2002 exp headlight harness upgrade help

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chamberedcoal

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Anyone have the relay numbers for making your own upgrade harness? Looked around in this category and the 1st generation category. Guess I didn't search for the right thing. I bought some new headlight housings and fog light housings. Would like to wire both up using relays for piece of mind. Also is anyone using a waterproof box for added relay protection from the elements?
 
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chamberedcoal

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Got the answer to the relay to the headlights. Now what about the wiring to run both hi & Lo beams when the high beams are on? I'm taking a wild guess at this but adding a third relay in with the hi beam trigger wire spliced to both relays and the power output pole of the third relay spliced into the low beam output wiring. Would this work or am I asking for an electrical fire?
 
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chamberedcoal

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12v to 10a fuse to pole 30 (each relay having its own fuse)
High beam trigger wire to pole 86 on #1 & #2 relays
Low beam trigger to pole 86 on #3 relay
Pole 85 to ground on all relays
#1 relay pole 87 to positive on high beam bulb
#2 & #3 relay pole 87 to positive on low beam bulb

This what I came up with. I'll post a drawing when I get to a computer.
 

Thermo

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Coal, let me ask this: are you running aftermarket headlights that have separate high and low beam housings? If not, I would not recommend running both high and low beam at the same time. You are going to generate too much heat in a very limited area if you are running halogen bulbs (especially if you are running the higher wattage bulbs).

As for the relays, if you are running halogen bulbs, then a 20 amp relay is enough for the low beams and a second 20 amp relay for the high beams. If you are running 35W HIDs for either the low or high beams, then you need a 30 amp relay to power both of the bulbs. If you chose to run the 50W HIDs for your high beams (if running in the low beams, talk to me first), then you need atleast a 20 amp relay for each bulb.

As for making the low beams come on with the high beams, as long as you meet my warning above, you can get away for much cheaper. Get your hands on a 1 amp diode that has atleast a 15V reverse voltage rating to it. Now, wire the diode so the black band on the diode is towards the low beam relay. The wiring will run from Post 87 of the high beam, to the end of the diode without the black band, then a second wire from the end of the diode with the black band to either post 85 or 86 (which ever has the positive voltage applied to it). This will force the low beams on whenever you have the high beams on.

As for the fog lights, they already have a relay powering them. So, no need for a relay harness for them.
 
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chamberedcoal

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Thermo,

Yes I bought some aftermarket housings that have a separate hi and low beams. One of those halo/6leds across the bottom jobs. My low beams are h1 bulbs and h3 for the high's. As for the diode trick that sounds a lot better instead of running 2 extra relays. Would it harm anything to also run another diode to the fog light relay to keep them on in high beam operation?
 
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