Headlight Motor Removal, Cleaning, and Installation

Overview

This guide details the removal, cleaning, and reinstallation of the headlight motor on a Porsche 944 S2 with the 3.0L engine. If your headlights cycle up and down unexpectedly when operated, the issue is likely corrosion on the electrical contact wheel inside the motor’s gear assembly. This procedure cleans that wheel to restore proper function. It’s designed for DIY enthusiasts with mechanical experience and applies specifically to the S2 variant, which features a manual raising/lowering dial as standard.

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Tools Required

• Metric wrench/socket set (includes 10mm (3/8 inch) and 13mm wrenches)
• Steel wool, emery cloth, or fine grit sandpaper (e.g., 440 grit recommended, 220 grit as an alternative)
• Flat tip screwdriver
• Pry bar (optional, for separating linkage)

Step-by-Step Procedure

Step 1: Remove the Headlight Motor

1. Disconnect the battery to ensure safety while working on the Porsche 944 S2’s electrical system.
2. Unplug the headlight motor electrical connector and remove the relay from the motor assembly, located near the firewall on the driver’s side (left side in LHD models).

3. Using the manual raising/lowering dial on the S2’s headlight motor, turn it to raise the headlight to the 1/2 to 3/4 raised position. This position provides clear access to the motor mounting bolts despite the 3.0L engine’s layout.
4. With a 10mm (3/8 inch) wrench, remove the two bottom bolts securing the motor to its mounting bracket.

5. Lower the headlight back to the fully down position using the manual dial to maintain motor-to-linkage alignment for the S2’s setup.
6. Remove the 13mm nut from the motor’s drive shaft, which connects the headlight linkage to the shaft, using a 13mm wrench.

7. Using a 10mm (3/8 inch) wrench, remove the top bolt holding the motor to the bracket.
8. Carefully separate the linkage from the motor shaft using a flat tip screwdriver or pry bar, then remove the motor from the vehicle.

Step 2: Clean the Headlight Motor Assembly

9. Remove the rubber boot covering the bottom of the motor and gear housing. Work it off slowly by sliding it down the motor, around the gear assembly, over the drive shaft (the toughest part), and off the relay block. Avoid tearing it, as it’s reusable on the S2.

10. Remove the six flathead screws securing the gear assembly cover. One screw is hidden under the relay block. First, remove the two screws (one long, one short) holding the relay block, shift it aside, then remove the screw beneath it. Remove the remaining three screws, noting their lengths for reassembly.

11. Lift the gear assembly cover gently, watching for electrical contacts on its underside. Remove the small ball bearing from the contact wheel’s center and set it aside safely.

12. Clean the contact wheel inside the gear assembly, which will likely show corrosion. Use steel wool, emery cloth, or 440 grit sandpaper (preferred for the S2’s delicate components; 220 grit works if sanded lightly). Focus on the two plastic inserts.

13. Blow out debris from the gear assembly after cleaning to keep it clear.
14. Reinstall the gear assembly cover and relay block, ensuring screws return to their original positions based on length.
15. Reattach the rubber boot by sliding it over the relay block first, then working it over the gear assembly and drive shaft. Place two fingers inside the boot on either side of the shaft to pull it over gradually until fully seated.

Step 3: Install the Headlight Motor

16. Reconnect the relay and electrical plug to the motor. Place the motor on a stable surface (e.g., atop the washer reservoir) without the shaft touching anything. Temporarily reconnect the battery to reset the motor to the fully lowered position, then disconnect the battery, relay, and plug again.

17. Position the motor onto the mounting bracket without disturbing the linkage. Install the top 10mm (3/8 inch) bolt and the bottom front 10mm (3/8 inch) bolt loosely to align with the S2’s linkage.
18. Secure the linkage to the motor shaft with the 13mm nut and tighten it firmly using a 13mm wrench.
19. Using the manual dial, raise the headlight to the 1/2 to 3/4 position to access the bottom rear mounting point.
20. Install and tighten the bottom rear 10mm (3/8 inch) bolt, then fully tighten the top and bottom front bolts.
21. Lower the headlight to the fully down position using the dial.
22. Reconnect the relay and motor electrical plug.
23. Reconnect the battery.
24. Test the headlights using the switch to confirm they operate smoothly without unintended cycling.

Post Procedure Checklist

• Verify the headlights raise and lower fully without stuttering or cycling unexpectedly.
• Ensure the manual dial turns freely and positions the headlights correctly.
• Check that all 10mm (3/8 inch) bolts and the 13mm nut are tightened securely.
• Confirm the electrical plug and relay are firmly connected with no loose connections.

Sources

• Clark’s Garage
• Pelican Parts
• Porsche 944 Workshop Manual, Volume 1
• Youtube