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Refitting 993 headlights

H

hanhams81

New member
Help please, because I have almost lost the will to live!
Having replaced the headlight lenses with new sparkling Bosch items (an easy task) refitting has been a nightmare. Two hours into refitting, the light units refuse to lock in position. Whichever way I move the locking bar the units pop out! I deduce the units are not seating properly in the wing aperatures despite using good force. The small guide blocks of the headlight gasket seem too big on one side. I would have thought the light unit would deflect slightly to secure a correct alignment. But what do I know? After taking the units in and out I checked that the correct lenses are attached to the main body. No error because Porsche thoughtfully make fool proof fittings.
I cannot imagine I am the first to be so troubled so please can anyone help me through this issue.
Hanhams81
ps The locking bar is positioned as recommended in the handbook.

 
Hey, I had exactly the same problem with one of mine when also replacing the lenses. I found that the white connector which the headlight unit was supposed to plug into was misaligned. After moving it slightly and gently pushing the headlight unit back in it locked. (I think you can take the connector out attach it then put the headlight back in as well).
Hope this helps!
Dev
 
I had similar problem when fitting the HiDS upgrade. You shouldn't need much force at all if the lights are being slid back in the right position. If memory serves on the inboard side (closest to the bonnet) there is a nub on each light unit which has to locate between two runners in the headlamp aperture.

If you've got it in the right place then slides easily in and locking bar can be swung gently down.

Good luck

Michael
 
Thanks Dev I checked that connection is complete. The nearside plug is held in a bracket whilst the offside is free. Both units exhibit the same problem.
Michael thanks. No problems re runners and slots. I have had these units out several times before without much trouble refitting them hence my bafflement.
Hi John. From one New Forester to another I have wiggled these damn things time and again and still they throw the units forward. The strange thing is that the seals top and bottom are well home on the panel work but at the sides there is a gap. It suggests the lower seal has someway to go before the sides fit nicely. What is stopping these seating just baffles me. I thought maybe the seals are just rather hard and need to soften, but how?.
I cannot put the problem down to repaired panels because the car is original in all respects. I even made a cup of tea and contemplated but to no avail as yet!
Hanhams81
 
Thanks John. The tea did not help but a night's rest worked wonders together with assurances offered. I think I have been a bit of an "Edmund". I decided at apply force on the locking lever much to the detriment of my fingers. The light unit moved well forward again but then was sharply drawn back into the wing making a brilliant seal. Much better that before. I repeated and am delighted the car now has two very bright eyes. I had clearly fogotten the units move forward when locking and no doubt the new seals called for what seemed excessive force. To celebrate I went for a run in the car today only for the brake wear sensor light to come on! Murphy turns up uninvited. My two gentle track days took their toll presumably. So now its new discs and pads (which colour I wonder), braided brake pipes and blue fluid. Thanks everyone.
Hanhams81
 
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