2002rs swapped with 04 wrx

[rs420]

Project bugeye swap.
2002 2.5rs // 2004 wrx
Im just going to be diving into this project later this week, and I just want to try and save myself a little bit of time by finding out some answers to questions I have rather than trial and error

All threads for this topic seem to be for GC body style, and end at 2001. I want this to be a good source of information for anyone wanting to swap into a bugeye.

The tale begins:
I have 2002 rs which I'm putting a 2004 wrx 2.0. It came as a complete engine and cradle assembly. 19000miles when pulled
Dropped out of the car with the front axles/hub&knuckles/calipers, auto tranny etc... very complete.
stock turbo cross member from the 04.
Exhaust
stock intake box setup
engine wiring harness
interior wiring harness
fuel pump controller and harness
Front Sway Bar
WRX ecu
WRX Powersteering assembly
WRX throttle cable



Questions:
-I dont know if I need to redo the interior wiring in my car to work with the newer wrx ecu, or if it is the same and is plug and play (all info I can find refers to the 2001 and older cars, not bugeye's)

-Will turbo cross member direct bolt on to my car without needing to shim it? or do I need to get a early model legacy cross member (like all documentation on gc swaps need)? Yes it does work!

-Does the bugeye steering rack work? or does it have to be changed too? Yes it does work!

-Does anyone have any write-up or advice to give on this swap?




I will update this thread as I do my swap, and will ask more questions hopefully that can be answered!

Thanks!
Here is the car

[rs420]

figured mechanically everything should bolt up (or hoped it would!)



Today I made some progress. I stripped down the assembly I got, removed the knuckes and lower control arms. Removed the auto tranny/torque contertor/flex plate and got my new flywheel prepped to go in.









It looks like the wiring harness I got might not include the rear section of the car like I had asked the guy for (he was stripping a dismantle only title car) and so how ****ed am I not having that?








Can I just run new wires and wire it up myself, or do I have to go and buy the rear harness? Do I need anything off the rear wiring harness for tail lights, etc...? or is it just the fuel pump controller I need?


I think it might be easier on the bugeye with less chance for error to re+re the whole dash to swap the harness (rather than cut and splice)

[rs420]

Just started tonight, had an hour or 2 before the shop closed to get some work done.

Pulled the rad, evac the a/c system, removed my header, disconnected the throttle and cruise control cables, and got the intake off.


tomorrow morning it is goodbye stock n/a and hello turbo

[rs420]

My memory card is not working to upload the pics right now, but I will do so asap.

Today I made quite a bit of progress!
I pulled the engine and swapped out the cross member.
I got the new engine in and all bolted up and also put in a new clutch.
All steering and suspension components are back in and bolted up.

I have only the rad, lower cowling, downpipe, intercooler, cat back and air intake system left to reinstall. Most everything went pretty smooth. It was all straight forward re+re and used same mounting points, etc...

I did run into a bit of trouble with the throttle/cruise cables not routing properly, and had to take the bracket off my old engine and modify it to work properly.



I also have a bit of a problem with my rad, and the new coolant resevoir location on top of the intake manifold. My stock rad doesnt have the 2 extra connections needed for the turbo motor. There has to be a proven way to do it, because I never hear about people having to replace their rads with the swap. I figured I would pick up a coolant T from lordco and fab something up.

Tomorrow I tackle the wiring. Ill be stripping the engine bay wiring and putting in the new harness. I hopefully have a ecu to borrow, and a cat-back coming from a friend tonight so I can bolt on the downpipe and cat-back tomorrow. I may or may not get into stripping the dash to replace the harness. Ill see how much time I have, as Im going out of town for the long weekend and have limited time to work on it.

I also aquired a new hood, and its being prepped and painted my custom grey color, and im going to rock a black scoop. I think it should look pretty good!

[rs420]

Im missing the fuel pump harness and the controller. Can I just run new wires and wire it up myself, or do I have to go and buy the rear harness? Do I need anything off the rear wiring harness for tail lights, etc...? or is it just the fuel pump controller I need?

[Zephyr]

Originally Posted by rs420

Im missing the fuel pump harness and the controller. Can I just run new wires and wire it up myself, or do I have to go and buy the rear harness? Do I need anything off the rear wiring harness for tail lights, etc...? or is it just the fuel pump controller I need?

Yup, you can run the wires yourself. You'll want to get the FPC from an 04 WRX as it comes with a short pigtail of wire that you can splice into.

[rs420]

FPC - is that the little controller in this image?

[Monster]

yup

[rs420]

got the ecu and catback so I can work on finishing my swap.

I had to get a T connector for the extra hoses that come off the upper coolant tank on the turbo motor because the stock RS rad doesnt have the same setup.
-Pulled the dash and all lower console covers to get to the wiring



Heater controlls are cable operated on the RS and the 04 wrx

-tamper proof bolts suck and are a pain in the ass. there are 4 that hold the airbag ecu in place that have to be removed to get the dash rebar out. I really hate plastic connectors now, and think it will be challenging to remember where everything goes. I hope I dont have lots of left over bolts when im done


\

-removed the heater core and fan motor/box behind the dash. I had limited time before I had to go away for the long weekend, so I had to put a hold on progress until tuesday.


-got the hood fixed and painted. got the dings fixed and got the scoop painted up to match my 2 tone scheme.


RS heater controls are cable and so are 04 wrx!

Updated build thread

If anyone has any questions about the build, let me know

[rs420]

AND she runs!! It got a bit tricky with the auto wiring in the harness (it was looking for a park or neutral signal) and I couldnt get any power to the starter. I traced the wiring and found the 2 wires, spliced them together and the car cranked right away. After priming the oil through to the turbo I fired it up! booya baby.
Thanks to Loomin who wired up my fuel pump controller.
It still has some kinks to be worked out. I need to rewire some stuff. The
-headlights/fog lights/turn signals (because harness is for 04, different headlights)
-speed sensor
-reverse lights
I had to use newer fans (didnt have to, but easier than rewiring my stock ones) to work with the 04 harness plugs. I had to rewire the mirror controls and abs sensor by the e-brake. Also had to rewire the plugs that went up by the seatbelts (seatbelt indicator and door switches)
My factory keyless entry also isnt working yet...
New clutch is butter smooth, will take some getting used to for sure. I fired it up with only the downpipe on, so it was loud but sounded sooo sexy.
a day or 2 more work and she should be ready to rock and roll