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Light Bulb Replacement
 
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Pelican Technical Article:

Light Bulb Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$10 to $200

Talent:

***

Tools:

5mm hex wrench, screwdrivers, factory headlight tool

Applicable Models:

Porsche 955 Cayenne (2004-08)
Porsche 955 Cayenne S (2003-08)
Porsche 955 Cayenne Turbo (2003-08)

Parts Required:

Bulbs

Hot Tip:

Do not touch bulbs with bare fingers

Performance Gain:

Working lights.

Complementary Modification:

Change headlight and brake lenses

Eventually, you'll need to replace the light bulbs in your Cayenne. Replacement of the bulbs is not a difficult job, but there are a few unique ways in which the light bulbs are mounted within the car.

In this article, I'll go over all the steps required to replace nearly all the outside bulbs on your Cayenne. For the front fog lamps and turn signal lenses, you'll need to jack up the car, place it on jack stands and also remove the inner wheel liners. Please see our articles on Jacking up your Cayenne and also Removing Wheel Liners for more information.

TIP: Do not do this when vehicle has been outside in colder weather as most plastic parts loose flexibility or become brittle in the cold.

Begin by opening the hood and locating the access panel at the front of the engine compartment near the headlight assembly (green arrow).
Figure 1

Begin by opening the hood and locating the access panel at the front of the engine compartment near the headlight assembly (green arrow).

Press the access panel in towards the center of the car and rotate it until you can pull it up and out of the plastic cover.
Figure 2

Press the access panel in towards the center of the car and rotate it until you can pull it up and out of the plastic cover. There is a small tether attached to the panel to keep it from falling in the hole.

Inside the access hole, you'll see a small hex head shaft (green arrow) this is the top of the mechanism that releases the headlight assembly.
Figure 3

Inside the access hole, you'll see a small hex head shaft (green arrow) this is the top of the mechanism that releases the headlight assembly.

Locate the headlight removal tool from the tool kit in the rear of your Cayenne and place the end of the tool over the hex nut inside the access hole.
Figure 4

Locate the headlight removal tool from the tool kit in the rear of your Cayenne and place the end of the tool over the hex nut inside the access hole.

To eject the headlight assembly, you'll need to turn the tool counter-clockwise on the right side headlight as shown here (green arrow), or clockwise on the left side headlight.
Figure 5

To eject the headlight assembly, you'll need to turn the tool counter-clockwise on the right side headlight as shown here (green arrow), or clockwise on the left side headlight. Don't be surprised if it takes a little effort for the headlight to pop out of the mechanism.

Shown here are the rails that guide the headlight assembly in place once installed (green arrows).
Figure 6

Shown here are the rails that guide the headlight assembly in place once installed (green arrows). The headlight assembly has a series of "fingers" that slide into each rail. It is important to make sure that these rails are lined up before pushing the headlight assembly back into the car.

Shown here is the rear of the headlight assembly removed form the car.
Figure 7

Shown here is the rear of the headlight assembly removed form the car. To access the low beam, high beam and cornering lights, you'll need to remove the access cover. Gently pry the two wire clips (green arrows) outward and remove the rear cover.

Our project car is outfitted with Bi-Xenon headlights; however, the process for removing conventional halogen bulbs is similar.
Figure 8

Our project car is outfitted with Bi-Xenon headlights; however, the process for removing conventional halogen bulbs is similar. Release the wire clip holding the bulb in place by prying it over the securing hook (green arrow).

Once the wire clip is removed, pull the bulb assembly out of the housing.
Figure 9

Once the wire clip is removed, pull the bulb assembly out of the housing. Take care not to touch the bulb with bare fingers. The oils in your fingers can damage the bulb once it heats up to operating temperature.

With the bulb removed, disconnect the electrical harness (green arrow) by pulling it off the bottom of the bulb.
Figure 10

With the bulb removed, disconnect the electrical harness (green arrow) by pulling it off the bottom of the bulb.

Remove the cornering lights by prying the wire clips (green arrows) over the securing hooks on the housing and pulling them back to clear the bulb.
Figure 11

Remove the cornering lights by prying the wire clips (green arrows) over the securing hooks on the housing and pulling them back to clear the bulb.

Now remove the cornering light from the housing and pull the grounding connection off the bulb (green arrow).
Figure 12

Now remove the cornering light from the housing and pull the grounding connection off the bulb (green arrow).

Once the cornering light is free of the headlight housing, disconnect the positive lead by pulling it out of the connector (green arrow).
Figure 13

Once the cornering light is free of the headlight housing, disconnect the positive lead by pulling it out of the connector (green arrow).

The side lights are located below the main headlight bulb (green arrow).
Figure 14

The side lights are located below the main headlight bulb (green arrow). Use a pair of needle-nose pliers to gently pull the bulb holder out of the headlight housing.

Once removed, pull the old bulb out of the housing.
Figure 15

Once removed, pull the old bulb out of the housing.

Now move to the outside of the housing to remove the high beam bulb.
Figure 16

Now move to the outside of the housing to remove the high beam bulb. Pull off the rubber boot (green arrow) to gain access.

Inside, you'll see the electrical connector attached to the bulb (green arrow).
Figure 17

Inside, you'll see the electrical connector attached to the bulb (green arrow). Pull the connector off.

Now gently pry the wire clip off the securing hook (green arrow) and move it over to clear the bulb.
Figure 18

Now gently pry the wire clip off the securing hook (green arrow) and move it over to clear the bulb. Once free, remove the bulb from the housing.

Note the orientation of the new high beam bulb while installing it.
Figure 19

Note the orientation of the new high beam bulb while installing it. The tab shown here (green arrow) must be facing up.

The turn signal bulb is located directly above the high beam light.
Figure 20

The turn signal bulb is located directly above the high beam light. Turn the holder counter-clockwise to remove it (green arrow).

Once the holder is removed, press the old bulb slightly down and turn to release it from the holder.
Figure 21

Once the holder is removed, press the old bulb slightly down and turn to release it from the holder. Make sure that the alignment pins on the new bulb line up with the tracks in the holder.

You'll need to remove the taillight housings from the car to replace the bulbs.
Figure 22

You'll need to remove the taillight housings from the car to replace the bulbs. Begin by opening the tailgate and locating the two plugs on the housing. Pry both out them out with a pick to access the screws underneath.

Remove the two 5mm Allen head screws securing the taillight housing to the car (green arrows).
Figure 23

Remove the two 5mm Allen head screws securing the taillight housing to the car (green arrows).

Having a set of hex bit sockets makes jobs like these much easier.
Figure 24

Having a set of hex bit sockets makes jobs like these much easier.

Gently pull the taillight housing off the rear off the car.
Figure 25

Gently pull the taillight housing off the rear off the car. (There is a metal locator plug mated to a plastic socket on the Tail fixtures which when cold can't be gently pulled. Move vehicle into a warmer garage and do work after a few hours. See Figure 27 for plug.)

Now turn the taillight housing over and press the locking tab (green arrow) to remove the electrical connector from the housing.
Figure 26

Now turn the taillight housing over and press the locking tab (green arrow) to remove the electrical connector from the housing.

Remove the four securing nuts (green arrows) to release the bulb holder from the taillight housing.
Figure 27

Remove the four securing nuts (green arrows) to release the bulb holder from the taillight housing.

Now carefully remove the bulb holder from the taillight housing.
Figure 28

Now carefully remove the bulb holder from the taillight housing. ( Note that this better shows bulb usage. Top 3 bulbs are single filament clear P21W bulbs. Top is brake light, Middle is turn signal note Amber bulb cover, Bottom is reverse note Blue bulb cover which when combined with mainly red housing lens is white. The two bottom lights are P21/5W outer and P21/4W inner two filament bulbs. The outer bulb is a tail DRL 1 filament only used while the inner bulb is the Fog light as well as Tail DRL using both filaments.)

ThisPicture shows the location of each bulb in the taillight bulb holder.
Figure 29

This picture shows the location of each bulb in the taillight bulb holder. Brake Light (purple arrow), Reverse Light (yellow arrow), Tail Light (red arrow), Turn Signal AND Rear Fog Light (blue arrow), Brake Light (green arrow).

To replace the fog light bulbs, you'll first need to remove the wheel liner.
Figure 30

To replace the fog light bulbs, you'll first need to remove the wheel liner. Please see our article on Removing Wheel Liners for more info. Press the locking tab on the electrical connection (green arrow) and pull it off the bulb.

Rotate the bulb (green arrow) counter-clockwise to release it from the fog light lens.
Figure 31

Rotate the bulb (green arrow) counter-clockwise to release it from the fog light lens.

Plug the electrical connector into the new bulb and install it into the fog light lens.
Figure 32

Plug the electrical connector into the new bulb and install it into the fog light lens.

To replace the side turn signal bulb, you'll also have to have the wheel liner removed.
Figure 33

To replace the side turn signal bulb, you'll also have to have the wheel liner removed. Locate the T25 Torx screw holding the turn signal housing to the car (green arrow) and remove it.

Carefully pull the turn signal housing out from behind the front fender as shown here.
Figure 34

Carefully pull the turn signal housing out from behind the front fender as shown here.

Turn the housing over and pull the bulb holder out (green arrow).
Figure 35

Turn the housing over and pull the bulb holder out (green arrow).

Now pull the old bulb out of the holder.
Figure 36

Now pull the old bulb out of the holder.

Shown here are the license plate light holders on the rear hatch.
Figure 37

Shown here are the license plate light holders on the rear hatch. Remove the small Phillips head screws (green arrows) to take the holders out of the rear hatch.

Carefully pull the bulb holder down and out of the rear hatch.
Figure 38

Carefully pull the bulb holder down and out of the rear hatch. Now carefully pull the arms of the bulb holder apart (green arrows) to remove the bulb.

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Comments and Suggestions:
kent Comments: I purchased the brake light bulb for a 2006 Cayenne, but it was the wrong bulb. My cayenne has a single filament and the detents are at 180 degrees. The bulbs you sent me have two filaments and the detents are offset by 20 degrees. I called and you are now sending me two turn signal bulbs which are supposed to work.
November 18, 2016
  Followup from the Pelican Staff: Give The Pelican Parts parts specialists a call at 1-888-280-7799. They will get you the right bulb immediately.
- Nick at Pelican Parts
 
mitsuo212 Comments: question on how to remove the headlamp when the hex locking bolt has broken off. Which many have said it breaks easy.
June 7, 2016
  Followup from the Pelican Staff: Try using a pick or extractor to rotate the lock. If that doesn't work, you will likely have to drill the lock out then replace it. - Nick at Pelican Parts  
Doug Comments: If your Porsche cayenne toolkit is missing the headlight removal tool or its just buried under cargo; a 9mm hex wrench works too.
April 9, 2016
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 
JOSCUBA Comments: What's the easiest way to replace the interior rear hatch door light bulb. There are two red lights that are part of the door that light up when you lift te door. Do I need to take the panel off to get to the bulb? My first instinct is to pry it with a screw driver but afraid to crack the cover. Any recommendations?
January 29, 2016
  Followup from the Pelican Staff: If I remember correctly, the lenses pop out to allow the bulbs to be replaced. - Nick at Pelican Parts  
Johnno Comments: My prior comments apply specifically to Cayenne S 2006. Best to test for which bulb is which. Fig 29 and Zach's correction are not correct for my model.
January 7, 2016
  Followup from the Pelican Staff: Thanks for the note. I will have the vehicle application data updated. - Nick at Pelican Parts  
Johnno Comments: Add in general "Do not do this when vehicle has been outside in colder weather as most plastic parts loose flexibility or become brittle in the cold."
Fig 25 There is a metal locator plug mated to a plastic socket on the Tail fixtures which when cold can't be gently pulled. Move vehicle into a warmer garage and do work after a few hours. Ref Fig 27 which shows grey plug between two left arrows.
Fig 28 Note that this better shows bulb usage. Top 3 bulbs are single filament clear P21W bulbs Top is brake light, Middle is turn signal note Amber bulb cover, Bottom is reverse note Blue bulb cover which when combined with mainly red housing lens is white. The two bottom lights are P21/5W outer and P21/4W inner two filament bulbs. The outer bulb is a tail DRL 1 filament only used while the inner bulb is the Fog light as well as Tail DRL using both filaments. Suggest Fig 29 get corrected also.
January 7, 2016
  Followup from the Pelican Staff: Thanks for the additional info. We appreciate it. I will have the article updated.
- Nick at Pelican Parts
 
Steves Comments: I would just like to thank you for all the information and step by step guide to changing the bulbs etc
July 13, 2015
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Zachariah Comments: Correction to Figure #29:

Purple Arrow = Brake Light
Blue Arrow = Turn Signal AND Fog Light Bulb
July 11, 2015
  Followup from the Pelican Staff: Thanks for the note. We appreciate it. I will have the article updated. - Nick at Pelican Parts  
sri Comments: This is great help. Thank you for providing the detailed instructions
April 3, 2015
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Mr Bug Comments: Figure 5 wording is misleading. The comment reads that you are calling the headlight in the picture the right side light when in fact it is the left light pictured. It should read ,To eject the headlight assembly, you'll need to turn the tool clockwise on the left side headlight as shown here green arrow, or counter-clockwise on the right side headlight. Don't be surprised if it takes a little effort for the headlight to pop out of the mechanism.
January 11, 2015
  Followup from the Pelican Staff: I will have someone look into the procedure and update the article as needed. - Nick at Pelican Parts  
Gene Comments: Comments on figure 5 Needs to add remove the rubber cover just to the inside of the light assembly to enable pulling the assembly forward.
May 23, 2014
  Followup from the Pelican Staff: Thanks for the additional info and feedback. We appreciate it. I will have that info added to the article.
- Nick at Pelican Parts
 

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