Porsche 911 H4 headlamp upgrade

Porsche 911 H4 headlamp upgrade

After having a client ask about upgrading his 1986 911 to H4 headlights, I did some research by reading through Wayne Dempsey’s book “101 Projects for Your 911". This upgrade seams like it would be quick and easy to do. My best guess is that it would take about a half an hour and can be done with a Phillips screwdriver. (I suggest a good quality Phillips screwdriver because some of the screws will strip out fairly easy)

This popular upgrade replaces the entire headlamp assembly inside the headlamp bucket with a new Bosch H4 Euro headlamp assembly. Some folks say that the stock USA spec lights that came with the 911 are less than adequate for nighttime driving. This euro upgrade will allow you to project the light farther because the H4 lenses actually focus the light. (You can also upgrade the bulbs for off road use) I am not condoning or recommending you drive faster at night because you will be able to see further but that is up to you. (Prima facie applies here)

The first step is to get all the pieces. You will need 2 of the 911 631 113 00 Bosch H4 headlight assemblies 0-301-800-101(these are chrome). You will also need 2 of the 911 631 141 00 rims, 2 of the 911 631 033 00 screws, 2 of the 911 631 132 00 screws, 2 of the 911 631 103 90 bulbs, and 2 of the H4 bulbs*. It would be a good time to replace the fender seals 911 631 115 02 just because it’s apart and only costs $1.95. You can call us at 877-944-3056 or order them on line at pap-parts.com. Our current pricing as of 10/25/08 is:


$213.95 for the 911 631 113 00 H-4 Headlight Assembly

$69.95 for the 911 631 141 00 rim

$6.49 for the 911 631 033 00 screw

$.95 for the 911 631 132 00 screw

$1.95 for the 900 631 103 90 bulb

$1.95 for the 911 631 132 00 seal

$12.95 for the H-4-12V55/60W Bulb*

Or

The whole kit for 279.75 per side (part # 911 h4 kit) w/o the bulb or seal.

Once FedEx delivers your box, you can get started. I suggest a well light area with a flat surface ex: garage or driveway. Make sure you make mental notes about how everything comes apart because it will go together in a very similar fashion. Ready….

Step 1) Remove the screw at the bottom of the headlight ring. You might want to put some masking tape on the paint in that area incase you slip with the screwdriver. (Scratch prevention) Once the screw is removed you can lift the ring off the fender. If its being stubborn and doesn’t come off right away you will need to twist it a little to loosen it up. (Did you pay attention to the angle at which the screw is installed? Hope so because it will need to back together the same way)

Step 2) Remove the three small screws holding the chrome headlight retainer. (These screws can be troublesome so use a good screwdriver and some penetrating oil so you don’t strip the heads out) now you can remove the headlight from the assembly.

Step 3) Remove the electrical plug from the back of the old headlight.

Step 4) Remove the four screws that hold the headlight retainer and remove the entire assembly from the headlight bucket.

Step 5) Install the rubber seal around the headlight opening on the fender. (Good time to put new ones in)

Step 6) Install the H4 bulb

Step 7) Connect the plug to the back of the new headlight assembly.

Step 8) Install the new assembly in the headlight bucket.

Step 9) Install the headlight ring (remember it fits over the lip on the top of the fender opening and the screw at the bottom gets installed at the same angle it came out)

Step 10) remove the masking tape (were you careful not to let the screwdriver slip off or did the tape save you from a scratch in your paint)


Step 11) Test your headlights (you may have to readjust them)


Step 12) Have a beer you earned it.


*H4 bulbs are 55/60 watt standard but also come in 55/100 watt and 80/100 for off road use only.
o H-4-12v55/60w @ $11.95
o H-4-12v55/100w @ $12.95
http://www.pap-parts.com/prodinfo.asp?number=H4-12V80/100W

If you upgrade to 100W bulbs, I recommend installing an upgraded relay 141 951 253 B to safeguard against current overload and the inevitable fuse failure at high speed with no spares to be found. It’s fairly inexpensive at around $6


If you have tried this and have any suggestions, comments, or questions please send a note back.

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