Installing H4 Headlamps

Difficulty Level 2

Difficulty scale:
Adding air to your tires is level one
Rebuilding a 911 Motor is level ten

Figure 1:
Stock Headlamp Assembly

Figure 2:
Headlamp Retaining Screw

Figure 3:
Removing Headlamp Rim

Figure 4:
Removing Headlamp Rim

Figure 5:
Removing Headlamp from Retainer

Figure 6:
Removing Headlamp from Retainer

Figure 7:
Headlamp Removed

Figure 8:
Removing Retainer with Headlamp

Figure 9:
Removing Headlamp and Retainer

Figure 10:
Installing H4 Bulb

Figure 11:
Rear of 911 H4 Lamp Assembly

Figure 12:
Plugging in New Lamp

Figure 13:
Installing 911 H4 Headlamp Rim

Figure 14:
Installing the H4 Assembly

Figure 15:
Installed 911 H4 Headlamp

     Now remove the three small screws holding the chrome headlight retainer (see fig.5). These three screws tend to strip easily, so you may want to spray them with WD-40 first, and make sure you have a good grip on them before trying to turn the screw. Once these three screws come out you can remove the headlight from the assembly, as shown in Figure 6. Remove the electrical plug from the back of the existing headlight, as shown in Figure 12.

      To install the new H4 headlight: slide the old chrome retainer ring over the new headlight. Note that the retainer goes on one way only! If it is not installed correctly, the mounting screws will not line up.  Make sure that the bulb is installed in the assembly (Figure 10 and Figure 11) Plug the headlight electrical plug into the back of the headlight assembly (Figure 12), and then install the headlight and the chrome retainer with its’ three mounting screws (Figure 5).

     Reinstall the plastic headlight surround shroud and you are done! Reconnect your battery (or reinstall your headlight motor relays) and see if the lights work. Test to make sure both the low and high beams are working!

You will probably want to adjust your headlights after installing them.

Installation on the 911 (1969-83):

     To install a Hella H4 replacement headlight (or any other standard replacement headlight):

[If you are replacing the entire headlight assembly with the Bosch H4 unit, see the separate instructions below].

     Remove the screw at the bottom of the headlight ring (Figure 2 and Figure 3). Be careful when you remove this screw that the screwdriver doesn’t slip off and scratch your paint! Also note the angle at which this screw is installed. When reinstalling it you need to install it the same way. Once the screw is out you can lift the ring off the fender (Figure 4). If it doesn’t come right off, you may need to slightly twist the ring to loosen it up. Once it is off, check the rubber seal around the headlight opening in the fender. Now is a good time to replace it if it is worn or broken.

     Next remove the three small screws holding the chrome headlight retainer (Figure 5). These three screws tend to strip easily, so you may want to spray them with WD-40 first, and make sure you have a good grip on them before trying to turn the screw. Once these three screws come out you can remove the headlight from the assembly (Figure 6).  Figure 7 shows the headlamp removed.  Remove the electrical plug from the back of the existing headlight (Figure 12).

     To install the new H4 headlight: slide the old chrome retainer ring over the new headlight. Note that the retainer goes on one way only! If it is not on correctly, the mounting screws will not line up. Plug the headlight electrical plug into the back of the headlight assembly (Figure 12), and then install the headlight and the chrome retainer with its’ three mounting screws. You can then test the headlight at this time to make sure it works.

     Install the new rubber seal around the headlight opening on the fender, or make sure the old one is seated correctly.

     Install the headlight ring. Note that the ring fits over the lip on top of the fender opening, and then the screw at the bottom gets installed (Figure 13). Did you remember to note the angle of the headlight rim screw? It is sometimes hard to get it started correctly (Figure 14). Once again be careful not to let the screwdriver slip off and scratch your paint!

     That’s it! You will want to check the adjustment of your headlights after they are installed (Figure 15).

To replace your existing headlight assembly with the Bosch H4 headlight assembly:

     Remove the screw at the bottom of the headlight ring (Figure 2 and Figure 3).  Be careful when you remove this screw that the screwdriver doesn’t slip off and scratch your paint!  Also note the angle at which this screw is installed. When reinstalling it you need to install it the same way. Once the screw is out you can lift the ring off the fender (Figure 4). If it doesn’t come right off you may need to slightly twist the ring to loosen it up. Once it is off, check the rubber seal around the headlight opening in the fender. Now is a good time to replace it if it is worn or broken.

     Next remove the three small screws holding the chrome headlight retainer (Figure 5). These three screws tend to strip easily, so you may want to spray them with WD-40 first, and make sure you have a good grip on them before trying to turn the screw. Once these three screws come out you can remove the headlight from the assembly (Figure 6). Remove the electrical plug from the back of the existing headlight (Figure 12).

     Since you are replacing the entire headlight assembly, you will need to remove the four screws that hold the headlight retainer and remove the entire assembly from the headlight bucket (Figure 8 and Figure 9).

     Install the new rubber seal around the headlight opening on the fender, or make sure the old one is seated correctly.

     Connect the plug to the back of the new headlight assembly (Figure 12), and then install the new assembly in the headlight bucket. Note that the headlight ring fits over the lip on the top of the fender opening, and then the screw at the bottom gets installed (Figure 13 and Figure 14). Did you remember to note the angle of the headlight rim screw? It is sometimes hard to get it started correctly. Once again, be careful not to let the screwdriver slip off and scratch your paint!

Test your headlights and readjust them if necessary.

Installing H4 replacement headlights in a 65-68 911:

Note: We don't have any photos for this procedure.

     Remove the headlight assembly retaining screw at the bottom of the headlight assembly. Be careful not to let your screwdriver slip and scratch your paint!

     Lift the assembly away from the car and unplug the light bulb connection from the back of the unit.

     Remove the old headlight from the back of the headlamp assembly. The headlight is held in place with 4 spring clips – note carefully how these are installed! Carefully remove the spring clips (wear eye protection – these clips can really fly!), and then remove the old headlight. Place the new headlight in the retainer and install the spring clips (again, be careful!).

     Plug in the headlight electrical connector and reinstall the headlight assembly. Be careful installing the lower screw so as not to scratch your paint.

      Test your lights to see if they work, and adjust them if necessary.

   Well, that’s about it. If you have any questions or comments about this technical article, please drop us a line.   Please also remember that without your continued purchases of parts through Pelican Parts, the expansion of this site cannot continue.  We offer good prices and great customer support.  We sell all the headlamp packages featured in this article at very competitive prices!  If you need anything for your car, please don't hesitate to give us a try by calling toll-free, 1-888-280-7799, or by emailing us.  Also, be sure to check out our on-line catalog, with over 2000 parts!