How to Fix a New Beetle Door Lockby Chris Moore
The door lock not working on your Volkswagen New Beetle is a big problem that might only appear to be a little problem. There are two main components of the door lock that are likely to be the cause of the problem and need repair/replacement. You need to remove the inner trim panel to replace either, but the lock cylinder within the door is the easier of the two. The door latch is connected to the plastic carrier inside the door and will be more difficult.
Disconnect the negative (black) cable from the car battery.
Detach a manual window crank, if equipped, by sliding the spacer between the handle and trim panel away from the handle's knob to release the clip. For electrical controls, pry the switch panel off with a screwdriver or trim stick and unplug the connectors.
Pry the cover off the door's pull handle with a small screwdriver and remove the screws underneath it. Remove the screws along the panel's bottom edge.
Work a trim tool along the edges of the panel to release it from its clips. Grab and pull the panel off and disconnect the handle lock rod and all electrical connectors.
Install the panel in the reverse order of removal once you have fixed the lock.
Remove the plastic plug on the end of the door near the latch to reveal the set screw. Loosen the screw with a Torx wrench, but don't loosen it all the way.
Insert the key into the lock cylinder. Pull the cylinder out of the door.
Install the new lock cylinder into the door with its key inserted. Tighten the setscrew in the door and remove the key from the cylinder.
Remove the lock cylinder as described above.
Lower the window glass until you can access its track bolts through the holes in the door. Loosen the bolts with a wrench, pull the glass up by hand and tape it to the door in the up position.
Disconnect the electrical connectors for the door and feed the wires through the door hole.
Detach the latch from the door by removing the bolts at the end of the door with a Torx wrench. Remove the carrier's bolts, lift it up and away and disconnect the electrical connector for the lock solenoid.
Drive out the latch's two pins with a punch, flip the latch over and disconnect the cable and linkage rod to remove the latch.
Connect the replacement latch to the cable and linkage rod and then drive the pins into place to mount it on the carrier.
Reconnect the carrier with its bolts, connect all electrical connectors, fasten the latch's mounting bolts on the door end and un-tape and bolt the window glass back in place within its track.
- "Chilton Volkswagen New Beetle Repair Manual;" Bob Henderson; 2005
Things You'll Need
- Trim stick
- Torx wrench
- Lock cylinder with key
- Door latch
Chris Moore has been contributing to eHow since 2007 and is a member of the DFW Writers' Workshop. He received a Bachelor of Arts in journalism from the University of Texas-Arlington.