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Old 01-07-2005, 02:54 AM   #1
sevendhappy
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Default 02/03 STI headlight Relay harness

All parts bought at Radioshack. Didn’t want to make a second run to the store so I bought a little more than necessary to cover all my bases. Ran me around $30.
(2) Inline "Blade" Fuse Holders #270-1213 **Edit: Forgot to add this earlier.**
(2) 30A Auto Relay #275-226
(2) Quick Disconnects #64-3131
(2) Ring Tongues #64-3040
(1) 20A Auto Fast-Acting Fuses #270-1083 (comes w/ 3 fuses)
(1) 18 Gauge Speaker Wire #278-567
(1) Heat-Shrink tubing #278-1611
(1) Spade-Tongue Terminals #64-3125

I couldn’t find any wiring schematics for the ‘02/’03 STI EDM/JDM halogen headlights that showed how to wire the headlights to allow the low-beams and hi-beams to operate at the same time, so I had to work from the UK300 relay harness instructions/drawings from a thread on scoobymods.com. I took the drawing and changed it around a bit to make one for the STI headlights. The drawing is for those w/ an HID kit installed into them (like the setup I have right now), but the same wiring could be used with just the standard halogen setup. I already had the PnP harness from CC-B so I decided to work from that, but I’m sure other similar PnP harness could be used also.

My low-beam negative (blue wire) on the harness I got was a different color than the one pictured on CC-B’s website (black instead of blue), so I used that color in my drawing below. They are the same wire though. Here is a close up shot of the wires coming out of my CC-B PnP harness:

Here’s a pic of the CC-B harness from their website:


All the wiring connections can be done any way you like as long as the wiring follows this simple wiring schematic:


I think for regular halogen applications, just remove the HID ballast from the pic but run the ground wire coming from the bulb straight to the car chassis.

I made separate harnesses for each side so that if a wire harness fuse blows then it wouldn’t take out both headlights, just one side. Some of the other connectors on my harness were already from my HID kit. You can use many other male/female connectors in their place.
Driver side harness:

Passenger side harness (longer b/c you have to run it across the car to the battery):


Essentially the low-beams (HIDs) are powered by the battery, while the hi-beam still gets it's power from the stock wiring. Here is a pic of my car showing the results:



I drove around an empty parking lot for a little bit running both low & hi-beams on, and everything seemed to work out fine. No blow fuses so far. *knock on wood* I just got this done today so we’ll see how it holds up in the long run. I believe this harness also minimizes any voltage drops since you're grounding straight to the car chassis, which in turn maximizes light output.

Much thanks to Mulder for his helpfulness in answering my barrage of questions. LOL Anyway, hope some people find this helpful.
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Last edited by sevendhappy; 01-29-2005 at 02:43 AM.
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Old 01-13-2005, 10:39 PM   #2
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Impressive! I'm a UK300 owner myself but know what it's like - I share your pain and happiness!

Just a FYI, you can get a similar kit of parts from Daniel Stern lighting, but it's $55. It does include the connectors, though, like CC-B's harness provided you. So it may actually net to be cheaper. Really high quality stuff though. It has 2 relays, so you'd need to use a slightly different wiring scheme. It's the RIK-H4R, which has H4 (or is it H3? the one with 3 spades perpendicular to each other) plugs and the 9007 plugs. I don't think the STi lights use H4, but I'm sure he can provide you with the correct connectors.
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Old 01-24-2005, 02:21 AM   #3
Sputnik 5
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Default help...HIDs work but shut off when hi beams are on????

Hello

read your post and am using your tutorial to help me install my HIDs into a set of STi EDM headlights. So basically we have the exact same setup. Though I am using a EDM harness from member, Wagons Ho, not the CCB harness. So my harness has necessary connector for low beams, doesnt end in green/blue wire like CCB harness. I dont think that will make a difference?

HID install went smooth and HID is operational (jeez these things are bright!) Problem is my HIDs turn off when I kick on the high beams??? I dont know where the problem is?

I got my HID kit from XenonFactory, so it came with harnesses and is pretty much plug and play. You can download pics of harness and install directions here,towards bottom of page, red link: http://www.xenonfactory.com/products/hid/philips.htm

I think my HID kit harnesses are basically the harnesses you built yourself so I dont know where the problem is? all my wires seem to to be going same place as your schematic...One question I have is on your wiring schematic you state that you dont need the blue low beam ground from the CCB harness but in your harness pics its connected to a black connector? Is that connector going to the ballast?

I hope that makes sense? I am going to keep messing with it til it works. I am in burbank/glendale if you are in the area..

Thanks for your time and the tutorial! It was very helpful

-Mark
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Old 01-24-2005, 03:40 AM   #4
sevendhappy
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Hey Mark, I'll try and answer your Q's one at a time:

Quote:
Originally Posted by Sputnik 5
Hello

read your post and am using your tutorial to help me install my HIDs into a set of STi EDM headlights. So basically we have the exact same setup. Though I am using a EDM harness from member, Wagons Ho, not the CCB harness. So my harness has necessary connector for low beams, doesnt end in green/blue wire like CCB harness. I dont think that will make a difference?

HID install went smooth and HID is operational (jeez these things are bright!) Problem is my HIDs turn off when I kick on the high beams??? I dont know where the problem is?
The problem is that the on/off operation of the low/hi-beams through the stock wiring are determined by the ground wiring system (separate grounding wires for both low & hi-beams). The stock wiring system is designed to turn off the low-beams and activate the hi-beams when you flick the hi-beam switch on. This is why in my wiring schematics you need to wire the ballast directly to the car chasis. What this does is not allow the stock wiring to cut off the completed circuit for the low-beams, thus keeping them on even though you flick on your hi-beams*.

*Mulder (or someone else), please correct me if I'm wrong on this one.

Quote:
Originally Posted by Sputnik 5
One question I have is on your wiring schematic you state that you dont need the blue low beam ground from the CCB harness but in your harness pics its connected to a black connector? Is that connector going to the ballast?
I'm believing you're talking about this:


Yes, that connector runs to the ballast. And yeah, the blue wire runs into the the black connector b/c that's how I had my HIDs wired up prior to making this harness.



The part circled in yellow is the other half of that plug, w/ the red wire being the positive wire going to the ballast (in my ghetto fabulous wiring schematics, the positive is the green line....so the red wire in my pic=the green wire in my wiring schematic). If you notice though, the negative wire (black), circled in red, that's coming from the ballast I cut from the connector so that I could ground the ballast directly to the chasis. So essentially that blue wire running into the connector, runs out the other end of the connector into nothing, circled in green. So that's why I said you don't need the blue wire to begin with.


If you plan on having this setup, I was advised that you either have your low beams (HIDs) OR hi-beams powered by the battery so that you don't overload the stock wiring, by possibly melting something or blowing a fuse, when having both low & hi-beams on. For my setup, I decided to power my HIDs from the battery, and this is what my harness accomplishes. Hope this helps Mark. If you have any more problems, PM me and I can possibly meet up with you to help you out sometime this week.

RJ

edit: Looked over the installation instructions/pics on Xenonfactory's website, and I might have an idea of what's going wrong, although I wouldn't be able to tell for sure unless I saw everything wired up. Check the low-beam ground wire (the blue wire in my harness pic), it shouldn't lead anywhere like I have in the picture above. The relay harness supplied looks a little different, but I believe it still functions the same. So yeah, PM if you need anymore help.

Last edited by sevendhappy; 01-24-2005 at 04:25 AM.
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Old 01-24-2005, 04:20 AM   #5
soundwave
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awesome write-up, i will def. use this once my hid kit arrives later this week

Last edited by soundwave; 01-24-2005 at 04:27 AM.
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Old 01-25-2005, 12:06 AM   #6
Sputnik 5
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read through your reply and trying to diagnose where the problem is. Wiring is not my thing though...

I am trying to pinpoint the main difference between your harness wiring and the one listed on XenonFactory. I installed mine EXACTLY as listed on XenonFactory, so obviously this method does not allow for hi and low beams to be on simultaneously but does draw power for HID directly from battery,correct me if I am wrong. So once the difference is found then hopefully issue will be solved. Thanks for the very helpful reply. PM you if necessary.

Thanks!!!
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Old 01-25-2005, 12:52 AM   #7
sevendhappy
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Hmmm....my relay is grounded directly to the car chasis, while I noticed in the Xenonfactory installation instructions, theirs doesn't say to ground it to the chasis. Could that be it?
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Old 01-25-2005, 02:42 AM   #8
Sputnik 5
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I have my relays and grounding points coming off ballasts both grounded directly to car frame, no plastic interference whatsoever. I have my DRL module pulled from under hood by strut tower but not from under dash...maybe that?

yeah its a mystery to me. I am thinking it is because the spade connectors used to connect to the original H1 halogen are still in play here...they get connected to supplied male spade connectors in XenonFactory harness, designated "to factory headlight plug" in their PDF picture instructions. Instructions state"this will send signal to relay when you turn light switch on" So somewhere a switched ground from the stock system is still in effect?...that is pure speculation though.

I will admit that even though the HIDs are functioning perfectly, not being able to run the high beams at the same is frustrating.

Thanks!
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Old 01-29-2005, 12:39 AM   #9
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bump

i got my HID kit in today so i'll try this out asap.
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Old 01-29-2005, 12:55 AM   #10
Sputnik 5
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good luck with HIDs, got mine aligned and they are well worth the money. Let me know if you get hi beams and HIDs at the same time.

Thanks
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Old 01-29-2005, 12:58 AM   #11
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I'll be moving into my apt. in Burbank this weekend. I can meet up w/ any of y'all if you guys need help. I'm no expert at this stuff, but at least I can see what's up with the wiring.
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Old 01-29-2005, 01:03 AM   #12
soundwave
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sevendhappy - too bad you're in socal or i would take up your offer.
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Old 01-29-2005, 02:11 AM   #13
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I got a PM asking what plugs into where since my pics of the harnesses are kinda hard to intepret, so hopefully this clears up some things:

1) **I just realized that I forgot to mention to buy two Inline "Blade" Fuse Holders #270-1213 to place the 20amp fuses into for the relay to battery connection**

2) Use the Quick Disconnects #64-3131 (female connectors from the bag) to plug into the 30A Auto Relay #275-226. **Be sure to pay attention to the numbering on the back of the relay!**

3) You will use the Ring Tongues #64-3040 as ground connetors to the car chasis and for the connection to the car battery.

4) Use the Heat-Shrink tubing #278-1611 when splicing two wires together (if you aren't using male/female connectors) to protect the wiring connection.

5) The Spade-Tongue Terminals #64-3125 aren't really necessary to have if you bought more of the Ring Tongues #64-3040 (actually, you should definitely buy an extra bag or two of these).

6) And I'm assuming you all will know what to do with the 18 Gauge Speaker Wire #278-567.



Just take your time and make sure the wires are connected to the end connectors well enough. When you're done, just double check your wiring, install them, and you're good to go. Hope that helps. I don't know how much more detail I can go into. Haha! Good luck.

Last edited by sevendhappy; 01-29-2005 at 04:36 AM.
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Old 01-29-2005, 02:20 AM   #14
soundwave
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where did you mount everything (ballast/fuse holder/relay/etc)? lol
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Old 01-29-2005, 02:31 AM   #15
sevendhappy
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Quote:
Originally Posted by soundwave
where did you mount everything (ballast/fuse holder/relay/etc)? lol
The hid ballasts......well, you're on your own there. I found a place to put them, but I don't know if they are ideal mounting spots (or so I've been told). LOL Let's just say that 3M Automotive double-sided tape works wonders! So just mount them where they won't get in the way I guess. As far as everything else goes, there is so much wiring w/ having HIDs and all that I just tucked everything in behind the lights, so it's all kinda just scrunched together. I did use wire looms to clean up the wiring, since having this harness will make the back of your headlights look like a cobweb of wires (I'll take pics tomorrow to show you what I'm talking about).
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Old 01-29-2005, 02:35 AM   #16
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yeah, i had hids before on my edm headlights so i know where to mount the hid ballast. it's just the other stuff i'm not sure about. haha

thx
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Old 01-30-2005, 02:48 AM   #17
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More instructions in "n00b layman's terms." Yo Odeezie, here's the pic of your HIDs w/ instructions.



For more efficient wiring using the 18gauge speaker wires (see NOTE in step 4 up above) I made a pic in mspaint to show what I meant. You can leave the speaker wires together, but you split them on the ends. This makes the passenger side harness easier to manage since you have to wire them across the car. For the pic below I used the exact same color scheme of the 18 gauge speaker wire #278-567 (Red + Red/black) I bought from Radioshack



Okay...I'm spent now trying to explain it any further. LOL
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Old 02-01-2005, 03:15 AM   #18
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Thanks for the help RJ! Thats an awesome diagram. Sorry I wasn't coherant, it was a crazy Saturday night! Anyway, as soon as I find the time, I'm starting on this right away. In the meantime, I'll try not to drive at night.
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Old 02-01-2005, 06:34 AM   #19
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Nice!
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Old 02-05-2005, 09:18 PM   #20
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bump
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Old 02-07-2005, 06:11 PM   #21
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Quote:
Originally Posted by sevendhappy
The hid ballasts......well, you're on your own there. I found a place to put them, but I don't know if they are ideal mounting spots (or so I've been told). LOL Let's just say that 3M Automotive double-sided tape works wonders! So just mount them where they won't get in the way I guess. As far as everything else goes, there is so much wiring w/ having HIDs and all that I just tucked everything in behind the lights, so it's all kinda just scrunched together. I did use wire looms to clean up the wiring, since having this harness will make the back of your headlights look like a cobweb of wires (I'll take pics tomorrow to show you what I'm talking about).
I found that the 3M velcro works well. I found that I had to take my lights off the car and back on again and since it was velcro, it saved me from buying more tape. It is also a good strong hold.
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Old 02-07-2005, 07:29 PM   #22
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I installed mine yesterday with the above instructions during the super bowl and they work great !

Thanks
Preston
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Old 02-07-2005, 08:45 PM   #23
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i have the same hid's and a more or less identical setup down to the electrical tape on quick connect conectors, i found after about a year the lights started to noticably flicker on bumbs, i fixed it by making a small solder on each one of the quick conects on the relay, it was a bit of a pain to do but a good note for ppl taht live in places where connections will tend to corrode.
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Old 02-07-2005, 10:25 PM   #24
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Quote:
Originally Posted by Gruppe-S
I installed mine yesterday with the above instructions during the super bowl and they work great !

Thanks
Preston
Wow. I actually contributed something worthwhile here on Nasioc. w00t! LOL Glad it worked for you though!
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Old 02-07-2005, 10:48 PM   #25
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Quote:
Originally Posted by sevendhappy
Wow. I actually contributed something worthwhile here on Nasioc. w00t! LOL Glad it worked for you though!
<-- work @ gruppe-s

If you ever need anything, contact me and I'll give you better pricing.
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