The Roadster has a nasty habit of snapping the air conditioning pipes.
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450 Coolant Radiator Removal
Remove the front panels, remove the crash bar. Have the air conditioning gas professionally removed. Don't just remove the 10mm nut, lever the connection open and let the gas escape. Disconnect the bottom coolant hose and allow the coolant to drain into an antique bed...
450 AC Radiator Removal
Remove the radiator pack as shown here. Just hinge it down from the top... And it'll be free from the radiator pack. Behind that you'll find the air conditioning radiator. Grab the radiator from the hose connector block and open the radiator like a door. Once you've...
450 Larger Oil Sump Pan
More Oil, More Better OK, the grammar is terrible but facts are there. The more oil your engine has available, the slower it will degrade. Now, I'm not saying to put more oil in your engine, that'd be terrible. What we need is a bigger sump. Bigger Sump, Bigger Cost?...
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...
Roadster Wastegate Actuator Hoses
Understanding Engine Hose Position If you have a BCS (Boost Control Solenoid AKA Cycle Valve) as most new smarts do, you will notice that there is a maze of pipes surrounding the turbo. So here is a roundup of where they come from, the colour and where they all go....
Brake Hose Capping Tools
Air In The Brake System = Bad We all know what gravity does. What you might not know is what happens when you disconnect brake pipes and lines. The brake fluid reservoir, master cylinder, ABS pump and most of the hoses are higher than the points you disconnect. So,...
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 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 Belt Change
The 451 turbo and non turbo (before the MHD bullshit arrived) had the same belt arrangement. The belt (shown below in red) was driven by the crank pulley and that turned the water pump and the alternator. Obviously you want the water pump to spin so fitting a new belt...
Roadster Gearbox Fluid Change
Although smart say this is a non servicable item, it would be foolish to use the same oil year in, year out. I recommended you change it every 3rd service. People have found the gearchange is much improved after doing this.
451 Gearbox Fluid Change
Fortwo 451 Petrol Non Turbo (Including MHD) The transmission fluid change is similar to that of the older smart fortwo and Roadster. The main difference is the position of the draining hole. It is now on the right bottom side of the transmission housing. The upper...
452 Roadster Water Pump Change
Faulty Water Pump? The water pump is designed to leak slightly when it needs replacing. Most of the time it is worn bearings but the have been known to break blades. This reduces the performance of the pump and bits of the blade can block water ways and make noises in...
Roadster Belt Change
This page covers the AC belt and alternator/water pump belt. Air Conditioning Belt Look at the right hand side of the engine. It's not easy to see. Find the tensioner pulley wheel. Use a Torx45 bit to loosen the screw arrowed in the photo below. Push the pulley wheel...
450 Coil Pack Removal
Open the engine cover and look between you and the large smart logo on the air inlet manifold. They are covered in a bunch of shit so I have coloured them in so you can see where they are. Each one of the 3 coil packs have a 4 wire connector... ...disconnect it....
Roadster Coil Pack Removal
Open the engine cover and look between you and the large smart logo on the air inlet manifold. They are covered in a bunch of shit so I have coloured them in so you can see where they are. Each one of the 3 coil packs have a 4 wire connector... ...disconnect it....
450 Clutch Actuator Gaiter
I'm sure you know that the clutch actuator is a bit of a weak spot. It doesn't snap the spiral like the 451 and 454 however, it does dry up internally which will slow down the movement. The only thing that stops the water from getting into the casing is a rubber boot....
Roadster Clutch Actuator Gaiter
I'm sure you know that the clutch actuator is a bit of a weak spot. It doesn't snap the spiral like the 451 and 454 however, it does dry up internally which will slow down the movement. The only thing that stops the water from getting into the casing is a rubber boot....
451 Gear Change Motor Fault
Gear change motor failures are becoming a lot more common now. There are 2 motors. The 1st motor controls gear 1, gear 3 and gear 5. The 2nd motor controls gear 2, gear 4 and reverse. One will generally fail so you'll normally have issues with alternate gears. It's...
Roadster Larger Oil Sump Pan
More Oil, More Better OK, the grammar is terrible but facts are there. The more oil your engine has available, the slower it will degrade. Now, I'm not saying to put more oil in your engine, that'd be terrible. What we need is a bigger sump. Bigger Sump, Bigger Cost?...