Replacing headlight bulb on a Zafira?

I was horrified when I read both the manual and posts about replacing the Zafira headlight bulbs.
After trying all the various methods, I found that, firstly, it is darned near impossible to replace the passenger side low-beam bulb via the under-wing hatch. Forget it!
The easy way: under the bonnet, remove the plug with red locking mechanism from the front of the fuse box then remove the socket in which it fits, by sliding it vertically upwards. (Both will remain handy, on their respective wiring.)
Next remove the top of the fuse box by means of the ridiculous fastening mechanism.
You now have adequate room to get your hand to the rear cover of the light and then to the bulb holder, which is removed by turning anti-clockwise. The rest is easy and replacement the reverse of removal.
Job done.

David B
March 2017

Make sure you fit the new bulb in the right way up - I spent 20 minutes trying to refit the bulb holder into its socket in the tiny fiddly space that is allowed (offside dipped beam on a 52 plate RHD car) and swearing at GM for making it so difficult. Once I realised my error and reversed the fit of the bulb it was hardly any problem refitting the bulb holder

David Dutton
December 2016

not easy but tottaly do able through wheelarch flap took deep breath then went for it and took less than 10 mins start to finish im a big bloke with massive hands lol and i did it fine just dont force it when putting back in just gently twist till it slips in takes a few mins but worth it .saved a few quid :)

dj
November 2016

Just replaced the offside dipped headlight bulb on 51 plate Zafira. After reading useful advise on this page. Took indicator bulb out of the way first and unclipped the four metal straps holding the top of the air filter on. Turned the lamp housing round to release and wiggled the holder and bulb out. Refit new bulb and wiggle back in to place, had to hold lid of air filter up to relocate but no need to remove whole unit. Make sure the wiring is facing downwards as you attempt to relocate. Ease indicator bulb fitting back in, job done.

Mr. G.
September 2016

Just replaced the Offside dipped headlamp lamp. Tried trough the wheel arch flap but you'd have to be a contortionist with small nimble hands to do it that way.
Changed tactic after reading this thread and removed the air-box (6 off T25 torx screws to remove the top cover). Remove air filter and front top hose. The bottom box is held in place by two rubber bungs at the back (visible) and one into a clip below the box (just about visible through the front grill - Remove bottom hose then pull up on the air-filter box base to release this from the clip. Wriggling the box and pulling hard may be necessary).

Note: there is a drain hose below the box.

Now you have better access to the rubber cover and the lampholder. Twist the lamp holder 1/4 turn anti-clockwise looking into the back of the lamp and lift it out of the headlight fitting. Note its orientation as you remove it so you will know how to present it to the headlight fitting to fit it back in.

Pull lamp out of holder (has a small clip and might be tight on the electrical blades/socket), push new lamp into holder, fit holder to lamp housing (fiddly to get it right - I started of in the 1/4 turn position while looking at the lamp going into the housing from the front.) When its in turn it 1/4 turn clockwise to lock into place. If it does not feel secure then remove and try again.
You'll know when its right.

Refit rubber cover, then bottom of the air-filter box (fit the back bungs in first then the bottom one by moving the hose out of the way and pressing back and down on the bottom of the air-filter box) Check it has seated correctly by looking at the bottom bung through the front grill.

I have no idea how to check the drain hose is fitted correctly to the underside of the box, but hopefully it will slip onto the spigot below the bottom of the box.

Fit the bottom air intake hose, then the air filter then the top of the box (6 T25 torx screws) then fit the top hose. Tighten the hose clips and it's done.

It took me about 20 mins to it this way just as dusk was approaching.

Good luck

Kintara
January 2016

Thanks for the ideas. I've just replaced the dipped offside bulb successfully through the wheel arch flap.

You can reach it from below, but only really see it from above.

The hardest part was seeing/feeling how to get the bulb back in, so I used someone else as my eyes to tell me where to align it.

It took 15 minutes, but I wasted 10 fiddling until I got the spare pair of eyes to help.

IanB
December 2015

First time doing this bulb started by undoing the two screws holding the headlight in as expected the head light to just come out, no such luck.
Removed the front grill no luck here.

Then tried though the access panel under the wheel arch no luck here my hand was to big to get in.

Had a coffee and sat down on the internet and found this page

Removed air filter took all of 5 mins (Had it off so many time this last year with doing a cylinder head gasket and timing chain) this was easy bit.

Now getting the bulb out was a doddle removing it from the clip now that was a nightmare took ten mins to work out how it came out finally worked out it just pulled out and it was just very stiff and tight.

Had a practice go at getting the clip back in to the head light with no bulb in found this to be just about impossible put the old bulb back and it dropped back in to place after a little jiggle.

Paid a visit to my local motor factors £4 later and a new bulb in hand fitted the new bulb in to place, it dropped in first time no jiggling around this time a quick 1/4 turn clockwise had the job done

What did take the time was finding the rubber cover that had just fallen down as I hadn't realised it never had a strap or cord to stop it dropping down under the light unit

Next time I think it would take me around 20 mins to do the job, now I have done it once....

Gareth
November 2015

How do you disconnect the power cable connector to the back of the bulb it will not move this is on the passenger side. There is enough room when you remove the plastic clip on wheel arch panel but then you find the cable attached to the back of the bulb will not move there is no rubber cover just a hard plastic cable block connector.

Paul smith
March 2015

No idea how any of you managed the whole job through that stupid wheel arch panel. I ended up removing the whole airbox, after which it was a 1 minute job, but with a lot of swearing, as that airbox is a pig to get out first time. I'm sure it will be easier next time, but hope the bulbs last longer in this Zafira than my old one, which blew headlamps so often that I had to buy them 6 at a time. That was the type A model though, and far easier to replace.

Mick
August 2014

Hey guys, I managed to access the service hole under the wheel arch and take out the lamp...but couldn't disconnect the old lap from its placer to replace it with a new one...whats the secret..its driving me insane :(

wildaxe
May 2014

Thanks all of you, you really encouraged me to try myself. Went fine. As in all repairs to anything, when removing any part, not a bad idea to experiment pushing it back immediately before proceeding to next stage. eg if you remove rubber cap, refit it a few times before going on to bulb holder. Same with bulb - untwist a little, then retwist. That way you will get confidence to go the whole hog.

Bodger
November 2013

Very useful comments here. However I would like to add that, after removing the bulb unit from headlight use a flat screw driver to gently prise out the bulb from holder. The bulb is firmly fitted in the holder, good luck.

Salif
March 2013

You don't need to remove the airbox - not everyone has a T25 torx screwdriver! Just unplug the cable from the indicator bulb and there's enough room with a bit of wiggling.

Pete
February 2013

Replacing dip beam headlamp bulb (drivers side).
forget the under wing access.
1) remove 5 T25 torx screws around the air filter cover & remove the 3" air pipe removing the cover completely.
2) remove the air filter . Then remove the air intake pipe from the lower part of the air filter box.
3) lift the front of the air filter box & pull towards you (the lower air filter box is only held in rubber mounts)
This now gives easier access to the bulb IMPORTANT . the bulb holder needs a 1/4 anti-clockwise turn to remove MAKE A CLEAR NOTE OF HOW IT LOCATES WHEN YOU REMOVE IT.
replace bulb & re-fit air box in reverse.
NOTE when replacing lower air box there is a drain tube underneath make sure that is still connected.
I found this to be the easiest way instead of struggling in a small space Good Luck !

BOGWOBBIT FROM WOBBLEGOG
January 2013

There is a rubber cover over the bulb housing it has a tab so as you can easily pull it off, the bulb fitment requires a slight turn and comes out easily. Sipmple job when you know how.

Craig
December 2011

Wikianswers.com give a more up to date and simple solution.

Denny
September 2011

I work at Halfords and depending on the year of the zafira , anyway I fitted an headlight bulb on a 55 plate zafira and under the drivers and passengers side of the wheel arch is an inspection hole that is how you access the bulbs

Mr Jehu
March 2011

Not the easiest of tasks!

The headlamp is replaced from inside the front wheel arch.

1. Clean the inside of the wheel arch first as otherwise you will get very dirty arms. For nearside : turn the wheels to the right: offside wheels to the left.

2. Unclip the access cover and preferably remove by unclipping the attachment cord.

3. Reach in towards the back of the headlight and remove the rubber cover.

Before removing the lamp note its orientation!!

4. Reach in towards the back of the existing lamp and untwist anticlockwise. Remove carefully noting which way up the lamp is.

5. If you get 4. wrong and dont note the position of the lamp it can take an hour to get the lamp back in correctly!!

6. Install new lamp in the reverse of the removal and replace rubber cover and cover plate.

First time I did it it took 45 minutes for the first lamp with very sore forearms!!

Good Luck

Gareth
August 2010

Hi all...If its a 05 onwards, there is a door opening under the wheel arch to gain access to the bulb holders. You may have to turn the wheels one way or the other to aid access

zafira05
August 2009

I have just changed the driver side. Not a lot of room, but you need to take out the indicator bulb first (catch at bottom ??? for some reason).

I have BIG hands, but managed it without having to take the air filter etc. off.

Make a note of which way the bulb goes in (look for tab on bulb base) to ensure the new one goes in the same way (it is easier !!)

Steve Phillips
January 2006

Hi,

I replaced both bulbs as above (first removing indicators).

Turn left (anti clockwise) a 1/4 turn and lift unit out. You can remove the rubber gator, but it is not necessary.

I did not have to remove the airbox. Bit tight for room (I have hands like hams!), but do-able. Went for Halfords Super Brilliance. Buy one get one free at he moment

Andy
November 2005

If passenger side then changing the dipped H7 bulb or the main beam bulb is quite easy. Lamp holders rotate to the left then when stops after perhaps 30 degrees you just pull the lamp holder out of the headlight unit. I suggest you remove the indicator lamp holder 1st so to give a bit more room for the dipped bulb. The bulb then pulls out of the holder (quite stiff but if eased out gently it will disconnect from the lamp holder. Replacement is the revers. Remember DO NOT touch the glass of the buld directly with your fingers. Use a very clean cloth to hold the bulb when replacing / removing.

The offside requires you to remove the airbox assembly (Top, filter and bottom half of air box so that you can gain access to the bulb holders.

Steve
April 2005

try ask jeeve search engine and ask "how to repair vauxhall zafira which will take you to sight www.kotisivu.mtv3.fi/astra-g-service/Astra-g-pdf. this sight will show full repair manual. Warning the sight tries to add some files on your computer. keep your antivirous zone alarm, pop up blocker active.

ramesh kotecha
January 2005