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2008 (451) Smart Fortwo Passion Cabriolet, Gas (non turbo), Automatic with paddle shift. Canadian car, this Smart was assembled in France (not sure if that matters)

Has full heat, hot warning light activates, and coolant is overflowing from overflow tank when hot, engine light activates and throws code PO116

So thermostat works, sensors are working.

No sign of a relay as stated in many posts/threads I read threw.

fuse #14 and #28 are good. My manual does not show what fuse is connected to the fan, found these ones here.

fan has power when directly connected. any other info on what to check? I've been threw the web and this forum and can not find any more info. For me a 2 hour drive is required to nearest Smart center. So any help would be appreciated.
 

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Word of warning, when the overheat light is on you are seconds away from frying the engine. Not recommended to drive the car if overheating unless you want to replace the head.... :)
 

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Unfortunately (or fortunately for me) the radiator fans in mine have been fine, so I haven't explored them much.

If the cooling system was opened, it might need to have the air bled out. I can see if that were the case, you might have a hot motor, but since the coolant isn't really circulating, it could fail to trip the sensor? The expanding air could cause the burping.


Just in case @jwight warning isn't enough, the intake manifold is plastic.

Here's what they look like it they overheat....
65760
 
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