Pelican Technical Article: Replacing Lenses and Blubs / Adding Clear Corners Wayne R. Dempsey
Time: 30 minutes
Tab: $15-$250
Talent:
Tools:
-
Applicable Models:
986 Boxster (1997-04) 987 Boxster (2005-08)
Parts Required:
New lenses, bulbs
Hot Tip:
Don't tug heavily on the lenses when removing them – they may break
Performance Gain:
Better looking exterior, clearer lamps
Complementary Modification:
Upgrade to clear corners and clear/smoked rear lenses
This article is one in a series that have been released in conjunction with Wayne's new book, 101 Performance Projects for Your Porsche Boxster. The book contains 312 pages of full color projects detailing everything from performance mods to changing your brake pads. With more than 950+ full-color glossy photos accompanying extensive step-by-step procedures, this book is required reading in any Boxster owner's collection. The book is currently available and in stock now. See The Official Book Website for more details.
Check out some other sample projects from the book:
There are few projects that are as easy as lens replacement, yet improve the look of your car so significantly. Replacing old faded lenses not only improves your Boxster's overall appearance, it also increases its safety as well. Faded lenses tend to be harder to see and block much more light than brand new ones. On the front of the Boxster, the side marker lenses are removed by simply pulling on them. A snap-tab holds them in place.
The rear lenses are very easy too: they are simply held on with screws that you can access in the rear trunk. Pull back the trunk lining and you should have easy access to the screws and the bulbs. The third brake light is easily accessible from the rear trunk when the roof is lowered into the service position (see Photo 6 and Pelican Technical Article: Air Filter / Pollen Filter Replacement).
If you are replacing bulbs, make sure that you replace your old bulbs with the same exact style and wattage as the originals. Swapping in higher wattage bulbs could damage your wiring and possibly melt your lens and bulb holder.
The photos show the replacement process on the 1997-04 Boxster: the 2005-08 is very similar.
Figure 1
The Boxster headlamp is a somewhat complicated piece of equipment. A- To replace bulbs inside the assembly, first detach the end cover by squeezing the tabs on both sides (one side shown with green arrow). B- These are the adjustment wheels, and can be turned by inserting a 5mm hex head tool through access holes located in the chassis. Red: fog lamp adjustment, Yellow: left/right adjustment, Blue: up/down adjustment. C- The turn signal / parking lamp bulb is accessed through the bottom of the assembly. D- The two halogen bulbs are clipped into the rear of the lamp and are easily accessible once you remove the end cover. Don't touch the bulb with your fingers, as the oils in your hand will damage it. The purple arrow points to the access hole you use to replace the fog lamp bulb.
Installing the headlamp back into the car can be a bit tricky. A- The headlamp mates with the carrier plate (green arrow) and harness connector. A bar integrated within the carrier plate locks the headlamp assembly into place. B/C/D: Three circular tabs on the headlamp assembly fit into three channels located on the carrier plate. It's important to look carefully as you install the headlamp to make sure that these tabs are properly aligned in the channels.
With the assembly pushed back into the fender, use the headlamp tool from your Boxster tool kit to lock it into place. If you don't have this tool, you can also use a 5mm socket. With the tool facing upwards, rotate it towards the rear of the car to lock it into place, or rotate it towards the front of the car to unlock.
New side marker lenses take about 1 minute to install. I prefer the clear ones with orange bulbs. Simple reach in and pull on them to remove the lenses, then unclip the harness by pressing on the thin metal clip (2005 an later cars have an additional screw located in the wheel well that needs to be removed). For some reason, the amber USA lenses that are stock equipment just don't cut it. In order to maintain legal standards, you must run orange bulbs inside the lenses. This can cause the lens to take on an orange hue. There's a product out there that I recommend called Stealth Bulbs (inset) that is available online at PelicanParts.com. These bulbs are silver coated on the outside, but glow bright orange when electricity is applied. They look clear when installed in the clear lenses, but retain the orange illumination required for US roads.
Removal of the rear tail lamp is easy. Simply remove the four nuts that hold on the rear assembly (purple arrow). Then push out the assembly and pull from the opposite side (lower left). If all you need to do is change bulbs, then press the lock tab and remove the bulb carrier from the back of the tail lamp assembly (lower right).
To change the bulbs in the third brake lamp, put the roof into the service position (see Pelican Technical Article: Air Filter / Pollen Filter Replacement) and release the two screws on either side of the lamp. Unplug the harness connector, and then you should be able to unsnap the bulb carrier from the rear of the lamp. Be careful not to break any of the delicate plastic tabs on the bulb carrier. Also, when reinstalling the lamp, pay close attention to the two screws: they have a unique system for securing the lamp to the chassis. Push the screws and their rubber washers into the holes in the chassis, and then tighten them only slightly to make the screws expand the rubber and become snug in their holes.
Comments: Great pictures, great explanations... but they're applicable AFTER the headlight assembly is removed from the car. I'm looking for step #1... pulling the assembly out of the fender, to begin with. I can figure it out, but I'd think you'd want to start with that - or am I missing something obvious? highly possible!
February 11, 2012
John99Boxster
Comments: Perfect Instructions! Did my Low Beams today....took about 20 mins!
Thanks Wayne
December 9, 2011
Followup from the Pelican Staff: Great, glad to have helped! - Wayne at Pelican Parts
Pete
Comments: Are you able to advise me about fitting Xenon Platinum white Headlight globes to my 2001 Boxster. I am looking at "Euroline" brand in 55Watt which I'm told equals 100Watts at 7500K output? I've read threads where some globes have caused the headlightlens to discolour and even melt. The regulations here in Australia aren't as strict as USA for headlights etc. If I can use the above globes or similar should I change the high beam as well as low beam?
Many thanks
Pete
August 29, 2010
Followup from the Pelican Staff: I'm not sure where those stories about melting the lenses with Xenon lamps comes from. They are similar in nature to flourescent bulbs, and they run very, very cool. The 7500K figure refers to the light output and color - not the actual temperature of the bulb. With most Xenon bulbs, you can touch them with your hand while their on (not recommended), and you shouldn't be burned as they should run very cool.
