Tail Lamp: Service and Repair

Removing And Installing Tail Light

WARNING: Risk of short circuit: Before removing the tail lights, take out the ignition key and switch the light switch off.

NOTE: As of the beginning of 2003, a 2nd generation tail light has been used. When spare parts are needed, only the 2nd generation tail light will be supplied. The tail light can be installed in older vehicles. Line routing must be inserted when installing on the centre of vehicle side.

Remove Tail Light







1. Open the vehicle's rear lid.
2. Use a screwdriver, for example, to remove the two cover caps "1".
3. Unscrew the fastening screws "2".
4. Pull out the light unit sideways in the "direction of arrow" and also in the area of the ball head "3".







1st generation tail light:







2nd generation tail light:

5. Press latch on plug connection "4" and pull apart plug.

Install Rear Light

NOTE: Check the condition of the clip nuts on the tail lights and fastening screws; replace if necessary.

1. Push together the plug connection "4" until the plug can be felt to engage.







1st generation tail light:







2nd generation tail light:

2. Ensure that the clip nut "5" is not damaged (replace if necessary) and is properly inserted in the vehicle body mounting point.
3. Press the ball head on the tail light "3" in the clip nut "5" and place the tail light in the body "arrow".







4. Screw in the fastening screws "2" and press in the cover caps "1".

Replacing Bulbs
1. Remove the tail lights







1st generation tail light







2nd generation tail light

- "A" Brake light. P 21 W.
- "B" Direction indicator light. P 21 W.
- "C" Reverse light. P 21 W.
- "D" Rear fog light and tail light. P 21/4 W.
- "E" Tail light. P 21/5 W.

2. Turn the bulb holder and remove it.
3. Press the bulb in the holder, turn and remove.
4. Insert new bulb, press into the holder and turn, if necessary. Ensure it is fitted properly.
5. Ensure the lines are routed correctly and install the tail lights.

Additional Assembly Instructions For Installing The Tail Lights

NOTE:
- As a result of damage to the rear side section or when replacing the the tail lights, for example, it may be necessary to adapt the tail light due to an unacceptable gap dimension (body to rear light). In this case, an adjustable lamp bracket must be installed.
- As a result of the technical situation, it is not possible to provide a side section with a tail light holder with hole pattern for repair work. In this case, a specially developed, adjustable retainer plate is available which must also be installed.

1. Adjustable lamp bracket.







1x "A" Sheet metal part with clip, 1.2 mm.
2x "B" Adjusting shim, 1 mm.
2x "C" Adjusting shim, 0.5 mm.
1x "D" Sheet metal part with M5 internal thread.
"E" Fastening screws.

2. Prepare side section for the installation of the lamp bracket.







a. Mount the adjusting shim "B" on the tail light holder in the side section. Position centrally and mark the diameter "G" and "H".
b. Use a centre bit to drill holes at dimensions "G" = 22 mm and "H" = 8 mm.

3. Install lamp bracket.







a. Position the sheet metal part with clip "A", set the adjusting shims "B, C" underneath as necessary, press the sheet metal part with the internal thread behind the body panel, insert the fastening screws and tighten a little.
b. Move the bracket to a central position in directions "b, c". Tighten the fastening screws.
c. If necessary, the clip in the sheet metal part "A" can be shortened at the side projections "a". This increases the adjustment range.
d. Install the tail lights

4. Checking the gap dimension.







a. Check the gap dimension, maintaining the defined dimension of 3 ± 0.5 mm.
b. If necessary, remove the tail light again, reposition the lamp bracket or alter with the adjusting shims.