2008 Smart Fortwo 451 Passion 84 BHP - Door Panel Removal - Investigating Door Locking Fault

The vehicle is a 2008 Smart Fortwo 451 Passion 84 BHP. In this video, I remove the N/S exterior door panel (passenger side on RHD car) to investigate a problem with the central locking. The door does not always lock with the other doors and this appears to be temperature related, being more of a problem in hot weather. I remove the door handle, disconnect the cables, remove the outer weather seal rubber and the door mirror assembly, then finally the door outer panel. I lubricate the lock and inspect visually for any corrosion or faults but none found. If this reoccurs then I would consider this an issue with the electrical side of the door lock and would replace the complete lock assembly. The door panel and removed items were reassembled.
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Disclaimer - Please be advised that my videos are not instructional and are merely footage of me, with many years of motor trade experience, carrying out vehicle repairs and maintenance. Please conduct your own research, ensure you have the correct tools/necessary expertise and undertake your own due diligence before carrying out vehicle repairs. If in doubt, entrust an automotive technician / car mechanic.
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License code: 3HNACY5GNYCZYIXI

[@oldman213]

Hello, and thank you very much for these instructions. I had to change the lock on Saturday because it no longer locked. You don't necessarily have to remove the frame of the triangular window. With a little sensitivity you can get it expanded like this. The whole thing took a little over an hour. Translated with Google

[@bertlzansinger]

Oh yes, reassembling the door is also on my list. For many reasons. Cleaning the window guide, installing new speakers, especially vibration damping. You have no idea how much your videos help / mean to me. Cheers, mate!

[@tomkirby1982]

Thanks so much for this video. My driver's door was failing to lock. Used this video to get access to the lock mechanism but unfortunately turned out to be faulty. Ordered a used one on eBay for £50 and had to take the windows out and the bar blocking the mechanism but I have a working lock and a happy wife. Now just the EGR cooler to replace 😢

[@michaelglynn2638]

Another very useful video, my window sounds like it struggles to lift and i had considered investigating. Thanks again. 👍

[@harpermattw]

Removing this door panel seems to be the only non destructive way to replace the door speakers. It's really handy to have such a detailed video on it. I've actually used a gew of these videos to help me work on my 451 so thanks for continuing to make them.

[@garethcamp3048]

Excellent video, VERY clear and concise. I thankfully have no reason to need to remove the door panel on my 451 but i found the video very useful to build my knowledge of the car should I need to in future.

[@lilianaoszlanyi9674]

Thanks to you, I finished the panel changes today and my little one looks brand new. 🥰

[@autoknight747]

Great to hear. I’m so glad the videos have been helpful. These are brilliant little cars!

[@rapt666Or]

Sir, thank you very much for the great video, well explained and informative... Warm greetings from Germany👍🏻

[@svenhansen9618]

Another awesome video, thank you. Someone tried to break into my Smart car and they ripped the door handle off. I think at that point the alarm went off and they left. I bought a used door handle complete and after looking at your video I know what to expect.

[@makzzz1986]

Thank you for a great video! I fixed a lock today with your help. Some plastic parts inside got broken and seemed to block something. Anyway, one thing to mention: you don't need to remove this plastic pin to remove a handle. Only unscrew two bolts and pull the handle backwards.

[@jimmyadams628]

Anoher brilliant video 😊. Jimmy from Ireland 🇮🇪

[@RickyKennedy01]

I love these videos. Same model as me, and invaluable for every smart owner. You’re going to keep me busy with jobs now.. Thanks for everything you’re contributing! 👍🏻

[@autoknight747]

I’m glad they are proving useful. These cars are fantastic if you enjoy the journey of working through lots of jobs and really getting to understand a car and it’s construction. They are very quirky.

[@ribbitism]

thanks for the guide as always! i need to do this soon just to clean and maintain everything as its probably never been done on my 08 💀 just a small FYI, the seals 'move' because they expand and contract from temperature.. eventually they work their way along in either direction they can go! i notice the same phenomenon on my double glazing window seals too 😂😂

[@autoknight747]

Thank you for the explanation re the seal. I’ve always wondered why I’ve had to reposition them to close the gap at the rear, on all of my 451s. I did at one point wonder if they left the factory like that!

[@user-xk4db1gk1b]

Hello from Ukraine, thanks for another wonderful and useful video

[@williamyeh7135]

Great job, great video. We all like yopur procedures when dismantling your door panel. Unfortunatelly, we like to watch more videos about your Smart W451. I owned several Smart Fortwo W450s, also repaired and removed many materials of them. Right now, I own one Smart W451 MHD. It's really a nice car but there're some problems with it.

[@MrMark2409]

Hi thanks for your video I had same problem in winter car door was fine then when it came summer time it wouldn't lock .only at night when it was cooler it worked so I bought a second hand locking mechanism changed it now its fine works perfectly...

[@autoknight747]

Exactly like mine! I’m sure I’ll be fitting a lock once the weather warms up again.

[@WEHAVELIVECRAB]

cheers mate, very helpful video

[@blueberryadept6519]

Excellent editing! I loved the cuts at around 1:14 to get the project started. I wanted to try to remove everything from the door and rock around in the summer doorless for fun. I’ll let you know if I ever give it a try next year!

[@autoknight747]

Thank you! Brilliant - might improve the airflow in the Smart 🤣

[@andychips]

I hope I’ll never need to do this but if I do… thank you!

[@krisztianpasztor591]

Thank you sir !!

[@danielsun7214]

Well done, I thought I was the only one who was so fussy

[@autoknight747]

The struggle is real 🤣

[@WBSoCal]

Maybe using a blow dryer on the lock mechanism and simulate hot weather?

[@autoknight747]

Excellent idea!

[@WBSoCal]

@@autoknight747 Love your Smart videos. They are so helpful. I bet you could use that blow drier on the lock even when the door is assembled and see what happens. Seems it would be a bit of work to remove the outside door panel again! Looking forward to hearing/seeing an update.

[@Masonic1016]

Motorcycle Chain Grease is a good alternative to Whit Grease - it's designed to stay put on a fast moving, rotating chain.

[@Colors.animations-jy4hc]

Hola buena tarde que grasa ocupó para los marcos del vidrio por su atención gracias

[@Kemicaloid]

I would like to add a small information: To remove the plastic thingy where the handle is it's better to pull back the handle and than push the center plastic cilinder out and than pull the plastic thing out. This way you wont destroy it!

[@JCULLETON-ic8qh]

Hi I’ve been looking see if you’ve done a video door alignment on a smart 451 as my door are slight out after have something else fixed but said they were already like that anyway can you help thanks.

[@Smart451-ut6df]

I had the same passenger side lock fault but fully non functional. I tried the lubrication just as in your video but it didnt fix it. I purchased a used replacement lock and it works great now. The extra steps are to get the window glass out and the quarter glass lifts up out of the way to get the lock out. Got rid of the riveted case holding the wiring plug, not sure if I should try and refit that. Very happy with a working lock, but as it's me doing the work I now have a leaky door and wet footwell, something I havent done right with refitting, the window seal is not flush against the glass like it should be. I think I also refitted the glass slightly too low resting on the bottom holder when maybe it should be slightly elevated (a few mm). Will be interesting to see your video if you do the replacement lock, I couldnt wait for that unfortunately so had to give it a go. I also might take apart my old lock to see what it looks like inside if something seized. Refitting the handle was very annoying, also the emergency unlock cable kept popping out from its holder from the pressure I was putting on it. I dont trust that it will work if I need it.

[@autoknight747]

This is great feedback about a car with the same issue. Regarding the gap between door seal and glass, might be worth checking that the door panel is located correctly along the top edge. A lot of manufacturers like to use rivets in door structures and I bought a rivet gun for this reason! Mine is not fixed from the lubrication so there will likely be a video when I get a new lock. My suspicion is that the internal solenoid fails. Seems to behave itself in cooler weather so may not be for a little while. It is nested in the garage most of the time!

[@Smart451-ut6df]

I realligned the seal under the door mirror this has helped a lot to make it more flush to the glass. I looked inside the lock, it looks really well lubricated from factory in there, nice and clean no sign of anything broken, the motor with the spiral and cog moves by hand as I think it should. Dont have the skill to test the electrics. @@autoknight747

[@jimmyadams628]

How do you know so much about Smart Cars ? 🚗 😊

[@autoknight747]

I worked for many years in the motor trade and these car have been a fascination of mine since their launch - I have owned many!

[@jimmyadams628]

@autoknight747 thanks for the reply. I owned one for 2 years and and sold it 2 years ago. I still miss it and am constantly on the lookout for another one. I live in Ireland and the market is very limited. Usually only 12 cars are for sale. Fingers crossed 🤞 ☺️ 😀. Jimmy from Ireland 🇮🇪

[@punk71610]

窗戶無法降下是什麼原因?是哪一個零件壞掉了?

[@marievympranietsova3878]

Hi there, i have a question and i hope you can help me. They force my car (smart 451 2009 limited edition three) door to steel my steering wheel. I have managed to find one, and i have changed it. But i don't know what to do with the lock. The automatic lock is working. But the lock is destroyed. Do you have any suggestions for me? Thank you

[@autoknight747]

The components should be available at Mercedes/Smart dealerships or alternatively second hand from eBay.

[@ednasdiscomachine6049]

Excellent video. Could you consider doing on one removing the aerial? I'm looking to replace mine with a little stubby aftermarket replacement, (especially to reduce wind noise etc...) as I don't use the radio and have a bluetooth streamer. I'm thinking it's probably pretty easy.

[@autoknight747]

The aerial mast ‘should’ just unscrew from the base. Unfortunately the thread and aerial base threads corrode together and can seize solid. If it does unscrew it is always a good idea to apply an anti-seize product to the threads to ease future removal.

[@autoknight747]

There will be an aerial video next weekend!

[@williamyeh7135]

Do you have electric power steering on your Smart? I bought a electric steering, wanna put it on my 451.

[@autoknight747]

No power steering on this one. I find it light enough without it!

[@CLIVETHE125]

I,v got a defective drivers side door lock mechanism that stops the door from closeing . I,m not looking fwd to changing it that,s for sure 😪

[@autoknight747]

Don’t dread it, embrace it. No rush when you are on your own time, as opposed to company time. Should be a satisfying job!

[@CLIVETHE125]

@@autoknight747 Well ..i finally got around to changing my door lock assy with a mate ..gotta say .. we both agreed we could not have done it without your video.What a great help that was.One thing we did manage ,and that was to get it out without removing the window glass channel.We just pulled the inner door skin back a bit and it came out . Thanks again.

[@ronlundgren4682]

Where do you get your white grease

[@autoknight747]

Online or from a motor factor.

[@user-yr5mi8ic6l]

MY 451 Needs the drivers door to close a little tighter. To do a small modification, can I take both the torx screws out from the main frame without the back plate falling down inside the chassis box section and being lost forever?

[@autoknight747]

I’ve adjusted these striker plates before for the same reason but have only lightly loosened the bolts, not removed them all together, so cannot be entirely sure if the threaded plate behind is retained or free to fall. The latter would be a very poor design!

[@user-yr5mi8ic6l]

@@autoknight747 yes it would be bad design. But those two silly little pins on the plate only allow about 1mm of adjustment that is what I wanted to modify. Will try to take out one and then pass a piece of wire through before slackening the second torx. Perhaps I will be able to see if there is a lot of movement. Cheers for now

[@autoknight747]

@@user-yr5mi8ic6l Out of interest , is this to cure the creaking/rattling that the doors do?

[@user-yr5mi8ic6l]

Yes but mainly on the drivers side only.

[@autoknight747]

@@user-yr5mi8ic6l it’s very annoying. Another option is to fit a new door perimeter seal. They do compress over time.

[@rishrevsR13]

No need to remove the weather strip

[@autoknight747]

Get a much better view of the top locating clips without the weather strip in place, which was helpful to demonstrate to viewers of the video!

[@bertlzansinger]

Sot! Because I now know how to dismantle it. 💁🏼‍♂️😁

[@lucaottaviorovesti7436]

Che miseria auto tutta plastica se ti viene addosso una bicicletta sei morto 😂😂😂 almeno risparmi la bara ti mettono via con quella