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Electrical guides and mods

ZEE Unit (Fuse Box)

The ZEE unit is the fuse and relay module that is used in 600cc smarts instead of the SAM unit that is found in 700cc smarts.

Modification Details




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 very
much 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 housing 
cannot be removed without damaging something. Highlighted in blue is the outline of 
relays 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.



Todor T cut a hole in a ZEE unit to show us the relay. (2 relays in 1 package).



Main Fuse And Relay Holder

Located under the dashboard. The fuse ratings and layout can be found 
here.



From 16/11/1999
Relay Coupe Function
A Front fog lights
B Boot solenoid
C Rear wiper interval
D Horn
E Relief for igntion, heater and windows
F Rear window heater
G Front coolant and AC fan
H Left turn indicator
I Right turn indicator
K Front wiper interval
L Central locking (inside ZEE unit)
M Central locking (inside ZEE unit)

Relay Cabrio Function
A Front fog lights
B Soft top open
C Soft top close
D Horn
E Relief for igntion, heater and windows
F Boot solenoid
G Front coolant and AC fan
H Left turn indicator
I Right turn indicator
K Front wiper interval
L Central locking (inside ZEE unit)
M Central 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

Relay Coupe Function
A Front fog lights
B Central Locking Locked
C Central Locking Open
D NA
E Rear Hatch Remote Unlocking
F Rear window heater
G Front coolant and AC fan
H Left turn indicator
I Right turn indicator
K Front 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

A Wire Colors Connection Fuse
1 Red Green Wiper stalk  
2 Grey Red Wiper stalk  
3 Grey Blue Ignition position 2  
4 Brown White Safety triangle +v  
5 Red Green Wiper stalk  
6 Blue Blower switch  
7 Yellow Black Fog lamp switch  
8 Black Green Lighting stalk  
9 Black White Lighting stalk  
10 Black Door solenoid microswitch  
11 Yellow White Door catch microswitch left  
12 Blue White Handbrake switch  
14 Yellow Red Door catch microswitch right  
15 Black Blue Heater booster switch  
17 Yellow Green Restraint control  
18 Brown Earth  
19 White Grey OBD pin 1  
20 Grey Green   26
21 Grey Black ATA control unit  
22 Brown Blue Centre console lamp  
23 Violet ATA control unit  
24 White Key RF/IR receiver  
25 Green Safety triangle AC1  
26 Grey Safety triangle AC2  
27 Black Red/Blue Red Safety triangle window heater  
28 Blue Yellow Safety triangle lock  
29 Violet Blue Safety triangle hazards  

B Wire Colors Connection Fuse
31 Brown Red Instrument cluster  
32 Grey Blue Central locking open  
33 Red Green Multi connector Z50/2  
34 Red Blue   10
35 White Black Instrument Cluster  
36 White Blue Central locking closed  
37 Red White   15
38 Brown Earth  

Secondary Fuse And Relay Holder

Located under the carpet underneath the left hand seat.

Wiring

Connector 1

1 Wire Colors Connection Relay
1 Black Pink MEG 1.0 K5
2 Red Black Fuel pump K5
3 Red Blue Primary fuse box K2
4 Red Blue Primary fuse box K2
5 Blue MEG 1.0 K2
6 Black White MEG 1.0 K2
7 Pink Blue MEG 1.0 K2

Connector 2

2 Wire Colors Connection Relay
1 Green Charcoal valve K6
2 White Yellow MEG 1.0 K4
3 Green Blue MEG 1.0 K6
4 Red Green Primary fuse box K1 + K2
5 Yellow MEG 1.0 K3 + K4
6 Red Battery K1 + K4
7 Brown Earth K1
8 Black Yellow MEG 1.0 K3 + K5

Connector 3

M Wire Colors Connection Relay
1 Green Coil pack 1+2+3 K1
2 Green Injector 1+2+3 K5
3 Blue AC compressor K6
5 Blue Starter K3
6 Yellow Intercooler fan K4
7 White Wastegate valve K6

Relays



Thanks to Tony for the picture.

Relay Number Function
K1 Main Relay (powers F3, F4, K3)
K2 Auto transmission
K3 Starter Motor, Coil Packs
K4 Intercooler fan
K5 Fuel Pump
K6 A/C Compressor

Fuse Rating
1 15 Amps
2 10 Amps
3 15 Amps
4 10 Amps


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