youtube.com/auto_knight/gear_shifter_motor_replacement_including_intercooler_removal_smart_fortwo_451_pa¶
3 excerpts.
Excerpt¶
youtube.com/auto_knight/gear_shifter_motor_replacement_including_intercooler_removal_smart_fortwo_451_pa · p. 1 · Applies to: 450, 451, 452, 453, 454, #1, ebike
in today's video this car is having its new gear shifter motor and if this doesn't fix it it's going into that Lake I have already made a rear panel removal video for these cars so follow the link Down Below in the description and you can very quickly have your car looking like this now you certainly don't have to remove this rear crash box this crossmember here but I'm going to and whilst you can actually get to the fixings for the intake pipes and intercooler pipes I just think in the interest of video making and bringing you the best possible video it's better with this out the way and it's only held on with six bolts anyway they are Torx bolts t4s one here one here and there's also one that you get to from the other side so three on each side again the two outers and then the inner one that you can see right here and the rear crossmember is free the bolts can be very tight T45 I put lots of copper slip on them to prevent them from seizing in the future if you're really unlucky this will be corroded because on the 4551 it was made of steel whereas on the smart 450 it was aluminium and as you can see we now have completely unhindered access to anything that we want to remove down [Music] here we start from above now although you can see the gear shifter motor right there it's not quite that simple to remove it had this have been a non-turbo model an mhd model it would have been a simple case of removing an intake pipe and then we could have got to it but that's not the case here this is the 84 brake horsepower model so it has the turbo therefore the intercooler has to be removed along with the fan cing and the fan this intake pipe has to come out it's a bit more to do so we loosen this clamp so this intake pipe is removed from the air filter housing and this is lifted up from the kind of ball and socket joint thing that it clips into this is notoriously difficult to remove from here because much of this is actually under here a lot of people cut these off and do away with them cuz it's just a resonator for reducing intake noise I managed it last time though so I'll try again I could of course fit a silicon hose here in place of this a lot of people do it but I like to keep things standard if I can I'm not a massive fan of mods it's an incredibly tight fit but I did it I have to remember how I did that cuz it wasn't that easy last time now we deal with the lower part of this pipe I think from memory there were three hose connections onto this so we loosen the clamp for the intake pipe to the turbo and once that's loosened we can move on to this intercooler pipe removing this intercooler pipe and kind of tucking it up here makes it easier to remove the intake pipe I've kind of tucked that intercooler pipe out the way off to the right which gives a clear run for the intake pipe to be pulled up and off this clip is removed and this pulls off the intake pipe can tuck that to one side turbo intake pipe is removed from the turbo there's a small hose behind that needs to be disconnected this should be free now we pull it out from [Music] above don't forget to disconnect that like I did okay so we've got the intake pipe out what you will find is you've got three hose connections that little breather pipe there was the one that was snagging we're going to need to remove this intercooler fan and cowling there's a connector under there that needs to be disconnected very straightforward that is off we simply lift this clip squeeze in and that is removed need to loosen these clips for this pipe that goes between the intercooler and the throttle body moving back underneath right in the center of this shot there is a little clip that needs to be released and this releases the intercooler once the intercooler is released at the bottom with that little clip that I just mentioned the only thing holding it in place is the fact that it's actually slotted into here and here behind here
Excerpt¶
youtube.com/auto_knight/gear_shifter_motor_replacement_including_intercooler_removal_smart_fortwo_451_pa · p. 2 · Applies to: 450, 451, 452, 453, 454, #1, ebike
and we'll see if we can slot this out from here and the intercooler and now the only thing stopping us from getting to this is this scoop for the intercooler there's meant to be a proper mount a rubber Mount here but that was missing I think the person that fitted the clutch on this car was a bit hamfisted but it's fixed with a cable tie it was resonating until I fitted that especially since I fixed the air conditioning I did look at getting a new cowling but it was 50 Quid and I just can't justify paying 50 Quid because of that deep down in this recess is a t27 it can be very corroded because water gathers in there this can now be dislodged from its lower clips and the King can be moved sufficiently to gain access to the Gear motor finally we're in there I'm going to find a way of tying this up so it stays out the way so using a cable Tire I've actually tied this up out the way around this wire here that just gives it sufficient distance so now it's a case of removing this down here we've got two connectors one for each motor both color coded we've got one here in the sort of hearing aid beige and we've got another one here in Black I'll disconnect those and then it is just a case of moving that motor I want to take extreme care to not let anything drop into that gearbox so right now I'm going to clean and tidy this whole area just to make sure that nothing drops in there which could be catastrophic especially if it was a screw or a nut or something like that both are disconnected there are four bolts two at the top two at the bottom and they are t40 they are [Music] tight just cleaning these bolts up in a little jar of paraffin yes I know it looks like a urine sample it isn't and here we go the moment of truth how do these motors come out I know it's on a couple of dowels hopefully locates it some sealant from the past got to try and remove that without dropping it in that surface is nice and clean question is do I or do I not use sealant some people have said not to use sealant because it ends up in the gearbox but it just doesn't seem right fitting it without maybe I'll use just like the tiniest bead okay so I have used a very fine bead of sealant and I've decided to use it around the outer edge to reduce the chances of it going inside the motor the light is getting away from us now but that is back in position and to tap it very lightly with a soft-faced Hammer just for the dowels not for the actual gearing to mesh heaven forbid but no just for the dowels to to get into position everything is backed together and everything is plugged in now I don't know if this is going to operate right off the bat or if we're going to have to go for some rete before I can even get any gear selection so let's just go inside and see what we get hopefully not An Almighty crunch from the gearbox right so it is now just a case of refitting all the bits that I've removed and getting this little beast back together to refit this there are a couple of little locating tabs that have to fit into recesses in the gearbox with differential housing and refit that t27 bolt that lives down in there and also my makeshift rubber mount in the form of a cable tie we can now get the intercooler and the fan cing in this is a good moment to talk about the intercooler I mentioned earlier that that little resonator part of the intake pipe snaps in it's like a ball and socket well that's the ball right there bracket of which is uh mounted to the intercooler and if I turn it around here you can see just how easy it is to fit into position you've got these two slots here which go into two little pegs that stick out of the cowling and then you've got this clip here that snaps into position so very straightforward and then we come on to the fan and the cowling for the intercooler I've said in previous videos these can se's check they free because it does share its fuse with the air conditioning compressor so if this jams up it'll blow the fuse and it will take out your airon there are a couple of pegs there they locate into slots at the base here of the intercooler and as you've seen already there's a clip at the top we won't do that now we need to do that in the car if you get the fan cowling in first and then pull it towards the back of the car you can then slide slot the intercooler in really easily in front of
Excerpt¶
youtube.com/auto_knight/gear_shifter_motor_replacement_including_intercooler_removal_smart_fortwo_451_pa · p. 3 · Applies to: 450, 451, 452, 453, 454, #1, ebike
it the intercooler is refitted into its slots it's also snapped into position at the base just under there which is there it's now case of fitting the fan cing into these two little locating tabs here and snap it into position from above it's slightly easier to reconnect it from underneath both Clips were retightened at the back here intercooler pipes reconnected turbo pipes reconnected everything's tight and everything is refitted from above including the three pipes that attached to the intake pipe I ran out of daylight but that wasn't going to stop me and I've got everything back together all the panels as you can see and it's running beautifully and as we can see we're still able to select gears I might give this a little run and here is what is hopefully the offending item now a few people have mentioned different version numbers and I'm not sure sure what these numbers on here mean but if anyone uh can tell me which version number this is or or what any of that means then um feel free to comment I mean it's a grubby old thing we won't really know until I take these covers off even then I probably won't cuz the little Hall sensors are further in anyway and I'm not going to go crazy with this I'm dying to take these covers off but let's just leave that for another video I think I've done enough for a day the weather gods have cleared away the clouds and left me with beautiful blue sky just look at it but it's changing gears beautifully now I'm not going to make a video about how successful this repair has been with a fan fair and a great big fuss because last time I did that it was still knackered and I had to do a reverse feret I love that expression but I did and uh things weren't fixed even though i' covered several 100 miles um but this time let's just hope they are and that's as much as I'm going to say on the matter well I'm going to leave this video here hopefully this is the last we hear of this issue you might be as sick of hearing about it as I am of dealing with it but it has made for some pretty good content I look forward to seeing you again in another video very soon meantime thank you and goodbye