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Headlight Motor Replacement
 
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Pelican Technical Article:

Headlight Motor Replacement

Steve Vernon

Time:

1 hour1 hr

Tab:

$7 to $320

Talent:

**

Tools:

13mm, 10mm wrench, flathead screwdriver

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

Headlight motor, relay

Hot Tip:

Disconnect battery

Performance Gain:

Working headlights

Complementary Modification:

Check all your exterior lights

The hidden headlights on the Porsche 944 are controlled by a single motor on the right front of the vehicle. This motor controls a set of armatures that raise and lower the lights depending on whether or not there is current running through the headlight switch. If your headlights start acting up or refuse to raise or lower, it might be time to replace the motor. Before replacing the motor, make sure to replace the relay in the unit first. The relay is inexpensive and the motors are not. This article will show you how to replace both.

The headlight motor is located in the right front of the engine compartment beside the windshield washer reservoir (red arrow).
Figure 1

The headlight motor is located in the right front of the engine compartment beside the windshield washer reservoir (red arrow).

The first thing to do is remove the cover off the top of the motor to determine if the motor has a hand crank to raise and lower the lights (red arrow), as some of the earlier motors did not.
Figure 2

The first thing to do is remove the cover off the top of the motor to determine if the motor has a hand crank to raise and lower the lights (red arrow), as some of the earlier motors did not.

There should be a plastic cover over the electrical connection on the motor protecting the connection and the relay.
Figure 3

There should be a plastic cover over the electrical connection on the motor protecting the connection and the relay. Unfortunately, over the years these go missing and people replace them with all kinds of things. Our project car was wrapped with yards of duct tape (red arrow). Remove the cover or whatever you find protecting the wires.

With the cover removed, replace the relay and see if that solves the problem (red arrow).
Figure 4

With the cover removed, replace the relay and see if that solves the problem (red arrow).

If replacing the relay does not solve the problem and you are going to replace the motor, I like to disconnect the ground cable (red arrow) for the battery and place it so it cannot accidentally come in contact with the battery post while you are working.
Figure 5

If replacing the relay does not solve the problem and you are going to replace the motor, I like to disconnect the ground cable (red arrow) for the battery and place it so it cannot accidentally come in contact with the battery post while you are working. The motor has a surprising amount of torque. You do not want it moving while you have your hands in there.

Remove the electrical connection to the motor (red arrow).
Figure 6

Remove the electrical connection to the motor (red arrow).

Use the hand crank on the top of the motor (red arrow) to raise the headlights approximately 1/2 way up.
Figure 7

Use the hand crank on the top of the motor (red arrow) to raise the headlights approximately 1/2 way up. Part of the armature covers one of the mounting bolts (yellow arrow). By raising it you can get clearance to the bolt.

With the arm moved, remove the two 10mm side bolts (red arrows).
Figure 8

With the arm moved, remove the two 10mm side bolts (red arrows). Leave the top bolt in place.

Lower the headlights returning the armature to the down position.
Figure 9

Lower the headlights returning the armature to the down position. This will give you the proper geometry when installing the new motor. Use a 13mm wrench and remove the nut connecting the motor to the arm (red arrow).

You may need to use a flathead screwdriver to pry the arm off the motor (red arrow).
Figure 10

You may need to use a flathead screwdriver to pry the arm off the motor (red arrow). With the arm off, remove the last 10mm bolt (yellow arrow).

You can now remove the motor from the mount, leaving the mechanism in place ready to install the new motor (red arrow).
Figure 11

You can now remove the motor from the mount, leaving the mechanism in place ready to install the new motor (red arrow). Installation is the reverse of removal.


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Page last updated: Wed 12/7/2016 02:49:48 AM