Headlight Operating Mechanism Lubrication – 2.5L NA

Overview

This procedure lubricates the headlight operating mechanism on the Porsche 944 (8-valve engine configuration) to ensure smooth operation of the pop-up headlights. Regular lubrication every 15,000 miles (24,000 km) prevents wear and maintains functionality. The process involves applying grease to the rotating joints and cycling the mechanism.

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Tools Required

• Parts cleaning brush (small)

Parts Required

• White lithium grease, 000 043 305 02

Step-by-Step Procedure

Step 1: Remove the Headlight Motor Fuse

1. Locate and remove the fuse for the headlight motor to disable the mechanism:

For Pre-85.5 models:
Remove Fuse #1 from the Auxiliary Fuse Panel, typically located near the driver’s side footwell.

For 85.5 Onwards models:
Remove Fuse #2 from the Central Electric Panel, usually found in the same area.

2. Verify the correct fuse by checking the fuse panel diagram in your Porsche 944 owner’s manual.

Step 2: Lubricate the Headlight Mechanism

3. Use a small parts cleaning brush to apply white lithium grease, 000 043 305 02, to the rotating joints of the headlight operating mechanism.
4. Locate the headlight motor knob on top of the motor, typically near the headlight assembly under the hood.
5. Manually rotate the headlight motor by turning the knob by hand.
6. While rotating, continue applying grease to ensure it works into all rotating joints.

Step 3: Cycle and Finalize the Mechanism

7. Manually rotate the headlight mechanism through several up-and-down cycles using the motor knob to distribute the grease evenly.
8. Ensure the mechanism operates smoothly without sticking or resistance.
9. Rotate the headlights to the fully down position using the knob.
10. Reinstall the headlight motor fuse removed in Step 1:

For Pre-85.5 models:
Insert Fuse #1 into the Auxiliary Fuse Panel.

For 85.5 Onwards models:
Insert Fuse #2 into the Central Electric Panel.

Post Procedure Checklist

• Verify the headlight mechanism operates smoothly by manually cycling it a few times.
• Check that the headlights remain in the fully down position when closed.
• Test the headlights electrically by turning them on and off to ensure proper operation.
• Inspect the rotating joints for excess grease and wipe away any drips to prevent dirt buildup.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manuals
• YouTube