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1、Electro-mechanical Power Steering Design and Function Self-Study Program Course Number 892403 Volkswagen of America, Inc. Service Training Printed in U.S.A. Printed 12/04 Course Number 892403 2004 Volkswagen of America, Inc. All rights reserved. Information contained in this manual is based on the l
2、atest information available at the time of printing and is subject to the copyright and other intellectual property rights of Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be r
3、eproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed written permission of the publisher. All requests for permissi
4、on to copy and redistribute information should be referred to Volkswagen of America, Inc. Always check Technical Bulletins and the latest electronic service repair information that may supersede any information included in this booklet. Trademarks: All brand names and product names used in this manu
5、al are trade names, service marks, trademarks, or registered trademarks; and are the property of their respective owners. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Electro-mechanical Power Steering with Dual Pinion, Electro-mechanical Po
6、wer Steering Components System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 System Overview Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control Map Characteristics, The Steering Function, Strai
7、ght-Line Stability Steering Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 The Steering Gear Steering Electrics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering Angle Sensor G85, Steering Torque Sensor G269, Rotor Spee
8、d Sender, Road Speed, Engine Speed (RPM) Sensor G28, Electro-mechanical Power Steering Motor V187 , Power Steering Control Module J500, Electro-mechanical Power Steering Indicator Lamp K161, Special Features Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9、 . 24 Functional Diagram Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Diagnosis Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Table of Contents Page i New! Important/Note! The Self-Study Progr
10、am provides you with information regarding designs and functions. The Self-Study Program is not a Repair Manual! For maintenance and repair work, always refer to the current technical literature. ii 1 Introduction Steering Wheel Steering Column Universal Joint Shaft Steering Gear Electro-mechanical
11、Power Steering Motor V187 Steering Torque Sensor G269 Power Steering Control Module J500 Electro-mechanical Power Steering with Dual Pinion The steering system components are: Steering wheel Steering Angle Sensor G85 Steering column Steering Torque Sensor G269 Steering gear Electro-mechanical Power
12、Steering Motor V187 Power Steering Control Module J500 Introduction 2 What You Should Know About the Electro-mechanical Power Steering System: With electro-mechanical power steering, there is no requirement for hydraulic assistance to support the steering. Eliminating hydraulic oil from the steering
13、 system helps to protect the environment. The electro-mechanical power steering system is a dual pinion type. This is characterized by two pinions (steering and drive pinions), which enable the necessary steering force to be transmitted to the steering rack. To assist the steering, an electric motor
14、 is actuated based on input response. The system provides the driver with assistance depending on the driving conditions (servotronic). The electro-mechanical power steering supports return of the steering wheel back to the center position via the “active return” function. This results in a well-bal
15、anced feeling and extremely accurate straight-line stability in every driving situation. With the straight-line stability function, a force is generated and applied to make it easier for the driver to steer the vehicle in a straight line when the vehicle is being affected constantly by side winds or
16、 driven up or down hills. 3 Introduction The Advantages of Electro-mechanical Power Steering The electro-mechanical power steering system offers the following advantages over a traditional hydraulic system: no hydraulic components, for example power steering oil pump, hoses, oil tank, filter no hydraulic fluid space savings reduction in noise energy savings no complex hose and wiring system The electric motor and control module are located directly on the steering gea
