How do you change the headlight bulb on a 2004 Saab 9-3?

(1) On September 15, 2008 at 2:46 am Doolittleww [1] said:

(if working on driver's side headlamp, begin by removing the battery cover panel)

STEP 1 Remove the 4 1/2” D black rubber weather protection cap covering the cylindrical headlamp port at the back of the black plastic headlamp assembly.

STEP 2 Notice the POWER CONNECTOR (silver metal box 2” x 2 1/2” x 1 1/4”) at the back of the headlamp assembly and note that its rear facing surface displays directional arrows for OPEN and CLOSE. Twist the POWER CONNECTOR in the OPEN direction until it stops (approx. 1/8 of a turn) and wiggle it gently rearward to disengage it from the headlamp assembly. Take notice of the POWER CONNECTOR's orientation with respect to its mount as it is disengaged for later re-installation (in STEP 8). Disconnect the black separate wire's plug from its receptacle at the the top corner of the POWER CONNECTOR.

STEP 3 Notice two vertical silver wire retainers passing along either side of the headlamp bulb's base. Each latches into notched slots in the headlamp bulb socket at their lower ends and have “wire loop handles” at their extreme lower ends. Push the “wire loop handles” forward and slightly to the side to disengage (unlatch) them from their notched slots, freeing the headlamp bulb for removal.

STEP 4 Grasp the OLD headlamp bulb base and wiggle it gently rearward and out of the headlamp assembly.

STEP 5 Insert the NEW headlamp bulb into the bulb socket loosely and keep trying and turning it until the correct position is found where it sets squarely in its socket. DO NOT TOUCH THE GLASS PORTION WITH BARE FINGERS (skin oil on the hot glass reduces bulb life significantly).

STEP 6 – VERY IMPORTANT !! – On the POWER CONNECTOR unit, notice that on its forward facing surface there is a 1” ID hole in the metal with a 1/16” thick 1” ID fixed black plastic ring just beneath it and there are four notches (seperated by 90 degrees) in the perimeters of both to receive the bulb base alignment posts. Beneath the black plastic ring, there is a 1/8” thick, 1” ID rotate-able white nylon ring with four notches in its perimeter (seperated by 90 degrees) also. ALL NOTCHES MUST BE IN ALLIGNMENT BEFORE ATTEMPTING TO COMPLETE BULB INSTALLATION. IF NOT JAMMING WILL OCCUR. If the notches are NOT all aligned, use a pick to gently coax the white nylon ring to rotate counterclockwise (to the left) causing all notches to return to being in alignment. – VERY IMPORTANT !! – DO NOT ENGAGE THE SEPERATE BLACK WIRE's PLUG INTO ITS SOCKET AT THE TOP CORNER OF THE POWER CONNECTOR UNIT UNTIL STEP 8 because there is a tiny lever mechanism in the connection plug receptacle which rotates the 1” ID white nylon ring clockwise as the plug engages the receptacle causing the notches to become misaligned.

STEP 7 Using the same POWER CONNECTOR orientation with respect to its mount as taken notice of during its removal (in STEP 2), engage the POWER CONNECTOR's four black plastic legs into the four square cam lock holes in its mount at the back of the headlamp assembly, push it forward (inward) and twist it in the CLOSE direction until it stops (about 1/8 turn).

STEP 8 Engage the black separate wire's plug FULLY into its receptacle on the top corner of the POWER CONNECTOR.

STEP 9 Reinstall the 4 1/2” D black rubber weather protection cap over the cylindrical headlamp port at the back of the black plastic headlamp assembly. (replace battery cover if working on right side)

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