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Old 08-30-2024, 10:39 AM   #49
A 986 S
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Join Date: Jul 2016
Location: Napoleon, OH
Posts: 81
headlight washer nozzles

It's not uncommon to see 986/996 era Porsches with missing headlight washer nozzles. My theory is that the nozzles are lost after cracks form in the edge of the socket that holds the nozzle causing it to be unable to grip the nozzle tightly enough to keep it in place when the washer is activated. Inserting a replacement nozzle (obtained from another Porsche or a BMW) into the empty socket is the obvious fix but, if my theory is correct, any replacement nozzle installed in the original socket would also likely go flying the first time the washer was used and that the only way to return the washers to working order would be to replace the complete (expensive) headlight washer module.


It doesn't bother me that my headlight washers don't work as I can't imagine ever using such a feature. Empty washer sockets just look wrong and that does bother me. My solution to my Boxster's empty socket problem was to install nonfunctional replacement nozzles that my son Andy designed and made on his 3D resin printer. Andy told me that he used the resin printer because it produced a higher resolution, more durable part than his filament printer could. Note that these replacements are a simplified version of the originals and don't pretend to actually be able to clean headlights. These printed nozzles are a purely cosmetic fix to the empty socket problem but, if my theory is right, the same can be said of any nozzle that is inserted the original socket.

Personally, I like the look of the simple, smooth printed nozzles. If you'd like to print a set of replacements for yourself, you can find the STL file here: https://www.thingiverse.com/thing:6725822








more on my nozzle project here: https://rx19jones.wixsite.com/projectboxster/projectboxster5

Cheers - dj
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2002 Boxster S Orient Red Metallic / Graphite Gray
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