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Old 02-14-2012, 01:27 AM   #1
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Windshield mount light bar fog light wiring help!

Hey guys, So this is actually my first thread on the site

Anyway, I wanted to invest in a windshield mount light bar
(KC HiLiTES Windshield Mount Light Bar with 4 Apollo Pro Series Lights for 97-06 Jeep® Wrangler TJ - Quadratec)

BUT...I know nothing about wiring.

I'm just afraid that i'll get it, install it, and then look at the wiring parts and just say...well.."FFFUUUUUU...."

I was just wondering if anyone knows of any good step by step instructions (pictures are nice) Im not good with wiring diagrams. : /

SO i dont really know how to wire the fog lights on the light bar to the battery to a new switch...Im just lost..

Help?

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Old 02-14-2012, 05:39 AM   #2
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i recommend to add a relay and a fuse to the equation i just did it an hour ago without any drilling or mods to my jeep, i intend to keep it neat

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Old 02-14-2012, 09:51 AM   #3
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most light kits you buy will come with the wiring and relay. a relay is very simple and up until a month ago I was confused as to what it did and how it worked. Your lights will pull a decent amount of amps (think of it as water flow) you can hook up power going to the switch and from the switch to the lights, out of the lights and to ground...completes circuit and lights are on, but you are pulling that power through that little switch on the dash, which is not designed for that amount of flow. A relay allows the switch to only have to operate the "flood gates" of the flow, not feel the flow itself. If you buy it I guarantee I or someone else on here would be happy to walk you hooking it up right. And most kits have everything you need. You'd just have to do the manual mounting of the lights and running the wires. And on that note lots of folks have gone different direction with that part of it and can help out also.

This picture from another forum really shed the light on wiring up your own stuff for me.
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Old 02-14-2012, 12:13 PM   #4
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thanks! Do you know of any video tutorials showing the wiring process?
just curious.
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Old 02-14-2012, 12:21 PM   #5
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When you say wiring process, what do you mean? How to connect the wires physically, where to connect or where to run the wires?

I suggest you get the kit which will have instructions (The KC site probably has the instructions, so you can get it ahead of time) and see what you have, then ask your questions.

I suggest, you search the forum for windshield lights. There are lots of threads how you can run the wires.

Search youtube. I'm more than sure there are videos on KC lights and making the connections and probably a bunch on a jeep.
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Old 02-14-2012, 12:28 PM   #6
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ill check the kc lights, but again, theyre probably just going yo have wiring diagrams which im not great with. and ive searched youtube already and could not find any wiring videos :/
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Old 02-14-2012, 12:38 PM   #7
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everything is labeled from KC...check their website and find the diagram that comes with that light set and see if its something you can do.
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Old 02-14-2012, 01:53 PM   #8
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I installed 2 Apollo lights the other day. It was my first time wiring lights or anything for that matter, they come with super simple step by step instructions. Pretty impossible to mess up.
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Old 02-14-2012, 03:20 PM   #9
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Quote:
Originally Posted by CottageGrove4x4 View Post
ive searched youtube already and could not find any wiring videos :/

You are kidding, right? connecting KC, wrangler - YouTube
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Old 02-14-2012, 04:25 PM   #10
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...thank you neil. -_-once again, im new, im not a mechanic, ive never done wiring, and i was searching youtube for windshield mount fog light install. thank you all for your help!
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Old 02-14-2012, 08:43 PM   #11
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Don't feel bad dude, I watched the videos and look at those diagrams and still don't really get it. Some people are just wired different. I did my own fog lights but the relay and switch were already there so that isn't really doing much but running a few wires and making the connections. I am sure once you do it a time or two it will be second nature and you will be like, oh that was easy. Just give it a try and post pics where you get stuck. I don't think I really understand the relay/fuse part or how to wire a relay.
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Old 02-14-2012, 09:55 PM   #12
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Quote:
Originally Posted by doolyd
Don't feel bad dude, I watched the videos and look at those diagrams and still don't really get it. Some people are just wired different. I did my own fog lights but the relay and switch were already there so that isn't really doing much but running a few wires and making the connections. I am sure once you do it a time or two it will be second nature and you will be like, oh that was easy. Just give it a try and post pics where you get stuck. I don't think I really understand the relay/fuse part or how to wire a relay.
thanks! will do!
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Old 02-15-2012, 12:14 AM   #13
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To give you an idea of how easy it is I'll walk through the wiring diagram which I pictured here again. Inside the cab you will have a switch (it is provided in the KC light kit) you can mount it where ever you want.

The switch will have three post on the back of it. In the wiring diagram see the yellow wire...that is 12V keyed power, meaning it only is live when the key is on. The easiest place to find that wire is (on a 97-02 model TJ) behind the glovebox. Jeep provided two leads back there for the purpose of wiring up accessories like lights, etc. I pictured it here also. The blue wire is keyed power. You would run, with as much extra wire as is needed, from that blue wire to the back of the switch on to post #1 (its labeled "LINE" in the back of the switch). That is the "yellow" wire for our purposes. STOP RIGHT THERE, YOU ARE DONE WITH ONE PART OF IT

You need to now ground that circuit, so with another wire (black in the diagram) you would go from the back of the switch off of post #3 (labeled "EARTH" on the switch) to any metal part of the body. There are numerous places to do that, off hand i would say go to the braided ground wire located behind your radio. We now have the switch circuit wired...if you flipped the switch right now, the switch would light up but nothing else would happen. STOP RIGHT THERE, YOU ARE DONE WITH ONE PART OF IT

We need to get power to your lights, controlled by that switch. So we will run a wire from the engine area, where we will locate your relay, into the cab up to post #2 (labeled "LOAD" on the back of the switch.) The easiest way to do that is through the spongy foam located on firewall. I posted another pic of that area. You can see my screwdriver poking through it (red and black handle)

I say run the wire from the engine area to the switch and not the switch to the engine area only because in my experience its easier to push the wire into the cab and fish it out from behind the glove box, than it is to go from the cab out to the engine, there just to much crap in the way to even get your hands up there.

Once that engine bay wire is run, and connected to the post #2 on the switch, we are done in the cab. STOP RIGHT THERE, YOU ARE DONE WITH ONE PART OF IT

To recap, we have three wires, one is from the blue keyed power wire from behind the glove box to post #1, one is from post #3 to any metal, and one is from post #2 out to the engine area.

Now a relay has 4 posts on it. they are labeled #85, #86, #87, and #30. Your kit will have a plug that fits that relay, and you will notice the plug will only fit one way on it. Plug the relay into it and let it be. The post number on the relay are labeled next to them underneath. make note of them and what color wire KC uses for each post.

Our wire we ran into the engine bay from the switch will hook up to the #86 post on the relay. That part is done. STOP RIGHT THERE, YOU ARE DONE WITH ONE PART OF IT

from the #85 post on the relay we will take it to ground, anywhere on the sheetmetal, off hand on the passenger fender there are a few grounds (screws with a black wire going to them). Now that part is done. We only have two more wires to go. STOP RIGHT THERE, YOU ARE DONE WITH ONE PART OF IT

Lets concentrate on your lights and their wires. From what I can tell from the KC pictures they did the hard part for you and the four power wires and four ground wired are all just plug in. Plug the red to red and the black to black on all the lights. and you will be left with two wires coming down from your light bar. A red and a black (don't get to hung up on the colors i am using, KC might use different colors, but the will be labeled power and ground, in my scenario red is power and black is ground) The ground is easy, find a out of the way spot on the metal body and place it under a screw or bolt. Look around and go for easy but un-noticeable locations. you can use the same location as the #85 ground you just ran if its easy to get to. STOP RIGHT THERE, YOU ARE DONE WITH ONE PART OF IT

so now the light bar has its ground, lets move to the power wire.

It is going to hook up from the power wire (red) from the lights to #87 on the relay. nothing more to it. That part is done. STOP RIGHT THERE, YOU ARE DONE WITH ONE PART OF IT

all we have to do now is run a power wire from the positive battery post to the #30 post on the relay.

This power wire will be supplied by KC, and it will have a inline fuse in it already, try and place the fuse within 20 inches of the positive battery hook up, meaning no more than 20" of wire from the positive battery post. (Its just common practice to keep the fuse close to your power source) KC will most likely have less than 20" from one end of the wire to the fuse anyway. STOP RIGHT THERE, YOU ARE DONE WITH ONE PART OF IT

you are done. go turn your key on and flip the switch. at this point you can ziptie all the wires neat and tidy up your connections.

Every set up will be different so i am not sure you are going to get a exact video of what you want. I tried to explain it all without to much tech stuff and basic starting and stopping points.

If your wondering, the relay is like a remote controlled switch. the switch you put in the cab controls the heavier duty switch between posts #87 and 30 in the relay. its a switch that controls a switch!

Or if you want, buy two sets of lights, have one shipped to me, and i'll shoot a video of the install...but I keep my set of lights
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Old 02-15-2012, 02:06 AM   #14
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0.0

What would you like me to put in your shrine that I'm going to make for you? haha
SERIOUSLY. That has got to be the most perfect step by step instruction manual ever. I cannot express how much help that it going to be! Thank you so freakin much!
I really appreciate you taking the time to do this for me! I went from worried to excited to do this project! When i do install the light bar I promise to put up pictures of the final result!

This forum is amazing, you guys rock!
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Old 02-15-2012, 04:19 AM   #15
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Quote:
Originally Posted by CottageGrove4x4 View Post
0.0

This forum is amazing, you guys rock!
so true
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Old 02-15-2012, 07:05 AM   #16
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awesome, your welcome. I've been doing alot of electrical on the Jeep so I've got wiring diagrams floating around in my head lately. My wife wonders if I have a girl friend name Relay and why does she need constant power as I mumble in my sleep
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Old 02-15-2012, 07:57 AM   #17
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since that part is covered I'll talk a bit about the relay in the engine compartment since i grazed over mounting it. I know you said you have never read wiring diagrams so crimping wires may not be something you have done either. If i am preaching to the choir on this stuff I'm sorry.

All The connections are all good, now its about how pretty you want to make it. Some things that come to mind are:

1) KC is going to send you a lot of wire. Its universal for a mini cooper or a grayhound bus. those four connections we made at to the 4 relay plug pigtails will have extra wire. You can cut them to a more manageable length before hooking them up. Less to zip tie up at the end.

2) The relay will have a tab for mounting it with a screw, i put a picture of a Hella lights brand relay(black), and a generic relay (green) next to each other. You can see how the Hella has a tab, your KC relay will have the same thing. you can mount that where ever it seems to have room in the engine area. The passenger fender seems to afford the most space. I was lazy again and you can see my green relay just lays on the fender.

3) in my one picture you can see my battery, and the fuse box on the fender. You can also see the lazy Kevin hooked his lights up (red wire on the battery post) well, pretty lazy like. You can also see my power wire to my OBA is the yellow wire with the red end which is run to the power post on the fuse box, a lot cleaner and not so lazy. Pretty is the only difference between the to. But if you ever go to replace your battery, the lazy way gets in the way, the pretty way does not. That post on the fuse box is exactly the same as hooking up straight to the battery post.

4) in the pic with my green relay you can see the common ground on the fender you can use, its the screw with a couple black wires going to it. you can use that for the #85 ground and the ground wire coming down from the light bar. Grounding them in the same spot wont hurt anything.

5) you will need to get a terminal kit, found at walmart, any autoparts store, harbor Freight, ect. They are cheap and come with enough crimps that if you screw up you can cut the wire and do it again. KC might only give you four total. and having the right crimper is better than pliers or vice grips to make a crimp. I personally don't use the insulated type (with the red, blue or yellow collars on them) I like to crimp, solder and heat shrink mine. BUT crimping is perfectly fine, that's anal Kevin at work there.

All this has reminded me I need to go un-lazy the stuff I've wired up recently!

I look forward to seeing it done.
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Old 02-15-2012, 11:15 AM   #18
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awesome!!! thank you so much for doing that. It seriously is going to help me out when i finally do it!
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Old 02-15-2012, 03:14 PM   #19
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Thanks for me too. I'm still newbie and want to install some lights but had no Idea how to do that. Also how to hide the wiring so it looks neat. i'll print this out. thanks everyone.

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