How to replace sidelight & headlight bulbs 68 on bug/van

Tools Needed: Cross-head screwdriver 

Parts Needed: Replacement bulb(s)

Time taken: Couple of minutes

The procedure is the same for bay window vans except that the screw holding the lamp on is on the side of the lamp facing the centre of the front panel (see pic 2).

  1. Make sure the ignition & light switch is off.
  2. Using the screwdriver remove the screw that is located at the bottom centre of the headlamp rim (or for bays at the side - rusty one in the pic below). 
    Do NOT touch the other 2 smaller screws (if you have them) these are the headlight beam adjusters. 
     Some late bugs and vans don't have these but have a separate headlight rim and light unit
    fbulb1.jpg (29995 bytes) fbulb.jpg (58604 bytes) fbulb2.jpg (17938 bytes) fbulb3.jpg (30251 bytes)

  3. Once the screw is removed, pull the bottom of the headlight up and out and lift over the catch at the top (or sideways on a van), being careful to avoid scratching the wing or pull any wires off. You might need to lever  the base up carefully, so use something padded to prevent paint damage. Pic 4 above shows the locating tab for the top (bug) or side (bay) for the headlight rim
  4. The back of the unit is shown below. To access the bulbs, pull of the 3 pronged connector block in the centre and press and twist the black circular clip & remove. If the re is not connector block and the wires are separate, label their position before removal. The sidelight is the smaller of the 2 on the side of the reflector plate & the headlight bulb is the three pronged one in the middle of the unit. More often than not you'll find the wires have been oversprayed, so clean the connectors up whilst the light is off

    fbulb4.jpg (52744 bytes) fbulb5.jpg (54228 bytes)


  5. When replacing bulbs, especially headlight ones, be careful not to touch the glass part of the bulb as the grease from your skin will reduce the lifetime of the bulb.
  6. Replace the black clip and spring, by pressing down and twisting it into place - you'll see the tabs on the back of the light unit it needs to slot into.
  7. Replacement is the reversal of removal but make sure the unit is clipped onto the locating tab properly at the top/side of the recess.

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