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How to Fit new Headlamp Bulbs in a C4 (Non-Xenon)

First things first… disregard the handbook, its RUBBISH!!!
on 05 February 2007
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You will need the following…

Correct Bulbs… Dipped Beam H7’s, High Beam H1’s, Indicators PY21W’s

Some really long thin fingers and a lot of patience!!!

I personally have used... Osram Silverstar 55W H7 Headlamp Bulbs, Phillips Vision Plus H1 Headlamp Bulbs, Osram Diadem PY21W Indicator Bulbs


I started with Dipped Beams, then High Beams and finally, Indicators. Most of the pics you see relate to the Drivers Side Headlamp.

On my car, this was by far the easiest side to work on, after removing the coolant bottle cover. This is done by pressing the centre part of the clip in, then removing the whole clip. The clip is reusable, just pop the centre bit out, push the main bit back through the hole and then push the centre back in.

On the passenger side, the Airbox and Battery covers did get in the way a little, but I did not remove them.

[shadowbox=http://c4owners.org/images/c4/bulbs/bulb1.jpg|C4 Headlight Assembly||right][/shadowbox] 1. To start with, pull off all of the rubber covers. There are 4 in total, 1 over each of the Dipped Beam Lamps and High Beam Lamps.

In this picture, the Dipped Beam Lamp is on the right, closest to the radiator, with the Full Beam Lamp being on the left

2. Starting with the Dipped Beam Lamps, the book says to disconnect the lamp, undo release the spring clip (at the top of the fitting) and then remove the lamp.

I found this nigh on impossible given the space to work in. Also, the connector is on really tightly.

I therefore released the top of the spring clip as normal, then pinched the bottom together and totally removed it. REMEMBER which way it goes in, the ‘triangular’ protrusions face the front of the car, to push the bulb into the holder.

[shadowbox=http://c4owners.org/images/c4/bulbs/bulb2.jpg|C4 Headlight Assembly||left][/shadowbox] You can see in the picture (this is actually taken during re-fitting) that the spring clip pivots from top to bottom, and that the bottom of the wire clip is held in place on both sides. By squeezing the clip together at the bottom, it can just be pulled out.

Removing the clip now allows you to pull the bulb out and then, using both hands, disconnect the connector from the bulb.

At this point, I’d like to say DO NOT drop anything inside the light fitting. I did and it is difficult to retrieve. I ended up using one of those telescopic ‘pen’ magnets.

3. To replace the lamp, first of all replace the spring clip. Again, this is done by squeezing the bottom together and refitting into the lamp housing (triangular protrusions upwards so they pivot forwards).

Now, insert the new bulb. The bulb must be inserted so that the flat side of the metal part faces upwards. While you are holding the bulb in place, squat down by the headlamp lens and see that it is sitting square in the hole and that the bulb head is inside the light reflector.

If this is ok, while still holding the lamp in place with one hand, use the other hand to flip the spring clip back up and fix it into place.

Finally push the connector back on.

The procedure is exactly the same for the passenger side lamp, but the access is slightly more awkward.

I did the drivers side one first, made all my mistakes and learnt how to do it, then did the passenger side one, which I actually found quite easy having already done the first one.

Right, so that’s the difficult ones done!!!

4. Next I did the High Beam Bulbs. These are much easier.

There are two connector for these bulbs, a white one and a black one. Only the Black one needs to be disconnected.

This pulls off very easily I found (obviously helped by there only being one connection instead of two).

Again, there is a spring clip, but this time, just release it and pivot it downwards as it is meant to be.

The bulb then just pulls out.

[shadowbox=http://c4owners.org/images/c4/bulbs/bulb4.jpg|C4 Headlight Assembly||left][/shadowbox][shadowbox=http://c4owners.org/images/c4/bulbs/bulb3.jpg|C4 Headlight Assembly||right][/shadowbox] 5. The H1 bulbs have two little locating ‘blobs’ on the front, by the glass:

Because of these, the lamp can only be replaced in a certain position, making it easy to locate in the lamp holder when replacing:

Again, once the bulb is correctly located and fitted, replace the spring clip and re-connect the connector to the centre pin.

Finally, the Indicator bulb. This is very easy.

6. Locate the Indicator bulb holder.

Grip the finger grips and twist a quarter towards the centre of the car, then pull out.

The whole bulb holder assembly will pull out. Try to remember how these come out, it makes it a whole lot easier to put back in, as the locating lugs will only fit in one way.

To remove the bulb from the holder, push down, twist and remove.

7. Re-fit the new bulb and then replace the holder. Below can be seen two pictures showing the holders, the left shows the way to hold to replace on the Passenger side, and on the right, the way to hold to replace on the drivers side:

Replace the bulb holder and turn a quarter turn towards the outside of the car to lock.

[shadowbox=http://c4owners.org/images/c4/bulbs/bulb5.jpg|C4 Headlight Assembly|][/shadowbox] [shadowbox=http://c4owners.org/images/c4/bulbs/bulb6.jpg|C4 Headlight Assembly|][/shadowbox]

8. Finally, replace all rubber caps if you haven’t already done so, and that’s it, your done!!!

Thanks go to Mike 5438 for creating this tutorial and giving permission to use it