Hella 500 lights are lightweight driving lights designed to provide long-range lighting. The Hella 500 lights are housed in an aluminum vapor-coated housing and use H3 12V/55W bulbs. You can install the Hella 500 lights, inexpensively, yourself with a kit. The following instructions detail installation on a Toyota 4Runner, but instructions for varying models come with each light kit. Review the parts list that come with your instruction sheet to be sure you have all necessary parts before starting the installation.
Remove supplied light covers and the single screw from the bottom of the housing. Remove the housing and put aside for later use. Flip the light over and place it on a towel. Locate the blue wire and plug it into the empty male connector. Thread the bare end through the four-hole grommet. Crimp on a female blade connector then connect it to the male connector with the white wire. Repeat this process on the other light. Screw the housing down into place.
Measure the lower valence and divide by two to get the center measurement. Mark the center position and use a level to draw a straight line up the bumper of your vehicle. Draw another line on the upper bumper part, and using the tape measure, measure two inches forward, drawing a cross mark. This will be your midpoint. Choose where you want your lights mounted.
Place the bottom bracket against the front edge of the grill and mark a dot on the front edge. Center the brackets hole on the dot and draw another cross. Repeat for each light.
Center punch the location of your lights. Place tapping oil on the drill bit and on the hole position. Use a 10mm drill bit for the proper hole size. Repeat on the other side. Assemble bolts, lock washers and nuts onto your lights and finger tighten them. Place lights into the holes and fasten with lock washers and nuts. Run the dual black wire under the grill to the engine bay. Run the blue grounding wires under the grill.
Connect male connectors using blade connectors. Each of the blade connectors is numbered directly on the piece. Use the supplied Hella wires with female connectors to attach. Relay #30 is connected with the red 15amp fuse wire going to the battery. Relay #85 is connected with the yellow wire going to the switch. Relay #86 is connected with the dual black wires going to the lights. Relay #87 connects to the ground wire going to the chassis ground. Connect all wires to the relay before mounting the relay to the firewall. Drill a pilot hole and screw the relay onto the firewall using a self-tapping screw. Bundle wires together with electrical tape.
Run the red 15amp wire to the positive battery terminal using a yellow ring connector to attach to the battery post. Run the yellow and green wires through the rubber boot on the firewall and into the side kick panel on the driver's side. Connect a female blade connector to the auxiliary fuse box. Crimp a yellow ring connector onto the blue wire and ground it to the chassis.
Ground the lights to the chassis. If you prefer a single ground wire, fuse the blue wires together with solder, strip off the end of the longest wire and connect a yellow connector ring and ground to the chassis.
Remove the lower panel, kick panel and step plate. Take the fed yellow and green wires from the firewall grommet. Run the yellow or “source” wire to the middle prong and the green wire to the bottom prong. Attach a female connector to the blue ground wire, adding a female connector to the other end. Connect the female connector to the top prong and ground the other end to the chassis.
