Headlight Motor Removal, Cleaning, and Installation – 2.5L NA

Overview

This procedure outlines the steps to remove, clean, and reinstall the headlight motor on all Porsche 944 variants with an 8-valve engine, covering both pre-1985.5 (83-85.5) and 1985.5 onwards (86-88) models. The headlight motor may cause the headlights to cycle up and down due to corrosion on the internal electrical contact wheel. Cleaning the contact wheel restores proper function, ensuring the headlights raise and lower correctly. This guide is tailored for DIY enthusiasts with mechanical experience, focusing on clarity and precision.

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Tools Required

• Metric wrench set (10mm (3/8 inch), 13mm (1/2 inch))
• Metric socket set (10mm (3/8 inch), 13mm (1/2 inch))
• Flat tip screwdriver
• Steel wool, emery cloth, or fine grit sandpaper (440 grit recommended, or 220 grit if necessary)
• Small pry bar (optional)

Step-by-Step Procedure

Step 1: Prepare the Vehicle

1. Disconnect the negative terminal of the battery to ensure safety during electrical work.
2. Locate the headlight motor electrical plug and relay near the motor assembly. Disconnect the plug and remove the relay.

Step 2: Position the Headlight (Pre-85.5)

3. For Pre-85.5 models:

   If equipped with a manual raising and lowering dial, use the dial to raise the headlight to the 1/2 to 3/4 raised position. This provides access to the motor mounting bolts. Note: Some early models may not have this dial, in which case, manually rotate the motor shaft to position the headlight.

Step 3: Remove the Headlight Motor

4. Locate the two bottom 10mm (3/8 inch) bolts securing the motor to the mounting bracket. Remove these bolts using a wrench or socket.

5. Lower the headlights to the fully down position using the manual dial (if equipped) to maintain motor-to-linkage alignment.
6. Remove the 13mm (1/2 inch) nut from the end of the motor’s drive shaft that secures the headlight linkage. Use a wrench to loosen and remove the nut.

7. Remove the remaining top 10mm (3/8 inch) bolt holding the motor to the bracket.
8. Use a flat tip screwdriver or small pry bar to gently separate the linkage from the motor shaft. Carefully remove the motor from the vehicle.

Step 4: Disassemble the Headlight Motor Assembly

9. Locate the rubber boot covering the bottom of the motor and gear housing. Carefully work the boot off the motor, around the gear assembly, over the drive shaft, and off the relay block. Move slowly to avoid tearing the boot, especially around the drive shaft.

10. Identify the six flat-head screws securing the gear assembly cover. Note that one screw is hidden under the relay block. Remove the two screws (one long, one short) holding the relay block, then move the block to access and remove the hidden screw. Remove the remaining three screws, keeping track of their positions as they vary in length.

11. Gently lift the gear assembly cover, taking care not to disturb the electrical contacts on the back. Remove the small ball bearing in the center of the contact wheel and set it aside safely.

Step 5: Clean the Contact Wheel

12. Inspect the contact wheel behind the cover, which may have corrosion or dirt buildup. Clean the wheel using 440 grit sandpaper (preferred) or 220 grit sandpaper if necessary. Sand lightly to avoid damaging the wheel, focusing on the two plastic inserts and surrounding areas.

13. Blow out any debris from the gear assembly using compressed air or a clean cloth to ensure no residue remains.

Step 6: Reassemble the Headlight Motor Assembly

14. Place the gear assembly cover back onto the motor, ensuring the electrical contacts align correctly. Reinstall the small ball bearing in the center of the contact wheel.
15. Reinstall the six flat-head screws in their original positions, starting with the three accessible screws, then the screw under the relay block, and finally the two relay block screws (one long, one short).
16. Reinstall the rubber boot, starting by sliding it over the relay block, then carefully working it over the gear assembly and drive shaft. Use two fingers inside the boot, placed on either side of the drive shaft, to guide it over the shaft opening. Repeat this process as needed to fully seat the boot.

Step 7: Reset the Motor Position

17. Before reinstalling the motor, reconnect the relay and electrical plug. Place the motor on a stable surface (e.g., on top of the washer reservoir) where the shaft is not in contact with anything.
18. Temporarily reconnect the battery to power the motor, allowing it to reset to the fully lowered position. Once reset, disconnect the battery, relay, and electrical plug.

Step 8: Reinstall the Headlight Motor

19. Position the motor back onto the mounting bracket without moving the linkage. Install the top 10mm (3/8 inch) bolt and the bottom front 10mm (3/8 inch) bolt, but do not fully tighten them yet to allow for alignment.
20. Reinstall the 13mm (1/2 inch) nut onto the motor’s drive shaft to secure the linkage, and tighten it firmly with a wrench.

21. For Pre-85.5 models:

    If equipped with a manual dial, use it to rotate the headlights to the 1/2 to 3/4 raised position to access the bottom rear mounting bolt. Install the bottom rear 10mm (3/8 inch) bolt.

    For 85.5 Onwards models:

    Rotate the headlights to the 1/2 to 3/4 raised position using the motor’s manual adjustment mechanism, if available, or manually align the linkage. Install the bottom rear 10mm (3/8 inch) bolt.

22. Tighten all three 10mm (3/8 inch) motor mounting bolts securely, ensuring the motor is firmly attached to the bracket.
23. Lower the headlights to the fully down position using the manual dial or adjustment mechanism.
24. Apply lubricant to the headlight linkage joints to ensure smooth operation during raising and lowering.
25. Reconnect the relay and motor electrical plug to the motor assembly.
26. Reconnect the negative terminal of the battery.

Step 9: Test the Headlights

27. Test the headlights by turning on the headlight switch. Verify that they raise and lower smoothly without cycling up and down.
28. If the headlights do not operate correctly, recheck the electrical connections and ensure the contact wheel is clean.

Post Procedure Checklist

• Confirm the headlights raise and lower without cycling or hesitation.
• Check that all motor mounting bolts are tightened securely.
• Verify the rubber boot is properly seated and undamaged.
• Ensure the battery is reconnected and all electrical connections are secure.
• Inspect the headlight linkage for smooth operation and proper lubrication.

Sources

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