Air Inlet Temperature Sensor On the back of the intercooler, just behind the top pipe. Press the tab on the electrical connector and pull the connector free. When the electrical connector is out of the way, pinch the tabs on eaither side of the sensor and pull it out....
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451 CDI 54bhp Sensors
54bhp CDI - The Over-Engineered Pain In The Arse The 45bhp CDI engine was reliable and efficient, however, due to the Euro 5 emissions standards coming into force, smart had to make changes. They added a DPF (Diesel Particulate Filter) which removes the particulates...
451 CDI AC Belt Change
Changing the air conditioning belt on the diesel isn't the same as the petrol model, they didn't put a pretensioner on that belt for you to loosen to enable the belt to just pull off. However, the alternative is actually easier and doesn't require you to retention the belt correctly afterwards.
451 CDI Alternator Belt Change
Getting The Old Belt Off Take a 15mm spanner and under the alternator tensioner nut and swing the alternator down. The old belt can be removed (if you don't have AC, if you do, remove that first) and the new belt fitted. Re-tensioning The Belt - The New Way This is...
451 CDI Crankshaft Sensor
If you don't hate your life now, give it to the end of the page. This makes a 450 starter motor change look easy. 45bhp & 54bhp Crankshaft Sensor The arrow below shows the location of the crankshaft rotation sensor. It's sandwiched between the engine block, high...
451 CDI EGR Cooler
Why Would I Need To Change The EGR Cooler? They are very poorly manufactured and split internally. This allows all of your coolant to escape into the engine. Click here to read more about this failure. Changing The EGR Cooler Actually getting to the EGR cooler is a...
451 CDI Engine Removal
In the history of evilution, I had never had to remove an engine. Just my luck I had to start on the hardest one. Even then, I wouldn't go as far as saying it was hard, just time consuming, awkward and daunting. Including taking photos and notes, I achieved this in...
451 CDI Exhaust Pressure Sensor
What Happens When It Fails? Initially the car goes into a "kind of" safe mode. Normal safe mode severely reduces the power from the engine which normally limits the top speed of the car to about 40mph. When the exhaust pressure sensor fails, you'll get a reduction in...
451 CDI Exhaust Removal
45bhp Diesel Exhaust Remove the rear panels and the crash bar to get good access to the exhaust. Disconnect the breather pipe by squeezing the hose clamp with pliers... ...and pulling the pipe off. You have 2 options regarding the lambda sensor. If you are fitting a...
451 CDI Fuel Rail Removal
Before you remove the CDI fuel rail, you have to remove the injector feed pipes, seen here. I have removed the injectors totally gto give more room. The fuel rail has been highlighted below. Remove the high pressure feed pipe. You'll need an 18mm and a 14mm spanner to...
451 CDI Fuel Tank Drain
OK, so you put the wrong fuel in your car like a total moron. You know this already. You need to empty the tank so you can fill it with the correct fuel. Fuel Filter The fuel filter is quite well hidden, it is behind the offside rear wheel arch. Jack the car up,...
451 CDI Injector Removal
Uncover and lower the engine. Just underneath the "smart cdi" logo is the fuel rail. Attached to the fuel rail are 3 injectors. I have highlighted one of the injectors below. Here is a closer look of 1 of the 3 injectors. To disconnect the electrical connector, pull...
451 CDI Intercooler Removal
Should you decide to change the problem EGR cooler on your 54bhp CDI, You'll need to remove the intercooler. Before you do this I would recommend not bothing and just bypass it instead. Do You Wish To Continue? Mad man! Loosen both hose clamps using a 7mm socket....
451 CDI Oil Change
451 Diesel Oil Change (45bhp & 54bhp) Changing the oil on a diesel smart isn't like most other cars. You can't just undo the sump plug and let it all drain out, the main reason is because it doesn't have a sump plug. You have to adopt the same service technique as...
451 CDI Turbo Removal
The 45bhp diesel turbo and the 54bhp diesel turbo is the same unit. The only difference is the way that the wastegate is controlled. The 45bhp wastegate is boost controlled and the 54bhp wastegate is vacuum controlled. Once you've removed the rear panels, crash bar...
451 CDI Wastegate Actuator Hoses
45BHP Wastegate Actuator The 45bhp smart 451 diesel has the most simple vacuum hose set up. It goes from the wastegate actuator... ...straight into the high pressure outlet of the turbo. That is all. 54BHP Wastegate Actuator As soon as I can find the photos, I'll add...
451 Centre Console Removal
Go over to the passenger side... ...and pull back the carpet. Remove the polystyrene footwell block to reveal the battery tray. The centre console cover has a screw (arrowed below), remove it... ...and the same on the opposite side. If you have anything attached to...
451 Clutch Actuator Setting
Note Do not touch clutch actuator on the tappet or the rubber bellow. Never touch the electric connector. The servo motor sensor system can be destroyed by static discharge. Removing The Clutch Actuator Switch off the ignition. Wait for the stopping time of the...
451 Clutch Actuator Testing
Bench Testing The 451 Clutch Actuator Pin Wire colour in photo Function 1 Brown/Grey 0V 2 Blue/Yellow Channel A 3 Red/Green Motor 1 4 Grey/Violet Channel B 5 White/Yellow +5V 6 Violet/White Motor 2 Testing The Motor And Mechanics Service the mechanics of the...
451 Clutch Removal
Remove the gearbox to reveal the clutch assembly. Around the outside of the clutch housing are 6x E10 bolts. Take them all out. (20Nm on refitting). The front section will come away with the friction plate inside. If you are fitting a new friction plate, it's...