ZEE unit stands for Zentrale Einschub Elektrik which translated
means Central Electric Module.
The ZEE unit is the 600cc version of the SAM unit. It carries
the fuses in verymuch the same way but the relays are all external
so can be swapped over.
Where the 700cc SAM unit is one part, the ZEE unit comprises of
3 sections.
Fuses, OBD and partial relay holder.
ZEE insert module that controls the electronics.Secondary fuse
and relay box located under the seat.
Removing And Opening The ZEE Unit
The main ZEE connector (outlined red), if your car is doing
strange things, check this isn't loose.
The ZEE insert slides out of the side.
The insert fully removed. Circled in yellow is the small speaker
that makes all the beeping noises.
Surrounding the unit are plastic tabs, these are easy to
unclip.
With all of the clips undone you can remove the top to reveal
the cicuit board.
This is as far as you can get with viewing the ZEE insert, the
rear plastic housingcannot be removed without damaging something.
Highlighted in blue is the outline ofrelays L and M which are
located on the other side of the ZEE insert circuit board.These
cannot be removed or changed unlike the other relays.
Main Fuse And Relay Holder
Located under the dashboard. The fuse ratings and layout can be
foundhere.
From 16/11/1999RelayCoupe Function
AFront fog lights
BBoot solenoid
CRear wiper interval
DHorn
ERelief for igntion, heater and windows
FRear window heater
GFront coolant and AC fan
HLeft turn indicator
IRight turn indicator
KFront wiper interval
LCentral locking (inside ZEE unit)
MCentral locking (inside ZEE unit)
RelayCabrio Function
AFront fog lights
BSoft top open
CSoft top close
DHorn
ERelief for igntion, heater and windows
FBoot solenoid
GFront coolant and AC fan
HLeft turn indicator
IRight turn indicator
KFront wiper interval
LCentral locking (inside ZEE unit)
MCentral locking (inside ZEE unit)
Depending when your car was made, you could have hidden
headlight relays or none at all., read further down.
Up to 15/11/1999
RelayCoupe Function
AFront fog lights
BCentral Locking Locked
CCentral Locking Open
DNA
ERear Hatch Remote Unlocking
FRear window heater
GFront coolant and AC fan
HLeft turn indicator
IRight turn indicator
KFront wiper interval
The wipers, horn and relays are separate from the ZEE, they are
hidden behind the dash.
Headlight Relays?
This only applies to 600cc smarts made from 2002 onwards.
For some odd reason, smart decided to put the headlight relays
elsewhere.On a right hand drive smart, the relays are hidden behind
the stereo.On a left hand drive smart, the relays are behind the
main instrument cluster.
If your 600cc smart was made before 2002, there were no relays
for the headlights.
Main Loom Socket Wiring
AWire ColorsConnectionFuse
1Red GreenWiper stalk
2Grey RedWiper stalk
3Grey BlueIgnition position 2
4Brown WhiteSafety triangle +v
5Red GreenWiper stalk
6BlueBlower switch
7Yellow BlackFog lamp switch
8Black GreenLighting stalk
9Black WhiteLighting stalk
12Blue WhiteHandbrake switch
15Black BlueHeater booster switch
17Yellow GreenRestraint control
18BrownEarth
19White GreyOBD pin 1
20Grey Green26
21Grey BlackATA control unit
22Brown BlueCentre console lamp
23VioletATA control unit
25GreenSafety triangle AC1
26GreySafety triangle AC2
27Black Red/Blue RedSafety triangle window heater
28Blue YellowSafety triangle lock
29Violet BlueSafety triangle hazards
BWire ColorsConnectionFuse
31Brown RedInstrument cluster
33Red GreenMulti connector Z50/2
34Red Blue10
35White BlackInstrument Cluster
37Red White15
38BrownEarth
Secondary Fuse And Relay Holder
Located under the carpet underneath the left hand seat.
Wiring
Connector 1
1Wire ColorsConnectionRelay
1Black PinkMEG 1.0K5
2Red BlackFuel pumpK5
3Red BluePrimary fuse boxK2
4Red BluePrimary fuse boxK2
5BlueMEG 1.0K2
6Black WhiteMEG 1.0K2
7Pink BlueMEG 1.0K2
Connector 2
2Wire ColorsConnectionRelay
1GreenCharcoal valveK6
2White YellowMEG 1.0K4
3Green BlueMEG 1.0K6
4Red GreenPrimary fuse boxK1 + K2
5YellowMEG 1.0K3 + K4
6RedBatteryK1 + K4
7BrownEarthK1
8Black YellowMEG 1.0K3 + K5
Connector 3
MWire ColorsConnectionRelay
1GreenCoil pack 1+2+3K1
2GreenInjector 1+2+3K5
3BlueAC compressorK6
5BlueStarterK3
6YellowIntercooler fanK4
7WhiteWastegate valveK6
RelaysDisconnecting The 2 Connections
On the back of the connectors are slides that lock in position
to hold them in place.Slide them back out by levering them back
with a screwdriver.
As the slide is pushed back it will unlatch and lift the plug
off of the ECU.If you do the top one first it gives you better
access to the lower one.
Removing The ECU From The Car
Mine isn't what you normaly get. Normally you have the air box
with the ECU screwed into the side with 6 screws.I took my air box
out and replaced it with a Pipercross Viper so the ECU was moved
over to make room.
However, removal is easy. The screws are in the same positions
as the pockets on a pooltable so just take the screws out and the
ECU will be free to be removed from the car.
Thanks to Tony for the picture.
Relay NumberFunction
K1Fuel pump
K2Auto transmission
K3Main relay
K4Intercooler fan
K5Starter motor
K6A/C Compressor
FuseRating
115 Amps
210 Amps
315 Amps
410 Amps
Important
Adding a starter button does decrease your security a little but
as you still have to insertthe key in the ignition and turn to
position 1 before it will work, the risk is minimal.It is of
paramount importance that the smart is locked in reverse and the
doors lockedusing the remote fob every time you exit the vehicle.
This activates the immobiliser.
Background Info
The engine starter button was made popular by cars such as the
Honda S2000 and, as it iswith coveted items, they're soon copied
and added to other cars. The smart is no different.
Typing 'starter button' into Ebay will bring up a host of
universal kits,all of which are perfectly usable in a smart and are
very easy to fit.
Smart Starter Button History
Brabus
Apart from DIY retro-fitted third party versions, the first
proper start button was releasedin one of the Brabus Roadster
models. The button sat in the top of the gearknob.The key still had
to be inserted into the the ignition and turned to position 1 for
it to work.
It is possible to retro-fit the Brabus starter button into a
lower spec Roadster and theFortwo/City Coupe. The SE Drive
(electronic gear change box) contained all the necessaryelectrics
so you just have to swap them over and add the appropriate gear
knob.
The drawback to this design is it's a bit poncy and the total
price is astounding
MDC (Misterdotcom)
MDC soon came along with a full ignition replacement starter
button. Made from aluminium, the quality and style was good plus
the two colour LED indicates what the starter unit is doing at the
time. Retailing at 149 Euros, it's half the price of the Brabus
system but looks better and has more to it than a switch and a
relay.
I cannot recommend this system due to the severe security risk
that it creates.You don't need a key, you just disarm the
immobiliser with the fob, get in and press the starter
button.Imagine if you forgot to lock your car or you accidentally
pressed the unlock button as you put the keys away, anyone could
get in your car and drive away.
Also this unit removes the gear stick locking device meaning you
increase the chancethat your car can be rolled away or even rolled
off down a hill by some idiots.
700cc And 999cc Ignition Info
The original ignition uses 3 wires to turn the car on and to
turn the engine over.
All 3 of these wires come from the SAM unit which controls all
of the electronic functions.
Red/Black from SAM plug 7, connection 3.
Red/Black to SAM plug 4, connection 1.
Grey/Blue to SAM plug 8, connection 38.
The first wire listed is the permanent power from the
battery.Second takes the power back to the SAM when the key is
turned to position 2, this turns on all the electrical systems
required to start the car plus anything left turned on
previously.The final wire sends a voltage to the SAM unit to tell
it to activate the starting procedure.
Unlike most cars, the smart has a digital starter. On a standard
car, the key has to be held in the 2 position to apply power to the
starter motor. On a smart it only takes a quick turn and release.
This is because the SAM/ZEE unit takes care of the starter motor
switching.
Because it is digital, there are no huge currents passing
through the third wire.Not only does this mean the wire can be very
thin, it means we don't need to use a relay.
A relay is a method to switch high power loads with a low power
switch, because the smart start up is low power, we only need to
use a standard 12 volt switch.
Fitting Our DIY Starter Button
700cc Smart
Let's make our own for less than 20. Firstly, get on Ebay and
get a starter button.The hardest part of this How2 is deciding
where to put the button.Many of the Honda S2000 style starter
buttons are desiged to fit where the cigarette lighter goes, it is
an option although removing the lighter socket isn't at all
easy.
One way to access the wires we need is to remove the SE Drive,
although quite easy, it does involve removing the seats and using a
special 5 spline security torx bit.If you have seat airbags or
don't have the security torx bit this can be problematic.
My solution is to access the wires elsewhere, somewhere
easier.
Essentially what we will be doing is adding a switch between a
permanent live and the Grey/Blue wire going to SAM plug 8,
connection 38. You don't have to take the power from the original
ignition wires, you can take a fused feed from one of the aux
outlets on the SAM unit.
600cc Ignition Info
The original ignition uses 3 wires to turn the car on and to
turn the engine over.
Red from the battery.
Red/Black to an electrical distributer connection.
Grey/Blue to ZEE plug A, connection 3.
The first wire listed is the permanent power from the
battery.Second takes the power to a multi connector when the key is
turned to position 2, this turns on all the electrical systems
required to start the car.The final wire sends a voltage to the ZEE
unit to tell it to activate the starting procedure.
Fitting Our DIY Starter Button
600cc Smart
The idea is the same although instead of dealing with a SAM
unit, we now have a ZEE unit.
What we will be doing is adding a switch between a permanent
live and the Grey/Blue wire going to ZEE plug A, connection 3. You
don't have to take the power from the original ignition wires,
there are many permanent live wires around the car including one to
the stereo.
Warning
I haven't yet tested this theory so if your car bursts into
flames, it's not my fault.It will have died in the name of science.
I won't ever fit a start button so I am goingto have to leave it up
to you to let me know how you got on. I'll add info if I get it.Any
Help Or Info?
This is a fresh topic to me, I have grasped the basics and had a
quick read up about it.As can be expected, remappers are very cagey
about how it all works.If you can help or add any information to
this them please contact me.
Important Info
It is vital that you know four things before you start:
you can't just throw any old smart remap onto your car
you could be breaking copyright laws
this isn't the full story, it's just a starter guide to get you
thinking.
someone has already followed this and killed his car.
What You Need
To remap your car (and anyone elses), you will need the
following:
Windows Laptop
KWP2000 USB to K-line convertor
Remapping software
Remap code
Where To Get These Parts
Most people have a spare laptop, if you don't, just ask about.Go
to Ebay and type in KWP2000. You can buy preassembled units from 60
onwards but I bought mine from a seller called 'tuning-concept' in
January 2007. It cost me 25 and 8 p&p, he still sells them at
the time of writing this.
The remapping software and actual remaps are just as easy to get
although illegal.Again on Ebay, type in 'remap files' and you will
find a few people selling DVDs full of remap files and software.
The remapping software will be hacked copies, the remap files will
be someone elses property and therefore copyrighted. You have been
warned.
Build Your Own KWP2000
The unit I bought from 'tuning-concept' came with a PCB and an
OBD plug. You need to supply a serial cable, 3 LEDs and a box to
put it in. You'll need a soldering iron too.
This is the unit that I received, it has a USB to PC on the left
and serial to OBD on the right.
The board has spaces for 3 LEDs, almost any standard LED can be
soldered in here.Note the flat edges on the 3 circles, these will
tally with flat edges on the LEDs.
D2 = TransmitD3 = PowerD4 = Receive
The OBD plug that comes in the kit is basic but useable.
With the back off you can gain access to the pins of this budget
part.I found it easier to work on after I trimmed back some of the
white plastic.
A standard serial cable with a male plug is needed, cut the
other end off.
You only need to attach 4 wires, don't go by my colours.
The serial plug is numbered at the end. You should connect:
Serial plug Pin 6 to OBD pin 4 (earth)
Serial plug Pin 7 to OBD pin 5 (earth)
Serial plug Pin 9 to OBD pin 16 (12v)
Serial plug Pin 5 to OBD pin 7 (K-line)
Install it into a suitable box and the KWP2000 remapping unit is
now completed.
Installing The Drivers
With the laptop running, plug the KWP2000 unit in via the USB
cable. The laptop will discover the hardware and attempt to find
the drivers. Take the DVD with the remap software on and insert it
in the drive and tell the computer to search the DVD for
drivers.Eventually it will discover the USB to K-line convertor
driver and install it.
Remapping The Car
Go to the car and plug the OBD lead into the unit and start up
the remapping software on the disc. You will get a list of car
manufacturers on the left, click smart.At the top you will get the
option on 600cc, 700cc, CDi or 1.3 Forfour (depending on software).
Select the car you have and click connect.
There are conflicting rumours on reading from the ECU, there are
some that say you can read and save the map you have in the ECU at
the time. If you can do this, I would recommend it. If anything
goes wrong you can just put your original back on.
Of course this also opens up the possibilty that you could copy
your remap and install it on another car. Please don't do this as
you will be breaking the copyrights of the remap coder.
Look through the list of remaps, they tend to be repeated a bit
on the DVDs and the information isn't very clear but EDG and CDI
tells you it's for a diesel. It's quite important that you find out
what petrol engine you have, EU1, EU2, EU3 or EU4.Some remap file
CDs class them under these headings to make the choice easier.
Select a remap file and upload it to the car. Go and test out
the remap.
Warning
There is a risk when you flash anything, be it a car, firmware
on a new DVD drive or a Sony PSP. I am not responsible if you kill
your car. Make sure your car battery is ok, make sure the laptop
battery is ok and you have no other programs running.Most
importantly, make sure you pick a remap designed for your car.
Writing Your Own Remaps
Yes it is possible but not exactly easy. Search the internet for
a remap editor.Load up a few remaps from the DVD and compare them
to the originals, this will give you an insight as to what has
changed. There are a few forums out there that will be able to help
you to locate the addresses for the rev limiter, boost levels and
fueling etc.
Remember, although remaps are copyrighted by the owners, you
only need to change a few things to make it your own work as many
of the figures in the remaps are from the original map in the car.
Experiment if you have the balls.
Grab all your friend's remaps and compare them against each
other and the original.As long as you don't start applying them to
other cars you should be OK.
Don't ever remap someone elses car unless you own the
remap.Don't ever charge to remap someone elses car unless you own
the remap.
If you do write your own, please don't charge too much to
others. Pressing The Button Won't Select Auto
If you have the car running and in 1st gear but pushing the
button makes it go into auto, there are 2 things to check.
Pull the gear knob off. Pull straight up, do not press the auto
button, do not hit yourself in the face.This removal is the same
for all standard gear knobs and some Brabus ones.
With the gear knob off, look into the end and press the button.
You should see a plastic peg emerge.This plastic peg pushed the
microswitch attached to the SE drive shaft. If the peg is broken,
look here.
Peg Is Fine, Still No Auto
There have been more and more reported cases of the Burgess
F1NST8A1microswitch failing.Here it is below. It has 2 wires
although it is a 2 position switch, only the "normally open" side
is used.
Pull the microswitch out a little bit, you will see the 2 wires
going to it.If either of these wires are disconnected, solder it
back in place and retest the switch.
Look at the metal arm that goes over the red nub, this is what
transfers the movement of the gear knobbutton to the switch. If the
metal bar is deformed, it can bridge the red switch and stop it
from being pushed.
Either reshape the metal bar or take it off and bin it. The gear
knob button should still touch and activateit but the metal bar
does stop the red rubber switch cover from wearing out so it's not
an ideal fix.
With the car running and in gear, bridge the 2 terminals very
briefly with a short piece of wire or unfolded paperclip.
If the car shows an A for auto on the speedo, the switch has an
internal fault and needs to be replaced.
You will need aBurgess F1NST8A1 (do a search, companies like RS
will sell them).Desolder the old switch and solder the new one in
place. Hopefully it all works now. The ZEE Unit ZEE unit stands for
Zentrale Einschub Elektrik which translated means Central Electric
Module.
The ZEE unit is the 600cc version of the SAM unit. It carries
the fuses in verymuch the same way but the relays are all external
so can be swapped over.
Where the 700cc SAM unit is one part, the ZEE unit comprises of
3 sections.
Fuses, OBD and partial relay holder.
ZEE insert module that controls the electronics.Secondary fuse
and relay box located under the seat.
Removing And Opening The ZEE Unit
The main ZEE connector (outlined red), if your car is doing
strange things, check this isn't loose.
The ZEE insert slides out of the side.
The insert fully removed. Circled in yellow is the small speaker
that makes all the beeping noises.
Surrounding the unit are plastic tabs, these are easy to
unclip.
With all of the clips undone you can remove the top to reveal
the cicuit board.
This is as far as you can get with viewing the ZEE insert, the
rear plastic housingcannot be removed without damaging something.
Highlighted in blue is the outline ofrelays L and M which are
located on the other side of the ZEE insert circuit board.These
cannot be removed or changed unlike the other relays.
Main Fuse And Relay Holder
Located under the dashboard. The fuse ratings and layout can be
foundhere.
From 16/11/1999RelayCoupe Function
AFront fog lights
BBoot solenoid
CRear wiper interval
DHorn
ERelief for igntion, heater and windows
FRear window heater
GFront coolant and AC fan
HLeft turn indicator
IRight turn indicator
KFront wiper interval
LCentral locking (inside ZEE unit)
MCentral locking (inside ZEE unit)
RelayCabrio Function
AFront fog lights
BSoft top open
CSoft top close
DHorn
ERelief for igntion, heater and windows
FBoot solenoid
GFront coolant and AC fan
HLeft turn indicator
IRight turn indicator
KFront wiper interval
LCentral locking (inside ZEE unit)
MCentral locking (inside ZEE unit)
Depending when your car was made, you could have hidden
headlight relays or none at all., read further down.
Up to 15/11/1999
RelayCoupe Function
AFront fog lights
BCentral Locking Locked
CCentral Locking Open
DNA
ERear Hatch Remote Unlocking
FRear window heater
GFront coolant and AC fan
HLeft turn indicator
IRight turn indicator
KFront wiper interval
The wipers, horn and relays are separate from the ZEE, they are
hidden behind the dash.
Headlight Relays?
This only applies to 600cc smarts made from 2002 onwards.
For some odd reason, smart decided to put the headlight relays
elsewhere.On a right hand drive smart, the relays are hidden behind
the stereo.On a left hand drive smart, the relays are behind the
main instrument cluster.
If your 600cc smart was made before 2002, there were no relays
for the headlights.
Main Loom Socket Wiring
AWire ColorsConnectionFuse
1Red GreenWiper stalk
2Grey RedWiper stalk
3Grey BlueIgnition position 2
4Brown WhiteSafety triangle +v
5Red GreenWiper stalk
6BlueBlower switch
7Yellow BlackFog lamp switch
8Black GreenLighting stalk
9Black WhiteLighting stalk
12Blue WhiteHandbrake switch
15Black BlueHeater booster switch
17Yellow GreenRestraint control
18BrownEarth
19White GreyOBD pin 1
20Grey Green26
21Grey BlackATA control unit
22Brown BlueCentre console lamp
23VioletATA control unit
25GreenSafety triangle AC1
26GreySafety triangle AC2
27Black Red/Blue RedSafety triangle window heater
28Blue YellowSafety triangle lock
29Violet BlueSafety triangle hazards
BWire ColorsConnectionFuse
31Brown RedInstrument cluster
33Red GreenMulti connector Z50/2
34Red Blue10
35White BlackInstrument Cluster
37Red White15
38BrownEarth
Secondary Fuse And Relay Holder
Located under the carpet underneath the left hand seat.
Wiring
Connector 1
1Wire ColorsConnectionRelay
1Black PinkMEG 1.0K5
2Red BlackFuel pumpK5
3Red BluePrimary fuse boxK2
4Red BluePrimary fuse boxK2
5BlueMEG 1.0K2
6Black WhiteMEG 1.0K2
7Pink BlueMEG 1.0K2
Connector 2
2Wire ColorsConnectionRelay
1GreenCharcoal valveK6
2White YellowMEG 1.0K4
3Green BlueMEG 1.0K6
4Red GreenPrimary fuse boxK1 + K2
5YellowMEG 1.0K3 + K4
6RedBatteryK1 + K4
7BrownEarthK1
8Black YellowMEG 1.0K3 + K5
Connector 3
MWire ColorsConnectionRelay
1GreenCoil pack 1+2+3K1
2GreenInjector 1+2+3K5
3BlueAC compressorK6
5BlueStarterK3
6YellowIntercooler fanK4
7WhiteWastegate valveK6
Relays
Thanks to Tony for the picture.
Relay NumberFunction
K1Fuel pump
K2Auto transmission
K3Main relay
K4Intercooler fan
K5Starter motor
K6A/C Compressor
FuseRating
115 Amps
210 Amps
315 Amps
410 Amps
