Project Update:
I had some questions about the installation of these headlight covers. Our Moderator Dmitry set me up with a representative from Variel the manufacturer of the 996 Gen 1 headlight covers who was able to resolve my questions in less than a day. Here is the correspondence:
Question:
”A follow up question to your GEN 1 996 headlight cover.
I know removing the triangle headlight cover piece from the headlight assembly is required to properly fit the headlight cover.
Can the actual headlight washer remain (the unit that remains in the car when the headlight is removed) Or does that need to be taken out as well?
I’m putting the final coats on my covers and am curious if I will need to disassemble/remove/plug up the headlight washer system once the headlight comes out.
Thank You”
Answer from manufacturer
”Regarding your question, as long as you have popped out the washer and it's not keeping the covers from laying flat, then I don't see a reason why you would have to remove it entirely. I believe there is a fuse you can pull in the fuse box that would disable the headlight washers. That's probably the easiest way.”
I appreciate the prompt reply. I did some further research and found a thread on Rennlist that details how to completely remove the headlight washers. Apparently a very easy mod.
Thanks to dkraige who documented this procedure.
https://rennlist.com/forums/996-forum/1036783-litronic-headlight-washer-delete.html
”I think headlight washers are stupid, with the possible exception of a car that's going to get driven long-distance in high-salt winter conditions. Even then I think you can stop and wipe the lights off every couple hundred miles when you take a break for food or fuel. It's just not worth having them for the ugliness and potential leaks.
I decided to delete the headlight washers on my 2001 996. Here's what you need:
1) Left Side Non-Washer Lens Part Number: 99663104500
2) Right Side Non-Washer Lens Part Number: 99663104600
3) Plugs to terminate the washer fluid hoses in place of the washers, so washer fluid doesn't drool out. I used a small dowel of aluminum, about 3/8" in diameter, to clamp down on using the original hose clamps.
Steps to remove are as follows (I didn't take photos but this is pretty idiot-proof):
1) Remove the fuse for the headlight washer pump. This will prevent accidentally actuating the pump, meaning that your plugs only need to resist the head pressure, not pump pressure. Look up your fuse diagram since different years/configurations probably have it in a different location.
2) Remove the headlights using the tool in the toolkit or a 5mm socket.
3) Unbolt the headlight washers; each is held in place by a single nut.
4) Disconnect the hoses from the headlight washers.
5) Plug the hoses with the plug of your choice.
6) Secure the hoses with zip ties, etc. so they don't rattle around.
7) Carefully snap the lenses with holes out of your headlights.
8) Carefully snap your new non-hole lenses in place.
9) Reinstall headlights.
10) Enjoy!”
These still shots were taken from a couple of YouTube videos. They illustrate the headlight washer I will have to remove if they interfere with the headlight cover fit.
Should the cover fit with the washer nozzle still in place I will definitely have to pull the fuse or disconnect the pump to the headlight washer, since it is designed to lift up 2 inches during operation.
I will be adding some more color coats to my covers this week and begin polishing them up. Hopefully I will have some photos of my progress soon . . .