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Hella headlight burnt up 10A fuse but works on standard bulb

Discussion in 'XJ Technical Chat' started by Dougs82yamahaseca550, Jul 28, 2012.

  1. Dougs82yamahaseca550

    Dougs82yamahaseca550 Member

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    Bulb was working when I installed. I did not clean the H/L switch yet but will do. I was wondering if it was safe to up the fuse amps and have not seen any info on the installation reguarging Amperage. I also have the original fuse box which is in good shape but have not replaced it because I have not discovered the need. Any help would be appreciated.
     
    Dougs82yamahaseca550, Jul 28, 2012
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  2. patmac6075

    patmac6075 Active Member

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    Re: Hella headlight burnt up 10A fuse but works on standard

    It's my understanding that Japanesse vehicles of this era (I have an '83 RX7 as well) were engineered with very weak electrical systems...just barely capable of doing the job they were designed for. As a result any time you add something with a bigger draw than what was originally called for, you run the risk of overwhelming the system.
    I would suggest using a seperate relay with power coming directly from the battery.
    And DO NOT just add a larger fuse..you'll run the risk of burning up someting else.
     
    patmac6075, Jul 28, 2012
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  3. MN-Maxims

    MN-Maxims St. Paul Minnesota

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    I would figure out a way to use relays for that headlight. Hot feed fused right from the battery.

    MN
     
    MN-Maxims, Jul 28, 2012
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  4. bigfitz52

    bigfitz52 Well-Known Member Premium Member

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    The Hella H4 (60/55W) will work just fine without a relay if your stock electrical system is up to snuff.

    Yours is apparently not.

    The stock fuse clips crystallize and will break on their own; they also don't like to carry much current once crystallized. If you don't want to replace the fuse box, and don't mind living with glass fuses, you can rebuild it with similarly-shaped fuse holder clips from Radio Shack. XJ4Ever also offers replacement stock fuse boxes.

    Once the fuse box has been remediated, you need to go through the wiring harness, UNPLUG each connector and clean the contacts. Use dielectric grease as you reassemble. You're blowing fuses because the wiring is adding resistance to the headlight circuit; you can run the Hella with no mods but you'll have to get the system up to par first.

    You wanted a reason to replace/rebuild the fusebox? This is it.
     
    bigfitz52, Jul 28, 2012
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  5. MN-Maxims

    MN-Maxims St. Paul Minnesota

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    +1 on replacing the fuse box in any case. The cheap clips loosen up and the fuses don't make good connection even though they look ok they may not. Loose connections will overheat fuses and blow them.

    The headlight wattage should work like Fitz says but there are some here that use relays to get less voltage drop through heavier wire and relays. Look it up under XJ Mods.

    MN
     
    MN-Maxims, Jul 29, 2012
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