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Posted (edited)

My drivers' side headlight was replaced by the dealership after an accident. It has worked fine for two years since, but recently decided to stop working. I get a "check dipped beam" message on the cluster as a result. The turn signals work, as does a single little light on the outer side of the assembly. The main and high beam do not.

 

After taking it out to inspect, I noticed that the electrical harness connector on the back was the problem. When I could force it into the headlights socket, the lights all powered up and worked fine, as did the high beam. So a poor connection is the culprit.

 

One of the tabs on the side of the white connector was broken off, so the connector wiggles in its place. I imagine that the force of the headlight being pushed back wiggled it just enough that it wouldnt' seat into the headlight assembly. But getting that white connector into the socket and then back into its place without being able to get my hand in from the rear of the light was not apparent.  I also noted that the insulation on all the wires was terribly frayed and coming off in my hands as I examined it.

 

But with a new connector in hand, I don't see how to wiggle the old one out. It slides in from the side on the back of the tray holding the headlight assembly, but is blocked from sliding out all the way.

 

How do I rectify this?

Edited by Charles Bradley

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I dont see why i need such a tool.

 

The pin connector on the headlight is not a problem.

 

The wiring harness connector that it connects to, which also connects to the tray is the problem. How do you remove the tray holding it in place, because it won't wiggle free.

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To remove the white plastic part on the headlight harness (#19 left side), you have to pinch the tops of the connector toward the center and wiggle it free from the plastic tray. It is also connected to the wiring on the other side via a socket (#19 right side). I removed beauty covers from under the hood and opened the air filter housing on mine to gain more access to the space, but mine is a 955 Base V-6, so yours may have a different layout. I also had to use a file to shave some of the plastic tab on the underside of the headlight to gain the leverage needed to seat it all the way back into the newly installed headlight harness using the headlight tool.

Headlight Schematic.png

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Ok thank you, the air filter box and housing is preventing it from being able to slide out (the black end of 19 slides to the inside of the car, but the obstruction prevents it from going all the way)

 

Does removing bolt 18 allow this to come up, and what is part 15?

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There are 4 10mm bolts holding the tray in place, but even with their removal the whole tray doesn't come out, its blocked on the left and right by the body structure. However I was able to get it loose enough to get the harness connector replaced.

 

Unfortunately this didn't solve the problem and the drivers headlight will not turn on at all. Before, I could force the old connector to seat and the main light would come on intermittently, telling me it had to be a connection issue, but there is a tiny bulb to the outside and below the main bulb (3 in the diagram above) that was always on whenever the lights were turned on, so I was at least getting some connection on some of the pins.

 

Now, with the new harness, the tiny light (3 above) on the headlight assembly that is just below and to the outside of the main bulb does not come on at all, and there is no response from the main headlight assembly whatsoever to being pressed in to the connector and held in firmly, when the lights are turned on.  I was able to remove some of the vanity covers to get my hands around from behind and make sure it was pressed in all the way once it was in the car too, but no luck.

 

I did double check the part for the harness connector, its the factory as best I can tell. I'm pretty sure this idiot dealer will stick me for the charge of a brand new Porsche headlight assembly, but I don't know what else to do.

Edited by Charles Bradley

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Also, Xenon ones will have the control unit (#17 in the picture). Halogen will not. Each kind also has a specific wiring harness, so that may be the issue.

Headlight Schematic2.png

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