2005 PORSCHE BOXSTER headlight

Practical Tips, Emergency Service
241
Headlights
Caution!
Risk of damage to headlights due to abrasion
and excessive temperatures.
fDo not affix any coverings (e.g. “stone guards” or films) in the area of the headlights.
Note
The headlights can mist up depending on the
temperature and humidity.
fTo ensure optimum ventilation, do not cover
the gap between headlight and body
(e.g. “stone guards” or films).
Removal1. Unscrew plastic nut A.
Detach side carpeting.2. Remove rubber plugs from the unlocking
opening.
3. Place socket wrench (tool kit) on the unlocking
spindle.
The tongue of the wrench should point horizon-
tally to the rear.
4. Turn wrench approx. 180° A. The headlight is
unlocked and pushed forward slightly during
this process.
5. Turn socket wrench back until it is pointing
vertically downward B and leave in position.
6. The headlight is now unlocked and can be
pulled forward out of the wing.

242
Practical Tips, Emergency Service
Installing1. Insert the headlight into the guide rails and
push it fully into the wing.
2. Push headlight to the rear and at the same
time the turn socket wrench until it points
horizontally to the rear C.
The headlight locking device must perceptibly
and audibly engage.
3. Insert rubber plug into the unlocking opening
and secure the carpeting.
Check the function of all lights.
Low beam, high beam and additional high
beamOpening the lid of the headlight housing
1. Unscrew the 4 screws A.
2. First lift release tab B, then push both release
tabs C upwards and take off lid.

Practical Tips, Emergency Service
243
Halogen headlights
Changing bulb for low beam
1. Pull off plug A.
2. Disengage fixing loop B.
3. Replace defective bulb.
When doing so, ensure bulb is seated properly.
4. Reassemble in reverse order.Bi-Xenon headlight
Changing bulb for low beam and high beam
1. Turn the plug counter-clockwise (bayonet lock)
and pull it off.2. Disengage both fixing loops A.
3. Replace defective bulb B.
When doing so, ensure bulb is seated properly.
4. Engage both fixing loops A, push on plug and
turn right as far as the stop.

244
Practical Tips, Emergency Service Changing bulb for high beam or additional
high beam (Bi-Xenon headlight)
1. Turn the bulb holder.
Turn it counter-clockwise on the left headlight
and clockwise on the right headlight.
Take bulb holder out of the headlight housing.2. Pull both plug release tabs apart.
Pull plug out of the bulb holder.
3. Replace the defective bulb with bulb holder.
4. Reassemble in reverse order.Closing lid of headlight housing
1. Push on lid until it perceptibly engages.
2. Fasten lid with the 4 screws.

246
Practical Tips, Emergency Service
A - Fog light height adjustment
B - Fastening screwFog light/parking light1. Loosen the two screws B.2. Lower headlight slightly downward and
disengage locating cam in cover projection.
Unscrew light downwards at an angle.
A - Parking light
B - Fog light3. Turn the holder counter-clockwise and pull it
out.
Replace defective bulb (bayonet lock).
Push holder back in and turn towards the right.

Practical Tips, Emergency Service
247
4. Put guide pin of headlight on the guide rail,
engage locating cam in cover projection,
press headlight to the rear and push upward
until it can be felt to engage.
5. Screw in both screws.
6. Check operation of the headlight.

252
Practical Tips, Emergency Service
Adjusting Headlights fPlease observe the chapter “REPLACING BUL-
BS” on Page 238.
Adjustment
The adjustment is made with the vehicle ready to
drive and the fuel tank completely filled.
The driver’s seat must be loaded by a person or a
165 lbs. (75 kg) weight and the tire pressures
must meet the prescribed values.
After being loaded, the car must be rolled a few
meters so that the suspension can settle.
For checking the headlight adjustment, the verti-
cal position of the cutoff of the lowbeam (see fig.)
has to be projected on a vertical screen (wall) in
distance of 24.6 ft. (7.5 m) from the front lens of
the headlamp.
The correct position of the cutoff is 2.0 in. (5 cm)
at 24.6 ft. or 7.5 m (0.4°) below a horizontal line,
x cm from ground to the center of the headlamp
lens. Lateral adjustment of the headlights should be
carried out at a specialist workshop with an optical
adjustment unit.
Distance
Visual aim shall be performed at not less than
24.6 ft. (7.5) m (this value is a rounded down con-
version from the 25-foot distance typical of field
aim using a screen). The 24.6 ft. (7.5 m) distance
is measured from the headlamp lens to the view-
ing screen.

Practical Tips, Emergency Service
253
Floor
The surface upon which the vehicle rests is flat
and approximately level.
Screen
The screen upon which headlamp beams are pro-
jected is perpendicular to the floor and the vehi-
cle’s longitudinal axis, flat, uniformly light in color,
unobstructed, and wide and high enough to ac-
commodate the vehicle beam patterns to be
aimed.
The screen should be wide enough to provide at
least 3.3 ft. (1 m) of space outboard of the vehi-
cle’s headlamp spacing.
Adjustment screws
fDetach side carpeting in luggage compart-
ment.
Therefore unscrew plastic nut A.
Open the cover of the appropriate adjustment
screw.
The setting is adjusted by turning the hexagon
socket screws right or left, as appropriate.
B - Headlight vertical adjustmentVertical adjustment (screw B)
fturn clockwise = beam moves down
turn counter-clockwise = beam moves up
Note
fDo not alter the lateral adjustment.