Fully lower the engine using the engine lowering studs. Click here. The starter motor is down the back of the engine behind the inlet manifold. Disconnect the 2 coolant pipes that run over the top of the starter motor. It's hard to see what the hell is going on as...
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451 Valve Clearance Specs
Sometimes, information doesn't need to take up loads of pages. Sometimes, the information is really all that needs to be on the page. This is one of those pages. I could use a massive font to take up more room I suppose but I won't. Important These clearance readings...
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....
452 Roadster Fuel Tank Drain
Fuel Filter The fuel filter is quite well hidden, it is behind the nearside rear wheel arch. Jack the car up, remove the wheel and remove the arch liner. On each end of the filter is a connector with an orange clip. To disconnect the pipe you just have to push the...
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,...
450 Fuel Tank Drain
Fuel Filter The fuel filter is quite well hidden, it is behind the offside rear wheel arch. Jack the car up, remove the wheel and remove the arch liner. On each end of the filter is a connector with an orange clip. To disconnect the pipe you just have to push the...
Roadster Alternator Change
Get The Right Alternator When I initially fitted a replacement alternator to my Roadster it didn't actually work. I thought I had misdiagnosed the fault but actually I had been sold the wrong alternator for my car. On the smart there seems to be 6 different...
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...
Throttle Body Orientation
I get this question a few times a year. "I can't close my engine cover" When I first heard it back in 2006, I thought they were just being a mong with no dexterity. Then I received a photo. After that, every photo has been the same. I have no idea how they end up like...
Secondary Air Injection Pump
It is becoming more and more common for people to report a terrible noise for about 90 seconds on start up. This is due to the secondary air pump. People with no actual clue often call this an EGR pump. This secondary air injection pump can be found on 700cc fortwos...
451 DPF Regeneration
What Is A DPF? It's a diesel particulate filter, it's inside the exhaust. It catches all of the particles of soot from the engine. This improves the quality of the emissions from the exhaust. Do I Have A DPF The smart fortwo 451 diesel manufactured after October 2009...
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?...
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?...
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 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...
Roadster Fuel Tank Removal
It's a very good idea to have little to no fuel in the tank otherwise it'll be heavy and potentially explody. Remove the engine. Behind the engine is a heat shield (good idea huh!). Remove the fuel cap. Remove the top two E10 bolts. Then remove the lower two E10...
Roadster Coolant Draining/Filling
Draining The best way to drain the system is at its lowest point, in the smart's case they have actually installed a coolant drain plug that can be removed with a 6mm allen key. It is located on the back of the engine. Lay down under the back of the car and you'll see...
453 Gearbox Fluid Change
The 453 comes with 3 option for the gearbox. The turbo and non turbo petrol model had the option for either manual or auto. The electric drive model only came with a fixed ratio gearbox (not yet covered here). Manual Gearbox Fluid Change Post yourself under the car...
Roadster Clutch Removal
The clutch doesn't last forever. It wears down causing slipping and poor pull away.