dbd

I have purhased a new Headlight Combo relay to troublshoot and I am experiencing one oddity.

Symptoms are with ignition on:

1. Lights come on immediately when pod is moving to upright position.

2. When lights are fully upright and on and I move the headlight switch
to position 1 from 2 the lights do not turn off until I move the switch
to position 0 and then the pod moves to the down position.

Does this model year have limit switches in the pod motor which could
be suspect for this scenario?.


Thanks

DBD

Mrmerlin

what did it do with the old relay?
are they the same part #
do the headlamps look like they are in the same position?
Look at the motor and see if the 3 bolts that hold it to the chassis might have slipped.
From what you reported it may be a dirty internal contacts in the motor.

dbd

Hi Mrmerlin;

what did it do with the old relay?
Erratic Motor activity

are they the same part #
928 618 107 01 for old
928 618 107 04 for new


do the headlamps look like they are in the same position?
Yes

Look at the motor and see if the 3 bolts that hold it to the chassis might have slipped.
No slippage all is tight.

From what you reported it may be a dirty internal contacts in the motor.

So your sense is it may be the motor, do you know if this model year has a limit switch which controls the lighting of the headlights when the POD is in motion?

Mrmerlin

first you should try to get the correct part as it may affect function.
try getting a used relay,

or better,
take the cover off the old relay and clean all 4 of the internal contacts then retest

dbd

A quote from Alan regarding relays:

One contact set controls driving the pod motor - on a pre-S4 the headlight motor runs only one way and stops in 2 positions: up & down.

The second contact set controls the turning on of the headlight beams - it is disabled whenever the headlight motor is still running.

What component specifically causes the disabling of the headlights when the pod is in motion?

Alan

The relay and the limit switches (indirectly) inside the motor control turning on the beams. Basically whenever the headlight rotation motor is active the headlights should be disabled.

928 618 107 01 for old
928 618 107 04 for new

These 2 parts should be compatible and virtually equivalent in function (I believe there is a minor change - but does not affect general operation).

The older relay (928 618 107 05) for the Pre S4 ('80 - '86) is not compatible - it must be paired with the pre S4 motor (both changed in 87).

I would start by cleaning the limit switches in the pod motor (remove the manual **** end). Also check that none of the relay terminals have been pushed out of the back of the socket.

Alan

borland

The newer 04 part won't allow you to park the headlamps in the up position (such as for washing and drying the car) with the ignition key removed and the light switch in the off position.

Parking the headlights in the up position with the earlier part is done by turning the ignition switch off and removing the key with the light on, then turning off the headlights with the headlight switch.

Porsche made a similar mistake with the replacement window/sunroof controller for '90+ cars, where the window/sunroof switches can be operated after turning off the ignition switch until one of the doors is opened. The replacement part disables this feature.

dbd

Alan;

I have had this motor out and opened 3 times in an attempt to locate the limit switches.

I basically just cleaned and lubed the gears, did not realize the limit switches were in the motor housing
itself.

Thanks, I'll let you know the results.

shadowknight

There is a difference between 928.618.107.04 and 928.618.107.01 with regard to pin 56 and pin 58. I just recently acquired a headlight relay to trouble shoot my non operational highbeams. While leaving the headlight switch on position three and taking the keys out the headlights remained on which was new. I pulled the new relay and compared it against the older and noticed they are layed out differently. Attached is a picture of the new vs the old.



Still my highbeams only work when pushing the stalk towards driver "passing"... nothing at all when I push the stalk towards the dash. I replaced the ignition switch as it was faulty. Fuses are fine... any suggestions?

borland

Gary,

The S4/GT/GTS Additional High Beams are directly power from the Turn Signal/High Beam stalk switch. The headlight relay senses them on, it switches on the high beams for the headlights. WSM wiring diagrams will show this. So from your symptoms, you need to renew or repair the stalk switch.

Next time, you should start your own thread, instead of hijacking this one from dbd.

Alan

Gary
Pin 56 is not used - so thats not important. Later years do not use 58 (marker lights on).

The change I was referring to was as Stan noted - the "stay up" behaviour with key out.

What is your actual behaviour ?

A. Aux headlights only respond to the pull to flash? (in push for high beam do you just get low beam or no beam?)

Or

B. Main beams and aux both on with pull to flash? (in push for high beam do you just get low beam?)

Evaluation:

A. Likely means a relay or relay wiring problem

B. Likely means a combo switch problem

Alan

dbd

Hi Borland;

The newer 04 part won't allow you to park the headlamps in the up position (such as for washing and drying the car) with the ignition key removed and the light switch in the off position.

Interesting info, how would I faciliate the same action as with 928 618 107 01?

Thanks

Alan

Not easily...

One way - ignition/acc on, lights up - disconnect battery ground.

Or just wash the headlights with the markers on in Acc mode - not ideal - Porsche made a backwards step here...

Alan

borland

Yes, what Alan said. If you don't have a quick battery disconnect, you could also pull the fuse for the concealed headlight motor. Fuse #22 on my '90 S4.

I'd look at getting the earlier relay, by buying a good used headlight relay from RENNLIST sponsor 928 International.

dbd

Thank you both.