Smart Fortwo - How to remove / install the starter-alternator - Part 1 | W451

This smart was produced before 18 April 2011.
This model was not fitted with a starter-alternator with the new production bearing.
In the event of bearing damage, the starter-alternator does not have to be replaced, ...
... the following repair method can be used.
Check poly-V belt for signs of wear.
Frayed edges are an indication of excessive wear of the starter-alternator.
Note: Replace poly-V belt!
Remove mounting bolt of tensioning device and remove poly-V belt.
Lower vehicle lift, the starter-alternator must be accessible from above.
Open liftgate and remove cover behind it.
Check starter-alternator for play.
Replace bearing if there is play!
Before removal, disconnect the battery ground line.
Follow the work instructions for removing the starter-alternator.
Start by lowering the rear drive module.
Disconnect electrical connections on starter-alternator.
Remove nut on pin and disconnect three-phase line.
Remove mounting bolt and ...
... take-out starter-alternator.
Remove bushings from timing case cover.
Fabricate a removal fixture for removing the pilot bearings. From an internal extractor, ...
... and extraction tool and an impact extractor.
Insert internal extractor behind outer pilot bearing and clamp.
Knock outer pilot bearing out of timing case cover with removal fixture.
Using a cotter pin driver, remove the rear pilot bearing from the timing case cover.
Clamp the starter-alternator in a vise with protective jaws and remove belt tensioner.
Clamp the starter-alternator in the vise to work on the threaded insert.
Screw a bolt into the threaded insert and use it to pull it out.
Wrap starter-alternator in film and adhesive tape. Seal it completely!
Note: Any drill chips which enter can result in premature wear.

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More Information:
Starter-alternator removal AR01.00-P-3050MCC
Removal fixture AR15.40-P-6000-02MCC
Notes on threaded insert AR15.40-P-6000-03MCC
Notes on drilling jig W 451 589 00 23 00
Bearing A 132 150 01 16
Table for spacer washer requirement AR15.40-P-6000-03MCC
Adhesive A 003 989 32 71 10

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