Well I hooked up the bosch relay where the round relay went for the left headlight. I used spade connectors for a temp setup. Well I turned on the headlights to check it, and one of the wires burned up! I know I should have tested the wires before I hooked them up but the diagram looked like it was correct. What do I do now?

Ok, it looks like the wiring goes into the driver's side fender area. Can I just string a new wire once I find out where it goes or will I need to follow all the wires near it to see if it melted the insulation on those as well?

 

According to the diagram on the swap, the wire that burned was pin 4 on the round relay plug. I wired this to pin 87 on the bosch relay.

Edited May 31, 200916 yr by lorysloyale

I figured out the problem. I'm so stupid. It was the relay's base view, not the plug's view.

 

So... I fried the permanent ground line by wiring it up incorrectly. Great.

 

I managed to swap pin 3-1, 4-2, 1-3, 2-4. So I guess I sent 12 volts straight to ground, and that wire melted first because it was a smaller guage for some reason. Does that make sense?

Edited June 1, 200916 yr by lorysloyale

ok, I know that sofar I'm talking to myself, but I was wondering if that wire could be bypassed to a chassis ground? It appears to be just regular old ground.

FIXED? I wired it up correctly and now it works, but I'm definitely stringing a new wire to ground. Just goes to show if it can be messed up, I will always find a way. At least now I can wire up the rest and be done with it. Looks like the permanent ground is 14 gauge.

I figured out the problem. I'm so stupid. It was the relay's base view, not the plug's view. ... Does that make sense?

 

Yes.

Which Diagram you Used? ... The one I Did?

Well... it is Nice to know that you Found the Problem and it is Fixed Already... I Just want to Suggest you to Swap the Other Headlight Relay, Because Both have Around the same Life Rate, So if one went Wrong, the other one is about to do the same too...

Kind Regards.

Well, its kinda fixed. I need to trace the wire and find where it goes to really fix it. Right now its still using the bare melted wire, but I can let the car sit till I fix it. I did the swap because the headlights and interior lights were not very bright, and now they seem brighter.

 

I have to say I'm sorry I didn't read your guide close enough. I made an assumption about the diagram, thinking it was the plug on the wire side. So there is nothing wrong with the guide.