From: Dan [dbrindle@kondratyev.com] Sent: Saturday, March 17, 2001 3:13 PM To: 928 Subject: [928] RE: headlight positioning questions Dan, It dos not sound like a motor adjustment. The arm on the spline of the motor is not in the correct position. Put the lights in the off position Disconnect the battery Put a thin piece of plywood in front of the radiator Loosen the nut on the motor that holds the shaft Pry the shaft loose from the motor with a big screwdriver Let the lights slip down to the correct lowered position Re-tighten the nut on the motor Double check to make sure both C clips are on the arm connecting the motor to the head light bar. Remove the plywood Reconnect the battery. The tip off here is that the headlights are dipping to the correct position when they get turned on. The cut off of the reed switch in the motor is telling the motor to stop at the bottom of its swing, but the arm on the motor has not reached the bottom of the swing. So when the motor is first activated it first moves through the bottom of the swing and then pushes the headlights up. They are probably missing the top of the swing as well. I suspect that when the headlights are turned off they go up just a little before retracting. This would cause the headlights to point a little high and also be a little shaky, as they are not hitting their stops on the top. If you use the three bolts to slide the motors orientation then it will bind with the stops on the way down and the headlights will not reach the full up position thus pointing even higher. Good luck and be careful of that radiator Dan B. From: Rich [rich9928@earthlink.net] Sent: Wednesday, November 28, 2001 12:56 AM To: 928 Subject: [928] Re: broken headlight lens: H4 or H5? > folks, > > I am looking at my right headlight. It is a Wagner lens and the other one is > a Bosch. -- snip -- > > I'd like to find a replacement lens, but I am also looking on the 928intl > site to find that the entire headlight assembly is $125. Surely that is > something more than I need. > > I'm looking only for the lens itself and feel it must be available at a > local parts store for cheap. Also, there is an H4 and H5 distinction.--snip-- > > any thoughts? Many thanks in advance. > > David Cmelik > 81 5sp "moosgruenmetallic" David, Is it a 7 inch bulb with a ring around it to fill the gap to the outside of the housing, does it say DOT on it and have three alignment dimples sticking out? If yes, it is the "garden variety garbage" US sealed beam, you can purchase it at any auto parts store. A much better replacment is the 7 inch Hella H4 bulb "off road only" bulb, available at 928 Specialists and other off road shops. This features the Euro pattern and is only about 500 percent better IMHO. H4 bulbs are legal in some states and Canada, and I doubt any police would even know. You can even use "off road" 80W/100W bulbs (vs. std. 60@/80W) to get even better illumination. BE SURE TO ADJUST THEM PROPERLY (see below). The best and most expensive is upgrade to 8 inch H4s, that are what Euros have. You lose the ring and have full glass. But for about $250 each bulb and frame, that is a pretty penny just for the looks, the Hella 7 inch bulbs have the same pattern. H5 bulbs used in the the 8 inch US Spec S4 and GTS. The have the same "US garbage blob" pattern, they just look better. You don't want these. H4 Alignment Instructions: Locate the 928 on level ground 25 feet away from a vertical wall. The vertical wall should then be marked: + o + (c) (v) (c) b------------------------b where: + (c) is the axis, or aim-respective center, of each headlamp. o (v) is the centerline of the 928. b-b is a line parallel to and three inches below (c)-(c) Draw a vertical line through through the center of each (c) point. Do the same with the o (v) point. You now have an accurate plot on the wall of the locations of the headlamps. (The (c) and (v) designations are for purposes of clarity in this descriptive article. It is not necessary to draw "(c)" and "(v)" on the wall--just plot the points. 2.VERTICAL AIMING The upper horizontal edge of the low beam light pattern must be directly on line b-b. This will place the upper horizontal edge of the low beam light pattern 3 inches below the centerline of the headlamp at 25 feet with ECE-spec aiming. 3.HORIZONTAL AIMING The "break point" in the top edge of the low beam light pattern is where the horizontal upper edge of the low beam light pattern begins to rise to the right or steps upwards. Adjust the headlamps so that the break point is within +/- 2 inches of point (c). After adjusting a high/low beam headlamp in the low beam mode, do not attempt to readjust it in high beam mode. All high/low beam headlamps are meant to be adjusted on the low beam setting only -the high beam adjustment is correct when the low beam adjustment is correct. Rich -----Original Message----- From: BrianG [mailto:gushaty@telusplanet.net] Sent: Wednesday, January 01, 2003 5:15 PM To: 928 Subject: [928] Headlight Height Adjustment Question..... JP: Setting headlights is easy, if you have the "cut-off" low beam type of lamp characterized by the H4 Bosch, in either the 7" or the 8" version. You can easily tell if you have this type by parking about 10 yards from a blank (white) wall at night and pointing your lights at the wall. I use the local shopping center parking lot and a handy building wall. If, on low beam, there is a distinct horizontal cut-off, above which there is almost no beam, this will work. Park the car on a level surface and aim it, perpendicularly, at a white wall. Take a heavy towel, or some such thing, and cover one head light. you will note that the light projected shows a horizontal limit left of the center-point and then a rising edge from center-to-right. The first step is to get behind the car and stand right behind the headlight currently shining. Determine that the point where the horizontal limit of the beam meets the rising portion (the center of the beam) is directly ahead of the light, and not to the left or right. Then take a measuring tape and measure the distance (height) from the ground, to the center of the headlight lens. This is a bit of a trick with the 928 because the headlight lens is so far back from the bumper, but a level held horizontal to the lens will give you this point. With that number in hand, go to the wall with a long piece of duct tape and lay a horizontal line of tape on the wall at that height. Go to the car and adjust the light so that the horizontal cut-off matches that line of duct-tape. There you have one headlight aimed straight and horizontal. Repeat this process with the other headlight while covering the first with the towel. Note, that you should end up with the two beam center-points the same distance apart as the headlights, and NOT converging to the same single point on the wall. This will give you two parallel and horizontal headlight beams that shouldn't bother anyone and will give you the best lighting to drive by. Hope this helps. BrianG