Need Help Wiring Up Hella 500s

[67Customs]

I am going to start working on mounting my Hella 500s this weekend. There are a couple of things I need to know however.

I need to know which color wire going to the front headlights is the high beam wire. Anyone have a picture for reference?

Also, if I wanted to be able to turn them on at any time (or at least when the parking lights are on), could I wire the green wire that goes to the switch to the amber parking light instead of the high beam wire or is that wire to small?

And just to rant a little, I hate not being able to have a Haynes repair manual for my Jeep. I wish they could come out with them sooner.

Thanks.

 

[JeepJeepster]

I currently have mine wired up to my parking lights like you were talking about. The wire isnt to small as you will be using a relay that gives the hellas power. The wire from the park light will only be giving the relay power which is a very, very small amount.

So you will have power coming from the park light to the switch on the inside then from the switch back to the relay(+). The relay will also need a ground.

You will then have a wire coming from your battery to the relay(+) and from the relay(+) to the lights(+). The relay acts like a switch to cut the power on and off to this wire.

The lights will then be grounded.

After having them wired up to the park lights for some time Ive come to the conclusion that I would like they wired to the bright lights. I like to use them on the road(treat them light bright lights) but sometimes I cannot get to the switch as fast as I could the stalk.

Here are some pics.

Where I came through the firewall:

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Mounted the relay on the battery tray:

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Park light:

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[67Customs]

Dude, thanks so much for those pics and instructions. That really helps me see where I want to mount and run some items.

I was thinking the same thing about how I want to use them. I originally wanted to use them with my bright lights so I could use them on the road, but I also wanted my fog lights on at the same time if I were using them off road.

I believe my solution to that will be to mount some other fogs in the lower bumper openings and have them on their own switch.

Thanks for the help.

So, since I am going to wire them to the bright lights...which color wire is for the brights?

 

[JeepJeepster]

Im not sure which wire you need. Ive never looked at those and I cant seem to find it in the FSM..

If youve got a volt/ohm meter then just unplug the headlights and see which gets power when you kick the brights on.

 

[Corwyyn]

On the 2005 KJ the colors on the headlight connectors are as follows:
Left Headlight -
White w/Dark Blue stripe = Low Beam
White w/Light Green stripe = High Beam
Black = Ground

Right Headlight:
White w/Tan stripe = Low Beam
White w/Gray stripe = High Beam
Black = Ground

I've got my Hellas wired into the high beams with no switch, so when I switch on the brights they come on automatically - great for letting those idiot drivers who cut in front of you know just how much you like them

 

[patbluejeep]

ok so i have a question about these lights. I cant get mine to come on. I have power to the switch and the switch works just like it should. Could you tell me where the wires on the light connect? It should be that the black wires connect to the black wires to the relay and the blue ones are grounds? im confused.

sorry to hijack your thread.

 

[Corwyyn]

Yes, the two black wires are power for the lights and the blue wires are ground. Here's a color-coded wiring diagram that may make things easier:

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If you know the switch works then try this - unplug the double black wire and the red battery power wire from the relay, then unplug the wire that leads to terminal 86 on the relay (yellow in the diagram) but leave the blue ground wire connected. Now turn on your lights (whichever side you tapped the green wire to) and your switch, then try connecting the yellow switch wire to terminal 86. You should hear the relay click when the wire connects, if you don't check all the connections. If they're good then you may just need a new relay ($5-10 at your local auto parts store). One other thing you can try before replacing the relay is to make a wire long enough to go from the positive terminal on the battery to the relay - take this and just touch it to terminal 86 to double-check the relay. If the relay checks out when you connect the yellow switch wire then try replacing the fuse in the power wire from the battery. If the relay doesn't click when you connect the yellow switch wire but does when you connect a wire from the battery then the problem is somewhere in the switch or the connection on the green sense wire. If all that checks out and they still don't come on the double-check the grounds on the lights, then throw up your hands in utter defeat

 

[patbluejeep]

LOL thanks... i have a feeling ill be printing that set of directions out. thanks for the help

 

[67Customs]

On the 2005 KJ the colors on the headlight connectors are as follows:
Left Headlight -
White w/Dark Blue stripe = Low Beam
White w/Light Green stripe = High Beam
Black = Ground

Right Headlight:
White w/Tan stripe = Low Beam
White w/Gray stripe = High Beam
Black = Ground

I've got my Hellas wired into the high beams with no switch, so when I switch on the brights they come on automatically - great for letting those idiot drivers who cut in front of you know just how much you like them

Awesome! Thanks. That helps so much.

sorry to hijack your thread.

It's cool. It might be something I need to know later.

 

[patbluejeep]

well i got mine to work... wanna know the secret???


GROUND WIRES LOl!! i was pwn3d by the ground wires like a big noob.

 

[Corwyyn]

Nice!!! Now get out there and start blinding people

 

[JeepJeepster]

well i got mine to work... wanna know the secret???


GROUND WIRES LOl!! i was pwn3d by the ground wires like a big noob.

Haha, did you just not ground them at all or had bad grounds?

Bad grounds always get ya.

 

[patbluejeep]

they were bad grounds. figures huh?