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Left headlight out, puzzling

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Old Sep 3, 2025 | 04:30 PM
  #1  
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Default Left headlight out, puzzling

My 1997 993 C4S left headlight is still out. But strangely, first the replacement Xenon low beam failed, and after a couple of days, then the stock high beam also failed. I checked the fuses, replaced the low beam bulb, cleaned and checked all the connections to the headlight unit. Checked the ground wire. One thing I noticed was that the wire that leads up to near the fuse box is connewcte3d to a small black relay or something (I don't what the function of that small box is ... could be the cause of the problem?). And that lead that bundles into the main wiring harness seems like it might be kinked a bit.
Anybody know if that little black box up near the fuse box could be the source of the problem?
Ideas?
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Old Sep 5, 2025 | 05:31 PM
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Default One headlight, cont'd :-(

In my unending struggle to get my left headlight to work again, I've tried everything Rennlisters have suggested ...but so far, no cigar. I'm wondering what this little balck box does next to the fuse box . It seems to feed into the headlight wiring harness, and has a definate severe kink in it as it appears to head toward the headlight assembley itself. Possible cause of a headlight burning out one bulb and then another 2 days later? Photos attached.

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Old Sep 5, 2025 | 08:15 PM
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Fuel tank sender.
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Old Sep 6, 2025 | 10:51 AM
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Hi TFM,
Consider opening up the headlight pod and directly attaching a couple of wires from the battery to the 12-volt side of the HID ballast and see if the lamp illuminates.
Consider buying a few feet of stranded primary wire. Make up two lengths and attach a small alligator clip to each of the ends to make the jumper cables. It is a great tool to have around for general electrical sorting out of stuff like this.
This will rule out anything in the pod, including the ballast, the high voltage wires, and the bulb.
Report back with the results for next steps.
Andy
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Old Sep 6, 2025 | 03:04 PM
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Will do. Thanks Andy.
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Old Sep 8, 2025 | 03:06 AM
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Andy, I did as you suggested wired up the battery to the ballest ...not even a flicker of igniting. Guess tomorrow I'll try to figuire out which pins coming out of the harness are the 12v supply and put a multimeper on them.,This seems to be in some respects narrowing down to a failed ballest. Swap ballasts now to see if the one working on the otherside will tell the tale? I ordered a cheopo thin ballast but then ....why would the high beams as factory wired fail rtwo days later? I bought a used headlight module with free return thinkinhg maybe the entire headlight assemby is shot for ome reason. Obviously, I'm not an eletrician of any ilk. Just trying to stumble my way though it before I leaveing it to one of two or guys near me that I know can figure it out.
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Old Sep 8, 2025 | 05:34 AM
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Have you tried swapping someone's known good headlight into your car? One of the benefits of the oddly easy to remove headlights in the 993 is that I was able to do this for someone with a headlight issue at a car meet once which isolated the issue to his headlight itself and not a problem upstream in the car/wiring.
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Old Sep 8, 2025 | 10:33 PM
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Originally Posted by tfm
Andy, I did as you suggested wired up the battery to the ballest ...not even a flicker of igniting. Guess tomorrow I'll try to figuire out which pins coming out of the harness are the 12v supply and put a multimeper on them.,This seems to be in some respects narrowing down to a failed ballest. Swap ballasts now to see if the one working on the otherside will tell the tale? I ordered a cheopo thin ballast but then ....why would the high beams as factory wired fail rtwo days later? I bought a used headlight module with free return thinkinhg maybe the entire headlight assemby is shot for ome reason. Obviously, I'm not an eletrician of any ilk. Just trying to stumble my way though it before I leaveing it to one of two or guys near me that I know can figure it out.
Hi tfm,
Looks like you are on your way to finding the root cause. If you see 12 volts at the harness, it also points to a failed ballast.

It may be most economical to buy one of the complete HID kits off of eBay and either raid it for parts or just swap the complete kit out for what you have.
https://www.ebay.com/sch/i.html?_nkw...023.m570.l1313

Here is my page that includes the installation gotchas.
https://993servicerepair.blogspot.co...ing-zenon.html
Andy
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