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Pelican Technical Article:

Headlight Replacement

Steve Vernon

Time:

1 hour1 hr

Tab:

$15 to $220

Talent:

*

Tools:

Philips head screwdriver

Applicable Models:

Porsche 944 Turbo (1986-89)

Parts Required:

New headlights

Hot Tip:

Check your wiring

Performance Gain:

See better at night

Complementary Modification:

Change air filter

The Porsche 944 and 951s came with sealed beam headlights for the USA market. While there are plenty of aftermarket kits available to upgrade or increase the performance of your lights, this article will deal with the replacement of the factory units.

You will need the headlights in the up position to replace the lights. If you are not going to raise them by hand via the headlight motor, make sure you disconnect the battery so there will be no current flowing through the vehicle while you are working.

Begin by using the headlight motor on the right side of the car to raise the lights.
Figure 1

Begin by using the headlight motor on the right side of the car to raise the lights. Remove the cover on the motor and turn the wheel on the top (red arrow) until the lights are fully raised.

There is a plastic covering around the front of the light and housing (red arrow).
Figure 2

There is a plastic covering around the front of the light and housing (red arrow). Use a Philips head screwdriver and remove the single screw on the bottom front of the cover (yellow arrow).

With the screw removed unclip the cover from the assembly and remove it from around the light (red arrow).
Figure 3

With the screw removed unclip the cover from the assembly and remove it from around the light (red arrow).

There are several different Philips head screws for holding the light in place, aiming and adjusting and holding the entire mechanism in assembly.
Figure 4

There are several different Philips head screws for holding the light in place, aiming and adjusting and holding the entire mechanism in assembly. Locate the three screws that hold the trim ring in place (red arrows) and use a Philips head screwdriver and remove them.

With the screws removed the trim ring (red arrow) and light (yellow arrow) will probably fall forward from the mounting assembly (green arrow), so be prepared.
Figure 5

With the screws removed the trim ring (red arrow) and light (yellow arrow) will probably fall forward from the mounting assembly (green arrow), so be prepared.

Gently remove the wiring connection from the back of the bulb (red arrow).
Figure 6

Gently remove the wiring connection from the back of the bulb (red arrow). These are old at this point so use care.

This photo illustrates the back of a factory sealed light (red arrow).
Figure 7

This photo illustrates the back of a factory sealed light (red arrow).

Carefully check the condition of the wiring and connectors (red arrow).
Figure 8

Carefully check the condition of the wiring and connectors (red arrow). The wires and connectors can be dried out, splitting and full of corrosion. Make sure yours are safe, clean and you can apply a little di-electric grease to the back of the bulb connections

This photo illustrates the two Philips head adjusting screws for aiming the headlights (red arrows).
Figure 9

This photo illustrates the two Philips head adjusting screws for aiming the headlights (red arrows). Make sure that these are clean and not corroded or rusted. Installation is the reverse of removal.


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Comments and Suggestions:
R23 Comments: The above does not cover the models with adjustable headlights via the wheel on the console
These units have another fixing to the adjuster motor on the bottom left corner
How do you disconnect this so as to remove the ring to replace the light assembly
July 18, 2016
  Followup from the Pelican Staff: Thanks for the additional info. We appreciate it. I will have the article updated.
- Nick at Pelican Parts
 

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