Drive side Headlight Problem

[mk3tg]

Hey guys just wanted to say Thank you for all your help on previous posts! now however i have something else I have an issue with.... of course its a Porsche. but heres the deal I replaced my driver side headlamp twice the first time because the bulb went bad. the second time because the fuse kept on popping with the headlamp in it. now heres the problem I replace the fuse then i drive than the headlamp goes out again... i replace and it keeps on going out.
all and all i took the headlamp out and i inspected all the wiring i disconnected the plug that connects to the headlamp plug. and i put a fuse in and moved the wire the fuse popped again... any idea where the wire may be shorting out

I got pulled over twice because the headlamp fuse keeps popping and what not
ideas and locations of where the wires may short are appreciated

[mytrplseven]

First check the wiring diagram in the Haynes manual to see if there's anything else connected to that line. If there are, see if those items are functioning ok with the fuse replaced. If not, then pull the light switch and look at the wire bundle under the dash to see if there's anything obvious with the wire bundle rubbing on anything that moves, i.e., clutch or brake mechanisms. No? Then get under the hood and follow the wire bundles back in the areas of where things move like the headlight mechanism. An easy way to thoroughly follow this part is manually rotate the knob for the headlight mechanism while you have an ohm meter connected to the fuse block on the side that goes to the light (battery disconnected). Watch for a short indication while the mechanism is moving and then look around the mechanism at that point. If you have a short before you even start then It's likely somewhere else. It's even possible that the Headlight Relay is defective. Sorry you're not here in FL. I'd help you troubleshoot it.

[mk3tg]

i think i found the problem however i have no idea how to tell but only in this 1 section near the plug at the top, when i shake it the fuse blows ideas? new plug what do i do? also i took a meter and it was reading that the positive wasnt finding a ground it was at 0.1 and 0.0

[Dave Colangelo]

First clean all your grounds, I have found that this has solved many electrical issues I have had in my Porsche's. The haynes lists there locations, or just look for a bunch of brown wires bolted to one location. Take the bolt out, clean all the tabs, clean the bolt, and sand the area on the chassis to clean metal. Every thing should be sanded to clean copper.

Next make sure you are using the right fuse. When I got my 924S it had some wrong fuses in it and they would blow every so often. I think the haynes manual has the chart if not I have it some where ill look it up.

+1 for checking other things on the line. It sounds like there is a fault that is allowing it to draw a ton of current and blow the fuse.

Along with cleaning the fuses clean the tabs in the fuse panel as well. They corrode and can create issues. If you can check the back of the fuse panel and make sure all connections are clean and not shorting out to each other or ground.

Regards
Dave

[spec guy]

we need to know if your car is early or late.

[mytrplseven]

Which plug are you talking about? What year car? If you disconnect the plug and refer to a wiring diagram (haynes manual) you can check the pins on both male and femal plugs to see if there's a ground or visually look at the back of the connector(s) to see if there's a loose wire rubbing on an adjacent pin.

[zedsn]

Sounds like you have a couple of broken wires where the wire loom bends behind the headlight metal unit when the light goes up and down causing the hot and common to come in contact with each other. Gently cut off the outer wire protective layer that will expose the wires and you should see some cut wires. My 2 cents.

[mk3tg]

this is a 85.5 and fuse 22 and 23 keep popping low beam and high beam