 C1 1 3 2 4 6 5 8 9 10 7 11 2 1 3 5 4 C2 11 12 6 7 8 9 10 4 1 5 3 2 BRN BRN GRN/WHT GRN GRN WHT GRN RED BLU BRN RED/BLU RED BRN GRN GRN/WHT GRN BLK BLK/RED RED GRN BLK BLK/RED YEL YEL BRN BLK WHT (OR BLU/GRN) WHT VIO BRN VIO BRN/VIO VIO GRYBLU RED GRY RED/GRY BLU RED BLK BLK/GRY BLK/GRY BLK/GRY WHT/BLK BRN ORG PNK/YEL BRN/ORG ORG/BLU GRN GRN/YEL GRN/WHT PNK BLU PNK BLU BRN RED BLK RED YEL GRY WHT BRN GRY YEL GRN BLU GRN/WHT ORG/BLU PNK/YEL WHT/BLK GRN/WHT GRN BLU GRN/YEL BLK GRN GRY BLK YEL WHT GRY GRN/WHT YEL SAM CONTROL UNIT FUSE 14 FUSE 27 FUSE 20 INSTRUMENT CLUSTER ME-SFI (ME) CONTROL UNIT COMPUTER DATA L NES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM INTERIOR LIGHTS SYSTEM COMPUTER DATA L NES SYSTEM W9 W6 W43 W10 W7 W26 HEATER BLOWER RELAY CHARGE AIR FAN MOTOR RELAY FUSE 4 OUTSIDE TEMPERATURE DISPLAY TEMPERATURE SENSOR REFRIGERANT COMPRESSOR COOLANT TEMPERATURE WARNING LAMP CHARGE AR FAN MOTOR COOLANT FAN MOTOR BLOWER MOTOR REFRIGERANT PRESSURE SENSOR DEFROSTER SWITCH AIR CONDITIONING SWITCH REC RCULATED AR SWITCH INTERIOR TEMPERATURE SENSOR HEATING & AIR CONDIT ONING OPERATING UNIT COOLANT TEMPERATURE SENSOR BLOWER SWITCH AIR REC RCULATION FLAP ACTUATOR MOTOR EVAPORATOR TEMPERATURE SENSOR BLEND AIR FLAP ACTUATOR BLOWER MOTOR SERIES RESISTOR GROUP (UNDER LEFT SIDE OF DASH) (LEFT END OF FRONT BUMPER) (LEFT FRONT OF ENGINE) (NEAR BASE OF LEFT "A" PILLAR) (BEHIND REAR BUMPER) (BEHIND FRONT BUMPER) (FRONT OF VEHICLE) (LEFT SIDE OF DASH) (IN BATTERY COMPT) (ON REFRIGERANT LINE) (BEHIND REAR BUMPER) (RIGHT REAR OF LUGGAGE COMPT) (CENTER OF DASH) (REAR OF CYLINDER HEAD) ( N BATTERY COMPT) (R GHT SIDE OF DASH) (RIGHT SDE OF DASH) (RIGHT SDE OF DASH) Fig 3: Automatic A/C Circuit, W/O Electric Drive
ANTI-LOCK BRAKES >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4550 · Applies to: 450, 451, 452, 454
M 358665 HOT AT ALL TIMES ALL T MES HOT AT 25A 7.5A CAN L CAN H - + KI-30 KI-31 KI-15 K-LINE BRAKE SW 31 CAN L 15 CAN H 15 CAN H CAN L 31 HOT AT ALL TIMES 15A 10A OR START HOT N ON 40A ALL TIMES HOT AT HOT AT ALL TIMES 25A DF HR DF HL DF VR MDF VR DF VL MDF VL CAN H +BLS 31 30 HAS MDF HR 31 30 CAN L +BS BFL MDF HL 15 C1 X99/1 X99/1 2 1 X99/2 1 2 X1 1 2 R9 6 9 6 C3 C2 C1 2 1 2 1 5 4 3 2 1 8 1 2 3 4 1 2 3 4 1 4 2 3 C3 C3 2 C7 2 C1 5 2 2 1 1 2 1 2 1 2 1 2 1 1 3 2 5 6 7 4 8 10 9 12 13 14 11 15 17 16 19 20 21 18 22 23 24 26 27 28 25 29 30 31 33 35 34 32 (OR BLK/YEL) BRN RED/GRN BLK/GRN GRY RED GRN/WHT GRN BLK/RED GRY RED RED/GRN BRN BLK/GRN ORG BLK/RED BRN/BLK BLK/RED BLK/RED GRN GRN/WHT BLKRED BRN GRN BRN GRN/WHT BLK/RED BLK/RED BLK/RED BRN BLK BLKRED RED/YEL RED/YEL BLK/RED BLK/RED RED/GRN RED/PNK BRN BRN BRN/BLK BRN/WHT BLU/BLK NCA RED/BLK NCA RED/YEL BLU/YEL NCA NCA BLU/GRY NCA RED/GRY NCA BLU/GRN NCA NCA RED/GRN BLU BLK RED/YEL BLU GRY RED/GRY RED/GRN GRN/WHT BLK/RED BRN RED/GRN BRN/BLK RED/PNK BRN GRN BLK BLU/YEL BRN/WHT BLU GRN BLK/RED RED/BLK SAM CONTROL UNIT FUSE 44 FUSE 34 FUSE 18 FUSE 1 FUSE 11 FUSE 24 INSTRUMENT CLUSTER W6 W9 W14 W10 W10 W43 W7 BRAKE BOOSTER VACUUM PUMP ABS IND LAMP BRAKE FLUID & PARKING BRAKE WARNING IND BRAKE BOOSTER VACUUM PUMP CONTROL UNIT STEER NG ANGLE SENSOR YAW RATE, LATERAL & LONGITUDINAL ACCELERATION SENSOR STOP LAMP SWITCH ESP CONTROL UNIT PARKNG BRAKE INDICATOR SWITCH BRAKE FLUID INDICATOR SWITCH RIGHT REAR RPM SENSOR LEFT REAR RPM SENSOR LEFT FRONT RPM SENSOR RIGHT FRONT RPM SENSOR (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (NEAR BASE OF LEFT "A" PLLAR) (LEFT FLOOR PANEL) (IN BATTERY COMPT) (UNDER DRIVER S SEAT) (IN BATTERY COMPT) (ON BRAKE PEDAL ASSEMBLY) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (BEHIND FRONT BUMPER) (BEH ND REAR BUMPER) (AT RIGHT FRONT HUB ASSEMBLY) (AT LEFT REAR HUB ASSEMBLY) (AT RIGHT REAR HUB ASSEMBLY) (AT LEFT FRONT HUB ASSEMBLY) COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM EXTERIOR LIGHTS SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM SOUND SYSTEMS Fig 1: Anti-lock Brakes Circuit
ANTI-THEFT >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4551 · Applies to: 450, 451, 452, 454
M M M 358828 13 12 11 10 9 8 7 6 5 4 3 2 1 HOT AT ALL TIMES 20A HOT AT ALL TIMES 10A CAN L CAN H CLK GND U DATA ZV OPEN ZV CLOSE 1 C10 10 12 1 C2 6 X35/1 39 40 4 8 2 C9 5 2 36 C8 3 21 24 20 16 12 C9 X35/2 A4 A2 A3 A5 C E D B A A5 A3 A2 A4 C E D B A 1 3 18 4 19 C8 C10 PNK RED/WHT RED/WHT YEL YEL (OR BLU/RED) BLU/BLK VIO/GRN YEL/PNK PNK GRY/WHT VIO/WHT BRN/BLK RED/BLK BLKBLU BRN GRY/BLU VIO/GRN RED/WHT BLU BRN BRN GRN/WHT GRN GRY/YEL (OR BLU/RED) YEL YEL PNK PNK BLU/BLK YEL PNK GRY/WHT BRN/BLK RED/BLK VIO/WHT BLKBLU PNK PNK GRY/YEL YEL BLK WHT/GRN YEL WHT/GRN BRN PNK GRY/YEL WHT/GRN BRN YEL/BLK WHT/GRN YEL GRY/YEL PNK GRY/YEL PNK BRN YEL/WHT GRY/YEL PNK WHT/GRN YEL BLK SAM CONTROL UNIT FUSE 31 FUSE 12 HORNS SYSTEM COMPUTER DATA LINES SYSTEM EXTERIOR LIGHTS SYSTEM W9 W43 CHARGE AIR FAN MOTOR & HORN RELAY REAR END DOOR/TRUNK L D CL (ZV) RELAY CL (ZV) CLOSE RELAY CL (ZV) OPEN RELAY FUEL FILLER FLAP CL (ZV) MOTOR LEFT DOOR CL (ZV) MOTOR & LEFT DOOR ROTARY TUMBLER M CROSWITCH RIGHT DOOR CL (ZV) MOTOR & RIGHT DOOR ROTARY TUMBLER MICROSWITCH (UNDER LEFT SIDE OF DASH) (NEAR BASE OF LEFT "A" PILLAR) (BEH ND FRONT BUMPER) Fig 1: Anti-theft Circuit (1 of 2)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4552 · Applies to: 450, 451, 452, 454
M M M 358829 1 3 4 2 7 6 8 12 11 10 13 9 5 1 2 3 2 1 3 3 1 2 2 1 1 2 1 2 1 2 1 4 3 2 11 10 BLU/BLK BRN BRN BLU/BLK BLU/BLK BRN YEL/PNK BRN BRN VIO/GRN YEL RED/WHT RED/WHT YEL (OR BLU RED) BLU/BLK GRY/WHT VO WHT BRN/BLK RED/BLK BLK/BLU VO GRN YEL/PNK PNK BRN BRN VIO/GRN RED WHT BRN BRN RED WHT VIO/GRN YEL (OR BLU/RED) BRN YEL BRN BLU/RED BRN YEL PNK/YEL BRN GRY/WHT BRN BLK RED BLK VIO/WHT BLK/BLU PNK COCKPIT SWITCH GROUP W10 W10 W6 W6 W6 W6 W10 W6 W6 M CROWAVE SENSOR ALARM SIREN W/ INCL NATION SENSOR TRUNK LID OPENING ASSIST MOTOR 2 REAR END DOOR HANDLE SWITCH TRANSPONDER COIL TRUNK L D ROTARY TUMBLER MICROSWITCH TRUNK L D ROTARY TUMBLER MICROSWITCH TRUNK LID OPENING ASSIST MOTOR 1 INSIDE UNLOCK CL (ZV) SWITCH INSDE LOCK CL (ZV) SWITCH TRUNK LID OPENING ASSIST MOTOR (UNDER CENTER CONSOLE) (IN BATTERY COMPT) (IN BATTERY COMPT) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (UNDER ELECTRONIC SELECTOR LEVER) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (IN BATTERY COMPT) (BEH ND REAR BUMPER) (BEHIND REAR BUMPER) (W/ ATA (EDW) & SIREN) (W/ ATA (EDW) & SIREN) (COUPE) COUPE CONVERTIBLE COUPE CONVERTIBLE Fig 2: Anti-theft Circuit (2 of 2)
BODY CONTROL MODULES >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4553 · Applies to: 450, 451, 452, 454
358864 HOT AT ALL TIMES START RUN ACC LOCK 12 8 R6 R5 A R8 R7 8 R1 7 6 5 4 2 1 3 C7 3 1 2 C10 8 7 12 1 2 1 2 C4 7 4 6 5 C6 1 3 4 2 7 8 6 5 10 11 9 C5 6 5 4 1 3 2 C1 1 3 2 C2 3 1 2 7 5 6 4 10 8 9 C3 11 R9 RED WHT RED BRN (OR RED/GRN) BLK RED (OR RED/GRY) (OR RED/YEL) RED RED RED/BLK RED WHT RED BLK (OR BLU/RED) YEL RED BLK GRY/YEL GRY/YEL BLK/GRN BLK/BLU GRY/YEL PNK PNK BRN BLU WHT YEL RED RED/YEL RED GRN RED WHT RED BLU RED BLK RED BLU BRN GRY RED BLU BLU/RED RED BLU BLU VIO RED WHT RED BLU BRN BLK/BLU GRYGRN GRN/BLU BRN GRY RED/YEL RED GRY RED BLK YEL BLK/BLU BLK/YEL RED PNK RED GRN RED GRY RED WHT VIO/WHT RED VIO BLK/RED GRYVIO GRY/YEL WHT/RED RED/YEL RED BLK/YEL BLK/GRY BLK/GRN WHT/BLK RED GRN IGNITION/ STARTER SWITCH BATTERY SAM CONTROL UNIT (NEAR BASE OF LEFT "A" PILLAR) (NEAR BASE OF LEFT "A" PILLAR) (UNDER LEFT SIDE OF DASH) ENGINE CONTROLS SYSTEM ENGINE CONTROLS SYSTEM DEFOGGER SYSTEM SEATS & ANTI-LOCK BRAKES SYSTEMS ENGINE CONTROLS SYSTEM ENGINE CONTROLS & EXTERIOR L GHTS SYSTEMS AIR CONDITIONING SYSTEM ENGINE CONTROLS SYSTEM POWER WINDOWS SYSTEM ANTI-LOCK BRAKES SYSTEM STARTING/CHARGING & COOLING FANS SYSTEMS SOUND SYSTEMS INSTRUMENT CLUSTER, WIPER/WASHER, AIR CONDITIONING, EXTERIOR LIGHTS, COMPUTER DATA LINES, DEFOGGER, WARNING & TRANSMISSIONS SYSTEMS SEATS & EXTERIOR LIGHTS SYSTEMS ENGINE CONTROLS SYSTEM DEFOGGER SYSTEM ENG NE CONTROLS SYSTEM STARTING/ CHARG NG SYSTEM POWER TOPS SYSTEM TRANSMISSIONS SYSTEM POWER TOPS SYSTEM WIPER/WASHER SYSTEM INSTRUMENT CLUSTER, ELECTRONIC POWER STEERING, SEATS, SUPPLEMENTAL RESTRAINT & ANTI-LOCK BRAKES SYSTEMS ENGINE CONTROLS, COMPUTER DATA LINES, WARNING & TRANSMISSIONS SYSTEMS WIPER/WASHER, MIRRORS & POWER TOPS AIR CONDITIONING, SOUND & SEATS SYSTEMS & TRANSMISSIONS SYSTEM POWER DISTRIBUTION SYSTEM HEADL GHTS SYSTEM HEADL GHTS SYSTEM EXTERIOR LIGHTS & ANTI-LOCK BRAKES SYSTEM SH FT INTERLOCK SYSTEM HEADL GHTS SYSTEM HEADL GHTS SYSTEM ENGINE CONTROLS SYSTEM TRANSMISSIONS SYSTEM WIPER/WASHER SYSTEM HEADL GHTS SYSTEM HEADL GHTS SYSTEM WIPER/WASHER SYSTEM WIPER/WASHER SYSTEM EXTERIOR LIGHTS SYSTEM EXTERIOR LIGHTS SYSTEM EXTERIOR LIGHTS SYSTEM POWER TOPS & INTERIOR LIGHTS SYSTEMS ENG NE CONTROLS SYSTEM ENG NE CONTROLS & TRANSMISSIONS SYSTEMS ENGINE CONTROLS SYSTEM STARTING/CHARGING SYSTEM ENGINE CONTROLS SYSTEM ELECTRONIC POWER STEERING SYSTEM ANTI-LOCK BRAKES SYSTEM STARTING/CHARGING SYSTEM AIR CONDITIONING SYSTEM COOLING FANS SYSTEM DOOR LOCKS & ANTI-THEFT SYSTEMS DOOR LOCKS & ANTI-THEFT SYSTEMS DOOR LOCKS & ANTI-THEFT SYSTEMS HORNS SYSTEM COOLING FANS SYSTEM DOOR LOCKS, ANTI-THEFT & TRUNK, TAILGATE, FUEL DOORS SYSTEMS W9 W9 Fig 1: Body Control Modules Circuit (1 of 2)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4554 · Applies to: 450, 451, 452, 454
358865 1 6 7 C9 26 25 28 30 29 27 31 32 33 34 35 37 36 39 40 38 30 31 32 33 34 35 36 38 39 40 37 1 2 4 3 6 5 8 9 10 11 15 14 13 12 16 17 18 20 21 22 19 23 24 23 22 21 19 17 25 26 27 12 8 11 16 10 9 28 24 18 4 5 15 14 13 29 3 2 C8 20 7 RED VIO YEL GRY PNKBLK RED BLK BRN BLK BRN/WHT GRYBLK YEL/BLU BRN GRN PNK/BLU GRY/WHT VIO/WHT YEL/BLU YEL GRN/BLU GRN/RED RED GRN WHT BLK VO GRN YEL/RED BLK/BRN WHT/RED PNK/YEL YEL BLK VIO/BLU GRN/WHT GRN BLK/GRY GRN/YEL BRN/BLU YEL/GRY BLK/WHT GRY/WHT YEL BLKGRN PNK BLK/BLU VIO/BLU BLU/YEL VIO/WHT VO GRN BRN GRY/BLU BLU/GRY WHT GRN YEL GRN/WHT GRN GRY/BRN BLU BLK SAM CONTROL UNIT (IN BATTERY COMPT) (UNDER LEFT SIDE OF DASH) TRUNK, TALGATE, FUEL DOORS & DOOR LOCKS & ANTI-THEFT SYSTEMS WIPER/WASHER SYSTEM DOOR LOCKS & ANTI-THEFT SYSTEMS WIPER/WASHER SYSTEM EXTERIOR LIGHTS SYSTEM DOOR LOCKS & ANTI-THEFT SYSTEMS COMPUTER DATA L NES SYSTEM COMPUTER DATA L NES SYSTEM WIPER/WASHER SYSTEM DOOR LOCKS & ANTI-THEFT SYSTEMS DOOR LOCKS & ANTI-THEFT SYSTEMS DEFOGGER SYSTEM WARNING SYSTEMS INTERIOR LIGHTS SYSTEM POWER TOPS SYSTEM EXTERIOR LIGHTS SYSTEM POWER TOPS SYSTEM POWER TOPS SYSTEM POWER TOPS SYSTEM DOOR LOCKS, ANTI-THEFT & TRUNK, TAILGATE, FUEL DOORS SYSTEMS STARTING/CHARGING SYSTEM COMPUTER DATA L NES SYSTEM COMPUTER DATA L NES SYSTEM EXTERIOR LIGHTS SYSTEM DOOR LOCKS, ANTI-THEFT & TRUNK, TAILGATE, FUEL DOORS SYSTEMS DOOR LOCKS & ANTI-THEFT SYSTEMS INTERIOR LIGHTS SYSTEM POWER TOPS SYSTEM EXTERIOR LIGHTS SYSTEM EXTERIOR LIGHTS SYSTEM DOOR LOCKS & ANTI-THEFT SYSTEMS HEADLIGHTS SYSTEM WIPER WASHER & NSTRUMENT CLUSTER SYSTEMS DOOR LOCKS & ANTI-THEFT SYSTEMS WIPER/WASHER SYSTEM HEADLIGHTS SYSTEM DOOR LOCKS & ANTI-THEFT SYSTEMS DOOR LOCKS & ANTI-THEFT SYSTEMS INTERIOR LIGHTS SYSTEM DOOR LOCKS & ANTI-THEFT SYSTEMS INTERIOR LIGHTS SYSTEM INTERIOR LIGHTS SYSTEM HORNS SYSTEM DEFOGGER SYSTEM EXTERIOR LIGHTS SYSTEM EXTERIOR LIGHTS SYSTEM WIPER/WASHER SYSTEM EXTERIOR LIGHTS SYSTEM EXTERIOR LIGHTS SYSTEM WIPER/WASHER SYSTEM W10 Fig 2: Body Control Modules Circuit (2 of 2)
COMPUTER DATA LINES >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4555 · Applies to: 450, 451, 452, 454
1 1 1 1 1 358843 CAN L CAN H CAN H CAN L CAN L CAN H CAN H CAN L CAN H CAN L BAT CAN L SH ELD BAT CAN H BAT CAN H BAT CAN L SHIELD K-LINE CAN H CAN L CAN H CAN L CAN H CAN L ED CAN L ED CAN H SH ELD TX RX SEL 1 LOG CAN L LOG CAN H ALL TIMES HOT AT 7.5A 10A GND SH ELD BOOT W D CAN L CAN H CAN L CAN H CAN H CAN H CAN L CAN L CAN H CAN L CAN H CAN L CAN L CAN H CAN L CAN H SEL 2 SHIELD BAT CAN L BAT CAN H CAN H CAN L PCV PCRX SHIELD PCTX CAN H SHIELD CAN L LOG CAN H CAN L CAN H LOG CAN L OR START HOT N ON 3 X55/4 2 13 14 14 35 78 71 N116/1X1 3 4 17 8 8 3 12 C1 26 25 56 C1 2 1 2 6 8 5 9 2 1 18 10 9 4 3 11 12 C2 1 C3 B5 B6 B4 X99/3 20 13 C1 19 16 C3 9 5 C1 6 39 40 15 C8 14 2 3 C1 3 2 9 8 A 7 8 3 3 A8 B8 B6 C5 C6 A6 X99/1 31 8 20 22 10 2 4 3 1 5 7 6 9 11 10 8 12 14 13 16 15 A B D C F G H E A7 C7 C8 C1 1 2 C3 A4 B4 X99/4 I J K L A B C E G F D 62 85 C1 30 52 61 I H J L K 54 29 28 C2 27 6 5 X99/4 GRN WHT GRN GRN GRN BLK GRN GRN/BLK GRN/WHT GRN GRN/WHT GRN BRN/RED BRN BRN/RED BRN ORG NCA NCA GRN/WHT GRN NCA NCA GRN GRN/WHT GRN/WHT GRN NCA NCA NCA NCA GRN GRN/WHT NCA NCA GRN/WHT GRN NCA ORG GRN GRN/WHT GRN GRN GRN GRN/WHT GRN/WHT GRN/WHT NCA GRN GRN/WHT WHT GRN GRN GRN GRN BLU GRN/WHT RED/WHT RED/WHT NCA NCA GRN NCA GRN/WHT NCA ORG/BLK GRY/BLK GRN GRN WHT GRN GRN WHT GRN GRN GRN/WHT GRN/WHT GRN/WHT GRN GRN GRN/WHT GRN/WHT GRN GRN GRN/WHT BLK/YEL BLK/YEL BLK GRN GRN/WHT RED NCA BRN BLK GRN/WHT BRN RED GRN GRN GRN GRN/WHT RED WHT BLK/YEL GRN/WHT GRN GRN GRN BLU WHT/GRN GRN/WHT NCA GRN NCA GRN NCA WHT GRN GRN/ NCA NCA GRN NCA GRN/WHT GRN/WHT GRN GRN/WHT NCA NCA GRN GRN GRN/WHT GRN/WHT ORG/BLK GRY/BLK GRN GRN GRN/WHT ORG/BLK NCA NCA ORG/BLK GRN GRN/WHT NCA GRN/WHT BLU GRN NCA GRN GRN/WHT GRN/WHT NCA ESP CONTROL UNIT SAM CONTROL UNIT FUSE 19 FUSE 12 STEERING ANGLE SENSOR BATTERY MANAGEMENT SYSTEM CONTROL UNIT INSTRUMENT CLUSTER WEGHT SENSING SYSTEM (WSS) CONTROL UNIT BRAKE BOOSTER VACUUM PUMP CONTROL UNIT STEERING ASSIST CONTROL UNIT ELECTRON C SELECTOR LEVER MODULE CONTROL UNIT ELECTR C MOTOR CONTROL UNIT EVCM ELECTRIC VEHICLE CONTROL UNIT HIGH-VOLTAGE AC/DC BATTERY CHARGER CONTROL UNIT SAM CONTROL UNIT REFRIGERANT COMPRESSOR CONTROL UNIT (EAC) RESTRAINTS SYSTEMS CONTROL UNIT ME-SFI (ME) CONTROL UNIT HEATING & AIR CONDITIONING OPERAT NG UNIT AUTOMATED MANUAL TRANSMISSION CONTROL UNIT TURN RATE & LATERAL ACCELERATION SENSOR SMART BATTERY CHARGER CONTROL UNIT DATA LINK CONNECTOR EVCM DATA LINK CONNECTOR (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (UNDER LEFT SIDE OF DASH) (IN BATTERY COMPT) (LEFT SIDE OF DASH) (BEH ND NSTRUMENT CLUSTER) (UNDER CENTER CONSOLE) (LEFT SIDE OF DASH) (UNDER LEFT SIDE OF DASH) (RIGHT REAR OF LUGGAGE COMPT) (CENTER OF DASH) (CENTER OF DASH) (UNDER DRIVER'S SEAT) W26 W/ POWER STEERING Fig 1: Computer Data Lines Circuit, W/ Electric Drive
CAN H¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4556 · Applies to: 450, 451, 452, 454
358842 CAN H CAN L CAN H CAN L CAN H CAN L CAN H CAN L CAN H CAN L CAN H CAN L CAN H CAN L CAN L CAN H CAN L CAN H CAN L CAN H CAN H CAN L ALL T MES HOT AT OR START HOT IN ON 10A 7.5A CAN L CAN H CAN H CAN L CAN L CAN H CAN H CAN L CAN L CAN H 1 2 6 9 8 5 4 3 17 8 3 2 X55/4 16 9 C3 40 15 14 39 C8 C1 78 71 3 2 9 8 C2 1 3 C3 1 2 4 3 6 8 7 5 9 11 10 13 15 14 12 16 8 7 A 3 4 13 14 R 3 2 35 14 GRN GRN/WHT GRN GRN/WHT GRN/WHT GRN GRN BRN BRN/RED GRN/WHT BRN BRN/RED GRN/WHT GRN GRN GRN/WHT GRN GRN GRN/WHT GRN/WHT GRN GRN/WHT GRN GRN GRN/WHT GRN/WHT RED/WHT RED WHT BLK/YEL BLK/YEL BRN BRN BLK/YEL GRN/WHT GRN RED/WHT GRN/WHT GRN GRN/WHT GRN GRN/WHT GRN GRN GRN/WHT GRN GRN/WHT GRN GRN/WHT SAM CONTROL UNIT FUSE 19 FUSE 12 STEERING ANGLE SENSOR INSTRUMENT CLUSTER WEGHT SENSING SYSTEM (WSS) CONTROL UNIT AUTOMATED MANUAL TRANSMISSION CONTROL UNIT STEERING ASSIST CONTROL UNIT TURN RATE & LATERAL ACCELERATION SENSOR ESP CONTROL UNIT SAM CONTROL UNIT TPM (RDK) CONTROL UNIT RESTRAINTS SYSTEMS CONTROL UNIT HEATING & AIR CONDITIONING OPERAT NG UNIT ME-SFI (ME) CONTROL UNIT DATA LINK CONNECTOR (UNDER LEFT SIDE OF DASH) ( N BATTERY COMPT) (LEFT SIDE OF DASH) (UNDER DRIVER S SEAT) (BEHIND NSTRUMENT CLUSTER) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (UNDER LEFT SIDE OF DASH) (LEFT SIDE OF DASH) (RIGHT REAR OF LUGGAGE COMPT) (CENTER OF DASH) (CENTER OF DASH) W/ POWER STEER NG (W/ POWER STEERING) (IF EQUIPPED) W26 Fig 2: Computer Data Lines Circuit, W/O Electric Drive
COOLING FAN >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4557 · Applies to: 450, 451, 452, 454
358664 CAN L IGN OUT6 HOT IN ON OR START 7.5A GND HOT AT ALL T MES 15A COOL FAN2 COOL FAN1 MAIN RELAY SHIELD LOG CAN L LOG CAN H VBATT VBATT COOL FAN2 PUMP HOT W/ MAIN RELAY ENERGIZED 15A CAN H 31 CAN H CAN L (+) (-) 15 CAN L CAN H 31 8 15 C3 3 3 C2 7 3 R6 1 2 20 3 34 29 30 C2 52 C1 26 2 C5 11 X99/3 B8 B7 X99/3 C2 1 4 3 C1 A8 1 2 2 6 8 4 5 2 6 9 1 2 16 18 C1 5 8 9 7 GRN RED/GRN WHT/GRN YEL BLK/YEL BRN BRN BLU BRN/WHT RED/WHT RED/WHT RED/WHT BLK/YEL BLU BRN/WHT GRN/WHT GRN NCA WHT/BRN BLU/GRN WHT/BRN RED/YEL BRN BRN RED/GRN BRN RED/YEL WHT/BRN BRN YEL BRN RED/GRN YEL RED/GRN BLU GRN GRN WHT BRN GRN WHT GRN VIO BRN VIO BRN/VIO VIO WHT/GRN GRN BRN GRN/WHT SAM CONTROL UNIT AUTOMATED MANUAL TRANSMISSION RELAY MAIN RELAY FUSE 10 FUSE 19 FUSE 41 INSTRUMENT CLUSTER HEATING & AIR CONDIT ONING OPERATING UNIT EVCM ELECTRIC VEHICLE CONTROL UNIT COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM W9 W10 W7 W7 W7 OUTSDE TEMPERATURE DISPLAY TEMPERATURE SENSOR COOLANT TEMPERATURE WARNING LAMP ELECTRIC DRIVE HIGH-VOLTAGE CHARGER COOLANT PUMP RADIATOR FAN MOTOR RELAY ELECTRIC MOTOR COOLING FAN MOTOR (UNDER LEFT SDE OF DASH) (LEFT END OF FRONT BUMPER) (NEAR BASE OF LEFT "A" PILLAR) ( N BATTERY COMPT) (CENTER OF DASH) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) Fig 1: Cooling Fan Circuit, W/ Electric Drive
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4558 · Applies to: 450, 451, 452, 454
M M 358316 (+) (-) 31 CAN-H CAN-L HOT AT ALL TIMES CAN H CAN L HOT AT ALL TIMES HOT AT ALL TIMES 7.5A 31 CAN L CAN H MSENS 30 TMOT 15A HOT IN ON OR START 10A 15 CAN L CAN H 31 1 2 16 18 5 C2 40 C8 39 5 8 3 B A C10 C3 11 C1 58 71 78 C2 1 2 80 12 47 7 X26 6 A B 4 C1 5 8 9 7 VIO BRN/VIO BRN/VIO VIO BRN GRN/WHT GRN GRN/WHT GRN RED/BLU BRN RED/BLU RED BRN GRN GRN/WHT GRN/BLK BLK/RED RED GRN/BLK BLK/RED YEL YEL BRN BLK BLK/GRY BLK/GRY BLK/GRY GRN BRN GRN/WHT SAM CONTROL UNIT FUSE 14 FUSE 20 FUSE 27 INSTRUMENT CLUSTER ME-SFI (ME) CONTROL UNIT HEATING & AIR CONDITIONING OPERATING UNIT COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM W9 W43 W7 W6 W10 CHARGE AIR FAN MOTOR RELAY OUTSIDE TEMPERATURE DISPLAY TEMPERATURE SENSOR COOLANT TEMPERATURE WARNING LAMP COOLANT FAN MOTOR CHARGE AIR FAN MOTOR COOLANT TEMPERATURE SENSOR (UNDER LEFT SIDE OF DASH) (LEFT END OF FRONT BUMPER) (NEAR BASE OF LEFT "A" PILLAR) (BEHIND FRONT BUMPER) (FRONT OF VEHICLE) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (RIGHT REAR OF LUGGAGE COMPT) (IN BATTERY COMPT) (CENTER OF DASH) (REAR OF CYLINDER HEAD) Fig 2: Cooling Fan Circuit, W/O Electric Drive
CRUISE CONTROL >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4559 · Applies to: 450, 451, 452, 454
M 358666 HOT AT ALL TIMES 31 CC 15A +BLS +BS CAN H CAN L GND (SAL) SAL 58D CAN C-H CAN C-L HOT AT ALL TIMES 7.5A 30 CAN H CAN L PWG2 M SENS M SENS 5V TPSMAN TPSSUB + 5V PWG1 - GND 5 10 C A 4 3 8 C1 58 13 30 14 35 3 1 4 2 12 15 7 76 77 61 B C 6 9 6 5 4 3 3 4 9 8 11 C3 80 6 4 2 3 1 6 5 78 71 56 74 63 75 60 39 27 10 26 40 4 2 3 1 1 C2 BLU/PNK BRN/GRN BRN BRN/GRN BLU/PNK BLU/WHT BRN/GRN BLU WHT BRN/GRN GRYBLU RED/YEL BLK BLK/RED GRN/WHT GRN RED/YEL BLK/RED BLKRED BRN BLK BRN BRN/GRN BLU/PNK GRY/BLU BRN GRN BLU/PNK BLU/BLK BRN/GRN BLU/WHT GRN/WHT GRN BLK GRY/BLU BLU BLK BLU/WHT BRN GRN GRYBLU BLU/BLK GRY/BLU BLU/BLK RED RED VIO/YEL BRN/YEL GRN BLU/BRN BLU/BLK VIO GRN BRN/WHT GRN GRN WHT BRN/YEL VIO/GRN BRN/WHT VIO/YEL BLU/BRN BLU/BLK YEL BLU/WHT VIO GRN YEL/BLK YEL VIO YEL/BLK BLU/WHT SAM CONTROL UNIT FUSE 24 FUSE 27 FANFARE HORNS & AIR BAG CLOCK SPRING CONTACT INSTRUMENT CLUSTER ESP CONTROL UNIT ME-SFI (ME) CONTROL UNIT W110 W7 W10 (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) ( N BATTERY COMPT) (RIGHT REAR OF LUGGAGE COMPT) (ON BRAKE PEDAL ASSEMBLY) (ON ACCELERATOR PEDAL ASSEMBLY) (ON INTAKE MANIFOLD) NSTRUMENT CLUSTER SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM EXTERIOR LIGHTS SYSTEM LEFT & RIGHT CRUISE CONTROL SWITCH STEERING WHEEL GEAR SHIFTER LEFT CRUISE CONTROL SWITCH RIGHT CRUISE CONTROL SWITCH PLUS MINUS STOP LAMP SWITCH THROTTLE VALVE ACTUATOR ACCELERATOR PEDAL SENSOR (IF EQUIPPED) Fig 1: Cruise Control Circuit
DEFOGGERS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4560 · Applies to: 450, 451, 452, 454
358848 ALL TIMES HOT AT 10A 7.5A HOT IN RUN OR START R1 1 2 C2 C8 21 1 4 6 8 X35/2 C1 2 2 1 C1 X35/1 NCA NCA NCA NCA BRN/WHT RED/WHT RED/WHT BRN/WHT BLK/GRN BLK/GRN BLK/BLU BRN BLK/BLU BLK/BLU BRN BLK/BLU BRN BLK/BLU BRN BLK/BLU SAM CONTROL UNIT FUSE 12 FUSE 36 LEFT ELECTRICALLY ADJUSTABLE & HEATED EXTERIOR MIRROR RIGHT ELECTRICALLY ADJUSTABLE & HEATED EXTERIOR MIRROR W43 W43 (UNDER LEFT SIDE OF DASH) (IN SAM CONTROL UNIT) (BEHIND FRONT BUMPER) (BEHIND FRONT BUMPER) MIRROR HEATER RELAY Fig 1: Heated Mirrors Circuit
CAN-H¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4561 · Applies to: 450, 451, 452, 454
358847 31 RWH CAN-H CAN-L 31 RWH HOT AT ALL TIMES ALL TIMES HOT AT 40A CAN H CAN L X23/7-C2 X18/19-C2 6 7 C1 11 C2 C8 C9 39 40 1 2 4 33 4 1 2 3 BLK/BLU (OR BLK) BLK/BLU BLK/BLU BRN BRN GRN GRN/WHT BRN (OR BLK) BLK/BLU WHT/BLK BRN GRN WHT/BLK GRN/WHT SAM CONTROL UNIT FUSE 28 HEATING & AIR CONDITIONING OPERATING UNIT HEATED REAR WINDOW RELAY HEATED REAR WINDOW SWITCH HEATED REAR WINDOW (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (IN BATTERY COMPT) (CENTER OF DASH) (CONVERTIBLE) (COUPE) COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM W12 W6 W10 Fig 2: Rear Defogger Circuit
ELECTRONIC POWER STEERING >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4562 · Applies to: 450, 451, 452, 454
358852 CAN-L CAN-H M + M - TS EM VM TM HOT IN 10A ON OR START 15 CAN H CAN L 30 31 30A HOT AT ALL TIMES 1 2 2 C3 16 11 13 15 14 12 6 7 8 10 9 C7 1 4 3 2 1 C1 2 1 C3 C2 1 3 5 4 2 2 1 8 5 BRN BRN BRN RED BLU BLK RED RED BLU BRN BRN BRN GRN NCA NCA NCA NCA RED BLK/ RED BLK/ BLK/RED GRN/WHT GRN WHT RED/ GRY BRN YEL GRN RED/WHT BRN YEL GRY GRN GRN/WHT SAM CONTROL UNIT FUSE 18 FUSE 35 INSTRUMENT CLUSTER W30/2 W43 W43 POWER STEERING MOTOR ELECTRIC STEERING INDICATOR LAMP STEERING ASSIST CONTROL UNIT POWER STEERING TORQUE SENSOR (UNDER LEFT SIDE OF DASH) (UNDER DASH ASSEMBLY) (BEHIND FRONT BUMPER) (BEHIND INSTRUMENT CLUSTER) (BEHIND FRONT BUMPER) (ON STEERING RACK) COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM Fig 1: Electronic Power Steering Circuit
ENGINE PERFORMANCE >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4563 · Applies to: 450, 451, 452, 454
358307 25 21 14 13 12 11 10 4 7.5A 7.5A PWG 1 10A GST MAN RLY COOL FAN 1 5 3 2 1 27 26 24 23 22 20 19 18 17 16 15 9 8 7 6 PUMP HOT AT ALL TIMES 7.5A HOT IN ON OR START 7.5A 15A RELAY ENERGIZED HOT W/ MAIN PTC EN2 PTC EN1 PTC1 PWM PTC1 FB EAC CNTRL PTC3 PWM STATUS IGN 1 SG 5VOL ESS COOL CHARGE LED CAB TX OFF BATT TX OFF COOL FAN 2 IGN 1 A3 X99/3 R8 2 C1 X99/3 B7 C2 X99/3 B8 C2 1 3 C2 7 11 R5 C3 3 C5 2 1 5 4 3 1 4 3 2 1 2 4 1 3 1 2 2 1 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 C1 2 3 1 4 7 6 5 9 10 8 14 13 12 16 17 15 11 21 20 19 23 22 18 RED/YEL NCA GRY/VIO RED/WHT RED/WHT RED/WHT RED/WHT RED/GRY NCA NCA NCA NCA NCA NCA NCA RED/GRY RED BRN RED BRN RED/YEL WHT/BRN RED WHT RED/WHT RED GRN BRN/WHT BRN/WHT BLU BRN/WHT BLU BRN BRN NCA RED/GRY GRN NCA NCA NCA GRY RED BRN RED BRN GRY/YEL RED/GRY YEL/BLK BLU/BLK BLK/WHT BLU BLU BRN BRN/GRY VIO/GRN VO GRN BRN BRN WHT BRN WHT/BRN RED/YEL RED BRN BLK/YEL (OR BRN/WHT) RED/GRY NCA NCA NCA NCA BLU/BRN GRY/VIO GRY/YEL RED/GRY YEL/BLK BLU/BLK GRY BLK/WHT BRN/GRY RED/BRN RED/YEL BLU GRN BLU BLU RED/WHT GRN/BLK GRN/BLK BRN/YEL RED/WHT BRN/YEL BLK/YEL BLU/GRN SAM CONTROL UNIT AUTOMATED MANUAL TRANSMISSION REALY MAN RELAY FUSE 40 FUSE 9 FUSE 43 FUSE 10 FUSE 12 FUSE 19 RIGHT ELECTRIC DRIVE CONTROL UNIT EVCM ELECTRIC VEHICLE CONTROL UNIT ELECTRIC DRIVE & ELECTRIC DRIVE CHARGER COOLANT PUMP INTERIOR AIR CONDITIONING EXPANSION VALVE BATTERY AIR CONDIT ONING EXPANSION VALVE CHARGER FEED-IN SOCKET CHARGER FEED SOCKET INDICATOR LED HIGH-VOLTAGE BATTERY HEATER (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (IN BATTERY COMPT) W7 W10 AR CONDITIONING & COOLING FANS SYSTEMS Fig 1: Engine Performance Circuit, W/ Electric Drive (1 of 4)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4564 · Applies to: 450, 451, 452, 454
M 358308 27 22 19 21 14 13 12 11 10 4 THERM PTC EN2 PTC EN1 PWM PTC BB1 IGN 5 EACEB EACEN GND HVIL IN HVIL OUT PILOT SIG M LIVE M NEUTRAL M GND 23 21 20 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 9 26 25 24 23 22 20 19 18 17 16 15 8 7 6 5 3 2 1 GND +12V IGN3 CAN L CAN H CAN L CAN H PCV PCRX PCTX M SENSOR GND 6 A1 X99/3 C1 C2 6 4 3 5 1 2 2 N116/1X2 1 X99/3 X99/4 B3 X99/4 A1 C2 B2 A2 A3 5 X99/3 A4 A5 6 4 5 8 2 1 3 12 7 1 2 3 4 5 6 7 4 2 1 6 3 11 10 9 8 4 3 2 1 C1 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 72 71 70 69 68 66 67 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 RED/WHT RED WHT RED WHT RED/WHT BRN BRN NCA NCA NCA NCA RED/GRY NCA NCA NCA NCA RED GRY RED BRN RED BRN ORG ORG RED/WHT RED/GRN ORG ORG WHT/BRN BRN/YEL VIO/YEL BRN/GRY BLU NCA WHT/BLU NCA NCA NCA GRY/YEL VIO/WHT WHT/BLK BLK/WHT WHT/RED RED/BRN RED/BRN RED/BRN RED BRN RED BRN RED GRY GRY/YEL GRY BLK/WHT RED GRY NCA YEL/BLK NCA NCA BLU/BLK NCA BLU BRN GRY BLU/BRN VIO/GRN GRN ORG ORG ORG/BLK GRY/YEL WHT/BLU GRN GRN/WHT RED/GRN RED/GRN RED/GRY WHT/RED WHT BRN VIO/WHT ORG ORG BRN GRN GRN/WHT GRN/WHT GRN BRN/YEL VIO/YEL BRN/WHT BRN WHT VIO GRN BLU/BRN GRN RED GRN RED/GRY YEL BLK BLU BLK GRY WHT BLK RED/WHT GRY/YEL RED/BRN BRN RIGHT ELECTRIC DRIVE CONTROL MODULE EVCM ELECTRIC VEHICLE CONTROL UNIT SMART BATTERY CHARGER CONTROL UNIT HIGH-VOLTAGE DISTRIBUTOR CONTROL UNIT BATTERY COOL NG SYSTEM COOLANT PUMP REFR GERANT COMPRESSOR CONTROL UNIT H GH-VOLTAGE BATTERY HEATER BOOSTER RELAY ACCELERATOR PEDAL SENSOR (LEFT FRONT OF ENGINE) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (ON ACCELERATOR PEDAL ASSEMBLY) W7 W7 COMPUTER DATA LINES SYSTEM COMPUTER DATA L NES SYSTEM COMPUTER DATA LINES SYSTEM Fig 2: Engine Performance Circuit, W/ Electric Drive (2 of 4)
-300V¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4565 · Applies to: 450, 451, 452, 454
358309 22 19 -300V +300V - + CAN L PUMP CAN H 23 14 10 21 20 18 17 16 15 13 12 11 10 9 8 7 6 5 4 3 2 1 9 8 7 6 5 4 3 2 1 HVIL IN PILOT SIG M LIVE M NEUATRAL M GND MVP SHIELD BAT BAT HEATER GND GND GND IGN4 CONT NO IGN2 +12V PWM +12V PUMP GND +12V GND EMERG LINE BAT CAN L BAT CAN H SHIELD SIG GND HVL OUT MVP HV 5 1 2 3 4 HV 1 3 4 2 C1 X99/3 A2 35 34 33 32 B1 X99/3 C5 C4 3 1 C1 14 13 C2 6 3 4 1 2 10 11 12 7 8 9 5 4 5 6 1 2 3 3 2 1 1 2 3 2 1 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 WHT VIO/ ORG ORG ORG ORG ORG ORG NCA NCA RED/WHT RED/BLU NCA NCA RED/ WHT BRN WHT/RED BRN WHT BLU VIO/GRN WHT/YEL VIO/GRN RED/WHT WHT/BLK GRY/YEL WHT/BLU VIO/BLU BRN WHT BRN/YEL VIO/YEL RED/GRN ORG ORG RED WHT BRN RED/BRN RED/BRN BLK/WHT WHT BLK GRY/YEL BLU NCA NCA NCA NCA WHT BLU WHT RED BRN/GRY BRN/YEL VIO/YEL GRN BRN BRN BRN RED BLK WHT/BRN VIO/WHT BRN NCA NCA NCA NCA VIO/GRN VIO/GRN RED/GRN RED/BRN RED/BRN BLK/WHT BRN/GRY WHT/YEL VIO/GRN RED/BRN BRN GRN/WHT GRN/WHT GRN NCA NCA BRN BRN VIO/WHT RED/BLK RED/BLK VIO/WHT BRN VIO/BLU VIO/BLU RED/WHT BRN VIO/BLU BRN/WHT BLU HIGH-VOLTAGE AC/DC BATTERY CHARGER CONTROL UNIT HIGH-VOLTAGE AC/DC BATTERY CHARGER CONTROL UNIT BATTERY MANAGEMENT SYSTEM CONTROL UNIT HIGH VOLTAGE BATTERY LOGIC HIGH-VOLTAGE BATTERY ENERGY FLOW HIGH-VOLTAGE BATTERY SOS CHARGER LEVEL INDICATOR PARK PAWL SWITCH SERVCE SWITCH (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (NEAR BASE OF LEFT "A" PILLAR) (NEAR BASE OF LEFT "A" PILLAR) (SIDE OF TRANSMISSION) W6 W6 W6 W7 W9 W9 COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM LINES SYSTEM COMPUTER DATA AIR CONDITION NG SYSTEM Fig 3: Engine Performance Circuit, W/ Electric Drive (3 of 4)
IGN OUT2¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4566 · Applies to: 450, 451, 452, 454
M 358310 IGN OUT2 +300V -300V +12V -12V GDDL 3 HVIL IN GND GND 10 9 8 7 6 5 4 3 2 1 GN OUT3 GDEN OUT GN3 HVIL OUT +12V SHIELD GND BOOT WD SEL 2 TX LOG CAN L IGN 1 IGN 1 GDDL 1 RX SEL 1 ED CAN H LOG CAN H SH ELD SH ELD SH ELD VBATT 15A HOT AT ALL TIMES HOT AT ALL TIMES 7 5A SH ELD GND M SENSOR LIN ED CAN L PWG2 CAN H ED CAN H CAN L BAT CAN H BAT CAN L LOG CAN L LOG CAN H GN4 EACFB GN OUT6 GN OUT5 GN OUT HVIL_IN HVIL OUT GND GND GND VBATT GND C3 X99/3 HV 2 1 HV 2 1 3 4 C1 R6 R7 C2 54 56 55 51 53 52 57 47 49 48 43 46 45 44 40 42 41 36 38 37 39 32 34 35 33 29 30 31 25 27 26 22 23 24 28 18 19 20 16 15 17 13 14 10 9 11 12 5 6 7 8 3 2 4 1 21 50 23 22 X99/3 B3 X99/3 B3 A5 X99/4 X99/4 C4 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 (OR RED/YEL) WHT BLU WHT/BLU GRY/YEL ORG ORG ORG ORG ORG ORG BLK RED WHT/RED BRN RED/VIO BLK RED/WHT WHT/BLK WHT/YEL GRY/YEL WHT/BLU VO GRN BRN/WHT BRN/YEL VO BLU VO/YEL BLK/GRN WHT/GRN RED/WHT RED/WHT BRN BRN BRN BRN BRN BRN BRN BRN GRYBLK ORG BLK GRN/WHT BLU WHT GRN GRN GRN WHT GRN NCA RED/WHT RED/BLK RED/YEL NCA NCA NCA BRN WHT BRN/YEL VIO/BLU GRN GRN/WHT GRN VIO/YEL GRN/WHT GRN GRN/WHT GRN GRN/WHT BLK WHT/YEL WHT/BLK RED WHT WHT RED WHT BRN RED/GRY VIO GRN NCA GRN GRN/WHT WHT/BRN WHT/RED RED/GRY SAM CONTROL UNIT FUSE 42 FUSE 41 LEFT ELECTRIC DRIVE CONTROL UNIT EVCM ELECTRIC VEHICLE CONTROL UNIT HIGH-VOLTAGE DISTRIBUTOR CONTROL UNIT ELECTRIC MOTOR CONTROL UNIT ELECTRIC DRIVE MOTOR (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) W7 W7 W7 SYSTEM SYSTEM LINES SYSTEM L NES SYSTEM L NES SYSTEM LINES SYSTEM COMPUTER DATA COMPUTER DATA COMPUTER DATA AIR CONDITIONING COMPUTER DATA POWER DISTRIBUTION AIR CONDITIONING SYSTEM AIR CONDIT ONING SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM AIR CONDIT ONING SYSTEM Fig 4: Engine Performance Circuit, W/ Electric Drive (4 of 4)
ENGINE PERFORMANCE > 1.0L >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4567 · Applies to: 450, 451, 452, 454
358303 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 CC CAN L CAN H LSHHK KWDG GND NWDG NWS TEV - M SENSOR 87/1.1 EFPR 31 M SENSOR CAN L PWG2 30 MR 15 PWG1 87/1.1 CAN H M SENSOR 5V 31 PNS 1-53 NOT USED 8 5 1 2 1 1 6 C2 10 9 8 7 6 5 4 3 2 1 1 2 C1 80 79 78 77 76 75 74 73 72 70 69 68 67 66 65 64 63 71 61 60 59 62 57 56 55 54 58 3 2 4 GRN GRN/WHT BLK BLK BLK BLU/WHT GRN YEL/BLK RED BLK VIO/WHT YEL/BLK PNK RED/GRY RED/GRY BLK/YEL BRN/PNK BLU/RED YEL/BLK BLK WHT/RED BLU/BRN VIO/YEL GRN BLK BLU/WHT BLK WHT/RED BRN/WHT YEL BLK BLU/WHT VIO/YEL BRN/YEL PNK BRN RED/GRY RED BLK BRN WHT BRN/GRN GRN/WHT BLU/BLK BLK/YEL BLU/RED GRN VIO/WHT VIO/GRN RED/GRY BRN/PNK BRN BLU/BRN BRN/WHT BRN/WHT BRN/YEL VIO/GRN ME-SFI (ME) CONTROL UNIT INSTRUMENT CLUSTER CRUISE CONTROL SYSTEM COMPUTER DATA LINES SYSTEM CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA L NES SYSTEM ACCELERATOR PEDAL SENSOR CHECK ENGINE MIL IND ENGINE O L PRESSURE SWITCH ADJUSTABLE CAMSHAFT TIMING SOLENOID ACTIVATED CHARCOAL FILTER SHUT-OFF VALVE (ON ACCELERATOR PEDAL ASSEMBLY) (BEHIND REAR BUMPER) (RIGHT REAR OF LUGGAGE COMPT) (ON OIL FILTER HOUSING) (TOP FRONT OF ENGINE) W7 Fig 1: 1.0L, Engine Performance Circuit, W/O Electric Drive (1 of 4)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4568 · Applies to: 450, 451, 452, 454
M 358304 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 HOT AT ALL TIMES 11 10 9 8 7 6 5 4 3 2 1 ALL T MES HOT AT 7.5A 15A ALL T MES HOT AT 25A OR START HOT IN ON 7.5A HOT AT ALL TIMES 15A 7.5A 2 X26 10 C5 4 1 3 2 12 C5 2 C6 2 C1 3 C3 11 11 3 C2 BLK BLK BLK BLU/WHT GRN YEL/BLK BLK YEL/BLK RED/GRY RED GRN BLK BLK BLK BLK BLU/WHT GRN YEL/BLK RED BLK VIO/WHT YEL/BLK PNK RED GRY RED GRY BLK/YEL BRN PNK BLU/RED BLK RED/YEL RED/BLU BRN PNK BRN/PNK BLU/RED RED/BLU RED/GRN BLK/YEL BLK/YEL RED VIO/WHT RED/GRY SAM CONTROL UNIT FUSE 16 FUSE 19 FUSE 27 FUEL PUMP W/ FUEL LEVEL SENSOR MAN RELAY ELECTR C FUEL PUMP RELAY FUSE 8 FUSE 9 FUSE 10 (IN FUEL TANK) (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) W7 Fig 2: 1.0L, Engine Performance Circuit, W/O Electric Drive (2 of 4)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4569 · Applies to: 450, 451, 452, 454
358305 14 13 12 11 10 9 8 7 6 5 4 3 2 1 11 10 9 8 7 6 5 4 3 2 1 - + SIG 4 X26 X26 3 1 1 1 2 2 2 3 3 3 4 3 1 2 2 3 1 5 6 4 3 2 1 BLK GRN GRN BLU/BLK YEL BRN WHT/BLK YEL VIO RED BLU YEL/BLK RED/BLU BLK BLK BLK BLK BLU/WHT GRN YEL/BLK BLK YEL/BLK RED GRY RED GRN BLK BRN BRN BRN RED/GRY BLK BLK BLK BLK WHT/BLK BRN GRN BRN BRN BRN NCA NCA NCA YEL BLU GRN BLK NCA NCA NCA NCA BLK RED RED/BLU VIO YEL GRN BLU/BLK YEL/BLK BLU/WHT TO SPARK PLUGS TO SPARK PLUGS TO SPARK PLUGS THROTTLE VALVE ACTUATOR CRANKSHAFT POSITION SENSOR OXYGEN SENSOR (DOWNSTREAM) CYLINDER 1 IGNITION COIL CYLINDER 2 IGNIT ON COIL CYLINDER 3 IGNITION COIL (ON INTAKE MANIFOLD) (NEAR OIL FILTER) (BEH ND REAR BUMPER) (IN EXHAUST, AFTER CONVERTER) (TOP OF CYLINDER HEAD) (TOP OF CYLINDER HEAD) (TOP OF CYLINDER HEAD) W6 Fig 3: 1.0L, Engine Performance Circuit, W/O Electric Drive (3 of 4)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4570 · Applies to: 450, 451, 452, 454
358306 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ON 25A OR START HOT IN SIG - + F L G LSHK LSHM LSUVM LSVK LSUIA LSUIP ZUE2 ZUE1 EV1 TMOT KSB KSA M SENSOR M SENSOR 5V POEL + 5V LSHVK EV3 TANS ZEU3 TPSMAIN TPSSUB EV2 X26 1 2 1 1 3 2 C1 6 1 2 2 1 1 2 2 1 1 4 2 3 1 2 51 50 42 43 44 45 46 47 49 48 11 13 12 15 16 17 14 18 20 19 22 23 24 21 25 26 27 29 30 31 28 32 33 34 36 38 37 35 39 40 41 C2 3 1 2 3 4 2 1 BRN BLK/YEL BLK/YEL BLK/YEL BRN GRN BLK BRN/GRN BRN BLK/YEL BLK GRN GRN BLU/BLK YEL BRN WHT/BLK YEL VIO RED BLU YEL/BLK RED BLU BLK BLK BLK PNK BLK YEL BLU BLK BLK VIO GRN/BLK BLK/RED GRN/BLK GRN/RED VIO/WHT RED/BLK BLU YEL WHT/BLU GRN BLK BRN YEL BLU BLK BRN GRN YEL/BLU RED YEL BLU GRN/RED WHT BLK/RED GRN GRN BLK GRN BLK RED BLK RED RED/BLU YEL BLK YEL VIO PNK WHT BLK BLU VIO/WHT VIO BLU BLK GRN BLK RED GRN BLK NCA NCA NCA NCA BLK BLK BLK WHT BLU SAM CONTROL UNIT FUSE 1 ME-SFI (ME) CONTROL UNIT STARTING/ CHARGING SYSTEM STARTING/ CHARGING SYSTEM START NG/CHARGING SYSTEM STARTING/CHARGING SYSTEM CYL NDER 3 FUEL INJECTION VALVE CYLINDER 1 FUEL INJECTION VALVE CYLINDER 2 FUEL INJECTION VALVE INTAKE MANIFOLD PRESSURE SENSOR COOLANT TEMPERATURE SENSOR OXYGEN SENSOR (UPSTREAM) CAMSHAFT HALL SENSOR KNOCK SENSOR HEATING SYSTEM SHUTOFF VALVE ACTIVATED CHAR-COAL SHUT-OFF VALVE (TOP OF ENGINE) (TOP OF ENGINE) (TOP OF ENGINE) (ON INTAKE MAN FOLD) (UNDER LEFT SIDE OF DASH) (RIGHT REAR OF LUGGAGE COMPT) (BEHIND REAR BUMPER) (RIGHT FRONT OF ENG NE BLOCK) (IN EXHAUST, BEFORE CONVERTER) (REAR OF CYLINDER HEAD) (TOP REAR OF ENGINE) W6 Fig 4: 1.0L, Engine Performance Circuit, W/O Electric Drive (4 of 4)
EXTERIOR LIGHTS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4571 · Applies to: 450, 451, 452, 454
1 2 1 2 2 1 358837 HOT W/ MAIN RELAY ENERGIZED 25A BACK SUP CAN L CAN H BACK UP 30 HOT AT ALL TIMES 10A CAN L CAN H BACK OUT 2 C1 11 C5 1 6 5 5 2 2 11 1 9 C2 R 13 14 4 5 4 GRY RED/ RED/GRY GRN GRN/WHT YEL/RED BRN YEL/RED YEL/RED BRN BLU/RED YEL/RED YEL/RED YEL/RED YEL/RED BLU/RED WHT RED/WHT RED/ GRN/WHT GRN (OR BLU/RED) SAM CONTROL UNIT FUSE 12 FUSE 8 ELECTRONIC SELECTOR LEVER MODULE CONTROL UNIT AUTOMATED MANUAL TRANSMISSION CONTROL UNIT LEFT TAILLAMP RIGHT TAILLAMP COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM W6 W7 BACKUP LAMP BACKUP LAMP (UNDER LEFT SIDE OF DASH) (UNDER CENTER CONSOLE) (UNDER DRIVER'S SEAT) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) 1.0L ELECTRIC (1.0L) (ELECTRIC) (1.0L) Fig 1: Backup Lamps Circuit
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4572 · Applies to: 450, 451, 452, 454
1 2 1 2 358835 7 6 31 5 4 3 2 1 +BS +BLS CAN H CAN L CAN L 7.5A 7 5A ALL TIMES HOT AT ALL T MES 10A HOT AT ALL TIMES 15A HOT AT CAN H 2 X57/7 8 2 14 X23/7-C1 X18/19-C1 3 C3 1 2 13 30 35 4 2 1 3 C2 31 12 2 3 11 1 39 38 8 C5 11 1 2 3 4 5 6 7 10 1 C8 40 39 C8 10 9 35 34 C9 7 BLK/RED BLK/RED RED/VIO BRN BLK/WHT BLKGRN BRN/GRY BRN/GRY GRYGRN GRN BLK/RED BLK/RED BRN BLK BLKRED GRN WHT BLK BLK/RED BRN RED/YEL VIO/BLU VIO/BLU RED/VIO BRN BLK/GRN BLK/WHT BRN GRY WHT/RED BLKBRN WHT/RED BLK/BRN BRN GRY BRN RED/WHT RED/YEL GRY/BLU RED/WHT VIO/GRN YEL BRN YEL RED GRN/WHT GRN GRY/BLU VIO/GRN YEL YEL/RED GRYGRN SAM CONTROL UNIT FUSE 24 FUSE 12 COCKPIT SWITCH GROUP ESP CONTROL UNIT COMBINAT ON SWITCH COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM W10 W10 W9 W10 W6 STANDING LAMPS RELAY FUSE 6 FUSE 7 HAZARD WARNING FLASHER SWITCH CENTER HIGH MOUNTED STOP LAMP STOP LAMP SWITCH (UNDER LEFT SIDE OF DASH) (IN BATTERY COMPT) (IN BATTERY COMPT) (NEAR BASE OF LEFT "A" PILLAR) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (BEHIND REAR BUMPER) ( N BATTERY COMPT) (ON BRAKE PEDAL ASSEMBLY) (ON STEERING COLUMN) COUPE CONVERTIBLE Fig 2: Exterior Lamps Circuit (1 of 2)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4573 · Applies to: 450, 451, 452, 454
358836 7 6 5 4 3 2 1 CAN H CAN L X57/7 5 1 6 9 6 4 2 1 2 3 5 3 2 1 4 2 5 C1 C2 C1 C2 1 2 2 1 5 4 5 4 BLK/RED BLK/RED BLKWHT BLKRED BRN GRY/GRN BLK/GRN BLKRED BLK/RED BLK/WHT BLK/GRN BRN/GRY BRN/GRY GRY/GRN GRN GRN WHT BLK/GRN BLKGRN BRN BRN GRYGRN YEL/RED BLKWHT BLK/WHT BRN YEL RED YEL RED BRN BRN/GRY GRYGRN BRN BRN GRYGRN GRYGRN BRN BRN/GRY BRN BRN GRYGRN BRN BLK/GRN BRN BLK/WHT INSTRUMENT CLUSTER LEFT FRONT LAMP UNIT RIGHT FRONT LAMP UNIT COMPUTER DATA LINES SYSTEM BACKUP LAMPS CIRCUIT HEADLIGHTS SYSTEM BACKUP LAMPS CIRCUIT W43 W43 W6 W43 W6 W7 W43 W43 LEFT ADDIT ONAL TURN SIGNAL LAMP RIGHT ADDITIONAL TURN SIGNAL LAMP LEFT TURN SIGNAL NDICATOR LAMP R GHT TURN SIGNAL INDICATOR LAMP R GHT LICENSE PLATE LAMP LEFT LICENSE PLATE LAMP R GHT STAND NG LAMP LEFT STANDING LAMP TURN SIGNAL LAMP TAIL LAMP BACKUP/REAR FOG LAMP STOP LAMP LEFT TAILLAMP TAL LAMP TURN SGNAL LAMP BACKUP LAMP STOP LAMP TURN SIGNAL LAMP TURN SIGNAL LAMP RIGHT TALLAMP (BEHIND FRONT BUMPER) (BEH ND FRONT BUMPER) (BEH ND REAR BUMPER) (BEHIND FRONT BUMPER) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (BEH ND FRONT BUMPER) (BEHIND FRONT BUMPER) Fig 3: Exterior Lamps Circuit (2 of 2)
GROUND DISTRIBUTION >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4574 · Applies to: 450, 451, 452, 454
358841 GLOW OUTPUT STAGE REAR LUGGAGE CARRIER SEPARATION POINT BACKUP LAMP STOP LAMP RELAY & COMPRESSOR CONTROL UNIT, ELECTR C MOTOR COOLING FAN MOTOR, REFRIGERANT ELECTRIC MOTOR CONTROL MODULE (ELECTRIC), HIGH-VOLTAGE DISTRIBUTOR CONTROL UNIT, HIGH-VOLTAGE AC/DC BATTERY CHARGER CONTROL UNIT, EVCM ELECTRIC VEHICLE CONTROL UNIT (ELECTRIC), SMART BATTERY CHARGER CONTROL UNIT COOLANT PUMP (ELECTRIC), ELECTR C DRIVE & H GH-VOLTAGE CHARGER AIRBAG SHUTOFF SWITCH, PTC HEATER BOOSTER, FRONT PASSENGER BLOWER MOTOR RELAY 2 5TH RADIO REMOTE CONTROL RECEIVER, HIGH-VOLTAGE BATTERY HEATER, SAM CONTROL UNIT, BATTERY MANAGEMENT SYSTEM CONTROL UNIT (ELECTRIC), BRAKE BOOSTER VACUUM PUMP CONTROL UNIT, HEATING SYSTEM SHUTOFF VALVE, REAR HEATED WINDOW, RIGHT POWER W NDOW SWITCH, CARD READER WINDSH ELD, H GH VOLTAGE BATTERY SOC CHARGE LEVEL INDICATOR, HIGH VOLTAGE BATTERY ENERGY FLOW (ELECTRIC), RIGHT POWER WINDOW PASSENGER SIDE SWITCH, RIGHT POWER WINDOW LEFT FRONT FOOTWELL LAMP, RIGHT FRONT FOOTWELL LAMP, SHIELD FRONT PASSENGER DOOR POCKET AMBIANCE LLUM NATION DRIVER DOOR POCKET AMBIANCE ILLUMINATION & RIGHT LICENSE PLATE LAMP, DRIVER DOOR PRESSURE SENSOR SHIELD & FRONT PASSENGER DOOR PRESSURE SENSOR SHIELD R GHT CRUISE CONTROL SWITCH SMART PREM UM RADIO SMART ENTRY RADIO & SUBWOOFER LOUDSPEAKER, SOUND AMPLIFIER, SUBWOOFER TRUNK LID OPENING ASSIST MOTOR 1 (COUPE) & TRUNK LID OPENING ASSIST MOTOR 2 (COUPE) TRUNK LID OPENING ASSIST MOTOR (CONVERTIBLE), DRIVER HEAD/THORAXBAG SENSOR SHIELD MICROWAVE SENSOR (ELECTR C) ALARM SIREN W/ INCLINATION SENSOR & LEFT ELECTRICALLY ADJUSTABLE & HEATED EXTERIOR MIRROR, DRIVER SDE SWITCH, LEFT POWER WINDOW SWITCH, PASSENGER HEAD THORAXBAG SENSOR SHIELD SHUTOFF-CAPABLE INTERIOR LAMP RELAY, OVERHEAD CONTROL PANEL (OCP) AMBIANCE ILLUMINAT ON, CENTER COCKPIT AMBIANCE ILLUMINATION, LEFT COCKPIT AMBIANCE ILLUMINAT ON, RIGHT COCKPIT AMBIANCE ILLUMINATION, RIGHT HEATED SEAT CUSHION, TRUNK L D ROTARY TUMBLER MICRO SWITCH (CONVERTIBLE), TAILGATE WIPER MOTOR (COUPE), CHARGE AIR FAN MOTOR, REMOTE TRUNK OPEN NG SWITCH (COUPE), BATTERY, INTERIOR SOCKET LEFT STANDING LAMP, BRAKE FLUID NDICATOR SWITCH, TPM CONTROL MODULE, ELECTRON C SELECTOR LEVER CONTROL MODULE, AUTOMATED MANUAL TRANSMISSION CONTROL UNIT FRONT HS (SH) CONTROL MODULE FANFARE HORN & AIR BAG CLOCK SPRING CONTACT & REAR END DOOR HANDLE SWITCH, WIPER MOTOR, HORN, COOLANT FAN MOTOR, RIGHT STANDING LAMP, R GHT WIPER SWITCH, TACHOMETER, LEFT HEATED SEAT CUSHION & BLOWER SWITCH & DATA LINK CONNECTOR HEATER/AC OPERATING UNIT, M CROSWITCH, LEFT DOOR ROTARY TUMBLER MICROSWITCH, SHIELD, RIGHT DOOR ROTARY TUMBLER CONTROL UNIT, INSTRUMENT CLUSTER, SOFT TOP MICRO SWITCH, LEFT REAR SOFT TOP M CRO SWITCH, SAM CONTROL UNIT, POWER WINDOW CONVENIENCE FEATURE POWER STEERING MOTOR STEERING ASSIST CONTROL MODULE, POWER STEERING TORQUE SENSOR PARKNG BRAKE INDICATOR SWITCH, YAW RATE, LATERAL & LONGITUDINAL ACCELERATION SENSOR, ESP CONTROL UNIT, POWER SOFT TOP SWITCH, CENTER HIGH MOUNTED STOP LAMP, RIGHT ROOF CASSETTE MICRO SWITCH, COCKPIT SWITCH GROUP, STOP LAMP SWITCH, BRAKE FLU D IND CATOR SWITCH, COMBINATION SWITCH, STEERING ANGLE SENSOR, CYLINDER 2 GNITION COIL, CYLINDER 3 IGNITION COIL, FUEL PUMP W/ FUEL LEVEL SENSOR, HEATED REAR WINDOW, CYLINDER 1 GNITION COIL, RIGHT ELECTRICALLY ADJUSTABLE & HEATED EXTERIOR M RROR, OUTSDE REARVIEW M RROR ADJUSTMENT SWITCH, R GHT TAIL LAMP, ME-SFI (ME) CONTROL UNIT, LEFT FOG LAMP, RIGHT FOG LAMP (IF EQUIPPED), WEIGHT SENSNG SYSTEM (WSS) CONTROL UNIT, RESTRANT SYSTEMS CONTROL UNIT, LEFT TAIL LAMP, LEFT LICENSE PLATE LAMP, RAIN SENSOR/LIGHT SENSOR, LEFT FRONT HEADLAMP UNIT, RIGHT FRONT HEADLAMP UNIT, BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN W11/7 W7 W9 W26 W10 W43 W11 W11/5 W30/2 W6 W110 W12 W14 W83 (BEHIND REAR BUMPER) (ON FUEL FILLER NECK) (NEAR BASE OF LEFT "A" PILLAR) (IN BATTERY COMPT) (IN BATTERY COMPT) (BEH ND FRONT BUMPER) (BEHIND RIGHT REAR BUMPER) (BEHIND R GHT REAR BUMPER) (UNDER DASH ASSEMBLY) (BEHIND REAR BUMPER) (LEFT FLOOR PANEL) Fig 1: Ground Distribution Circuit
HEADLIGHTS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4575 · Applies to: 450, 451, 452, 454
M M 358832 31 ALL TIMES 15A HOT AT CAN H CAN L ALL TIMES HOT AT ALL T MES 10A HOT AT ALL TIMES HOT AT 10A 7 5A 7.5A ALL TIMES 7.5A 7.5A HOT AT CAN H CAN L X18/29-C1 1 5 4 X18/29-C1 1 5 4 2 6 39 38 3 1 C2 8 C9 18 8 4 8 5 1 2 2 1 11 9 C3 7 2 1 3 8 2 11 3 4 5 6 7 10 1 2 1 5 3 6 2 1 5 3 6 13 14 C9 40 39 C8 10 9 35 34 C9 6 10 C3 4 C5 YEL/RED BRN YEL/RED YEL/RED BRN YEL/RED RED/WHT BLK/BRN WHT/RED WHT/RED BLK/BRN BRN RED WHT YEL/BLU RED/YEL GRN/WHT GRN GRY/YEL BRN BRN GRY/YEL BRN WHT/BLK GRY/VIO BRN VIO/BLU RED/WHT BLU/YEL GRN/RED GRYBLU GRN/RED RED WHT VIO/GRN YEL BRN YEL/RED GRN/RED BRN BRN WHT/BLK GRY/VIO GRN/RED BRN BRN WHT/RED GRY/YEL GRY/YEL BLU/YEL VIO/BLU GRN/WHT GRN GRY/BLU VIO/GRN YEL YEL/RED GRY/YEL WHT/RED GRY/YEL SAM CONTROL UNIT FUSE 5 FUSE 24 FUSE 12 LEFT TAL LAMP COCKPIT SWITCH GROUP LEFT TAIL LAMP NSTRUMENT CLUSTER COMBINATION SWITCH LEFT FRONT LAMP UNIT R GHT FRONT LAMP UNIT COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM W6 W9 W10 W43 W10 W6 W9 W43 W43 LOW BEAM HEADLAMP RELAY HIGH BEAM RELAY FRONT FOG LAMP RELAY LEFT REAR FOG LAMP FUSE 26 FUSE 23 FUSE 25 FUSE 22 REAR FOG LAMP RELAY RAIN SENSOR/ LIGHT SENSOR FOG LAMP SWITCH R GHT FOG LAMP LEFT FOG LAMP LEFT REAR FOG LAMP LOW BEAM INDICATOR LAMP H GH BEAM HIGH BEAM LOW BEAM LOW BEAM H GH BEAM INDICATOR LAMP HEADLAMP RANGE ADJUSTMENT MOTOR HEADLAMP RANGE ADJUSTMENT MOTOR (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (NEAR BASE OF LEFT "A" PILLAR) (TOP CENTER OF WINDSHIELD) (IN BATTERY COMPT) (BEHIND FRONT BUMPER) (IN BATTERY COMPT) (NEAR BASE OF LEFT "A" PILLAR) (BEHIND REAR BUMPER) (BEHIND FRONT BUMPER) (BEHIND FRONT BUMPER) (ON STEERING COLUMN) (W/ RAN SENSOR/ LIGHT SENSOR) (W/ FRONT FOG LAMPS) (IF EQUIPPED) (IF EQUIPPED) (W/O RAIN SENSOR/ LIGHT SENSOR) Fig 1: Headlights Circuit
HORN >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4576 · Applies to: 450, 451, 452, 454
358854 HOT AT ALL TIMES 20A HOT AT ALL TIMES C B C10 C9 2 2 1 6 2 30 BLK BLK BLK BLU BRN PNK/BLK BLU PNK/BLK SAM CONTROL UNIT FUSE 31 FANFARE HORNS & AIR BAG CLOCK SPRING CONTACT W43 W110 HORN RELAY HORN FANFARE HORN SYSTEM BUTTON (UNDER LEFT SIDE OF DASH) (BEHIND FRONT BUMPER) Fig 1: Horn Circuit
INSTRUMENT CLUSTER >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4577 · Applies to: 450, 451, 452, 454
M 358830 GND CAN L CAN H M SENS HAS BFL CAN L CAN H 10A SAL 58D GND (SAL) CAN L CAN H (-) 30 CAN L CAN L 31 OR START HOT IN ON CAN H CAN H (+) 10A HOT AT ALL TIMES 40 39 1 2 13 3 C9 8 3 2 1 4 71 78 68 62 C1 2 1 1 2 35 14 17 20 C3 2 B 10 5 1 2 1 C2 1 18 14 17 16 15 11 13 12 7 8 9 10 4 6 5 2 3 YEL/BRN GRN GRN/WHT YEL YEL/BRN YEL BRN YEL BRN BLU BRN BLU BRN/PNK PNK RED/BLU BRN BRN/PNK PNK GRN GRN/WHT BRN BRN BRN/WHT BRN/BLK BRN BRN/WHT BRN/BLK GRN WHT GRN RED/WHT BLU/BLK BRN/GRN BLU/BLK BRN/GRN BRN/RED BRN GRN GRN GRN/WHT GRN/WHT VIO BRN VIO BRN/VIO RED/WHT GRN BLK/RED RED/WHT BRN GRN/WHT GRY/BLU VIO SAM CONTROL UNIT FUSE 18 FUSE 12 INSTRUMENT ILLUMINAT ON BR GHTNESS SENSOR LOW BEAM INDICATOR LAMP "CHECK ENG NE" M L NDICATOR LAMP HIGH BEAM INDICATOR LAMP ABS IND LAMP AIR BAG INDICATOR & WARNING LAMP COCKPIT SWITCH GROUP ESP WARNING INDICATOR LAMP SEAT BELT WARNING LAMP LEFT TURN SIGNAL NDICATOR LAMP FANFARE HORNS & AIR BAG CLOCK SPRING CONTACT COOLANT TEMPERATURE WARNING NDICATOR LAMP ELECTRIC STEERING INDICATOR LAMP OIL PRESSURE WARNING LAMP OIL PRESSURE WARNING INDICATOR LAMP ALTERNATOR CHARGE MONITORING & WARNING INDICATOR LAMP R GHT TURN SIGNAL INDICATOR LAMP DRIVE DIAGNOSIS WARNING LAMP RBS WARNING LAMP ME-SFI (ME) CONTROL UNIT HIGH-VOLTAGE SYSTEM INDICATOR LAMP DRIVE DIAGNOSIS INDICATOR LAMP 12V BATTERY WARNING LAMP ESP CONTROL UNIT COMPUTER DATA LINES SYSTEM COMPUTER DATA L NES SYSTEM COMPUTER DATA LINES SYSTEM NTER OR LIGHTS SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES ENGINE CONTROLS SYSTEM SYSTEM (1.0L) (1.0L) (1.0L) 1.0L ELECTRIC (ELECTR C) (1.0L) (1.0L) (ELECTRIC) (ELECTRIC) (1 0L) (ELECTRIC) (ELECTRIC) (ELECTR C) W10 W9 W43 W7 TWO-AWAY PROTECTION/ NTER OR PROTECT ON SWITCH BRAKE FLUID & PARKNG BRAKE WARN NG INDICATOR LAMP ELECTRONIC SPEEDOMETER OUTSDE TEMPERATURE DISPLAY TEMPERATURE SENSOR MULTI-FUNCTION DISPLAY INSTRUMENT CLUSTER FUEL PUMP W/ FUEL LEVEL SENSOR BRAKE FLUID INDICATOR SWITCH R GHT STEERING WHEEL PITMAN ARM PARKING BRAKE NDICATOR SWITCH (UNDER LEFT SIDE OF DASH) (NEAR BATTERY COMPT) (NEAR BASE OF LEFT "A" PILLAR) (LEFT END OF FRONT BUMPER) (RIGHT REAR OF LUGGAGE COMPT) (IN FUEL TANK) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (BEHIND FRONT BUMPER) (BEHIND REAR BUMPER) Fig 1: Instrument Cluster Circuit
INTERIOR LIGHTS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4578 · Applies to: 450, 451, 452, 454
358851 HOT AT ALL TIMES 31 10A 58D 30 HOT AT ALL TIMES 15A B3 X35/2 3 4 9 3 3 8 7 3 2 1 3 C 2 1 C2 B3 X35/1 4 4 C1 B A 6 3 11 1 12 1 2 1 1 2 1 2 2 1 1 3 2 A8 X35/1 A8 X35/2 2 1 2 1 2 1 29 C8 C9 23 C5 6 6 A3 X35/2 C D X35/1 A3 D C 19 4 4 8 2 4 6 26 GRY/BLU BRN BRN GRY/BLU BRN BRN BRN BRN BRN BRN BRN BRN BRN BRN GRY RED VIO BLK NCA BLU/WHT NCA NCA NCA BLU/WHT BRN RED/WHT RED/WHT GRY/BLU GRY/BLU GRY/BLU GRY/BLU GRY/BLU GRY/BLU GRY/BLU GRY/BLU GRY/BLU GRY/BLU RED/WHT GRY BRN BRN GRY BRN NCA NCA NCA BRN NCA RED VIO RED VIO BRN/GRN BRN/BLU RED/BLK BRN BRN RED/VO RED/VIO NCA NCA NCA NCA GRY BRN RED VIO BRN RED VIO BRN BRN RED VIO RED/VIO GRY RED/BLK RED/BLK RED/BLK RED/BLK YEL/BLK BRN BRN YEL/BLK YEL YEL/WHT BRN BRN YEL/BLK YEL BRN/BLU BRN BRN BRN/GRN RED/BLK BLK/GRY BLK/GRY INSTRUMENT CLUSTER SAM CONTROL UNIT FUSE 15 FUSE 12 LEFT DOOR ROTARY TUMBLER MICRO SWITCH COCKPIT SWITCH GROUP RIGHT DOOR ROTARY TUMBLER MICRO SWITCH HEAT NG & AIR CONDITIONING OPERATING UNIT LEFT CRUISE CONTROL SWITCH RIGHT CRUISE CONTROL SWITCH FANFARE HORNS & AIR BAG CLOCK SPRING CONTACT SMART ENTRY RADIO/ PREMIUM RADIO LEFT POWER WINDOW SWITCH RIGHT POWER W NDOW DRIVER SIDE SWITCH RIGHT POWER WINDOW PASSENGER SIDE SWITCH CLOSE SOFT TOP RELAY OPEN SOFT TOP RELAY LEFT FRONT FOOTWELL LAMP RIGHT FRONT FOOTWELL LAMP NSTRUMENT LLUM NATION BRIGHTNESS SENSOR FRONT PASSENGER DOOR POCKET AMBIANCE ILLUMINAT ON DRIVER DOOR POCKET AMBIANCE ILLUMINATION LEFT COCKPIT AMBIANCE ILLUMINAT ON CENTER COCKPIT AMBIANCE ILLUMINATION RIGHT COCKPIT AMBIANCE ILLUMINATION OVERHEAD CONTROL PANEL (OCP) AMBIANCE ILLUMINATION SHUTOFF-CAPABLE INTERIOR LAMP RELAY FRONT NTER OR LAMP (UNDER LEFT SIDE OF DASH) (BEHIND FRONT BUMPER) (NEAR BASE OF LEFT "A" PILLAR) (NEAR BASE OF LEFT "A" PILLAR) (BEHIND FRONT BUMPER) (IN BATTERY COMPT) (IN BATTERY COMPT) (CENTER OF DASH) (BEHIND FRONT BUMPER) (BEHIND FRONT BUMPER) (NEAR BASE OF LEFT "A" PLLAR) (BEH ND FRONT BUMPER) (NEAR BASE OF LEFT "A" PLLAR) (BEH ND FRONT BUMPER) (NEAR BASE OF LEFT "A" PLLAR) (BEH ND FRONT BUMPER) (NEAR BASE OF LEFT "A" PLLAR) (NEAR BASE OF LEFT "A" PILLAR) W43 W9 W9 W43 W10 W10 W43 W110 W43 W9 W12 W9 W43 W43 W9 W43 W9 W9 (1 0L) (IF EQUIPPED) (IF EQUIPPED) (W/ INTERIOR LIGHT PACKAGE) Fig 1: Interior Lights Circuit
POWER DISTRIBUTION >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4579 · Applies to: 450, 451, 452, 454
A 358838 C 7.5A 7.5A START RUN ACC LOCK B 25A 15A START RUN LOCK ACC 10A 25A 25A 40A 30A 5A 15A 10A 7.5A 15A 50A 3 C3 1 2 C8 9 C3 1 D 38 C8 A C 2 C1 6 C3 C1 5 2 C7 1 R7 C5 9 C1 7 4 C3 R1 5 C3 C4 1 3 C7 RED/BLK BLK BLK/YEL RED RED GRY/BLK RED/BLK BRN BLU/GRY BLKGRN BLK/YEL RED BLK/RED RED/PNK RED GRN RED/WHT (OR RED/YEL) RED BLK RED/BLU BLK/GRY BLK/GRN BLK/BLU RED RED SAM CONTROL UNIT BATTERY STARTER RELAY SAM CONTROL UNIT REAR WIPER RELAY FRONT WIPER RELAY W10 FUSE 42 FUSE 35 FUSE 34 FUSE 11 FUSE 15 FUSE 33 IGNITION/ STARTER SWITCH 12V CHARGE LINE PRE FUSE FUSE 90 FUSE 1 FUSE 18 FUSE 36 FUSE 20 FUSE 21 INTERIOR SOCKET FUSE 17 FUSE 2 FUSE 19 (UNDER LEFT SIDE OF DASH) (IN BATTERY COMPT) (UNDER LEFT SIDE OF DASH) TPM CONTROL UNIT, (W/ POWER STEERING) (ELECTRIC) (1.0L) (1.0L) (1.0L) (ELECTR C), (ELECTR C), (ELECTRIC) (1.0L) (COUPE) (1.0L), (ELECTRIC) TO FUSE 12 (DIAGRAM 2 OF 3) TO FUSE 40 (DIAGRAM 3 OF 3) STEERING ASSIST CONTROL UNIT OPEN SOFT TOP RELAY, FRONT INTERIOR LAMP & SHUTOFF-CAPABLE INTERIOR LAMP RELAY ESP CONTROL UNIT SMART ENTRY RAD O SMART PREM UM RADIO & SUB WOOFER ELECTRIC MOTOR CONTROL UNIT STARTER & ALTERNATOR ELECTRIC MOTOR CONTROL UNIT (ELECTRIC) TO HEATER BLOWER RELAY (DIAGRAM 2 OF 3) ESP CONTROL UNIT, WEIGHT SENSNG SYSTEM (WSS) CONTROL UNIT, STEER NG ASSIST CONTROL UNIT, RESTRAINTS SYSTEMS CONTROL UNIT, STEERING ANGLE SENSOR, YAW RATE, LATERAL & LONGITUDINAL ACCELERAT ON SENSOR, AUTOMATIC CHILD SEAT RECOGNITION AIR BAG OFF INDICATOR LAMP DRIVER SIDE SEAT BELT BUCKLE RESTRAINT SYSTEMS SWITCH & PASSENGER SDE SEAT BELT BUCKLE RESTRAINT SYSTEMS SWITCH ALTERNATOR BRAKE BOOSTER VACCUM PUMP CONTROL UNIT ELECTRIC HIGH-VOLTAGE CHARGER COOLANT PUMP RADIATOR FAN MOTOR HEAT NG SYSTEM SHUTOFF VALUE POWER SOFT TOP SWITCH, ELECTRONIC SELECTOR LEVER CONTROL UNIT, SMART ENTRY RADIO SMART PREMIUM RADIO, OUTSIDE REARVEW MIRROR ADJUSTMENT SWITCH, FRONT HS (SIH) CONTROL MODULE, RIGHT WIPER SWITCH & HEATER/AIR CONDITIONING OPERATING UNIT MIRROR HEATER RELAY & RELAY ME-SFI (ME) CONTROL UNIT DATA L NK CONNECTOR, AUTOMATED MANUAL TRANSMISSION CONTROL UNIT & EVCM ELECTR C VEHICLE TAILGATE WIPER MOTOR WIPER MOTOR CONTROL UNIT Fig 1: Power Distribution Circuit (1 of 3)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4580 · Applies to: 450, 451, 452, 454
A 358839 D B 15A 20A 10A 15A 25A 10A 40A 40A 30A 7.5A 15A 25A 20A 3 C2 R9 C2 2 1 11 C3 C3 8 C1 1 3 VIO/WHT RED/YEL RED/GRN RED/VIO RED/WHT RED RED/GRY RED WHT SAM CONTROL UNIT REAR END DOOR/ TRUNK LID CL (ZV) RELAY CHARGE AIR FAN MOTOR & HORN RELAY CL (ZV) OPEN RELAY CL (ZV) LOCKED RELAY CHARGE AR FAN MOTOR RELAY STANDING LAMPS RELAY HIGH BEAM RELAY LOW BEAM HEADLAMP RELAY HEATED REAR W NDOW RELAY ELECTRIC FUEL PUMP RELAY FRONT FOG LAMP RELAY AUTOMATED MANUAL TRANSMISSION RELAY SOFT TOP CLOSED RELAY SOFT TOP OPEN RELAY FUSE 31 FUSE 12 FUSE 44 FUSE 14 FUSE 24 MAIN RELAY HEATER BLOWER RELAY FUSE 4 FUSE 3 FUSE 16 FUSE 28 FUSE 29 FUSE 5 FUSE 30 FUSE 27 (UNDER LEFT SIDE OF DASH) (IF EQU PPED), (IF EQU PPED), (ELECTR C) (1.0L) (ELECTRIC), (ELECTR C) (ELECTRIC) (1.0L), (ELECTRIC) (ELECTRIC) (1 0L) (W/ RAIN LIGHT SENSOR) (ELECTRIC) (IF EQUIPPED) (1.0L) FROM FUSE 11 (DIAGRAM 1 OF 3) COCKPIT SWITCH GROUP TPM CONTROL UNIT, RAIN SENSOR LIGHT SENSOR DATA LINK CONNECTOR, AUTOMATED MANUAL TRANSMISSION CONTROL UNIT, MIRROR HEATER RELAY, ALARM SIREN W/ INCL NATION SENSOR NSTRUMENT CLUSTER, M CROWAVE SENSOR, COMBINATION SWITCH, R GHT TURN SIGNAL/STOP LAMP RELAY, LEFT TURN SGNAL/STOP LAMP RELAY, STH RADIO REMOTE CONTROL RECEVER BATTERY AR CONDITION NG EXPANSION VALUE INTERIOR AIR CONDITIONING EXPANSON VALUE BRAKE BOOSTER VACUUM FRONT HS (SIH) CONTROL UNIT & CONTROL UNIT & TO FUSE 8 (DIAGRAM 3 OF 3) FROM FUSE 18 (DIAGRAM 1 OF 3) POWER WINDOW CONVENIENCE FEATURE CONTROL UNIT ELECTRONIC SELECTOR LEVER CONTROL UNIT, STOPLAMP SWITCH & REAR FOG LAMP RELAY BLOWER MOTOR BLOWER MOTOR RELAY 1 BLOWER MOTOR RELAY 2 ME-SFI (ME) CONTROL UNIT EVCM ELECTRIC VEHICLE & & CONTROL UNIT ME-SFI (ME) CONTROL UNIT Fig 2: Power Distribution Circuit (2 of 3)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4581 · Applies to: 450, 451, 452, 454
2 1 1 2 1 2 1 2 358840 15A 7.5A 25A D N/A 15A 7.5A C C5 11 10 C1 2 R8 R6 R5 RED/GRY RED GRY (OR RED/GRN) RED/YEL (OR RED/GRN) RED/WHT RED/WHT RED GRN SAM CONTROL UNIT FUSE 43 FUSE 41 FUSE 40 FUSE 10 FUSE 8 FUSE 9 (UNDER LEFT SIDE OF DASH) (ELECTRIC) (SPARE) (1.0L), (1.0L) (ELECTRIC) (ELECTR C) 1.0L ELECTRIC (1.0L), (ELECTRIC), (ELECTRIC) (1.0L) (1.0L), (1.0L), (1.0L), (1.0L), (1.0L) (1.0L) FROM FUSE 11 (DIAGRAM 1 OF 3) H GH VOLTAGE DISTRIBUTOR CONTROL UNIT BATTERY MANAGEMENT SYSTEM CONTROL UNIT, HIGH VOLTAGE AC/DC BATTERY CHARGER CONTROL UNIT, SMART BATTERY CHARGER CONTROL UNIT & CHARGER FEED SOCKET NDICATOR LED BACKUP LAMP RELAY STOPLAMP EVCM ELECTRIC VEH CLE CONTROL UNIT RELAY & FROM MAIN RELAY (DIAGRAM 2 OF 3) CYLINDER 1 FUEL INJECTION VALVE, CYLINDER 2 FUEL INJECT ON VALVE & CYLINDER 3 FUEL INJECTION VALVE ME-SFI (ME) CONTROL UNIT ELECTRIC DRIVE & HIGH VOLTAGE CHARGER COOLANT PUMP & RADIATOR FAN RELAY AUTOMATED MANUAL TRANSMISSION CONTROL UNIT ELECTRIC SELECTOR LEVER MODULE CONTROL UNIT, HIGH VOLTAGE BATTERY HEATER BOOSTER RELAY (ELECTRIC), OXYGEN SENSOR (DOWNSTREAM) OXYGEN SENSOR (UPSTREAM) ACTIVATED CHARCOAL FILTER SHUTOFF VALVE ADJUSTABLE CAM SHAFT TIMING SOLENOID PRESSURE REGULAR VALVE EGR (ARF) SWITCHOVER VALVE & Fig 3: Power Distribution Circuit (3 of 3)
POWER DOOR LOCKS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4582 · Applies to: 450, 451, 452, 454
M M M 358828 13 12 11 10 9 8 7 6 5 4 3 2 1 HOT AT ALL TIMES 20A HOT AT ALL TIMES 10A CAN L CAN H CLK GND U DATA ZV OPEN ZV CLOSE 1 C10 10 12 1 C2 6 X35/1 39 40 4 8 2 C9 5 2 36 C8 3 21 24 20 16 12 C9 X35/2 A4 A2 A3 A5 C E D B A A5 A3 A2 A4 C E D B A 1 3 18 4 19 C8 C10 PNK RED/WHT RED/WHT YEL YEL (OR BLU/RED) BLU/BLK VIO/GRN YEL/PNK PNK GRY/WHT VIO/WHT BRN/BLK RED/BLK BLKBLU BRN GRY/BLU VIO/GRN RED/WHT BLU BRN BRN GRN/WHT GRN GRY/YEL (OR BLU/RED) YEL YEL PNK PNK BLU/BLK YEL PNK GRY/WHT BRN/BLK RED/BLK VIO/WHT BLKBLU PNK PNK GRY/YEL YEL BLK WHT/GRN YEL WHT/GRN BRN PNK GRY/YEL WHT/GRN BRN YEL/BLK WHT/GRN YEL GRY/YEL PNK GRY/YEL PNK BRN YEL/WHT GRY/YEL PNK WHT/GRN YEL BLK SAM CONTROL UNIT FUSE 31 FUSE 12 HORNS SYSTEM COMPUTER DATA LINES SYSTEM EXTERIOR LIGHTS SYSTEM W9 W43 CHARGE AIR FAN MOTOR & HORN RELAY REAR END DOOR/TRUNK L D CL (ZV) RELAY CL (ZV) CLOSE RELAY CL (ZV) OPEN RELAY FUEL FILLER FLAP CL (ZV) MOTOR LEFT DOOR CL (ZV) MOTOR & LEFT DOOR ROTARY TUMBLER M CROSWITCH RIGHT DOOR CL (ZV) MOTOR & RIGHT DOOR ROTARY TUMBLER MICROSWITCH (UNDER LEFT SIDE OF DASH) (NEAR BASE OF LEFT "A" PILLAR) (BEH ND FRONT BUMPER) Fig 1: Power Door Locks Circuit (1 of 2)
Excerpt¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4583 · Applies to: 450, 451, 452, 454
M M M 358829 1 3 4 2 7 6 8 12 11 10 13 9 5 1 2 3 2 1 3 3 1 2 2 1 1 2 1 2 1 2 1 4 3 2 11 10 BLU/BLK BRN BRN BLU/BLK BLU/BLK BRN YEL/PNK BRN BRN VIO/GRN YEL RED/WHT RED/WHT YEL (OR BLU RED) BLU/BLK GRY/WHT VO WHT BRN/BLK RED/BLK BLK/BLU VO GRN YEL/PNK PNK BRN BRN VIO/GRN RED WHT BRN BRN RED WHT VIO/GRN YEL (OR BLU/RED) BRN YEL BRN BLU/RED BRN YEL PNK/YEL BRN GRY/WHT BRN BLK RED BLK VIO/WHT BLK/BLU PNK COCKPIT SWITCH GROUP W10 W10 W6 W6 W6 W6 W10 W6 W6 M CROWAVE SENSOR ALARM SIREN W/ INCL NATION SENSOR TRUNK LID OPENING ASSIST MOTOR 2 REAR END DOOR HANDLE SWITCH TRANSPONDER COIL TRUNK L D ROTARY TUMBLER MICROSWITCH TRUNK L D ROTARY TUMBLER MICROSWITCH TRUNK LID OPENING ASSIST MOTOR 1 INSIDE UNLOCK CL (ZV) SWITCH INSDE LOCK CL (ZV) SWITCH TRUNK LID OPENING ASSIST MOTOR (UNDER CENTER CONSOLE) (IN BATTERY COMPT) (IN BATTERY COMPT) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (UNDER ELECTRONIC SELECTOR LEVER) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (IN BATTERY COMPT) (BEH ND REAR BUMPER) (BEHIND REAR BUMPER) (W/ ATA (EDW) & SIREN) (W/ ATA (EDW) & SIREN) (COUPE) COUPE CONVERTIBLE COUPE CONVERTIBLE Fig 2: Power Door Locks Circuit (2 of 2)
POWER MIRRORS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4584 · Applies to: 450, 451, 452, 454
M M M M 338828 HOT N ON 10A OR START X35/2 X35/1 C2 10 8 2 9 1 6 7 C4 X35/1 X35 1 C3 X35/1 C5 C3 C5 C4 4 C3 2 1 3 4 5 2 1 5 4 3 BLK/GRY BLK/GRY BRN BRN VIO/BLK VIO BLK/VIO BLU/BLK BLU VIO BLU BLK/GRY BLK/VIO BRN BLK/BLU BLU BLK/VIO BLU BLK/VIO VIO VIO BLU BLK BLK/VIO VIO/BLK BLK/BLU BRN NCA NCA NCA NCA NCA NCA NCA NCA NCA BRN BRN NCA SAM CONTROL UNIT FUSE 20 W43 W43 W43 OUTSIDE REARVIEW MIRROR ADJUSTMENT SWITCH IN/OUT ADJUSTMENT MOTOR UP/DOWN ADJUSTMENT MOTOR IN/OUT ADJUSTMENT MOTOR UP/DOWN ADJUSTMENT MOTOR MIRROR HEATER M RROR HEATER RIGHT ELECTRICALLY ADJUSTABLE & HEATED EXTERIOR MIRROR LEFT ELECTRICALLY ADJUSTABLE & HEATED EXTERIOR MIRROR (UNDER LEFT SDE OF DASH) (BEHIND FRONT BUMPER) (BEHIND FRONT BUMPER) (BEHIND FRONT BUMPER) DEFOGGER SYSTEM DEFOGGER SYSTEM Fig 1: Power Mirrors Circuit
POWER SEATS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4585 · Applies to: 450, 451, 452, 454
358856 HOT AT ALL TIMES 10A 10A HOT IN ON OR START 25A ALL TIMES HOT AT LED1 SW L LED2 R LED2 L 30 15 LED1 SW R 31 1 2 X28/5 X1 2 1 1 2 X1 X28/4 2 1 X28/5 1 2 2 1 3 2 C2 4 C3 R9 6 4 5 2 7 2 1 1 2 9 8 7 6 5 4 3 2 1 RED/YEL RED BRN RED BRN RED/BLK BRN BRN BRN BRN RED/VIO BLK/GRY BLK/GRY RED/GRN WHT/RED YEL/RED BLU/YEL RED/VIO BLK/WHT YEL/RED BRN RED RED/BLK BLK/WHT RED/YEL BLU/YEL RED/GRN BLK/GRY RED/BLU WHT/RED BRN SAM CONTROL UNIT FUSE 12 FUSE 44 FUSE 20 COCKPIT SWITCH GROUP W9 W14 W7 W10 LEFT SEAT HEATED CUSHION LEFT SEAT BACKREST HEATED CUSHION FRONT HS (SIH) CONTROL UNIT RIGHT BACKREST HEATED CUSHION RIGHT SEAT HEATED CUSHION LEFT SEAT HEATER SWITCH RIGHT SEAT HEATER SWITCH (UNDER LEFT SIDE OF DASH) (NEAR BASE OF LEFT "A" PILLAR) (LEFT FLOOR PANEL) (LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (IN BATTERY COMPT) Fig 1: Heated Seats Circuit
POWER TOP/SUNROOF >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4586 · Applies to: 450, 451, 452, 454
M M M 358853 ALL T MES HOT AT 30A HOT IN ON OR START 10A HOT AT ALL TIMES 15A 4 X23/7-C1 40 39 X23/7-C1 X23/7 C2 X23/7-C2 4 C3 2 1 2 1 4 35 C8 2 1 10 4 X23/7-C1 3 2 1 1 2 1 2 1 5 6 2 C5 9 2 1 11 12 1 2 7 X23/7-C1 8 2 1 33 6 C9 5 8 2 4 6 5 2 4 6 8 8 C2 32 30 6 5 RED/BLK BLK/GRN BLK/GRN BRN BRN BRN GRN/WHT GRN BLK/GRY RED/WHT RED/GRN BLK/GRY GRY/BLK BRN RED/GRN RED/WHT BLK/GRY PNKBLU BRN PNK/BLU RED/BLU RED/WHT BRN GRY/BLK GRY/WHT BRN RED BLK/RED YEL/WHT BRN BRN/WHT BRN/WHT VIO/WHT YEL/BLU WHT/GRN RED BLK BLU/GRN RED/WHT RED/GRN RED/BLU RED/GRN BLK/WHT BLK RED/WHT VIO/WHT RED BLK RED/GRN RED/WHT RED BLK BLK/WHT RED BLK RED BLK YEL/GRY YEL/GRY YEL/GRY YEL GRY RED/BLU RED/BLU YEL BLU GRY/WHT RED/BLK BRN FUSE 20 FUSE 15 FUSE 29 SAM CONTROL UNIT W9 W10 W6 (NEAR BASE OF LEFT "A" PILLAR) (UNDER LEFT SDE OF DASH) ( N BATTERY COMPT) (BEHIND REAR BUMPER) OPEN SOFT TOP RELAY CLOSE SOFT TOP RELAY POWER SOFT TOP SWITCH RIGHT REAR SOFT TOP MICRO SWITCH LEFT REAR SOFT TOP MICRO SWITCH R GHT ROOF CASSETTE MICRO SWITCH RIGHT SOFT TOP DRIVE LEFT ROOF CASSETTE M CRO SWITCH SOFT TOP MICRO SWITCH LEFT SOFT TOP DRIVE ELECTRIC SOFT TOP MOTOR COMPUTER DATA LINES SYSTEM Fig 1: Power Top/Sunroof Circuit
POWER WINDOWS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4587 · Applies to: 450, 451, 452, 454
M M 358827 OR START HOT IN ON 20A P-UP D-DOWN P-DOWN D-UP P-UP P-DOWN DOWN UP 31 DOWN UP 15 X1 X1 1 2 1 2 B8 B1 X35/2 1 2 B5 B4 X35/2 3 2 1 4 1 2 B1 B8 C1 3 X35/1 B2 B7 B4 B5 3 2 1 4 3 4 2 1 7 C2 C1 1 2 3 4 5 6 6 5 4 3 2 1 BLU RED WHT YEL RED BLU VIO/WHT VIO/BLU BRN BRN VIO/WHT VIO/BLU GRY/BLU BLU RED RED/WHT BRN BRN WHT/YEL BLK/YEL GRY/BLU BRN GRY/BLU PNK/BLU PNK/WHT PNK/WHT WHT/YEL VIO/WHT PNK/BLU BLK/YEL VIO/BLU YEL WHT BRN WHT/BLK YEL/BLK RED/WHT RIGHT POWER WINDOW PASSENGER SIDE SWITCH POWER WINDOW CONVENIENCE FEATURE CONTROL UNIT LEFT POWER WINDOW MOTOR RIGHT POWER WINDOW MOTOR RIGHT POWER WINDOW DRIVER SIDE SWITCH LEFT POWER WINDOW SWITCH SAM CONTROL UNIT FUSE 3 (UNDER LEFT SIDE OF DASH) (BEHIND FRONT BUMPER) (NEAR BASE OF LEFT 'A' PILLAR) (BEHIND FRONT BUMPER) (LEFT SIDE OF DASH) (IN PASSENGER'S DOOR) (IN DRIVER'S DOOR) INTERIOR LIGHTS SYSTEM INTERIOR LIGHTS SYSTEM INTERIOR LIGHTS SYSTEM W43 W9 W43 Fig 1: Power Windows Circuit
RADIO >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4588 · Applies to: 450, 451, 452, 454
358861 SHIELD ANT ANT SHIELD 15 58D SIG HAS USB BUS USB GND USB - LIN IN SHIELD USB + L N GND (+) (+) (-) (+) (-) (+) (-) (-) OR START HOT IN ON 15A 10A HOT AT ALL TIMES 31 30 PARK SW X134/2 9 X134/1 13 10 7 8 3 X134/1 10 X134/1 9 2 3 2 3 1 2 1 2 3 2 1 2 A6 X35/2 A7 X35/1 A7 A6 R8 2 3 2 1 11 12 X134/1 X134/2 11 14 4 8 1 5 12 13 3 6 7 2 2 1 3 4 X134/1 1 3 7 5 2 8 4 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 F S S S G L X26/8 1 21 2 1 20 1 2 4 5 1 3 2 20 18 19 C 4 F S B 1 2 3 4 5 7 8 6 C1 7 4 C3 A 8 7 6 5 4 3 2 1 BRN BLK RED/BLU BRN BLK BLK RED BLU YEL/BRN YEL BLU BLU/BRN BRN/BLK BLK BRN/BLK BLK BRN/WHT BRN WHT WHT WHT GRY/BLK GRYWHT GRYWHT GRY/BLK GRY/WHT GRY/BLK GRY/WHT GRY/BLK BRN GRN BRN/GRN GRN GRN RED/GRY BRN/GRN GRN GRN BRN/GRN BRN RED/GRY RED/YEL RED BLU YEL/BRN GRN GRY/WHT YEL/WHT BRN/RED BLU/BRN YEL BRN/GRN GRY/BLK BLK BLK BLK BLK BLU PNK YEL VIO BRN/BLU BRN/YEL BRN/PNK BRN/VIO BRN RED/GRY RED/YEL RED GRY/WHT BLK BRN/WHT GRN YEL/WHT BRN/RED GRY/BLK BRN/BLK WHT BRN/GRN BLU YEL PNK VIO BRN/BLU BRN/YEL BRN/PNK BRN/VIO WHT BRN BLK SHIELD NCA NCA SHIELD SHIELD NCA BLK/GRY BLK/GRY GRYBLU BRN/BLK BRN/BLK BRN/BLK BRN/BLK BRN BLK BRN BRN/BLK BRN/BLK RED/YEL BRN/RED RED YEL/WHT BLK BRN WHT BLK BLK BLK BLK NCA SHIELD BLU BRN BLU PNK BRN PNK VIO YEL BRN/YEL BRN VIO RED/BLU BLK/GRY BRN RED BLU BRN BLK SAM CONTROL UNIT FUSE 20 FUSE 15 AUTOMATED MANUAL TRANSMISSION CONTROL UNIT ESP CONTROL UNIT EXTERNAL AUDIO SOURCE SEPARATION POINT USB CONNECTION CONNECTOR W7 W12 W14 PARKING BRAKE IND CATOR SWITCH LEFT DOOR SOUND SYSTEM WOOFER LEFT DOOR SOUND SYSTEM TWEETER RIGHT DOOR SOUND SYSTEM WOOFER RIGHT DOOR SOUND SYSTEM TWEETER LEFT REAR SPEAKER RIGHT REAR SPEAKER RIGHT TWEETER SMART PREMIUM RADIO LEFT TWEETER GPS ANTENNA RADIO ANTENNA SUBWOOFER SOUND AMPLIFIER (UNDER DRIVER'S SEAT) (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (LEFT FLOOR PANEL) (1.0L) W/O ECE W/ ECE (NOT USED) (NOT USED) W/ ECE (NOT USED) (IF EQU PPED) (W/ EXTERNAL AUDIO SOURCE) TRANSMISSIONS SYSTEM NTER OR LIGHTS SYSTEM Fig 1: Premium Radio Circuit, W/ Premium Sound
SHIELD¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4589 · Applies to: 450, 451, 452, 454
358862 15 SHIELD ANT ANT SHIELD 15 58D SIG HAS USB BUS USB GND USB - L N IN SHIELD USB + LIN GND (+) (+) (-) (+) (-) (+) (-) (-) OR START HOT IN ON 15A 10A HOT AT ALL TIMES 31 30 PARK SW X134/2 2 8 10 3 9 13 12 10 9 2 3 2 3 3 2 1 2 3 2 1 2 A6 X35/2 A7 X35/1 A7 A6 2 3 2 1 11 14 4 8 1 5 12 13 3 6 7 2 2 1 3 4 X134/1 1 3 7 5 2 8 4 6 F S S S G L X26/8 1 21 2 1 20 1 7 4 5 1 3 2 1 3 2 C 4 F S B 1 2 3 4 5 7 8 6 C1 7 4 C3 A 8 7 6 5 4 3 2 1 BRN/BLK BRN/BLK BRN/VIO BRN/VIO VIO VIO BRN BLU BRN BLU BRN BLU BRN/RED BRN BRN BLK BLK BLK RED/BLU RED/BLU RED BLU BRN BRN BLK BLK RED/BLU RED BLU BRN/VIO BRN/VIO VIO VIO BRN BLU BRN BLU BLU BRN BRN/YEL BRN/YEL YEL YEL BRN/PNK BRN/PNK PNK PNK BLK RED/BLU YEL/BRN YEL BLU BLU/BRN BRN/BLK BLK BRN/BLK BLK BRN/WHT BRN WHT WHT WHT GRY/BLK GRYWHT GRYWHT GRY/BLK GRY/WHT GRY/BLK GRY/WHT GRY/BLK BRN GRN BRN/GRN GRN GRN BRN/GRN GRN GRN BRN/GRN RED/YEL RED BLU YEL/BRN GRN GRY/WHT YEL/WHT BRN/RED BLU/BRN YEL BRN/GRN GRY/BLK BLK BLK BLK BLK BLU PNK YEL VIO BRN/BLU BRN/YEL BRN/PNK BRN/VIO WHT BRN BLK SH ELD NCA NCA SHIELD SHIELD NCA BLK/GRY BLK/GRY GRY/BLU BRN/BLK BRN/BLK BRN/BLK BRN/BLK BRN BRN/BLK BRN/BLK RED/YEL BRN RED YEL/WHT BLK BRN WHT BLK BLK BLK BLK NCA SH ELD BLU BRN/BLU PNK BRN/PNK VIO YEL BRN/YEL BRN/VIO RED/BLU BLK/GRY BRN RED/BLU BRN/BLK SAM CONTROL UNIT FUSE 15 FUSE 20 AUTOMATED MANUAL TRANSMISSION CONTROL UNIT ESP CONTROL UNIT EXTERNAL AUDIO SOURCE SEPARATION POINT USB CONNECTION CONNECTOR W7 W12 W14 RIGHT REAR SPEAKER PARKING BRAKE IND CATOR SWITCH RIGHT DOOR SOUND SYSTEM WOOFER RIGHT DOOR SOUND SYSTEM TWEETER LEFT DOOR SOUND SYSTEM WOOFER LEFT DOOR SOUND SYSTEM TWEETER RIGHT TWEETER LEFT REAR SPEAKER LEFT TWEETER SMART PREMIUM RADIO SUBWOOFER GPS ANTENNA RADIO ANTENNA (UNDER DRIVER'S SEAT) (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (LEFT FLOOR PANEL) (1.0L) W/O ECE W/ ECE ( F EQUIPPED) (W/ EXTERNAL AUDIO SOURCE) TRANSMISSIONS SYSTEM NTER OR LIGHTS SYSTEM Fig 2: Premium Radio Circuit, W/O Premium Sound
SHIELD¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4590 · Applies to: 450, 451, 452, 454
358860 15 ANT SHIELD 58D SIG HAS USB BUS USB GND USB - LIN IN SHIELD USB + L N GND (+) (+) (-) (+) (-) (+) (-) (-) OR START HOT IN ON 15A 10A HOT AT ALL T MES 31 15 30 PARK SW G L X26/8 1 21 2 1 20 1 5 2 4 2 3 A6 A7 2 1 X35 1 X35/2 A6 A7 2 1 S 2 3 1 4 3 2 1 3 2 1 3 2 C 4 7 3 8 F S B 1 2 3 4 5 7 8 6 C1 7 4 C3 A 8 6 5 4 3 2 1 BLK/GRY BRN/BLK BRN BLK SHIELD BLK/GRY RED BLU GRYBLU BRN/BLK BRN/BLK BRN/BLK BRN BLK BRN BRN/BLK BRN/BLK BRN GRN BLU GRN BLU/BRN BLU BLU/BRN BLU BLU/BRN BRN GRN GRN GRN BRN GRN GRN BRN/GRN ORG ORG/BRN GRY/BLK GRY/WHT NCA NCA YEL YEL BRN BLK BLK BLK BLK WHT BRN NCA BLK BRN WHT NCA BLK BLK BLK BRN RED/BLU BLK NCA SHIELD BLU BLU/BRN ORG ORG/BRN GRN YEL YEL/BRN BRN GRN RED BLU BLK/GRY BRN BLK RED BLU BRN BLK AUTOMATED MANUAL TRANSMISSION CONTROL UNIT SAM CONTROL UNIT FUSE 20 FUSE 15 ESP CONTROL UNIT EXTERNAL AUD O SOURCE SEPARATION POINT USB CONNECT ON CONNECTOR W7 W14 W12 PARKING BRAKE IND CATOR SWITCH SUBWOOFER SMART ENTRY RADIO RIGHT TWEETER RIGHT FRONT SPEAKER LEFT TWEETER LEFT FRONT SPEAKER RADIO ANTENNA (UNDER DRIVER'S SEAT) (UNDER LEFT SDE OF DASH) (BEHIND REAR BUMPER) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (LEFT FLOOR PANEL) (1.0L) W/O ECE W/ ECE (IF EQUIPPED) (W/ EXTERNAL AUDIO SOURCE) (IF EQUIPPED) (W/ SOUND SYSTEM) (W/ SOUND SYSTEM) TRANSMISSIONS SYSTEM INTERIOR LIGHTS SYSTEM Fig 3: Radio Circuit
SHIFT INTERLOCK >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4591 · Applies to: 450, 451, 452, 454
358844 87/1 87/1 CAN H CAN L CAN L CAN H HAS HOT AT 25A ALL TIMES BACK OUT CAN L CAN H 31 30 BACK SUP ALL TIMES HOT AT +BS CAN L +BLS CAN H 15A 13 R 14 15 14 11 C8 C5 C3 2 1 20 7 8 3 4 4 5 3 2 1 6 13 1 3 2 4 8 35 14 30 RED/YEL BRN/BLK GRN GRN/WHT GRN/WHT GRN BRN BRN/BLK BRN/BLK BLK/RED RED/GRY RED/GRY RED/GRY RED/GRY RED/GRY RED/GRY YEL/RED YEL/RED YEL/RED RED/YEL GRN GRN/WHT BRN YEL/RED RED/YEL RED/GRY BLK BRN BLK/RED RED/YEL BLK GRN GRN/WHT BLK/RED SAM CONTROL UNIT FUSE 24 FUSE 8 ESP CONTROL UNIT AUTOMATED MANUAL TRANSMISSION CONTROL UNIT LEFT BACKUP LAMP RIGHT BACKUP LAMP COMPUTER DATA LINES SYSTEM EXTERIOR LIGHTS SYSTEM COMPUTER DATA LINES SYSTEM SOUND SYSTEMS COMPUTER DATA LINES SYSTEM STOP LAMP SWITCH PARKING BRAKE INDICATOR SWITCH ELECTRONIC SELECTOR LEVER MODULE CONTROL UNIT (UNDER LEFT SIDE OF DASH) (IN BATTERY COMPT) (ON BRAKE PEDAL ASSEMBLY) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (UNDER DRIVER'S SEAT) (BEHIND REAR BUMPER) (IN BATTERY COMPT) (UNDER CENTER CONSOLE) W10 W7 W10 Fig 1: Shift Interlock Circuit
STARTING/CHARGING > 1.0L >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4592 · Applies to: 450, 451, 452, 454
358311 OR START HOT IN ON 25A 30 F L CAN H CAN L CAN L CAN H G 30 2 X26 1 C1 6 33 46 2 1 6 9 C1 C2 71 78 43 4 3 (OR GRN/BLU) (OR GRN/BLU) BLK/YEL BLK/YEL BLK WHT/BLU GRN/BLK GRN/BLK WHT/BLU BRN BLK RED GRN/WHT GRN GRN GRN/WHT BRN BLK BLK BRN BLK SAM CONTROL UNIT FUSE 1 ME-SFI (ME) CONTROL UNIT HEATING SYSTEM SHUTOFF VALVE INSTRUMENT CLUSTER STARTER BATTERY MULTIFUNCTION DISPLAY ALTERNATOR CHARGE MONITORING & WARNING LAMP IND GENERATOR (UNDER LEFT SIDE OF DASH) (RIGHT REAR OF LUGGAGE COMPT) (IN BATTERY COMPT) W10 STARTING CIRCUIT COMPUTER DATA LINES SYSTEM Fig 1: 1.0L, Charging Circuit
ALL TIMES¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4593 · Applies to: 450, 451, 452, 454
M 358312 ALL TIMES HOT AT CAN-H CAN-L CAN H CAN L CAN H CAN L START RUN LOCK ACC 50A 25A OR START HOT N ON 50 30 5 C2 40 C8 39 R 13 14 5 6 C D 38 C8 3 5 X26 1 C6 BRN RED GRN/WHT GRN GRN/WHT GRN GRN/WHT GRN BLK RED GRY/BLK GRY/BLK RED BLU BLU VIO BLK BLK RED BRN BLK IGNITION/ STARTER SWITCH SAM CONTROL UNIT FUSE 1 ELECTRON C SELECTOR LEVER MODULE CONTROL UNIT AUTOMATED MANUAL TRANSMISSION CONTROL UNIT ALTERNATOR FUSE 33 STARTER RELAY BATTERY STARTER (UNDER LEFT SIDE OF DASH) (NEAR BASE OF LEFT "A" PLLAR) (UNDER CENTER CONSOLE) (UNDER DRIVER'S SEAT) ( N BATTERY COMPT) W9 W10 COMPUTER DATA LINES SYSTEM COMPUTER DATA L NES SYSTEM COMPUTER DATA L NES SYSTEM Fig 2: 1.0L, Starting Circuit
SUPPLEMENTAL RESTRAINTS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4594 · Applies to: 450, 451, 452, 454
358849 10 9 8 7 D BELT- D BELT+ PADSW ON OR START HOT IN RUN 10A 2 4 3 6 5 1 31 15 PADL STPS CAN L CAN H STPS DAT D WBAG- D WBAG+ P WBAG+ P WBAG- D TENSI- D TENSI+ SIG SIG 31 VREF 15 GND CAN L VREF CAN H GND 18 2 5 2 1 1 2 1 3 1 3 X28/7 X28/6 1 2 1 2 1 2 X1 1 1 2 2 1 2 2 1 C3 3 X35/1 6 7 8 8 7 6 X35/2 1 3 4 5 2 6 8 7 10 11 12 9 13 15 14 17 19 18 16 20 22 21 24 B 23 X28 10 4 X55/4 1 3 1 1 X55/4 2 3 4 6 8 7 5 9 10 11 13 15 14 12 1 2 X28/9 1 X28/8 2 1 2 1 2 1 3 3 1 2 2 3 1 17 16 BLU/YEL YEL BLK WHT/ YEL BLK VO BLU RED RED/VO WHT/BRN BRN GRN/BLK GRN/BLK WHT/BRN RED/VIO WHT/BRN RED/VIO RED/VIO WHT/BRN BLU/RED WHT/VIO BRN BRN BLK WHT BLK WHT NCA YEL/BLK NCA PNK BRN PNK BLK/RED YEL/BLK BLK/RED BLU/YEL BLK NCA WHT BLK WHT NCA NCA NCA BLK WHT NCA BRN WHT BLK WHT BLK WHT BLK BRN/BLU GRY/VIO BRN PNK BRN/PNK BRN PNK YEL BLK BLKRED GRN GRN/WHT BRN/PNK YEL BLK RED WHT RED/BLK RED/YEL BLK RED/BLK YEL/BLK RED/YEL BLK BRN BLK/RED BLU WHT BRN BLU/YEL RED/YEL BRN BLK/RED BLU BRN/WHT BRN/BLU BLK/RED RED WHT BLK RED BLU BLK/RED BRN/WHT BLU WHT RED/YEL BLU/YEL NCA NCA NCA NCA NCA NCA BRN/RED BLK/RED BLKRED GRY/VIO BLKRED BRN/BLU SAM CONTROL UNIT FUSE 18 RESTRAINTS SYSTEMS CONTROL UNIT FRONT PASSENGER HEAD/THORAXBAG SQUIB DRIVER HEAD/THORAXBAG SQUIB DRIVER SEAT ADJUSTMENT DETECTION SENSOR AUTOMATIC CHILD SEAT RECOGNITION AIR BAG OFF INDICATOR LAMP FRONT PASSENGER DOOR PRESSURE SENSOR DRIVER DOOR PRESSURE SENSOR DRIVER SIDE ANCHOR FITTING TENSIONER SQU B DRIVER BELT FORCE LIMITER RIGHT WINDOW BAG SQUIB WEGHT SENSING SYSTEM (WSS) CONTROL UNIT SEAT OCCUPIED PRESSURE SENSOR RECOGNITION FRONT PASSENGER SEAT BELT BUCKLE RESTRAINT SYSTEMS SWITCH DRIVER SEAT BELT BUCKLE RESTRAINT SYSTEMS SWITCH FRONT PASSENGER AIRBAG SHUTOFF SWITCH LEFT WINDOWBAG SQUIB BELT TENSION SENSOR W26 W83 W7 W26 COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA L NES SYSTEM (UNDER LEFT SIDE OF DASH) (IN BATTERY COMPT) (CENTER OF DASH) (BEH ND REAR BUMPER) (IN BATTERY COMPT) (IN SEAT BOTTOM) (IF EQUIPPED) ( F EQUIPPED) (IF EQUIPPED) Fig 1: Supplemental Restraint Circuit (1 of 2)
(OR D-BAG 2 +)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4595 · Applies to: 450, 451, 452, 454
358850 (OR D-BAG 2 +) (OR D-BAG 2 -) (OR D-BAG 1 +) (OR D-BAG 1 -) (OR D-PRET -) (OR D-PRET +) (OR D-PRET +) (OR D-PRET -) 10 9 8 7 CAN L CAN H P HTB+ P HTB- P HTB+ P HTB- P PR DSI- P PR DSI+ D PR DSI+ D PR DSI+ P BKL ON P BAG2- P BAG2+ P SA DSI+ SK BF KTB- BF KTB+ FA KTB+ GF, BF- GS, FA+ AB FA1+ AB BF1- P SA DSI- LF KTB- CAN-H CAN-L AB FA1- AB BF1+ GF, BF+ GS, FA- FA KTB- LF KTB+ 6 5 4 3 2 1 (OR 2) (OR 3) 6 1 10 5 3 1 1 3 1 3 1 2 1 2 3 1 1 2 3 1 B 1 6 1 3 5 4 2 6 8 7 10 12 11 9 13 15 14 17 19 18 16 20 22 21 24 26 25 23 28 27 29 31 32 A 30 9 6 5 X99/17 4 2 1 1 3 3 1 2 1 4 3 2 1 2 1 3 4 2 1 BLK WHT BRN/WHT VIO RED WHT/VIO BLU RED RED/VO WHT/BRN RED/VO WHT/BRN WHT BLK GRN VIO BLU YEL NCA NCA GRN GRN/WHT NCA NCA NCA NCA NCA BLU/BLK BRN/GRN BLU YEL GRN VIO BLU/GRN BRN/BLK NCA VO BLU/BLK BRN/GRN GRN VIO/BLU BRN/YEL BLU BRN/BLK BLU/GRN WHT/GRN WHT/VO RED/VO BLU/RED WHT WHT/BRN BLK WHT BLK BRN/BLU BRN BLU/YEL GRY/VO WHT BLK WHT BLK BRN/BLU GRY/VO BRN YEL/BLK WHT/YEL GRN/YEL BRN/VO RED/BLK GRN GRN/WHT BRN WHT/YEL BRN/VIO RED/BLK GRN/YEL YEL/BLK NCA BLU/YEL BLK WHT BRN BRN WHT BLK WHT BLK BRN/VIO RED/BLK GRN/YEL YEL/BLK NCA WHT BLK BRN FANFARE HORNS & AIR BAG CLOCK SPRING CONTACT RESTRANTS SYSTEMS CONTROL UNIT INSTRUMENT CLUSTER DRIVER REEL TENSIONER SQUIB (OR LEFT EMERGENCY TENSIONING RETRACTOR SQUIB) FRONT PASSENGER AR BAG SQUIB 2 RIGHT EMERGENCY TENSION NG RETRACTOR SQUIB (OR FRONT PASSENGER REEL TENSIONER SQUIB) DRIVER AIR BAG IGNITION SQU B 1 DRIVER AR BAG IGNITION SQUIB 2 DRIVER AIR BAG IGNITION SQUIB 1 FRONT PASSENGER AR BAG SQUIB 1 AIR BAG INDICATOR & WARNING LAMP SEAT BELT WARNING LAMP DRIVER SIDE FRONT ACCELERATION SENSOR PASSENGER SIDE FRONT ACCELERATION SENSOR FRONT PASSENGER KNEEBAG SQUIB DRIVER KNEEBAG SQU B DRIVER HEAD THORAXBAG SENSOR PASSENGER HEAD/THORAXBAG SENSOR W6 W7 COMPUTER DATA LINES SYSTEM COMPUTER DATA L NES SYSTEM (CENTER OF DASH) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (RIGHT SIDE OF FRONT BUMPER) (LEFT SIDE OF FRONT BUMPER) (ON LEFT "B" PILLAR) (ON RIGHT "B" PILLAR) (EXCEPT USA) Fig 2: Supplemental Restraint Circuit (2 of 2)
VREF¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4596 · Applies to: 450, 451, 452, 454
358857 GND GND VREF 15 SIG VREF CAN H 31 CAN L SIG HOT IN ON OR START 10A 18 2 1 3 1 X55/4 X55/4 4 1 3 2 C3 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 2 BLK/RED BRN NCA NCA NCA BLU BLU/WHT BRN/WHT BLK/RED BRN/WHT NCA NCA BLK/RED BLK/RED RED/YEL BLU/YEL BRN/RED BLK/RED BRN BRN BLU/WHT NCA RED/YEL BLU/YEL BLU SAM CONTROL UNIT FUSE 18 W7 SEAT OCCUPIED RECOGNITION PRESSURE SENSOR BELT TENSION SENSOR WEIGHT SENSING SYSTEM (WSS) CONTROL UNIT (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (IN SEAT BOTTOM) COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM Fig 3: Weight Sensing System Circuit
TRANSMISSION >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4597 · Applies to: 450, 451, 452, 454
358859 MAIN RELAY ENERGIZED HOT W/ 25A ALL TIMES HOT AT 15A CAN L CAN H BACK OUT 31 30 BACK UP 3 4 C1 2 8 C3 6 5 4 3 2 1 RED/YEL RED/GRY YEL/RED GRN GRN/WHT YEL/RED BRN RED/YEL RED/GRY SAM CONTROL UNIT FUSE 8 FUSE 24 RIGHT TAILLAMP LEFT TAILLAMP (UNDER LEFT SIDE OF DASH) (IN BATTERY COMPARTMENT) (UNDER CENTER CONSOLE) COMPUTER DATA LINES SYSTEM W10 ELECTRONIC SELECTOR LEVER MODULE CONTROL UNIT Fig 1: Transmission Circuit, W/ Electric Drive
WS GND¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4598 · Applies to: 450, 451, 452, 454
M M M 358858 WS GND ESWMA RNO2 DOWN RNDI UP 40A CAN L CAN H BACK OUT + M- M+ - POS2 POS1 M+ M- + - POS2 POS1 M+ M- + POS2 POS1 - CAN L CAN H 31 30 BACK SUP HOT N ON OR START 15A HOT IN ON OR START 7.5A RELAY ENERGIZED HOT W/ MAN 25A 10A HOT AT ALL T MES ALL T MES HOT AT (-) (-) (-) KUPINKB GETINKB GETINKB NGETB PARK SW KUPINKA GETINKA GETINKA NGETA 5V 5V 5V KUPM KUPP GETM GETP GETM GETP IGN SW AMT REL CAN L CAN H 30 87/1 87/1 31 AMT1 31 AMT2 12 11 10 9 8 7 38 37 C2 A 1 2 X26/8 1 1 3 6 4 5 1 2 1 6 3 2 4 5 3 5 4 6 1 2 9 6 6 5 4 3 2 1 C3 4 3 7 1 C2 11 C5 2 C4 L 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 R 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 WHT/GRN BRN BLK BLU/BLK BRN WHT BRN/YEL BLU/RED WHT/GRN BRN/BLK BLU/BLK RED/ WHT YEL BLK/ GRN GRN/WHT BLK BRN/ BRN/ BLK VIO/WHT RED/GRN WHT/YEL GRY/VO BLU/YEL BRN/GRY BRN RED/BLU WHT/BRN BLU/BRN BRN/VO VIO/GRN WHT/RED VO/YEL BRN/YEL VO BLU/GRN BLU GRN GRN/WHT BLK/GRY BRN/WHT BLU/RED BRN/YEL YEL/RED RED/GRY BLK/ GRY YEL BLK/ BLU RED/ WHT RED/ GRY BLU RED/ BRN GRY BRN VIO BRN/YEL SHIELD BLU/YEL BLU/BRN BLU/GRN GRN/WHT BRN BLK GRYVIO VIO/GRN VIO/YEL GRN WHT/YEL WHT/BRN WHT/RED VIO/WHT RED GRN BRN RED BLU BLU VIO BLK/YEL BLU GRN GRN/WHT RED WHT RED GRY RED GRY BRN RED BLU BRN RED BLU SAM CONTROL UNIT FUSE 30 FUSE 8 FUSE 24 FUSE 19 FUSE 12 INSTRUMENT CLUSTER SMART ENTRY RADIO SMART PREM UM RADIO EXTER OR LIGHTS SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA L NES SYSTEM AUTOMATED MANUAL TRANSMISSION RELAY ELECTRONIC SELECTOR LEVER MODULE CONTROL UNIT TRANSMISSION RPM SENSOR TRANSMISSION MOTOR 1 TRANSMISSION MOTOR 2 AUTOMATED MANUAL TRANSMISSION CONTROL UNIT CLUTCH MOTOR (UNDER LEFT SIDE OF DASH) (LEFT FLOOR PANEL) (UNDER CENTER CONSOLE) (BOTTOM REAR OF TRANSMISSON) (UNDER DRIVER'S SEAT) W14 (ENTRY RADIO) (PREMIUM RADIO) Fig 2: Transmission Circuit, W/O Electric Drive
TRUNK, TAILGATE, FUEL DOOR >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4599 · Applies to: 450, 451, 452, 454
M M M M 358855 ALL TIMES HOT AT 20A HOT AT ALL TIMES 2 1 8 C10 1 2 1 2 C10 5 C2 1 2 3 5 1 4 2 1 2 1 2 C9 40 39 C8 36 2 GRY/ PNK/ YEL BRN BLU/ BLK BRN BLU/ BLK BRN YEL BLU/RED (OR BLU/RED) YEL BRN BLU/RED BRN YEL PNK BRN BRN YEL PNK PNK YEL GRY/YEL GRY/YEL BRN PNK/YEL BRN BLU/BLK YEL GRN GRN/WHT PNK/YEL BLU/BLK SAM CONTROL UNIT FUSE 31 W6 W6 W9 W6 W6 W6 W6 (UNDER LEFT SIDE OF DASH) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (NEAR BASE OF LEFT "A" PILLAR) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) (BEHIND REAR BUMPER) COMPUTER DATA LINES SYSTEM DOOR LOCKS SYSTEM DOOR LOCKS SYSTEM REAR-END DOOR/ TRUNK LID CL (ZV) RELAY TRUNK LID OPENING ASSIST MOTOR 2 TRUNK LID OPENING ASSIST MOTOR TRUNK LID OPENING ASSIST MOTOR 1 REMOTE TRUNK OPENING SWITCH REAR-END DOOR HANDLE SWITCH TRUNK LID ROTARY TUMBLER MICROSWITCH FUEL FILLER FLAP CL (ZV) MOTOR (COUPE) CONVERTIBLE COUPE CONVERTIBLE COUPE Fig 1: Trunk & Fuel Door Release Circuit
WARNING SYSTEMS >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4600 · Applies to: 450, 451, 452, 454
358846 CAN L CAN H DISPLAY 15 HOT IN ON OR START 10A HAS HOT AT ALL TIMES 31 CAN H CAN L SK 31 10A CAN L CAN H 30 31 BFL 30 CAN H CAN L 25A 2 23 1 18 17 A B A X28/8 C8 39 40 2 C3 1 2 20 1 2 1 2 C1 5 1 2 C2 1 8 5 1 2 4 17 3 35 14 BRN/BLK GRN GRN/WHT BLK/RED BLK/RED GRY/VIO BLK/RED BRN/BLK BRN/BLK BRN RED/PNK RED/WHT RED/WHT GRN GRN/WHT BRN GRY/VIO RED BLK GRN GRN/WHT RED/WHT BRN BRN BRN BRN/WHT BRN/WHT RED/PNK GRN/WHT GRN SAM CONTROL UNIT FUSE 18 FUSE 12 FUSE 11 RESTRAINTS SYSTEMS CONTROL MODULE ESP CONTROL UNIT INSTRUMENT CLUSTER DRIVER SEAT BELT BUCKLE RESTRAINT SYSTEMS SWITCH BRAKE FLUID INDICATOR SWITCH BRAKE FLUID AND PARKING BRAKE WARNING LAMP MULTI- FUNCTION DISPLAY SEAT BELT WARNING LAMP PARKING BRAKE INDICATOR SWITCH COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM SOUND SYSTEMS W26 W10 W43 W9 W7 (UNDER LEFT SIDE OF DASH) (IN BATTERY COMPT) (CENTER OF DASH) (IN BATTERY COMPT) (LEFT CENTER OF VEHICLE UNDERCARRIAGE) (NEAR BASE OF LEFT "A" PILLAR) (BEHIND FRONT BUMPER) (BEHIND REAR BUMPER) Fig 1: Seat Belt Warning Circuit
CAN-H¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4601 · Applies to: 450, 451, 452, 454
358845 CAN-H CAN-L 15 30 HOT AT ALL TIMES HOT IN ON OR START 10A 7.5A 31 CAN H CAN L 39 40 9 6 C2 2 14 3 C8 C2 C3 28 1 2 3 4 3 1 5 2 GRN GRN/WHT GRN GRN/WHT RED/VIO GRN/YEL BRN GRN/YEL BLK/YEL RED/VIO RED/WHT GRN GRN/WHT RED/WHT BLK/YEL BRN SAM CONTROL UNIT INSTRUMENT CLUSTER FUSE 12 FUSE 19 COCKPIT SWITCH GROUP TPM (RDK) SWITCH TPM (RDK) CONTROL UNIT LEFT FRONT TPM (RDK) WHEEL SENSOR RIGHT FRONT TPM (RDK) WHEEL SENSOR RIGHT REAR TPM (RDK) WHEEL SENSOR LEFT REAR TPM (RDK) WHEEL SENSOR (UNDER LEFT SIDE OF DASH) (IN BATTERY COMPT) (IN BATTERY COMPT) (LEFT SIDE OF DASH) COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM W10 W10 Fig 2: Tire Pressure Monitoring Circuit
WIPER/WASHER >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4602 · Applies to: 450, 451, 452, 454
M M M 358831 ALL TIMES HOT AT CAN L CAN H LIN 15A HOT AT ALL T MES 15A OR START HOT N ON HOT IN ON OR START 25A OR START HOT IN ON 10A C2 5 39 40 9 6 2 14 C2 1 1 2 3 2 1 X18 19 C1 C5 6 3 2 1 C3 1 C5 5 3 9 4 3 2 1 3 C8 17 36 C9 7 8 10 4 1 11 5 9 C3 17 4 1 2 40 BRN GRN/WHT GRN RED/GRN GRN GRN WHT RED/WHT BLK/GRY VIO/BLU NCA VIO BLU RED/WHT RED/WHT BRN VIO/BLU GRN/BLU BLKGRN GRN BLU BRN BRN BLK/GRN GRN/BLU BLK/GRN YEL BLKBLU BLU GRY BLK/BLU BLU/GRY YEL BRN GRY/BRN YEL GRN/RED GRN/BLU BRN/BLU RED/GRN GRY/BRN GRN/RED YEL BLK/GRY BRN GRN BLU BLKGRY RED/GRN BRN/BLU RED/GRN SAM CONTROL UNIT FUSE 2 FUSE 17 FUSE 20 FUSE 12 ADDITIONAL NSTRUMENTS INSTRUMENT CLUSTER W9 W9 W6 W43 W9 REAR WIPER RELAY FRONT WIPER RELAY RAIN SENSOR/ LIGHT SENSOR TALGATE WIPER MOTOR WIPER MOTOR WINDSH ELD WASHER FLU D PUMP R GHT WIPER SWITCH (UNDER LEFT SIDE OF DASH) (NEAR BASE OF LEFT "A" PLLAR) (NEAR BASE OF LEFT "A" PILLAR) (TOP CENTER OF WINDSHIELD) (TOP CENTER OF TAILGATE) (BEHIND REAR BUMPER) (BEHIND FRONT BUMPER) (NEAR BASE OF LEFT "A" PLLAR) (CENTER REAR OF FRONT COMPT) ( F EQUIPPED) (COUPE) COUPE COMPUTER DATA LINES SYSTEM COMPUTER DATA LINES SYSTEM Fig 1: Wiper/Washer Circuit