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Old 11-23-2008, 03:32 AM   #1
Loomin
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Default 05+ auto HVAC in 02 WRX. im doing it and it WILL work. but i need help!

Im installing 05+ STI auto HVAC into my 02 WRX. I SEARCHED THROUGH OVER 400 THREADS READING UP ON THIS:

YES it can be done
YES it requires effort.

you need to remove EVERYTHING from the dashboard including the dash cover its self. its alot to remove.

Drain the coolant
Discharge the A/C (do it properly for the sake of our ozone)

I have the following parts:

complete 05+ STI center console
05+ auto HVAC control panel ( knobs and buttons)
05+ auto HVAC Heater core and A/C evaporator assembly with servos
the appropriate plugs that connect to the above units.
Making my own wiring harness



I have 2 questions:

1) is there anything else needed? i heard something about a sunlight load sensor and also something about a "control module" is there any other components i need? special module boxes that may be hidded beneath the dash? Maybe the STI blower motor?

2) Does anyone have a wiring diagram for these components?


when finished i will publish a full how-to on this subject but i need a bit of help.
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Old 11-23-2008, 04:49 PM   #2
jdubya301
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i would see if you can find some wiring diagrams for the specific MY of the parts you are using. compare the charts to yours and see what else would be needed.
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Old 11-23-2008, 04:57 PM   #3
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Quote:
Originally Posted by jdubya301 View Post
i would see if you can find some wiring diagrams for the specific MY of the parts you are using. compare the charts to yours and see what else would be needed.
hmm ive been googling all morning but i have yet to find an actual diagram.

ill have to call my dealer tomorrow and get both diagrams.

after doing a basic eyeball comparison between the two harnesses,

there are 15 wires on the 02 harness plus 8 wires for the servos on the new heater core...and 4 for the blower motor and resistor thing for the blower.

So that makes 27 wires for the 02 WRX HVAC system w/ 05 auto heatercore installed.


i then counted the number of wires on the two harnesses that plug into the 05 auto HVAC control panel.

there are 26....

one wire difference.... ill have to find out what that one wire difference is tomorrow after i get the diagram. i noticed i have 2 black wires for the 3 servos. maybe they are supposed to be connected together.
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Old 11-24-2008, 03:44 AM   #4
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i got impatient and bought a wiring diagram for $4 online.

ive finished making the pin-out diagram.


turns out you need a lot of little parts to make this work.

the 02 and 05+ blower motors are different. well the speed control units are anyways,
02's have a 4 wire resistor and the the 05+ has a 3 wire "amplifier"

youll also need the ambient air temperature sensor. (cheap on subarugenuineparts.com)

theres also a "sun load" sensor that measures the suns intensity because it will have an effect on the cabin air temp. its a tiny 2 wire photocell on top of the dash. its enclosed in a black dome thing.

the other thing is that this unit connects the outside (ambient) air temp sensor to the gauge cluster. so a gauge cluster with an LCD temp readout would be nice. i have an sti cluster already so im all set.

the amount of wiring for this project is simply intense. im making my own harness. i couldnt get the original harness from the donor car.

if i have one reccomendation, its GET the original harness for an 05+ STI.
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Old 11-24-2008, 02:48 PM   #5
steve
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wow loomin, this is intense. I had no idea how many little bits, pieces and sensors were involved in the 05+. That's a big project to take on.

I'm not surprised though. If anyone's going to make this work, it's going to be you.

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Old 11-24-2008, 04:03 PM   #6
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It's loomin. He can make 'anything' possible

Good luck with the project.
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Old 11-24-2008, 05:14 PM   #7
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since im a subaru tech i have access to all the service manuals, if you need any wiring diagrams PM me
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Old 11-26-2008, 12:20 AM   #8
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Quote:
Originally Posted by hypa View Post
wow loomin, this is intense. I had no idea how many little bits, pieces and sensors were involved in the 05+. That's a big project to take on.

I'm not surprised though. If anyone's going to make this work, it's going to be you.

Thanks! its pretty intese to make a wiring harness for this... im looking for one i can buy. the 05 wrx looks promising... 2.0L, 16bit ECU, etc etc. and... auto climate controls....

Quote:
Originally Posted by J-Chow View Post
It's loomin. He can make 'anything' possible

Good luck with the project.
Thanks!

Quote:
Originally Posted by carnz-pj-410 View Post
since im a subaru tech i have access to all the service manuals, if you need any wiring diagrams PM me
Thanks man! any chance you can hook me up with an ECU pin out for an 05 WRX? i want to make sure that its the same as an 02 wrx.... Thanks!
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Old 11-27-2008, 03:16 AM   #9
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ok so upon hours of further research, ive concluded that the 02 and 05 ECU's are not compatable. the 05 ECU has 5 plugs with a total of 88 pins. the 02 has 5 different shaped plugs with 120+ pins. not one plug is the same between the two cars. now some of the pins are unused so i even counted the number of wires on all of my plugs. there are 93 IIRC. The 04+ STI's have only 4 plugs but they each have MANY more wires. so long story short: id need some kind of wacky conversion harness.

im almost positive they made a JDM WRX with auto climate controls in 01-02 (bugeye years in japan) but the harness would be RHD and almost unusable in a LHD car.

im wiring it all up my self. ive made my own pin out chart which i will post once its tested and working properly.

pics to come soon....
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Old 11-28-2008, 10:32 PM   #10
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heres the progress:






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Old 12-01-2008, 10:17 PM   #11
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Ok so the climate control works!! Perfectly too!! it took about 10 gours to pull what was left apart, wire it all up test it and reassemble it to running condition again.

my advice to anyone trying this: make sure you do it neatly and make sure you know how to read a wiring diagram!



pics of the wiring process....







i also took the time to install these Defi STI geNome Gauges.



pics of the finished product still to come!
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Old 12-02-2008, 02:41 AM   #12
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Special thanks goes out to carnz-pj-410 who helped me alot with this swap. this guy is a real life scooby guru. he knows his ****!!! Thanks again man!!
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Old 12-02-2008, 01:49 PM   #13
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looks great! you going to do a write up after its all done
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Old 12-02-2008, 04:11 PM   #14
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You're welcome man, glad to help
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Old 12-02-2008, 08:27 PM   #15
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Quote:
Originally Posted by StupidFastWagon View Post
looks great! you going to do a write up after its all done
yep ill make a list of all of the parts youll need as well as some basic directions.....
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Old 12-19-2008, 04:21 PM   #16
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Any update?
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Old 12-19-2008, 11:05 PM   #17
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Quote:
Originally Posted by StupidFastWagon View Post
Any update?
Heres a list of everything youll need:

04 sti/05+ wrx/sti heater core assembly with servos. (includes thermo switch)
04 sti/05+ wrx/sti Blower motor - the fans are the same but the fan speed controllers are different.
04 sti/05+ wrx/sti fresh air selector duct (the part that selects fresh air/recirc and also holds the cabin air filter
04 sti/05+ wrx/sti heater control knobs 05+ will require an entirely new center console to fit. if you have an 02-04 WRX, use the 04 sti knobs so that it will fit your old console. youll still need to buy the HVAC trim piece because it has a small vent in it.
04 sti/05+ wrx/sti wiring harness plugs:

2 plugs for the back of the controller, 1 for the mode selector servo, 1 for the fresh air servo, 1 for the new thermo switch, 1 for air mix servo, 1 for sunload sensor, 1 for ambient air temp sensor, 1 for the new fan amp, a new gauge cluster pin, and several ring terminal connectors for new grounds.

04 sti/05+ wrx/sti sunload sensor
-Any subaru ambient air temp sensor (mines from a 2001 forester)
-any subaru gauge cluster with an outside temp readout. this isnt necessary but this mod will make the readout work properly.
if you are doing the 05+ center console conversion, you will also need the 05+ E-brake lever because its on the opposite side and the armrest piece wont fit with the 02-04 e-brake lever.
-a ****load of wire.
-a ****load of time for research and atleast a full weekend to do the mod.\




tools you will need:

-wiring diagrams. the most important tool of all. complete HVAC diagrams, gauge cluster diagrams, defogger system diagrams, ECU diagrams, for both the 02/03 and 04+ automatic systems.

- a VERY good soldering iron. i prefer pencil types. dont bother with butane you will go through 8 cans of butane by the time this is done.

5-6 feet of shrink tube. this is how much i used. i used 1" pieces, and yes thats how many solder connections you have to make.

a good size roll of small diameter flux-core solder.

a whole roll of electrical tape for taping the harnesses together.

zip ties. various sizes

ring terminals for new grounds. you only need 2 or 3

female spade connectors- i didnt have the plug for the new fan amp but these worked fine.

wire. 16-18ga works well. buy a big roll. i used the same colour for all the wires. just make tags. which brings me to:

masking tape - 2" wide and a sharpie pen for making tags for the wires. label them carefully so you dont get confused.

lighter for shrinking shrink tube

New coolant

New R134a for recharging your AC after.







other helpful tips:

remove as much of the interior as you can: seats, the entire console and dashboard, steering column can stay but the rebar behind the dash has gotta go, pull the carpet back around the ECU and pedals so you dont get solder on it.... a-pillar covers, etc etc. youll see once you get started.


ill add more later

Last edited by Loomin; 12-19-2008 at 11:19 PM.
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Old 12-20-2008, 02:21 PM   #18
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oh snaps! lol thanks for the update, im looking forward to see more!
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Old 12-29-2008, 07:26 PM   #19
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Thanks for the info. I have an 04 WRX trying to do the same conversion. Although I haven't done any research beyond this thread and my own visual inspection what are some things you think will be different since the 04 and 05 are so similar minus the auto HVAC?
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Old 12-29-2008, 09:17 PM   #20
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on top of all that you need a good conversion diagram
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Old 12-30-2008, 04:13 AM   #21
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Quote:
Originally Posted by MotorolaBizz View Post
Thanks for the info. I have an 04 WRX trying to do the same conversion. Although I haven't done any research beyond this thread and my own visual inspection what are some things you think will be different since the 04 and 05 are so similar minus the auto HVAC?
Theoretically, you could just buy the 05 cabin wiring harness and it would all be plug and play and uber clean. the 02 uses a different ECU with different plugs so that would have been very difficult for me.

Quote:
Originally Posted by carnz-pj-410 View Post
on top of all that you need a good conversion diagram
oh yes the most important part for thopse DIY harness guys. Where might one find one of those diagrams? probably from some kinda subie guru.
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Old 12-30-2008, 12:17 PM   #22
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that cabin (bulkhead interior) harness is over $1000 new. so i think thats out of the question for most people
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Old 12-31-2008, 05:09 PM   #23
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so wait... I have an 04 and all I would need to do is just change the bulk head wiring?
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Old 12-31-2008, 05:20 PM   #24
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Im subscribing to this. Im starting with an 02 WRX chassis with 04 JDM STi chassis harness and swapping in an 05 setup.........hopefully mine is mostly plug and play.
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Old 01-02-2009, 04:36 PM   #25
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Quote:
Originally Posted by StupidFastWagon View Post
so wait... I have an 04 and all I would need to do is just change the bulk head wiring?
you dont need to change the bulkhead harness, that would be too much work, just get the parts and connectors and wire it up, a conversion wiring diagram to follow would help greatly

the 04 wrx and 04 sti bulkhead harnesses are not the same, so you need to find which wires to use on the wrx vs the sti
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