The latest problem to surface is odd behaviour with the headlights. The headlights would function as they should except when turning them off. When I turned the switch off the light would go off but the headlights wouldn't retract. A tap on the headlight relay and they went down fine. The dash illumination also ceased to work.

Relay, right? That's what I thought so I picked one up. I put in the new relay and the headlights turn on fine...they just won't go off. They stay on and up whether the key is in, turned on, off or even removed. The lights just stay on. When I turn the headlight switch off the lights stay on but other lights gets turned on including the driving lights, the under hood light, and the emergency (4 way) flasher **** is illuminated. A tap on the new relay and these other lights go out. A second tap gets the headlights to retract.

I have yet to clean the grounds at the CE panel so I'll try that. Any ideas would be greatly appreciated.

 

Double-check the P/N of the relay. It should be 928.618.107.04 for 87+ cars.

 

Thanks Dave...that's the number. I got a new genuine Porsche relay from one of the suppliers here. The relay I removed was 928.618.107.01.

I'm starting to think the new part may be faulty. Is there a way I can test the relay?

 

take the old relay cover off and clean the contacts and refit it, see if this does anything get a fuse realy chart here and see if you have the part it calls for.
www.928gt.com
find page 2 then click on tips and links

 

Took the cover off the old relay and cleaned the contacts, reassembled and no change...Correction, one change...now tapping the old relay does nothing when before it would get the headlights to retract

The new relay is the correct number according to the chart but different than the original one.

 

check the wire (motor) connection under the hood..
Ahh what was the last thing that you fixed??

 

The wire and motor appear fine. The last thing I fixed? Just about everything...Replaced a TBF motor and installed a complete new leather interior.

The new relay also seems to turn the headlights on immediately...even before they are up. The old (original relay) doesn't turn the headlights on until they are up.

 

I wonder if the CE panel has been replaced with a different year

 

Could be a problem with the wipers and/or diodes inside the headlight motor.

Make sure you don't have a relay in position III just above the HL relay. Might as well check all of the light-related relays WYAIT: https://www.928gt.com/t-8788fuse.aspx

 

I disassembled and apparently wrongly reassembled a headlight switch. (don't even try, impossible to reassemble due to tiny concentric springs deep inside). 84 car.

I think it then caused a brand new relay to go bad. (Else it was also bad new from factory)

Had to change the switch and get another expensive new relay.

Had to trace every wire from the headlight switch down at the fuse panel to figure it all out.
Took 3 weeks for me. Probably hours for somebody skilled.

If you have another switch, it would be a reasonable thing to try it and possibly save some troubleshooting.
But a new relay could be bad as well.

I realize this isn't a lot of help, and provides some uncertainty to your troubleshooting path, but don't discount the switch as a source.

It is possible from the wiring diagrams to also isolate and test the headlight motor, as mentioned, it could have an electrical problem but I don't know if the various failure modes match with what you are seeing.

 

TS switches do go bad, but sometimes removing them and spraying the internals with ELEX contact cleaner while moving the levers around will return function, blow out the switch prior to reinstalling it, and spray the fluid/switch outside of the car. Taking the switch apart is only recommended if you have already taken the parts donor switch apart first, this will let you see all of the little springs and such that will fall out

 

Mike if you want to try the relay in my car for comparison let me know.
Ole

 

It looks original but quite honestly I doubt I could tell the difference. The original relay 928.618.107.01 shows up in PET and has the comment (GB) associate to it???

No relay above the H/L relay...The H/L's worked fine when I got the car and I really didn't turn them on other than to check them after the purchase. I hope it's not the motor.

Chris, I may be hunting for a switch as well although I didn't take it apart...I just unplugged it and plugged it back in after reinstalling the dash / pod.

TS switches? Is that the headlight switch? Is this ELEX cleaner a standard item available at auto stores or Home Depot?

Ole, that would be great but how would it be safer if I tried my relays in your car? I had almost resigned myself to buying another...I'll PM you later and thanks for the offer...much appreciated!

 

TS = turn signal switch
Elex cleaner = electrical contact spray cleaner, made by CRC found at Autozone, red can.
Sorry about the abbreviations

 

I had a similar problem a couple of years ago. It turned out to be the ignition switch.