KrazyJeeper said:
90Xjay, I could definitley use some help and instruction. I finally found the Hella 500's that you recommended and I have already mounted them, but I started looking at the wiring diagram and decided to have another beer. Well, then the beer told me to ask another beer and well, should I go on? After the last beer, my last brain cell told me to seek professional help, but then I went fishing. Yeah, I think I have attention deficit DX. I have the Hella's mounted on a 98 XJ, on the light bar I installed last week. I placed four of them bad boys up top and I have been told numerous ways of running the wiring, but they always end the conversation stating that I will eventually have a leak. I really don't want to drill if I can avoid it, but I don't want the wires crimping and causing a fire or short either. Please teach me. Thanks and Take Care, KJ
Sure thing. I am assuming this is an XJ.
I ran my light wires down along the factory roof rails and tucked them inside the grove, mind you that was after I covered them with the smallest diameter wire loom I had. Then, I removed the headliner trim from the drivers side and raised the rear hatch. I drilled a 5/16th hole just above the weather seal,(it is hidden by the rear hatch) I'll post a pic if you want, and pulled the wires inside through that hole, if you fill the hole back with good silicone sealer, it won't leak at all, there is enough gap in between the roof and top of the hatch that the wires don't pinch. I then tucked the wires up behind the headliner molding inside and down behind the molding that covers the front post and connects to the dash. Then I just tucked them up and under the dash neatly. With that many watts flowing you will want to consider your wire size here. I would suggest at least 12 ga wire or larger maybe 10ga. Next get you a standard 4 pin relay.
I don't recall if one comes in the kit or not??
The relays are really simple to wire. They are pretty standard and have little numbers that correspond with what componante they hook to. There is a diagram on the back of the relay box that tells you what to plug where. They usually use numbers like 87,86, 85, and 30.
Just remember, one plug goes to ground. Be sure to find a good ground source under the dash somewhere, like a bolt that holds the steering column or something that fastens to metal. Use a big solderless terminal round connector to secure it.
Another plug with be for the direct battery wire. It is important that you use heavy wire like 10ga or so and come from the battery under the hood, run the wire around the fender and along the back firewall area neatly and come through the firewall with it. If you look down to the right of the brake booster you will see a small rubber plug, you can usually just pop it out and there is your hole! Feed the wire through there and leave enough to reach your relay.
Another plug will be the hot wire to your lights. When you bring your light wire(s) down, if you can ground them well from on top, then do it, if not bring you ground wire down with your hot wire and ground you lights as well.
The other plug is to your switch. The other wire on your switch goes to key-on only power, which you can find a plug in your fuse box marked "ACC", use your test light to check for key on power only and plug into that spot.
I know it seems like alot, but it can be done in a short time. I hope I did not go into too much detail.
Ohh, almost forgot, go to the parts store and get you some good, fully insulated solderless terminals and a crimper/stripper. it is important to get the fully insulated where the plastic covers the whole piece so that when you start plugging these things in beside each other on switchs and relays that they don't touch and cause problems.
PM me if you get into someting and need help.
