Nose / Header Panel – Removal and Installation – 2.5L NA

Overview

This guide outlines the procedure for removing and installing the nose or header panel on a Porsche 944 with an 8-valve engine, covering both pre-1985.5 (1983-85.5) and 1985.5 onwards (1986-88) variants. The nose panel, located between the headlights and holding the Porsche crest, may need to be removed to replace the crest or access other components. This procedure is tailored for DIY enthusiasts with mechanical experience, ensuring safe and accurate panel removal and installation. For early models (pre-1985.5), the panel is spot-welded, requiring drilling, while later models (1985.5 onwards) use screws and nuts for easier removal.

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Tools Required

• Phillips Head Screwdriver
• 10mm (3/8 inch) Socket, 1/4″ Drive
• 8mm (5/16 inch) Socket, 1/4″ Drive
• 2 inch (50mm) Short Extension, 1/4″ Drive
• Ratchet, 1/4″ Drive
• Universal Adapter, 1/4″ Drive
• Drill with Appropriate Bit for Spot Welds (Pre-85.5 only)

Step-by-Step Procedure

Step 1: Prepare the Headlights

1. Turn the ignition switch to the ON position.
2. Turn the headlight switch to the ON position to raise the headlights. Leave them in the raised position.
3. Remove the fuse for the headlamp motor:

For Pre-85.5 models:
Remove Fuse 1 from the Additional Fuse Panel.

For 85.5 Onwards models:
Remove Fuse 2 from the Central Electric Panel.

4. Turn the ignition switch OFF.
5. Optionally, manually raise the headlights using the knurled knob on top of the headlamp motor if the fuse removal doesn’t allow automatic raising.

Step 2: Remove the Nose/Header Panel

6. Inspect the nose panel for damage or corrosion before removal to ensure it can be reused or replaced if necessary.
7. Remove the nose panel based on your model year:

For Pre-85.5 models:
Drill through all spot welds securing the nose panel to the body using a drill with an appropriate bit. Take care to avoid damaging surrounding components.

For 85.5 Onwards models:
Remove the four Phillips head screws along the back edge of the panel.

Loosen the four 8mm (5/16 inch) retaining nuts (two in each headlight bucket) at the bottom of the headlight buckets. Do not remove the nuts completely; just loosen them.

Remove the machine screw under the front lip of the nose panel in each headlight bucket.

Lift the back edge of the panel and slide it toward the front of the car to remove it.

Step 3: Install the Nose/Header Panel

8. Slide the nose panel into place in the headlight buckets, ensuring the washers on the nose panel studs are positioned on top of the bottom panel of the headlight bucket.
9. For Pre-85.5 models, reattach the panel using fasteners similar to those used in 85.5 onwards models (e.g., machine screws and nuts as described in Step 2).
10. Install the machine screw under the front lip of the nose panel in each headlight bucket using a 10mm (3/8 inch) Socket, 1/4″ Drive, 2 inch (50mm) Short Extension, 1/4″ Drive, Universal Adapter, 1/4″ Drive, and Ratchet, 1/4″ Drive.
11. Install the four Phillips head screws along the back edge of the panel using a Phillips Head Screwdriver.
12. Tighten the four 8mm (5/16 inch) retaining nuts in the bottom of each headlight bucket using an 8mm (5/16 inch) Socket, 1/4″ Drive and Ratchet, 1/4″ Drive.

Post Procedure Checklist

• Verify that the nose panel is securely attached and aligned properly with the headlight buckets.
• Check that all screws and nuts are tightened to prevent rattling or movement.
• Reinstall the headlamp motor fuse and test the headlights to ensure they raise and lower correctly.
• Inspect the panel for any gaps or misalignment, adjusting as needed.

Sources

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