Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSSMART2012FORTWO ELECTRIC DRIVE, 2D COUPEREPAIR AND DIAGNOSIS (SINGLE PAGE)COLLISIONBODY PANELSSIDE WALL - 451 CHASSISTESTING & REPAIRPARTIALLY REPLACE SIDE WALL PANELINGPARTIALLY REPLACE SIDE WALL PANELING - AR63.10-P-0115MCO
2012 Smart Fortwo Electric Drive, 2D Coupe
Partially replace side wall paneling - AR63.10-P-0115MCO
2012 Smart Fortwo Electric Drive, 2D CoupeSECTION Partially replace side wall paneling - AR63.10-P-0115MCO
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 splatter 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 body repair | AH60.00-P-0001-01FF | ||
| The following workshop equipment and tools are required for repair: Hole punching pliers, Ø 6 mm Tarp (fire-resistant) |
Round wire brush Backup pad Cutting grinder Cartridge gun Drill Angle grinder Body jig saw Wet/dry vacuum cleaner Punching pliers Spot wed cutter Vise grip pliers MIG MAG gas welder (steel, brazing, aluminum) Inverter 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) | ||
| 3 | Partially remove side wall paneling (1) | 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 | ||
| 5 | Prepare side 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 repair area 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 | |
| 11 | Paint repair area 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 | White sealing compound, 310 ml, DBL 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 wax Art. no.: 122.73Q |
Henkel Loctite |
| BR00.45-Z-1001-07A | Zinc dust paint suitable for spot welding | A 000 986 34 42 |
RENDER: 1.0x
NO RELATED
Recommended Tools & Savings
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Affiliate disclosure: We may earn a commission at no extra cost to you.
When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.