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post #1 of 13 (permalink) Old 03-17-2017, 07:16 AM Thread Starter
 
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2003 Smart won't start after engine rebuilt

Hi,

I own a 2003 Fortwo (type 450) 0.6 turbo.

Last week I rebuilt the whole engine. I've changed all the internals parts (pistons, piston rings, valves, rod bearings, timing chain...), plus clutch, coils, spark plugs, filters, sensors, and so on...

Problem is, the engine turns over but won't fire up. All lights on the instrument cluster are normal. And there is no DTC codes raised by the ECU...

What I've checked so far :

- There are sparks on the spark plugs
- Fuel is coming to the rail AND into the cylinders (spark plugs are wet)
- Timing is good (and I think even with a tooth off, the engine would (badly) start)
- Checked and rechecked that clutch has been mounted properly (because of the gap in the flywheel for the CPS - crankshaft position sensor)
- CPS is brand new
- No error in the wiring
- All fuses are OK
- Compressions are good
- I guess ECU is OK since it responds to my Scantool, I even can read parameters in realtime (advance, air intake temp, throttle position, etc)

I surely miss something here but I'm totally stuck. There is fuel, there is spark, the camshaft moves : how a engine could not start with all that ?

Any help would be greatly appreciated !

Last edited by Akura; 03-17-2017 at 08:38 AM.
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post #2 of 13 (permalink) Old 03-18-2017, 11:25 AM Thread Starter
 
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Anyone ? Please ?
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post #3 of 13 (permalink) Old 03-18-2017, 12:06 PM
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There are not a huge amount of the 450 cars in the USA, Might want to try the Canadian smart car site as they have a lot more of the 450 models up there

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Sounds to me like you have everything covered and it should run.
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post #4 of 13 (permalink) Old 03-19-2017, 06:28 AM
 
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Originally Posted by Akura View Post
I surely miss something here but I'm totally stuck. There is fuel, there is spark, the camshaft moves : how a engine could not start with all that ?

Any help would be greatly appreciated !
Seems like you've checked everything already, but it sounds like a distributor which is 180-degrees out of phase, and firing on the exhaust stroke... if you only had a distributor.

I'd pull the valve cover, rig up a timing light and aim it at the cam to verify correct engine timing - both mechanical & electrical.

~toaster
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post #5 of 13 (permalink) Old 03-19-2017, 01:25 PM
 
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I think the Canadians only got the 450 with the TDI engine. For your gas turbo 600cc the UK website may prove more useful:

fq101.co.uk

Timing the smart engine

600cc engine rebuild

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post #6 of 13 (permalink) Old 03-19-2017, 07:55 PM
 
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Make sure the flywheel is indexed. If you did not install the flywheel in one of three holes the timing will be off. Any other questions IM me.

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post #7 of 13 (permalink) Old 03-20-2017, 04:32 AM Thread Starter
 
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Thank you guys. I'll try to post my question on an Canadian or UK forum as well.

About the flywheel, I've already checked it twice. There is a location pin to prevent improper mounting of the clutch assembly, so it seems unlikely to make a mistake here.

But I have the feeling, like Toaster, that the ignition may be out of phase.

Unfortunately I don't have a strobe light... Is there anything I can do to check the ignition phase without this particular tool ?
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post #8 of 13 (permalink) Old 03-20-2017, 05:20 AM
 
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If you are sure the flywheel is indexed correctly that is good. I have overhauled many 450 engines gas and diesel engines. When people bring me their cars after replacing the clutch the most common problem was the indexing. Have you made sure the fuel line is not backwards? The pressure and return lines if they are hooked up wrong it can cause a no start. Will it fire on starting fluid? When you set the timing marks did you have the engine on top dead center by the mark on the balancer on the timing cover? and on the top gear were the marks aligned? Did you use a picture to line them up? Did you use new lifters or did you pre oiled the lifters? Did you bleed off the lifters when installing them? Does the engine turn over real fast with the no start? If the lifters are not siting correctly it can cause the valves to stay open. Were the valves ground or new valves? It can cause change the valve closing all the way. The way that can be checked is with a compression gauge? That can tell me a lot if you have parts installed correctly. Is your car a G&K car? Do you have access to a STAR machine? It can help to determined if all the sensors are sending the correct readings that do not show up as a engine code. When you installed the rings did you check to make sure they were the correct ones. There were two types of rings that were used on the engine. If you were to use the wrong ones you would have very low compression.

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post #9 of 13 (permalink) Old 03-20-2017, 05:31 AM
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Akura is in France
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post #10 of 13 (permalink) Old 03-20-2017, 05:41 AM
 
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In France, that makes a big difference in helping someone. We can always give advise. But hands on is hard to do when so far away.

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