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 

1 

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 

B 

Require replacement. 

See note below. 

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

Hard-spotted 

2 

Suggest 

reconditioning or 

replacement. 

Measured diameter is greater than OEM discard 
specifications 

B 

Require replacement. 

Out-of-round (runout), affecting performance 

A 

Require 

reconditioning or 

replacement. 

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

B 

Require 

reconditioning or 

replacement. 

Scored 

B 

Require 

reconditioning or 

replacement. 

Surface threaded due to improper machining 

B 

Require 

reconditioning or 

replacement. 

Tapered, affecting performance 

A 

Require 

reconditioning or 

replacement. 

Condition 

Code 

Procedure 

Attaching hardware broken 

A 

Require repair or replacement of 

hardware. 

Attaching hardware missing 

C 

Require replacement of hardware. 

Attaching hardware not functioning 

A 

Require repair or replacement of 

hardware. 

Connector broken 

A 

Require repair or replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

ELECTRONIC CONTROLLERS 

Electronic Controllers 

Connector (Weatherpack type) leaking 

A 

Require repair or replacement. 

Connector melted 

A 

Require repair or replacement. See note 

below. 

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

Connector missing 

C 

Require replacement. 

Contaminated 

A 

Require replacement. 

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

Inoperative 

A 

Require repair or replacement. See note 

below. 

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

Leaking externally 

A 

Require repair or replacement. 

Leaking internally 

A 

Require repair or replacement. 

Noisy 

2 

Suggest repair or replacement. 

Terminal broken 

A 

Require repair or replacement. 

Terminal burned, affecting performance 

A 

Require repair or replacement. See note 

below. 

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

Terminal burned, not affecting 
performance 

2 

Suggest repair or replacement. 

Terminal corroded, affecting 
performance 

A 

Require repair or replacement. 

Terminal corroded, not affecting 
performance 

2 

Suggest repair or replacement. 

Terminal loose, affecting performance 

B 

Require repair or replacement. 

Terminal loose, not affecting 
performance 

1 

Suggest repair or replacement. 

Threads damaged 

A 

Require repair or replacement. 

Threads stripped (threads missing) 

A 

Require replacement. 

Wire lead conductors exposed 

B 

Require repair or replacement. 

Wire lead corroded 

A 

Require repair or replacement. 

Wire lead open 

A 

Require repair or replacement. 

Wire lead shorted 

A 

Require repair or replacement. 

Condition 

Code 

Procedure 

Application incorrect 

B 

Require replacement. 

Attaching hardware missing 

C 

Require replacement of hardware. 

Attaching hardware threads 

A 

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) 

A 

Require repair or replacement of hardware. 

Code set (if applicable) 

A 

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 

A 

Require repair or replacement. 

Connector melted 

A 

Require repair or replacement. See note 

below. 

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

Connector missing 

A 

Require repair. 

Contaminated 

A 

Require repair or replacement. 

Inoperative 

B 

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 

A 

Require repair or replacement. 

Missing 

C 

Require replacement. 

Terminal broken 

A 

Require repair or replacement. 

Terminal burned, affecting 
performance 

A 

Require repair or replacement. See note 

below. 

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

Terminal burned, not affecting 
performance 

2 

Suggest repair or replacement. 

Terminal corroded, affecting 
performance 

A 

Require repair or replacement. 

Terminal corroded, not affecting 
performance 

2 

Suggest repair or replacement. 

Terminal loose, affecting 
performance 

B 

Require repair or replacement. 

Terminal loose, not affecting 
performance 

1 

Suggest repair or replacement. 

Threads damaged 

A 

Require repair or replacement. 

Threads stripped (threads missing) 

A 

Require replacement. 

Wire lead conductors exposed 

B 

Require repair or replacement. 

Wire lead corroded 

A 

Require repair or replacement. 

Wire lead open 

A 

Require repair or replacement. 

Wire lead shorted 

A 

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 

A 

Require replacement. See note below 

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

Cracked through 

B 

Require replacement. 

Flaking or chunking 

B 

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 

A 

Require replacement. 

Permanently attached hardware 
broken 

A 

Require replacement. 

Permanently attached hardware 
loose 

A 

Require replacement. 

Permanently attached hardware 
missing 

C 

Require replacement. 

Permanently attached hardware 
seized 

A 

Require repair or replacement. 

Rivets loose 

B 

Require replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

 

 

 

 

 

 

 

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