Electro Mechanical Power Steering 1bb

34
Electro-mechanical Power Steering Design and Function Self-Study Program Course Number 892403

Transcript of Electro Mechanical Power Steering 1bb

Page 1: Electro Mechanical Power Steering 1bb

Electro-mechanical Power Steering

Design and Function

Self-Study Program

Course Number 892403

Page 2: Electro Mechanical Power Steering 1bb

Volkswagen of America, Inc.Service TrainingPrinted in U.S.A.Printed 12/04Course Number 892403

©2004 Volkswagen of America, Inc.

All rights reserved. Information containedin this manual is based on the latest 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 anytime without notice. No part of this documentmay be reproduced, stored in a retrievalsystem, or transmitted in any form or by anymeans, electronic, mechanical, photocopying,recording or otherwise, nor may these materials be modified or reposted to other sites without the prior expressed writtenpermission of the publisher.

All requests for permission 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 manual are trade names, service marks, trademarks, or registered trademarks; and are the property of their respective owners.

Page 3: Electro Mechanical Power Steering 1bb

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Electro-mechanical Power Steering with Dual Pinion,Electro-mechanical Power Steering Components

System Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

System Overview

Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Control Map Characteristics, The Steering Function, Straight-LineStability

Steering Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

The Steering Gear

Steering Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Steering Angle Sensor G85, Steering Torque Sensor G269, RotorSpeed Sender, Road Speed, Engine Speed (RPM) Sensor G28,Electro-mechanical Power Steering Motor V187, Power SteeringControl Module J500, Electro-mechanical Power Steering IndicatorLamp K161, Special Features

Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Functional Diagram

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Diagnosis

Knowledge Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table of Contents

Page

i

New!

Important/Note!

The Self-Study Program provides you with informationregarding designs and functions.

The Self-Study Program is not a Repair Manual!

For maintenance and repair work, always refer to thecurrent technical literature.

Page 4: Electro Mechanical Power Steering 1bb

ii

Page 5: Electro Mechanical Power Steering 1bb

1

Introduction

Steering Wheel

Steering Column

Universal Joint ShaftSteering Gear

Electro-mechanical PowerSteering Motor V187

Steering TorqueSensor G269

Power SteeringControl 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 SteeringMotor V187

• Power Steering Control Module J500

Page 6: Electro Mechanical Power Steering 1bb

Introduction

2

What You Should Know About theElectro-mechanical Power SteeringSystem:

With electro-mechanical power steering,there is no requirement for hydraulicassistance to support the steering.Eliminating hydraulic oil from the steeringsystem helps to protect the environment.

The electro-mechanical power steeringsystem is a dual pinion type. This ischaracterized by two pinions (steering anddrive pinions), which enable the necessarysteering force to be transmitted to thesteering rack.

To assist the steering, an electric motor isactuated based on input response. Thesystem provides the driver with assistancedepending on the driving conditions(servotronic).

The electro-mechanical power steeringsupports return of the steering wheel backto the center position via the “active return”function. This results in a well-balancedfeeling and extremely accurate straight-linestability in every driving situation.

With the straight-line stability function, aforce is generated and applied to make iteasier for the driver to steer the vehicle ina straight line when the vehicle is beingaffected constantly by side winds or drivenup or down hills.

Page 7: Electro Mechanical Power Steering 1bb

3

Introduction

The Advantages of Electro-mechanicalPower Steering

The electro-mechanical power steeringsystem offers the following advantages overa traditional hydraulic system:

• no hydraulic components, for examplepower steering oil pump, hoses, oiltank, filter

• no hydraulic fluid

• space savings

• reduction in noise

• energy savings

• no complex hose and wiring system

The electric motor and control module arelocated directly on the steering gear.

This results in a notable energy savings.Unlike hydraulically assisted steering, whichrequires a permanent circuit flow, theelectro-mechanical power steering onlydraws energy when steering force isnecessary. This input response performanceleads to a reduction in fuel consumption.

The driver has an optimal driving feeling inevery situation thanks to:

• good straight-line stability (return of thesteering wheel to the center position isactively supported by the electro-mechanical power steering system)

• direct but soft application of the steeringinput

• no uncomfortable steering reactionsover uneven driving surfaces

The fuel consumption savingsover 620 miles (1000 km) isapproximately 0.5 gallons(2.0 liters).

Page 8: Electro Mechanical Power Steering 1bb

Introduction

4

Electro-mechanical Power Steering

Components

Steering Pinion

Steering TorqueSensor G269

Power SteeringControl Module J500

Electro-mechanical PowerSteering Motor V187

Worm GearDrive Pinion

Page 9: Electro Mechanical Power Steering 1bb

5

System Overview

System Overview

Engine Speed (RPM)Sensor G28

ABS ControlModule J104

Left Rear ABS WheelSpeed Sensor G46

Left Front ABS WheelSpeed Sensor G47

Data Bus On BoardDiagnostic Interface J533

Instrument ClusterControl Module J285

Terminal 15

Electro-mechanical Power SteeringIndicator Lamp K161

Power Steering Control Module J500

Engine Control Module (ECM)

Steering Column Electronic SystemsControl Module J527

Steering AngleSensor G85

Steering Torque Sensor G269

Drivetrain CANData Bus

Electro-mechanical PowerSteering Motor V187

Right Rear ABS WheelSpeed Sensor G44

Right Front ABS WheelSpeed Sensor G45

Page 10: Electro Mechanical Power Steering 1bb

6

Control Map Characteristics

Steering assistance is controlled via a map,which is stored permanently in the programmemory of Power Steering Control ModuleJ500. The memory has a capacity for up to16 different maps. Maps are activated in thefactory depending on requirements (e.g.vehicle weight).

However, maps can also be activated withthe scan tool if the Power Steering ControlModule J500 or steering system were to beserviced or replaced.

Function

V=0 mph(0 km/h)

V=10 mph(15 km/h)

V=31 mph(50 km/h)

V=62 mph(100 km/h)

V=155 mph(250 km/h)

Steering Force lbs-ft (Nm)

Ass

istin

g Fo

rce

lbs-

ft (N

m)

Heavy VehicleLight Vehicle

For any given vehicle, both a heavy and a light map are selected. Each map has five differentcharacteristics that are calculated using vehicle speed. These maps determine the amountof steering assistance available to the driver.

4 (2.95)

3 (2.21)

2 (1.47)

1 (0.74)

00 2 (1.48) 4 (2.95) 6 (4.43) 8 (5.90)

Page 11: Electro Mechanical Power Steering 1bb

7

1. The power steering assistance startswhen the driver uses force to turn thesteering wheel.

2. The force on the steering wheel causesa torsion bar in the steering gear to turn.The Steering Torque Sensor G269detects the rotation and sends thecalculated steering force figure to thePower Steering Control Module J500.

3. The Steering Angle Sensor G85 reportsthe current steering angle and steeringspeed.

4. Depending on the steering force, roadspeed, engine speed, steering angle,steering speed and maps stored inPower Steering Control Module J500, itcalculates the necessary assisting forceand actuates Electro-mechanical PowerSteering Motor V187.

The Steering Function

Function

5. The steering assistance comes from asecond pinion, which applies its energyin parallel on the steering rack. Thispinion is driven by Electro-mechanicalPower Steering Motor V187. The motorengages in the steering rack via a wormgear and drive pinion, which transmitsthe force required for steeringassistance.

6. The sum of the turning force on thesteering wheel and the assisting forceis the effective force applied on thesteering gear to move the rack.

Turning Force at Steering Wheel

Assisting Force

Effective Force

Page 12: Electro Mechanical Power Steering 1bb

8

The Steering Function for ParkingManeuvers

5. In this way, the largest amount ofsteering assistance is applied on thesteering rack via the second pinion forparking maneuvers.

6. The sum of the turning force on thesteering wheel and the maximumassisting force is the effective forceapplied on the steering gear formovement of the rack during parkingmaneuvers.

Function

1. When parking the vehicle, the driverturns the steering wheel rapidly.

2. The torsion bar is turned. The SteeringTorque Sensor G269 picks up therotation and sends a signal to the PowerSteering Control Module J500,indicating that a large amount of forcehas been placed on the steering wheel.

3. The Steering Angle Sensor G85 reportsthe current steering angle and steeringspeed.

4. Based on the large amount of steeringforce, the road speed of 0 mph(0 km/h), the engine speed, the largesteering angle, the steering speed andthe maps stored in it for V=0 mph(0 km/h), Power Steering ControlModule J500 detects that a largeamount of assisting force is requiredand actuates Electro-mechanical PowerSteering Motor V187.

Turning Force at Steering Wheel

Assisting Force

Effective Force

V=0 mph(0 km/h)

Page 13: Electro Mechanical Power Steering 1bb

9

1. When cornering in urban areas, thedriver uses force to turn the steeringwheel.

2. The torsion bar is turned. The SteeringTorque Sensor G269 picks up therotation and sends a signal to the PowerSteering Control Module J500,indicating that a medium amount offorce has been placed on the steeringwheel.

3. The Steering Angle Sensor G85 reportsthe current steering angle and steeringspeed.

The Steering Function in Urban Areas

Function

4. Based on the medium amount ofsteering force, the road speed of31 mph (50 km/h), the engine speed,the medium steering angle, thesteering speed and the maps stored init for V=31 mph (50 km/h), PowerSteering Control Module J500 detectsthat a medium amount of assistingforce is required and actuates Electro-mechanical Power Steering Motor V187.

5. In this way, a medium amount ofsteering assistance is applied on thesteering rack via the second pinionduring cornering.

6. The sum of the turning force on thesteering wheel and the mediumassisting force is the effective forceapplied on the steering gear formovement of the rack during corneringin urban areas.

Turning Force at Steering Wheel

Assisting Force

Effective Force

V=31 mph(50 km/h)

Page 14: Electro Mechanical Power Steering 1bb

10

The Steering Function on Highways

4. Based on the small amount of steeringforce, the road speed of 62 mph(100 km/h), the engine speed, the smallsteering angle, the steering speed andthe maps stored in Power SteeringControl Module J500 for V=62 mph (100km/h), it detects that a small amount ofassisting force is required and actuatesElectro-mechanical Power SteeringMotor V187.

5. In this way, a small amount of steeringassistance is applied on the steeringrack via the second pinion during lanechange maneuvers on the highway, orno assistance at all.

6. The sum of the turning force on thesteering wheel and the minimumassisting force is the effective forceapplied on the steering gear to movethe steering rack during lane changingmaneuvers.

Function

1. To change lanes, the driver imparts lightforce on the steering wheel.

2. The torsion bar is turned. The SteeringTorque Sensor G269 picks up therotation and sends a signal to the PowerSteering Control Module J500,indicating that a small amount of forcehas been placed on the steering wheel.

3. The Steering Angle Sensor G85 reportsthe current steering angle and steeringspeed.

Turning Force at Steering Wheel

Assisting Force

Effective Force

V=62 mph(100 km/h)

Page 15: Electro Mechanical Power Steering 1bb

11

1. If the driver reduces the force on thesteering wheel during cornering, torsionbar tension is relieved.

2. In conjunction with the reduced steeringforce, inclusion of the steering angleand the steering speed, a return speedspecification is calculated. This iscompared with the steering anglespeed. The result of this is the returningforce required.

3. Return forces are applied on thesteering wheels as a result of therunning gear layout. The return forcesare often too weak, due to friction in thesteering system and in the axle(suspension), to bring the wheels backto the center position.

The Active Return Function

Function

4. Power Steering Control Module J500calculates the necessary return forcerequired from Electro-mechanical PowerSteering Motor V187 by evaluating thesteering force, road speed, enginespeed, steering angle, steering speedand the map characteristics stored inPower Steering Control Module J500.

5. Electro-mechanical Power SteeringMotor V187 is actuated and the wheelsare returned to the straight-aheadposition.

Return Force

Assisting Force

Effective Force

Page 16: Electro Mechanical Power Steering 1bb

12

Straight-Line Stability

Straight-line stability is an extension of theactive return function. An assisting force isgenerated to bring the wheels of the vehiclein the center position, when no force isapplied. To do this, a difference is madebetween a short period algorithm and a longperiod algorithm.

Long Period Algorithm

The long period algorithm has the task ofbalancing deviations either side of the centerposition that occur over a long period oftime. For example, deviations that could becaused when summer tires are changed forwinter tires (used or with different diameter).

1. A constant side force is applied on thevehicle, e.g. side wind.

2. The driver applies force on the steeringwheel to keep the vehicle in a straightline.

3. Power Steering Control Module J500calculates the necessary force requiredfrom Electro-mechanical Power SteeringMotor V187 to maintain the straightahead position by evaluating thesteering force, road speed, enginespeed, steering angle, steering speedand the map characteristics stored inPower Steering Control Module J500.

4. Electro-mechanical Power SteeringMotor V187 is actuated. The vehicle isbrought into the straight-ahead position.The driver no longer has to steer againstthe resistance.

Function

Return Forces

Assisting Force

Effective Force

Short Period Algorithm

The short period algorithm is responsible forcorrecting deviations that occur briefly. Thismakes driving easier for the driver when, forexample, permanent side winds make itnecessary to steer against a resistance.

Page 17: Electro Mechanical Power Steering 1bb

13

Electro-mechanical Power Steering MotorV187, Power Steering Control Module J500and steering assistance sensors can befound on the second pinion. This designmeans that there is a mechanical connectionbetween the steering wheel and steeringrack. In this way, the vehicle can still besteered mechanically in the event of failureof Electro-mechanical Power Steering MotorV187.

The Steering Gear

The steering gear consists of SteeringTorque Sensor G269, a torsion bar, asteering and drive pinion, a worm gear,Electro-mechanical Power Steering MotorV187, and Power Steering Control ModuleJ500. The core of the electro-mechanicalpower steering is a steering rack with twoteeth engaged in the steering gear.

On the electro-mechanical power steeringwith dual pinion, the steering force requiredis transferred via the steering pinion and thedrive pinion to the steering rack. The steeringpinion transfers the steering force applied bythe driver and the drive pinion transfers theassisting force from Electro-mechanicalPower Steering Motor V187 via a worm gear.

Steering Mechanics

Steering Torque Sensor G269

Power Steering Control Module J500 Electro-mechanical PowerSteering Motor V187

Drive PinionSteering Rack

Steering Angle Sensor G85

Steering Column

Steering Pinion

Page 18: Electro Mechanical Power Steering 1bb

14

Steering Angle Sensor G85

Steering Electrics

Airbag Spiral Spring/Return SpringWith Slip Ring F138

Steering Angle Sensor G85

Steering Column ElectronicSystems Control Module J527

The Steering Angle Sensor G85 can befound behind Airbag Spiral Spring/ReturnSpring With Slip Ring F138. It is located onthe steering column between the steeringcolumn switch and the steering wheel.

It sends the signal for steering angle analysisto Steering Column Electronic SystemsControl Module J527 via the CAN data bus.The electronic system for analysis of thesignals is located in Steering ColumnElectronic Systems Control Module J527.

Effects of Failure

In the event of signal failure, an emergencyrunning mode is started. The missing signalis replaced by a substitute figure. Powersteering assistance remains intact. Electro-mechanical Power Steering Indicator LampK161 will light up to indicate the fault.

Page 19: Electro Mechanical Power Steering 1bb

15

Principles of Operation

Basic components of Steering Angle SensorG85 are:

• Absolute and increment ring with twocodes

• Photoelectric beam pairs, each with oneLight-Emitting Diode (LED) and oneoptical sensor.

The code plate consists of two rings, anouter absolute ring and an inner incrementring.

The increment ring is separated into fivesegments, each is 72°, and is read by aphotoelectric beam pair. Within eachsegment the ring is split. The gap of the splitis equal within the segments but differentbetween the segments. This provides thecode for the segments.

The absolute ring determines the angle. It isread by six photoelectric beam pairs.

Steering Angle Sensor G85 can detect asteering angle of up to 1044°. It accumulatesthe degrees after each turn of the steeringwheel. In this way, it can detect that a fullsteering circle is complete when the 360°mark is exceeded.

The design of the steering gear allows 2.76turns of the steering wheel.

Steering Electrics

Increment Ring

Steering Angle Sensor G85

Absolute Ring

Increment Ring

Steering Angle Sensor G85

Absolute Ring

Segment 3

Segment 4

Segment 5

Segment 2

Segment 1

72º

Page 20: Electro Mechanical Power Steering 1bb

16

Angle measurement is by means of thephotoelectric beam principle.

If, for purposes of simplification, theincrement ring is used as an example, thelight source is on one side of the segmentring and the optical sensor is on the other.

When light shines through a gap onto asensor, signal voltage is generated. Whenthe light source is covered, voltage isinterrupted.

If the increment ring is moved, a sequenceof signal voltages is given.

This is precisely how the sequence of signalvoltages occurs on each photoelectric beampair of the absolute ring. All signal voltagesequences are processed by the SteeringColumn Electronic Systems Control ModuleJ527.

By comparing the signals, the system cancalculate how far the rings have beenmoved. This is how the starting point formovement of the absolute ring isdetermined.

Steering Electrics

Page 21: Electro Mechanical Power Steering 1bb

17

The steering force is calculated directly atthe steering pinion with help from theSteering Torque Sensor G269. The sensorworks on the principle of magneticresistance. It is a twin (redundant) sensor,which assures a high level of safety.

The steering column and steering gear arejoined together at Steering Torque SensorG269 via a torsion bar. The connecting pieceat the steering column features a magneticrotor, which turns about 24 areas of differentmagnetic polarity. For current evaluation, twoterminals are used.

Steering Electrics

Steering Torque Sensor G269

The counterpart is a magnetic resistorsensor element, which is attached to thesteering gear connecting piece.

If the steering wheel is turned, bothconnecting pieces move against each other,depending on the amount of force that isapplied. The magnetic rotor also movesagainst the sensor element during thisperiod, which means that the steering forcecan be measured and sent to PowerSteering Control Module J500 as a signal.

Effects of Failure

The Steering Torque Sensor G269 isintegrated into the steering gear assemblyand cannot be replaced separately.

If a fault is detected, the power steeringassistance is shut down. This shut down is asoft and gradual process, rather thansudden. To achieve a soft and gradualshutdown, a substitute steering force signalis calculated in Power Steering ControlModule J500 using the steering and rotorangle of Electro-mechanical Power SteeringMotor V187. Faults are indicated by theElectro-mechanical Power Steering IndicatorLamp K161.

Steering ColumnConnecting Piece

Torsion Bar

MagneticRotor

Redundant, MagneticResistor SensorElement

Steering GearConnecting Piece

Page 22: Electro Mechanical Power Steering 1bb

18

Rotor Speed Sender

The rotor speed sender is integral to Electro-mechanical Power Steering Motor V187, andcannot be replaced separately.

Signal Application

The rotor speed sender operates on theprinciple of magnetic resistance and issimilar in design to the Steering TorqueSensor G269. It registers the rotor speed ofthe Electro-mechanical Power SteeringMotor V187. This speed signal is necessaryfor precise motor actuation.

Effects of Failure

In the event of failure of the sensor, thesteering angle speed is used as a substitutefigure. To avoid a sudden loss, powersteering assistance is shut down gradually.Faults are indicated by Electro-mechanicalPower Steering Indicator Lamp K161 lightingup red.

Road Speed

The signal for the road speed is supplied byABS Control Module J104.

Effects of Failure

In the event of failure of the road speedsignal, an emergency running program isstarted. The driver has full power steeringassistance but there is no servotronicvariable assistance function. The fault isshown by Electro-mechanical PowerSteering Indicator Lamp K161 lighting upyellow.

Steering Electrics

Page 23: Electro Mechanical Power Steering 1bb

19

Engine Speed (RPM) Sensor G28

The Engine Speed (RPM) Sensor G28 is aHall sender. It is attached inside thecrankshaft sealing flange housing.

Signal Application

The Engine Speed (RPM) Sensor G28 signalprovides the speed of the engine and theexact position of the crankshaft to theengine control module.

Effects of Failure

In the event of Engine Speed (RPM) SensorG28 failure, the steering is actuated viaterminal 15. The fault is not shown byElectro-mechanical Power Steering IndicatorLamp K161.

Steering Electrics

Page 24: Electro Mechanical Power Steering 1bb

20

Electro-mechanical Power Steering MotorV187 is a brushless asynchronous motor. Itdevelops a maximum torque of 3.02 lbs-ft(4.1 Nm) to assist the steering.

Asynchronous motors do not feature apermanent magnetic field or an electricalexciter. Asynchronous motors get their namefrom the difference between the frequencyof the voltage applied and the rotationalfrequency of the motor. Both frequenciesare different, hence the term asynchronous.

Asynchronous motors are simple inconstruction (without brushes) and have ahigh level of operational efficiency.

They feature a short response time and aresuitable for quick steering wheelmovements.

Electro-mechanical Power Steering MotorV187 is installed in an aluminum housing. Itengages in the steering rack via a worm gearand drive pinion and transmits the forcerequired for steering assistance.

A magnet on the control end of the shaft isused by Power Steering Control ModuleJ500 to detect the rotor speed. The signal isused to determine the steering speed.

Effects of Failure

An advantage of the asynchronous motor isthat the motor can be moved by the steeringgear even when no voltage is available.

This means that, in the event of failure ofElectro-mechanical Power Steering MotorV187 and loss of power steering assistance,the steering can still be operated by applyinga slightly greater amount of force. Even inthe event of a short circuit, Electro-mechanical Power Steering Motor V187 willnot freeze. Faults are indicated by Electro-mechanical Power Steering Indicator LampK161 lighting up red.

Steering Electrics

Electro-mechanical Power Steering

Motor V187

Page 25: Electro Mechanical Power Steering 1bb

21

Effects of Failure

A temperature sensor is integrated intoPower Steering Control Module J500. Thissensor is used to measure the temperatureof the steering system. If the temperaturerises above 212° F (100° C), power steeringassistance is reduced gradually.

If the power steering capability is below60%, the Electro-mechanical Power SteeringIndicator Lamp K161 will light up yellow andan entry is made in the fault memory.

The Power Steering Control Module J500 isattached directly to Electro-mechanicalPower Steering Motor V187, which meansthat there is no need for complex routing ofwiring to the components of the powersteering servo.

Based on the input signals, such as:

• the steering angle signal from SteeringAngle Sensor G85

• the engine speed from Engine Speed(RPM) Sensor G28

• the steering force

• the rotor speed

• the road speed signal

• the signal that identifies the ignition keyas being correct from Power SteeringControl Module J500 with display inInstrument Cluster Control Module J285

Power Steering Control Module J500calculates the correct level of force requiredto assist the steering. The strength of theexcitor current is calculated and Electro-mechanical Power Steering Motor V187 isactuated.

Steering Electrics

If the steering assembly needs tobe replaced, use applicable repairinformation and the scan tool torestore the correct map for thevehicle.

Power Steering Control Module

J500

Page 26: Electro Mechanical Power Steering 1bb

22

Steering Electrics

Electro-mechanical Power Steering

Indicator Lamp K161

Electro-mechanical Power Steering IndicatorLamp K161 can be found in the displayscreen of the instrument cluster. It servesas a means of displaying malfunctions ordisturbances in the electro-mechanicalpower steering system.

Electro-mechanical Power Steering IndicatorLamp K161 lights up in two colors iffunctional faults are detected. If it lights upyellow, the warning is of a lower priority. If itlights up red, the vehicle should be servicedimmediately. If Electro-mechanical PowerSteering Indicator Lamp K161 lights up red,it will be accompanied at the same time byan acoustic warning signal (threerepetitions).

When the ignition is switched on, Electro-mechanical Power Steering Indicator LampK161 will light up red as part of the self-testprocedure carried out by the electro-mechanical power steering system.

Once Power Steering Control Module J500receives a signal, indicating that all systemsare working correctly, Electro-mechanicalPower Steering Indicator Lamp K161 will goout. This self-test lasts for approximatelytwo seconds. When the engine is started,Electro-mechanical Power Steering IndicatorLamp K161 will go out immediately.

Page 27: Electro Mechanical Power Steering 1bb

23

Special Features

Towing

Power steering assistance is available whilethe vehicle is being towed under thefollowing conditions:

• speed greater than 5 mph (7 km/h) and

• ignition switch on

Discharged Batteries

The steering system can detect and react tolow voltage situations. If battery voltagedrops below 9 volts, power steeringassistance will be reduced until it shutsdown completely and Electro-mechanicalPower Steering Indicator Lamp K161 willlight up red.

In the case of brief voltage drops below9 volts, Electro-mechanical Power SteeringIndicator Lamp K161 will light up yellow.

Steering Electrics

Page 28: Electro Mechanical Power Steering 1bb

24

Functional Diagram

Functional Diagram

Term. 30Term. 15Term. 31

S S

V187

J500

G269

A CAN LowB CAN HighG269 Steering Torque SensorJ500 Power Steering Control ModuleS FuseV187 Electro-mechanical Power Steering Motor

= Input Signal= Output Signal= Positive= Ground= CAN Data Bus

Color Codes/Key

Page 29: Electro Mechanical Power Steering 1bb

25

Diagnosis

The system components of the electro-mechanical power steering system arecapable of self-diagnosis.

Adaptation of Steering End Stops

To avoid the hard mechanical end stops ofthe steering, limitation of the steering angleis carried out by the software. The software-based end stop, i.e. the damping motion, isactivated at approximately 5° steering anglebefore the mechanical end stop.

The assisting force is reduced depending onthe steering angle and steering force. Usingthe scan tool, the steering end stops can bedeleted using the "basic setting" function.

End stop adaptation is carried out withoutthe scan tool, while driving the vehicle.

Service

Page 30: Electro Mechanical Power Steering 1bb

26

Notes

Page 31: Electro Mechanical Power Steering 1bb

27

An on-line Knowledge Assessment (exam) is available for this Self-Study Program.

The Knowledge Assessment may or may not be required for Certification.

You can find this Knowledge Assessment at:

www.vwwebsource.com

From the vwwebsource.com Homepage, do the following:

- Click on the Certification tab

- Type the course number in the Search box

- Click “Go!” and wait until the screen refreshes

- Click “Start” to begin the Assessment

For assistance, please call:

Certification Program Headquarters

1 - 877 - CU4 - CERT

(1 - 877 - 284 - 2378)

(8:00 a.m. to 8:00 p.m. EST)

Or, E-mail:

[email protected]

Knowledge Assessment

Page 32: Electro Mechanical Power Steering 1bb
Page 33: Electro Mechanical Power Steering 1bb
Page 34: Electro Mechanical Power Steering 1bb

Volkswagen of America, Inc.3800 Hamlin RoadAuburn Hills, MI 48326Printed in U.S.A.December 2004