Jump to content

Welcome to RennTech.org Community, Guest

There are many great features available to you once you register at RennTech.org
You are free to view posts here, but you must log in to reply to existing posts, or to start your own new topic. Like most online communities, there are costs involved to maintain a site like this - so we encourage our members to donate. All donations go to the costs operating and maintaining this site. We prefer that guests take part in our community and we offer a lot in return to those willing to join our corner of the Porsche world. This site is 99 percent member supported (less than 1 percent comes from advertising) - so please consider an annual donation to keep this site running.

Here are some of the features available - once you register at RennTech.org

  • View Classified Ads
  • DIY Tutorials
  • Porsche TSB Listings (limited)
  • VIN Decoder
  • Special Offers
  • OBD II P-Codes
  • Paint Codes
  • Registry
  • Videos System
  • View Reviews
  • and get rid of this welcome message

It takes just a few minutes to register, and it's FREE

Contributing Members also get these additional benefits:
(you become a Contributing Member by donating money to the operation of this site)

  • No ads - advertisements are removed
  • Access the Contributors Only Forum
  • Contributing Members Only Downloads
  • Send attachments with PMs
  • All image/file storage limits are substantially increased for all Contributing Members
  • Option Codes Lookup
  • VIN Option Lookups (limited)

03 996 Headlight Rear Access - Morimoto Projector Conversion

Recommended Posts

I have been considering converting the halogen headlights on my 2003 Targa by installing a Morimoto Bi-Xenon HID projector. The facelift 996 models  (post 2002) with halogen headlights, are fitted with a projector dip beam, mounted above a conventional reflector for main beam. Part number is 996.631.066.50.  They are quite different to earlier 996 headlights. On first inspection the conversion appears a straightforward project - as the existing dip beam projector is bolted to a carrier fame inside the headlight, and is the same shape and just slightly larger than a Morimoto Mini 6.0 H1 HID projector, which is a popular, good value, retrofit projector with an outstanding beam pattern. All the headlight access is from the rear -   there would be no difficult front cover removal with oven heating, no Dremel surgery.  So - change out that halogen projector for the Morimoto, find a place to site the HID ballasts, sort out the wiring and you are good to go.

Or are you? Why can't I find any reference to this particular conversion on the Web - someone must surely have tried it already?  I think the answer is that rear headlamp access to the existing dip projector isn't as easy as it looks.


The halogen headlight is made by Hella, and is well-engineered and substantially built. The headlight has a projector assembly for the dip beam (with an H7 bulb), and below that a half-circular reflector for a main beam conventional headlight fitted with an H9 bulb (in the UK). Inside the headlight, the H7 projector is a separate assembly, as is the H9 main beam reflector, and both are bolted to a single frame or carrier made of transparent yellow engineering plastic. This carrier engages with plastic ball joints at three points within the  main headlight shell, with white nylon gear wheels and threaded rods to allow height and  lateral positioning of the headlight beams from outside the headlight. Both dip and main beam adjust linked together.


It appears that, in manufacture at Hella in Germany, the yellow frame carrying the dip projector and the main beam reflector is inserted from the rear of the headlight, after which the adjustment mechanisms for height and lateral position would be added behind the frame to the inside side of the headlight outer shell. These assemblies are in black plastic and include sliding tracks. It's not clear how these parts are secured to the inside of the main headlight shell - clipped or bonded.  However - if these parts could be removed  (to be re-installed later), the carrier frame could be moved out rearwards very easily, allowing the dip beam projector to be simply unbolted, and the Morimoto Mini 6.0 projector to be substituted, almost on the existing mounting holes. It's a perfect match for length as well. But if the adjustment sub-assemblies can't be shifted, the only way to mount the new projector will be by cutting off, in-situ, the back plate of the carrier frame, and then making up a replacement plate for the retrofit projector. No so straightforward.

So - after this long intro  - has anybody with a facelift 996 car and halogen headlights, tried this? Or has  anybody attempted to dismantle that particular Hella headlight non-destructively, and can say how it all comes apart?

I am really interested.        

Link to comment
Share on other sites

I have not tried what you suggest, but I have tried fitting Bi-Xenon bulbs with the ballast resistors to a 2003 996.  It was not too difficult.  The actual bulb is easy to replace and the control unit I fitted outside the pod and secured it to the side of the rails with double sided foam mounting tape. I had to drill the pod at the back - there is a flat area - where I inserted a rubber grommet for the control wires.  The light was fantastic and much better than the standard fitting. 


Now for the hard part.  When I used the headlight flasher occasionally warning lights would come one.  One day the oil warning light came on when I flashed the headlights.  It went off again after I stopped and re-stared the engine.  On another occasion I had a different warning light.  There was nothing wrong with the vehicle.  I had no problems before fitting the bulbs and no problems after removing them.


I have heard that these non-standard fitting do give similar problems.  The manufacturer's blurb did say that these non OEM parts would be compatible, but I was not prepared to continue with these occasional apparent false warning signals which I related to the Bi Xenons.


Having said that, you might be OK.

Link to comment
Share on other sites

  • 1 year later...


to stop warning light just put a 16.7 tvs diode on the power supply cable of the xenon ballast.

I did the same mod and solve warning light problem and spoiler stop working with this.

RS code 815-2575.


Edited by kenobiben
Link to comment
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
  • Create New...

Important Information

We have placed cookies on your device to help make this website better. You can adjust your cookie settings, otherwise we'll assume you're okay to continue.