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How to Remove the Intercooler from the Smart Fortwo 0.8 CDI

Model: Smart Smart 450 - Years: 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

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Video tutorial

In this short video, we will see the main steps to remove and replace the intercooler of the Smart Fortwo with a 0.8 CDI engine. First, access the rear engine compartment and start by disconnecting the electrical connector of the EGR valve, as well as the pipe located on the top; then remove the EGR valve to access the intercooler.

At this point, disconnect the hoses of the intercooler and unscrew the fixing screws to remove it and replace it with the new one; now reassemble the new part and then install the EGR valve!


Updated on 8 May 2026 by ScegliAuto


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