Volkswagen New Beetle. Manual - part 87

 

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Volkswagen New Beetle. Manual - part 87

 

 

LATERAL ACCELERATION SWITCHES 

See Accelerometers.  

LEDS 

See Bulbs and LEDs.  

LENSES 

Lenses 

MASTER CYLINDERS 

Master Cylinders 

Condition 

Code 

Procedure 

Application incorrect 

Require replacement. 

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. 

Broken, affecting performance 

Require replacement. 

Broke n, not affecting performance 

No service suggested or required. 

Cracked 

Require replacement. 

Discolored 

Require replacement. 

Leaking 

Require repair or replacement. 

Melted, affecting performance 

Require replacement. 

Melted, not affecting performance 

Suggest replacement. 

Missing 

Require replacement. 

Condition 

Code 

Procedure 

Brake fluid leaking from rear of master 
cylinder bore 

Require repair or replacement.. 

Brake pedal drops intermittently 

Require repair or replacement. See 

note below. 

NOTE: This condition may be normal on some vehicles equipped with anti-lock brakes. 

Fluid level low 

Further inspection required. See note 

below. 

NOTE: Refer to OEM procedures for adjusting low fluid level. Inspect for brake 
hydraulic system leaks and friction material wear. 

Internal valve failure 

Require repair or replacement. 

Master cylinder leaking brake fluid 
internally 

Require repair or replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

MODULATORS 

See Hydraulic Modulators.  

MOTORS 

See Electrical Pumps and Motors.  

PARKING BRAKE SWITCHES 

See Switches.  

PARKING BRAKE SYSTEMS 

Parking Brake Systems 

Piston does not return 

Require repair or replacement. 

Ports plugged 

Require repair or replacement. 

Rubber master cylinder cover gasket 
distorted and gummy 

Require replacement of the gasket. 

See note below. 

NOTE: This condition may indicate contaminated brake fluid. See Brake Fluid. 

NOTE:

The parking brake is an integral part of the brake system. It is important that the 
parking brake function properly when brake service is performed. 

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. 

Cable improperly adjusted 

Require cable adjustment. 

Cable or individual wires in the cable are broken  A 

Require replacement of cable 

assembly. 

Cable sticking 

Require cable lubrication. 

Cable stuck inside conduit and cannot be 
lubricated so that parking brake functions 
properly 

Require replacement of cable 

assembly. 

Inoperative 

Require replacement of 

inoperative parts. See note 

below. 

NOTE: Inoperative includes intermittent operation. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

PADS 

See Friction Material.  

PEDAL TRAVEL SWITCHES 

See Switches.  

PEDALS 

See Brake Pedals.  

POWERMASTER 

See Hydro-Boosters.  

PUMPS 

See Electrical Pumps and Motors.  

PRESSURE DIFFERENTIAL SWITCHES 

See Switches.  

PRESSURE SWITCHES 

See Switches.  

RELAYS 

Relays 

Parking brake parts bent 

Require repair or replacement of 

bent parts. 

Parking brake parts broken 

Require replacement of broken 

parts. 

Parking brake parts missing 

Require replacement of missing 

parts. 

Threads damaged 

Require repair or replacement. 

Threads stripped (threads missing) 

Require replacement. 

Condition 

Code 

Procedure 

Attaching hardware broken 

Require repair or replacement of 

hardware. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

ROTORS 

Determine the need to recondition based upon individual rotor conditions that follow. Friction material 
replacement does not require rotor reconditioning unless other justifications exist. Do not recondition new 
rotors unless they are being pressed or bolted onto an existing hub. It is not necessary to replace rotors in axle 
sets. However, when replacing or reconditioning a rotor due to the conditions that follow, you may suggest 
reconditioning of the other rotor on the same axle to eliminate uneven braking behavior.  

Determine the need to replace based upon the individual rotor conditions that follow. Reconditioning is defined 
as machining and block sanding, or block sanding only. Block sanding is defined as using 120-150 grit 
sandpaper with moderate to heavy force for 60 seconds per side. Always wash rotors after servicing or before 
installing.  

Rotors 

Attaching hardware missing 

Require replacement of hardware. 

Attaching hardware not functioning 

Require repair or replacement of 

hardware. 

Housing broken 

Require replacement. 

Housing cracked 

Suggest replacement. 

Inoperative 

Require replacement. See note below. 

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

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. 

Condition 

Code 

Procedure 

Corrosion affecting structural integrity 

Require replacement. See note 

below. 

NOTE: Examples of severe corrosion are: composite plate separated from friction 
surfaces and cooling fins cracked or missing. 

Cracked 

Require replacement. 

 

1998 Chevrolet Pickup C1500 

Uniform Inspection and Communication Standards BRAKE SYSTEMS

  

 

 

 

 

 

 

 

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