Volkswagen New Beetle. Manual - part 85

 

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Volkswagen New Beetle. Manual - part 85

 

 

ELECTRICAL PUMPS AND MOTORS 

Copied fuel pump conditions from engine UIGs & deleted pulsator from leaking conditions.  

Electrical Pumps and Motors 

Drum diameter is greater than OEM "machine to" 
specifications but less than "discard at" specifications, and 
the drum does not require reconditioning 

Suggest replacement. 

See note below. 

NOTE: Only applies to vehicles for which OEM "machine to" specifications exist. If 
OEM does not supply "machine to" specifications, the drum may be worn to discard 
specifications. 

Drum diameter will exceed OEM "machine to" 
specifications after required reconditioning 

Require replacement. 

See note below. 

NOTE: If OEM does not supply "machine to" specifications, you may machine to 
discard specifications. 

Hard-spotted 

Suggest 

reconditioning or 

replacement. 

Measured diameter is greater than OEM discard 
specifications 

Require replacement. 

Out-of-round (runout), affecting performance 

Require 

reconditioning or 

replacement. 

Out-of-round (runout), exceeding manufacturer's 
specifications 

Require 

reconditioning or 

replacement. 

Scored 

Require 

reconditioning or 

replacement. 

Surface threaded due to improper machining 

Require 

reconditioning or 

replacement. 

Tapered, affecting performance 

Require 

reconditioning or 

replacement. 

Condition 

Code 

Procedure 

Attaching hardware broken 

Require repair or replacement of 

hardware. 

Attaching hardware missing 

Require replacement of hardware. 

Attaching hardware not functioning 

Require repair or replacement of 

hardware. 

Connector broken 

Require repair or replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

ELECTRONIC CONTROLLERS 

Electronic Controllers 

Connector (Weatherpack type) leaking 

Require repair or replacement. 

Connector melted 

Require repair or replacement. See note 

below. 

NOTE: Determine cause and correct prior to repair or replacement of part. 

Connector missing 

Require replacement. 

Contaminated 

Require replacement. 

NOTE: Determine source of contamination. Require repair or replacement. 

Inoperative 

Require repair or replacement. See note 

below. 

NOTE: Inoperative includes intermittent operation or out of OEM specifications. 

Leaking externally 

Require repair or replacement. 

Leaking internally 

Require repair or replacement. 

Noisy 

Suggest repair or replacement. 

Terminal broken 

Require repair or replacement. 

Terminal burned, affecting performance 

Require repair or replacement. See note 

below. 

NOTE: Determine cause and correct prior to repair or replacement of part. 

Terminal burned, not affecting 
performance 

Suggest repair or replacement. 

Terminal corroded, affecting 
performance 

Require repair or replacement. 

Terminal corroded, not affecting 
performance 

Suggest repair or replacement. 

Terminal loose, affecting performance 

Require repair or replacement. 

Terminal loose, not affecting 
performance 

Suggest repair or replacement. 

Threads damaged 

Require repair or replacement. 

Threads stripped (threads missing) 

Require replacement. 

Wire lead conductors exposed 

Require repair or replacement. 

Wire lead corroded 

Require repair or replacement. 

Wire lead open 

Require repair or replacement. 

Wire lead shorted 

Require repair or replacement. 

Condition 

Code 

Procedure 

Application incorrect 

Require replacement. 

Attaching hardware missing 

Require replacement of hardware. 

Attaching hardware threads 

Require repair or replacement of hardware. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

FLUID 

damaged 

Attaching hardware threads 
stripped (threads missing) 

Require repair or replacement of hardware. 

Code set (if applicable) 

Further inspection required. See note below. 

NOTE: Refer to manufacturer's diagnostic trouble code procedure and require repair or 
replacement of affected component(s). 

Connector broken 

Require repair or replacement. 

Connector melted 

Require repair or replacement. See note 

below. 

NOTE: Determine cause and correct prior to repair or replacement of part. 

Connector missing 

Require repair. 

Contaminated 

Require repair or replacement. 

Inoperative 

Require repair or replacement. Further 

inspection required. See note below. 

NOTE: Inoperative includes intermittent operation or out of OEM specification. Some 
components may be serviceable; check for accepted cleaning procedure. 

Leaking 

Require repair or replacement. 

Missing 

Require replacement. 

Terminal broken 

Require repair or replacement. 

Terminal burned, affecting 
performance 

Require repair or replacement. See note 

below. 

NOTE: Determine cause and correct prior to repair or replacement of part. 

Terminal burned, not affecting 
performance 

Suggest repair or replacement. 

Terminal corroded, affecting 
performance 

Require repair or replacement. 

Terminal corroded, not affecting 
performance 

Suggest repair or replacement. 

Terminal loose, affecting 
performance 

Require repair or replacement. 

Terminal loose, not affecting 
performance 

Suggest repair or replacement. 

Threads damaged 

Require repair or replacement. 

Threads stripped (threads missing) 

Require replacement. 

Wire lead conductors exposed 

Require repair or replacement. 

Wire lead corroded 

Require repair or replacement. 

Wire lead open 

Require repair or replacement. 

Wire lead shorted 

Require repair or replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

See Brake Fluid.  

FLUID LEVEL SENSOR SWITCHES 

See Switches.  

FOUR WHEEL DRIVE SWITCHES 

See Switches.  

FRICTION MATERIAL 

Friction Material 

NOTE:

Original Equipment Manufacturer (OEM) specifications designate replacement 
at different thicknesses. 

CAUTION: It is required that friction material be matched in axle sets for consistent 

braking characteristics. 

Condition 

Code 

Procedure 

Contaminated, for example, fluid 
that leaked from caliper, wheel 
cylinder, or axle seal 

Require replacement. See note below 

NOTE: Identify and repair cause of contamination prior to replacing friction material. 

Cracked through 

Require replacement. 

Flaking or chunking 

Require replacement. 

Glazed (shiny) 

No service suggested or required. 

Grooves or ridges 

No service suggested or required. See note 

below. 

NOTE: When reconditioning or replacing drums or rotors, replacement of friction 
material may be suggested depending on the severity of the grooves or ridges. 

Permanently attached hardware 
bent 

Require replacement. 

Permanently attached hardware 
broken 

Require replacement. 

Permanently attached hardware 
loose 

Require replacement. 

Permanently attached hardware 
missing 

Require replacement. 

Permanently attached hardware 
seized 

Require repair or replacement. 

Rivets loose 

Require replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

 

 

 

 

 

 

 

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