Repairing Headlights

Information 

If the guide pins on the headlight are damaged or broken, the headlights must be repaired by gluing in new guide pins.

A repair kit, Porsche Part No. 958.631.121.00 (March 2012), and Teromix 6700 adhesive, Porsche Part No. 999.915.650.40 (March 2012), are required.

1. Unscrew fastening screw -1-  from the guide pins.
2. Pull out guide pin -2-  using a suitable tool. -A- 
   Fig 1: Removing Guide Pin

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3. Clean guide hole -1-  to remove any large particles of dirt.
4. Screw fastening screw -2-  back in again.
Fig 2: Identifying Guide Hole
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5. Fill the guide hole -1-  with Teromix 6700 adhesive until 3/4  of the guide hole is filled.
6. Insert guide pin.
   1. 6.1. Insert the rear guide pins -1-  approx. 3/4  way into the guide hole -2-  on the headlight.
   2. 6.2. Fit the front guide pin -3-  into the headlight mounting point on the vehicle.
   Fig 3: Identifying Guide Pin
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7. Carefully insert the headlight into installation position.

   The electric plug connection must not be connected at this time.

8. Adjust gap dimension between headlight and front apron (S1). Position two star gauges Nr.127-1 Pos.1 -1-  underneath the headlight.

   → Gap dimension S1: 3.5 mm+/-0.5 mm 

   Fig 4: Checking Front Apron To Headlight

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   Fig 5: Adjusting Gap Dimension For Headlights

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9. Lock the headlight. → Installing Headlights 
10. Secure the headlight at the top and adjust it.
    1. 10.1. Fit suction holder VAS 6801 WE 1496 -1-  to the top of the headlight -2-  .
    2. 10.2. Adjust the height of the headlight -2-  with respect to the wing -3-  using the winged nut. → Gap dimension S3: 1.2 mm+/-0.5 mm 
       Fig 6: Securing Headlight At Top

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       Fig 7: Adjusting Headlight To Top Of Wing

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11. Leave adhesive to harden for 30 minutes  .
12. Remove tools.
13. Check that the headlight is fitted properly.
    1. 13.1. Remove and install headlight. → Removing Headlights 
    2. 13.2. Check gap dimensions.