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...
Smartmods
for all your modding needs, recommended by Evilution
Kane Harrison
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 Climate Control Faults
The new fortwo has a more sophisticated climate control rather than the air conditioning in the 450 and Roadster. More to go wrong.
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...
451 Control Stalk Removal
How to access and remove the lighting stalk or the wiper stalk
451 Coolant Drain
Draining Unless you like to be scalded, wait until the car is cold. Remove the front service panel and undo the cap to the coolant header tank. Look under the car at the engine over to the right. Just behind the long drive shaft, partially hidden by some...
451 Coolant Radiator Removal
If you have a leak in your radiator, fit a new one, don't rely on fluids like RadWeld. Changing the front coolant radiator is easy but actually getting to it is a long task. If you don't have air conditioning, it'll be the only time that you are glad that you don't....
451 Cornering Lights
You may have seen them on expensive Mercs and BMWs but cornering lights are now available on the smart
451 Crash Bar Removal
After a crash it may need replacing. Remove it to fit an exhaust or to fit a towbar.
451 Dash Button Pin Out
Dashboard Button Bank Pin Connection Wire Colour Connects To Purpose 1 Grey/Blue Speedo Pin 12 Illumination 2 Red/Violet SAM Plug 2, Pin 2 Permanent live, fuse 12 3 Brown Ground Earth 4 Yellow/Red Heated Seat Controller, Pin 1 LH Heated Seat Switch LED 1 5...
451 Dash Pod LEDs
Change the SMD LEDs in the 451 dash pods