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Electro-mechanicalPowerSteeringDesignandFunctionSelf-StudyProgramCourseNumber892403VolkswagenofAmerica,Inc.ServiceTrainingPrintedinU.S.A.Printed12/04CourseNumber892403?2004VolkswagenofAmerica,Inc.Allrightsreserved.InformationcontainedinthismanualisbasedonthelatestinformationavailableatthetimeofprintingandissubjecttothecopyrightandotherintellectualpropertyrightsofVolkswagenofAmerica,Inc.,itsaffiliatedcompaniesanditslicensors.Allrightsarereservedtomakechangesatanytimewithoutnotice.Nopartofthisdocumentmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans,electronic,mechanical,photocopying,recordingorotherwise,normaythesematerialsbemodifiedorrepostedtoothersiteswithoutthepriorexpressedwrittenpermissionofthepublisher.AllrequestsforpermissiontocopyandredistributeinformationshouldbereferredtoVolkswagenofAmerica,Inc.AlwayscheckTechnicalBulletinsandthelatestelectronicservicerepairinformationthatmaysupersedeanyinformationincludedinthisbooklet.Trademarks:Allbrandnamesandproductnamesusedinthismanualaretradenames,servicemarks,trademarks,orregisteredtrademarks;andarethepropertyoftheirrespectiveowners.TableofContentsPageIntroduction.............................................1Electro-mechanicalPowerSteeringwithDualPinion,Electro-mechanicalPowerSteeringComponentsSystemOverview.........................................5SystemOverviewFunction...............................................6ControlMapCharacteristics,TheSteeringFunction,Straight-LineStabilitySteeringMechanics......................................13TheSteeringGearSteeringElectrics.......................................14SteeringAngleSensorG85,SteeringTorqueSensorG269,RotorSpeedSender,RoadSpeed,EngineSpeed(RPM)SensorG28,Electro-mechanicalPowerSteeringMotorV187,PowerSteeringControlModuleJ500,Electro-mechanicalPowerSteeringIndicatorLampK161,SpecialFeaturesFunctionalDiagram......................................24FunctionalDiagramService................................................25DiagnosisKnowledgeAssessment..................................27TheSelf-StudyProgramprovidesyouwithinformationregardingdesignsandfunctions.TheSelf-StudyProgramisnotaRepairManual!Formaintenanceandrepairwork,alwaysrefertothecurrenttechnicalliterature.iiiIntroduction1IntroductionIntroductionTheAdvantagesofElectro-mechanicalPowerSteeringTheelectro-mechanicalpowersteeringsystemoffersthefollowingadvantagesoveratraditionalhydraulicsystem:?nohydrauliccomponents,forexamplepowersteeringoilpump,hoses,oiltank,filter?nohydraulicfluid?spacesavings?reductioninnoise?energysavings?nocomplexhoseandwiringsystemTheelectricmotorandcontrolmodulearelocateddirectlyonthesteeringgear.Thisresultsinanotableenergysavings.Unlikehydraulicallyassistedsteering,whichrequiresapermanentcircuitflow,theelectro-mechanicalpowersteeringonlydrawsenergywhensteeringforceisnecessary.Thisinputresponseperformanceleadstoareductioninfuelconsumption.Thedriverhasanoptimaldrivingfeelingineverysituationthanksto:?goodstraight-linestability(returnofthesteeringwheeltothecenterpositionisactivelysupportedbytheelectro-mechanicalpowersteeringsystem)?directbutsoftapplicationofthesteeringinput?nouncomfortablesteeringreactionsoverunevendrivingsurfacesThefuelconsumptionsavingsover620miles(1000km)isapproximately0.5gallons(2.0liters).3IntroductionElectro-mechanicalPowerSteeringComponents4Sys...