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JCS05Rubi 12-24-2007 02:11 PM

Hella 500 wiring problem
A buddy gave me a set of Hella 500s with 100 watt sylvania bulbs for xmas, to hold me over until I get some IPFs. Those factory fogs weren't even visible with my IPF headlights :)

Anyway, I got them all wired up and worked through the evening. We get some food, come out, and they wont fire?! I replaced the fuses this morning, even though they were good (put 20a fuses in, since the 100 watt bulbs are drawing 16.5 amps). Now, I have power all the way to the switch and back to the relay. The relay is clicking, and I even tried a new relay. Right off the relay, there is zero power coming down the black wire to the lights. I am assuming its probably the relay mount that isnt connecting to the relay somehow, but what do you guys think? I have 12v to the relay, its clicking when the switch is pressed, but no power coming out of the relay and a brand new one is doing the same thing. BTW, the relay is 30a so it should still be good with the 100 watt bulbs.

JCS05Rubi 12-24-2007 02:48 PM

Nevermind. I don't know why I asked a forum for help with wiring anyway, that was pretty stupid :D The fuses were good, but the fuse HOLDER for the positive side was not making a connection with the fuse. How the switch and relay were getting power, I don't know. I just cut the fuse out of the equation until I can get an inline from radio shack on wensday.

richp 12-24-2007 08:23 PM

The hella relays I normally get with my hella lights has the fuse built into the relay, it's a bayonet type so I don't have the external fuse hanging around.

TeeJay 12-27-2007 06:44 PM

ecksjay just bought hella 500's and had be wire them, The only thing I used was the relay. I threw out the entire harness they came with and made my own from 16guage wire and soldered it all and heat shrank it. I feel much better about it knowing that snow, salt and rain won't destroy my hard work.

Ironicly though, the bulbs that came with it were defective out of the box? I had to bend the tabs to make them work. They also had the diagram labeled incorrectly.

MCG 12-28-2007 11:34 AM

When I got my Hella 500's I used the same wires that was installed with the oem fog lights.

JCS05Rubi 12-28-2007 12:53 PM

I was going to use the fog wires, but I ended up getting the new free form design and put 100watt bulbs in them. With 2 100 watt bulbs, I felt much better using hellas fused and relay'd harness.

TeeJay 12-28-2007 01:00 PM

Hella's harness scared me. It seemed very cheap. Wiring it with that felt like using the cables that came in the box with the DVD player. Why bother spending the money.

MCG 12-28-2007 02:58 PM

For me no problems at all.

TeeJay 12-28-2007 11:57 PM


Originally Posted by MCG (Post 176126)
For me no problems at all.

Oh no, I didn't mean the fog light harness. I meant the harness from the hella box.

richp 12-29-2007 12:50 AM

Yea, the Hella wiring is kinda light weight, I just went out and bought a few rolls of automotive 12ga stranded wire and used that from relay to battery and from relay to lights and lights to ground.
I decided to build my own aux harness for the headlights too using the same wire and dual fused hella relays on the TJ with it's CIBIE H4 7" rounds.

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