I connected my hella 500's with all new wires. I wired the lamps to the relay and the relay to the battery. The switch is hooked up. I have a problem with the fuse lock, I don't think the fuse is connecting right. Is there another way to hook it up?

 

Where it shows the wire going to the low beam on the headlamps, you can wire that up to 12v that is hot all the time so you have control over your lamps at any given time.

 

I wired it like that with the switch directly hooked up to the 12V, but still no response from the lamps. Should I use a voltmeter?

 

Check grounds and double check fuse. I was having the same problem with mine. I finally got a test light and tested the fuse with it. It was a bad fuse. Although it looked brand new and had no breaks.

 

hook up the green wire to any 12v source http://www.4runners.org/image/hella5...auxfusebox.jpg

 

i'm trying to install some hella 500s on my brushguard. i have everything wired up and mounted but the green wire which is supposed to go to the high beams or a 12v source??

elton i see on the diagram that you connected it to the aux fuse box which is what i would like to do but i have an 02 limited vs. a 98 and i dont think i have one.

 

Best bet is to try isolating each part of the circuit. Not sure what test equipment you have, but you should be able to hear the relay click on and off with the switch. If that does not happen, check the switch and wiring and you can try just connecting one side of the relay coil to 12v and the other to ground and hear it click. If that is not working, relay is bad. If relay is clicking, then check the power wires. If you have a test light, connect it to the relay output and see if there is power there (other side to ground and relay input wired to power).