For additonal information on this and other subjects URL:http://www.vwtdirepair.com (Darell's VW TDI Maintenance Page).

Following  the below steps, you can change  your Beetle's  brake light bulb  in the driveway in less than an hour. Doing the job yourself, you know that the job was done right and lastly you saved MONEY on professional repairs.

Project Repair Steps

1. Use the key remote or ignition key to raise the vehicles deck lid.

2. Use a small flat-blade screwdriver to pry off the lens assembly access cover (Figure B-1).

Figure B-1 Removing Lens Assembly Access Cover

3. Figure B-2 shows the lens assembly access cover removed.

Figure B-2 Lens Access Cover Removed

4. The lens assembly is secured to the housing by a threaded stud and  knob. The knob is removed by turning counter-clockwise with  the fingers (Figure B-3).

Figure B-3 Lens Assembly Housing Knob.

5. Figure B-4 shows the lens support housing knob removed.

Figure B-4 Lens Assembly Knob Removed

6. Use a non-marring trim tool (no sharp tools or screwdrivers) to pry loose the lens assemby from the body fender (Figure B-5). If a trim tool is not available, place strips of masking tape around lens to prevent paint damage.

Figure B-5 Loosening Lens With Trim Tool

7. Work the trim tool around the lens to loosen around gasket for removal (Figure B-6).

Figure B-6 Loosening Lens for Removal

8. Remove the lens from the support housing (Figure B-7).

Figure B-7 Lens Assembly Removed

9. Remove the bulb socket from the lens assembly. The socket is a push fit that mounts in the lens assemby. No screws are required for removal. A defective bulb socket is replaced as a piece part with a VW part number. Figure B-8 shows the socket  being removed from the lens assembly.

Figure B-8 Bulb Socket Being Removed From Lens Assembly

10. Carefully check the removed bulb socket for corrosion, cracks, and burned electrical contacts (Figure B-9).

Figure B-9 Checking Bulb Socket

11. Internal corrosion cannot be seen with the eyes. A digital multi-meter (DMM) is used by technicians' and DIY's to check the electrical contacts and wiring for continuity (unbroken electrical pathJ).

12. A DMM used for these checks can be bought at auto parts stores and Internet tool fronts for less than $20.00. The DMM comes with complete instructions for easy setup.

13. Most DMM's have a feature known as auto-ranging. With this feature the user selects the best range for electrical measurements; such as, volts, current, and resistance measurements. The units for ohms are: (1) ohms, (2) kilohms, and (3) megohms or one (1) milllion ohms.

14. To check the bulb socket for circuit continuity, place the DMM selector switch to the "OHM'S" position. Insert the red lead into the volts/ohms jack and the black lead (com) jack on the DMM. Place the black lead on one (1) terminal of the socket. Place the red lead on the other terminal of the socket. Figure B-10 shows the DMM being used to check for continuity of the bulb socket.

Figure B-10 Checking Socket With DMM

15. Next, understand the value of a measurement on the display of the DMM. An "OL" reading would indicate that there is an "OPEN" circuit internally in the socket from corrosion, or break in the wiring. A ".000" reading on the DMM display would indicate that there is continuity throughout the socket. Current should flow from the battery to the load (bulb). The reading on the display of the DMM (Figure B-11) shows ".001". This reading would indicate that there is continuity through the wiring and the socket. In this case, the DMM proved that the socket is good with no breaks or burned contacts.

Figure B-11 Checking Socket With DMM

16. Remove the bulb from the socket (Figure B-12). The bulb is removed by twisting slightly to disingage the ears of the bulb from the socket. The ears of the bulb mate to slots in the bulb socket.

 Figure B-12 Bulb Socket Removed

17. Check the bulb filament and internal connections with the DMM. To check the bulb filament, place the black lead of the DMM to the shell of the bulb. Place the red lead of the DMM to the base of the bulb. The reading on the display of the DMM showed "OL" or an open circuit. This reading would indicate that a filament wire is burned out or internal corrosion in the bulb. The bulb is diagnosed as being defective. Figure B-13 shows the DMM being used to check the bulb and internal connections for circuit continuity.

Figure B-13 Checking Bulb for Circuit Continuity

Warning

In all states, a defective brake light is a safety violation. If cited by a patrol officer the violation will result in a traffic citation. Secondly, the vehicle with a defective brake light will not pass the state safety inspection.

18. Order a replacement bulb from the VW parts center. Ask for P/N N0177836.

19. Install the new replacement bulb in the socket with the lens assembly removed.

20. Turn the ignition switch to the "ON" position.

21. Have an assistant press on the brake pedal.

22. Check the bulb filament. It should be burning bright yellow through the bulb glass (Figure B-14).

 Figure B-14 Checking New Replacement Bulb

23. Reinstall the lens assembly in the reverse order from which it was removed.

24. Road test you Beetle TDI.

Tools You'll Need

Flat-blade screwdriver
Non-marring trim tool
DMM multi-meter
Replacement bulb