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Everything posted by tolsen

  1. Good news. Hope present condition will remain permanent. I am pretty sure the normally closed switch inside brake light switch has no wired connection to any wheel speed sensor. I therefore conclude, as I indicated in my first post, that short in right rear wheel speed wiring was either tin whisker or trapped and shorted wiring.
  2. Replacing outer door handle cable is easy. Replacing inner door handle cable requires removal of door card and outer door panel. Smart only sells outer door handle cable with door handle. Inner cable is available and not expensive.
  3. Tin whiskers: Regrettably you will need subsription to view it all.
  4. Heat shield inboard on rear valance could have come loose causing quite a racket.
  5. I think the black box is an insurance gadget which can check whether you are a smart or unsmart driver.
  6. A freewheel pulley allows the alternator to continue spinning on its own inertia whilst engine is slowing down in preparation for a gear change. This results in less load on auxiliary drive belt and faster gear changes. Some claim they also improve fuel consumption. Pulley on the left is original pulley from my 2002 Smart 450 Cabrio Cdi and now very much worn. Pulley on the right came from a Renault, unsure which model and year. This pulley is a freewheel pulley made by INA. Original pulley has 5 grooves. This INA pulley has 6 grooves. No real problem, only have to ensure belt is in right grooves and correctly aligned. Diameters measured over top of ridges: Original pulley when new 54.2 mm. This INA freewheel pulley 55.7 mm. I had to machine the new pulley to make it align crank shaft pulley. Removed 1.1 mm where pulley faces alternator. Nowhere in WIS could I find any torque specification for alternator pulleys. Google also no good for same so I checked Renault Dialogys and found specified torque is 8.2 daNm. Freewheel pulley fitted on alternator. Protective cap fitted. Existing belt was in a poor state so I fitted an older used belt in a slightly better condition. Road test: Noticably faster gear changes shifting up. No change shifting down. Why faster gear changes shifting up? The high inertia of a fast spinning alternator with standard pulley will slow down (resist) speed changes of the wee Smart engine. A freewheel pulley allows alternator to continue spinning on its own inertia because decoupled from engine when engine slows down. Engine can therefore reduce its rotational speed faster.
  7. Study photo if a disassembled rear Smart 450 wheel bearing:
  8. My engine has done more than 260,000 km which is twice of Willys' and runs fine requiring no overhaul yet.
  9. Rear axle bolt also holds rear wheel bearing together and if bolt comes loose you may loose your rear roadwheel. The torque is not particularly high and the only tool I use to crack them loose is a socket, extension and a ratchet. I suggest you eat more porridge if you struggle with that bolt. Engine pulley bolt is torqued much higher, allegedly to 140Nm + 90° angle turn. You can exercise and gain strength on that one.
  10. Could be tin whiskers inside ESP unit shorting rigth rear side out or cable harness being trapped. There is ESP unit pinout on Evilution.
  11. Try freeing alternator. Normally quite easy. Due to their exposure to the elements, alternators on Smart cars tend to seize if car has been sitting for two to three weeks and brand new alternators are no better. You can buy sump with drain plug for about £18 if you live in the EU. Sucking the oil out with a Pela suction pump works reasonably well too.
  12. Wondering where you measure. Assume you have disconnected sensor plug from ABS/ESP harness. I cannot remember what resistance is specified but guess somewhere in the region of 1 to 2 kilo Ohm. Would therefore seem your new sensor is faulty.
  13. There was someone here with similar problem a few weeks back.
  14. Try the Evilution site for owner manual and service information
  15. I guess alternator is seized as usual when these cars sit. All you may need do is free it. Requires good elbow grease and a can of penetration oil.
  16. It is not entirely the freewheeling pulley. You also need a well working clutch actuator and clutch actuator must be correctly preloaded. Additionally I grease socket in release fork where clutch actuator rod seats. Greasing socket does not contribute much to increasing gear change speed but does reduce wear, corrosion and risk of rod punching through socket leaving you stranded for sure. Note that freewheeling pulleys do not last forever. They do wear out and probably will need replacement after five years in service. Perhaps will last longer where you live. I guess not much road salt and grit there although I have seen snow all the way down to the harbour of Funchal. I nearly froze my balls off then as no heating in my room and only linen sheet on bed no blankets at all to keep me warm.
  17. My collection of strimmers acquired from the local recycling centre. The Ryobi would not start and had rather poor compression. Turned out it had been run without oil mixed fuel. Both rings are well seized in their grooves. Cylinder wall is similarly scored. Spare piston and cylinder are not available. Think I will need lots of patience and plenty of elbow grease to sort this one out.
  18. I have two nearly 100 year old fantastic grass cutting tools that are remarkably reliable, economical to run and whisper quiet. They are so quiet I can operate these tools at night but normally I use them early mornings whilst grass is moist. They are both scythes. No carbs, no fuel, no smell and no noise.
  19. My experience is 2 stroke garden power tools are quickly and easily fixed. Most common problem is carburettor related. Then pull chord starter. Not common here to see one that has been run without oil. My Ryobi strimmer worked fine until a fool borrowed it from me. I succeeded in freeing its seized piston rings. Dressed both rings and ring grooves with a file. Also dressed scores in piston. Lightly honed cylinder. Then assembled strimmer and did compression test. Engine started on first pull.
  20. Best I think is uploading your photos to Clubsmartcar. Picture size will be automatically adjusted to fit screen and we can view your photo in higher resolution by double clicking your photo.
  21. My method for removing rusty Torx bolts and broken bolts where what remains of bolt is no deeper than a couple of millimeters below surface. I simply weld a partly bored out nut to bolt. Torx bolts are totally useless in rust belts. On my Smart most exposed Torx headed bolts were rusted such that nothing would fit. With hex bolts one can always file head to next size down. Impossible with Torx.
  22. Replacing hand brake cable is tricky unless subframe is lowered. The difficulty is releasing inboard end of cable outer. Many years ago I made a special tool that releases inboard end:
  23. Two each side is enough. Best to pull them in using a front bearing centre bolt, suitable sizes of short exhaust pipe and thick washers cut out of minimum 6 mm steel plate.
  24. Bush part number is A4503330014. Fits all 450, 451 and 452 models.
  25. Cheapest supplier of front lower arm bushes is of course your Smart dealer. About £5 per bush in the UK.