Need electrical help. Headlights.

[size:11pt]Problem: My high beams are out.[/size]

Car Info:
87 with Auto Dim. Relays installed for Lows, Highs and Fogs with fuses and good grounds. Just did the 130A Alternator upgrade last night. (WHICH IS AWESOME!)

The relays have been done for a while. There is fuses in them. This happened after the 130A Alternator upgrade from last night. All three relays are wired the same and I am not having issues with the low or fogs.


RESEARCH:
I did a search and after some additional trouble shooting from those posts nothing fixed it. I eventually found out why they weren't working.
I keep blowing the lamps out.
When I figured out they were burnt and went to store and replaced them and blew them in front of the store worker while testing them. They flickered on and burnt out.

Graciously the parts store(O'Reilly's) warrantied the bulbs I paid $40 for and At the moment I am stumped. I dis-connected the relay so I can't burn $40 at the flick of a switch again.(Sylvania bulbs).


I don't have any wiring diagrams of the lights. How is too much juice going to lights to blow them and not blowing the fuse? I read that the lights are grounded as well?

There is no way that 14.2V or so at the bulb will burn them out. I have had headlight relays to delive max voltage to the bulbs on my 86 Tbird 5.0 for years with Phillips Extreme vision 9003 Halogen bulbs (converted from the original sealed beams) with zero problems. Either the bulbs are bad out of the box, or there is some contamination on the bulb glass. Halogen bulbs will die a very quick death if there is any grease / oil on or foreign material on them, even from fingerprints or dirt that gets on them when inserting them into the housings. A drop of water on them is certain instantaneous death.

Have you measured the voltage at the bulb socket with the car running? Should be in the low 14V range with engine running. If its WAY higher, like 16+V, the bulbs will also fry quick. If you have 16+V, the alt is running at max output due to 1) faulty regulator, or 2) incorrect wiring.

Must be 1 or 2. It has burned 3 sets today. I just started the car to come home from work and burned my low beams. Left the car at work.

It is wired exactly to the directions that came with the kit. What should I check?

I'm with Jeff, first thing I'd check is voltage at the headlight bulb connector. I would check with engine off, then engine running. If it looks normal, Get someone to help raise the rpms to about 2500 and check the voltage again. If voltage is high, something may have been connected wrong or your voltage regulator could be bad.

The wiring is very simple. I will double check it. Would a regulator be bad out of the box from PA performance?

I don't want to say anything bad about anyone, especially a business I don't know anything about. But it is possible, I would check your voltage with the engine on and off. If your voltage is too high I'd see if pa performance has a tech line.

Regulator is bad. I had 16 volts at my headlights, 16 across the battery and 17 at the sensor wire. PA performance has a tech line and they sent me a label to return it.

wow that baby was over charging! Good to see you figured it out.