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Self-Study Program Course Number 861403 The new Jetta Steering and Suspension

The new Jetta Steering and Suspension

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Page 1: The new Jetta Steering and Suspension

Self-Study ProgramCourse Number 861403

The new JettaSteering and Suspension

Page 2: The new Jetta Steering and Suspension

Volkswagen of America, Inc.Volkswagen AcademyPrinted in U.S.A.Printed 12/2004Course Number 861403

©2004 Volkswagen of America, Inc.

All rights reserved. All information containedin this manual is based on the latestinformation available at the time of printingand is subject to the copyright and otherintellectual property rights of Volkswagen ofAmerica, Inc., its affiliated companies and itslicensors. All rights are reserved to makechanges at any time without notice. No partof this document may be reproduced,stored in a retrieval system, or transmitted inany form or by any means, electronic,mechanical, photocopying, recording orotherwise, nor may these materials bemodified or reposted to other sites withoutthe prior expressed written permission ofthe publisher.

All requests for permission to copy andredistribute information should be referredto Volkswagen of America, Inc.

Always check Technical Bulletins and the latestelectronic repair information for informationthat may supersede any information includedin this booklet.

Trademarks: All brand names and productnames used in this manual are trade names,service marks, trademarks, or registeredtrademarks; and are the property of theirrespective owners.

Page 3: The new Jetta Steering and Suspension

i

Table of Contents

Important/Note!

New!

This Self-Study Program covers the steering and suspensionsystem of the new Jetta!

This Self-Study Program is not a Repair Manual. Thisinformation will not be updated.

For testing, adjustment and repair procedures, always referto the latest electronic service information.

Introduction ................................................................................1Course Introduction, Steering and Suspension

Front Axle ....................................................................................4Front Axle, Half Shafts

Rear Axle ................................................................................... 10Rear Axle

Steering .....................................................................................13Steering System, Electro-Mechanical Power Steering,Steering Wheels, Steering Column

Brake System ............................................................................19Brake System, Brake Caliper Assemblies, Anti-Lock BrakingSystem ABS/ESP, Brake Pressure Sensor 1 G201, OptimizedHydraulic Brake Servo (OHBS), ESP and CANCommunication, Handbrake

Pedal Assemblies ......................................................................29Pedal Assemblies, Clutch Position Sensor G476, AcceleratorPedal Position Sensors G79 and G185

Service.......................................................................................34Axle Geometry, Special Tools

Page 4: The new Jetta Steering and Suspension
Page 5: The new Jetta Steering and Suspension

1

Introduction

Course Introduction

Volkswagen has set the standard in theautomobile industry for steering andsuspension technology by enhancing thedesign of the new Jetta. Best in classsteering and suspension componentsinclude: optimized front axle strutsuspension, multi-link rear suspension, newelectro-mechanical power steering and thelatest generation of ESP and brake assistsystems. All were developed to provide anunmatched driving experience.

S861403_12

Page 6: The new Jetta Steering and Suspension

2

Introduction

Steering and Suspension

The electro-mechanical power steeringsystem of the new Jetta supports thevehicle's improved driving characteristics bytransmitting a precise steering feel thatvaries the amount of assist with the speedof the vehicle.

• Optimized McPherson strutsuspension axle based on thedesign

• Direct anti-roll bar connectionwith a 1:1 ratio

• Electro-mechanical powersteering

• Dual rate brake servo

• Brake assist system

• Electronic StabilizationProgram (ESP) based onContinental Teves MK 60

The suspension system of the new Jettahas been optimized through the installationof a suspension strut axle and a new four-link rear axle. This redesigned systemprovides unsurpassed driving comfort anddynamics.

Page 7: The new Jetta Steering and Suspension

3

Introduction

• Floor mounted accelerator pedalwith accelerator pedal positionsensors

• Four-link rear suspension

• Tire pressure monitoringsystem

• Track and camber onrear axle can beadjusted separately

• New wheel designs

S861403_03

Page 8: The new Jetta Steering and Suspension

4

Front Axle

Front Axle

The new Jetta is equipped with aMcPherson strut front suspension with adouble wishbone design. This designoptimizes comfort while maintainingstability.

Wheel BearingS321_007

Wishbone Suspension

Suspension StrutAnti-Roll Bar

Subframe

Wheel BearingHousing

CasterAdjustment

CamberBalancing

Toe Adjustment

Page 9: The new Jetta Steering and Suspension

5

Front Axle

Subframe

The subframe includes three aluminumcomponents that are joined to the body atsix points. This design results in a morerugged front suspension. The bondedrubber bushings in the wishbones andsuspension strut mountings enhancedriving dynamics and noise dampeningqualities.

ControlArm

Wheel Bearing Assembly

Compact wheel bearing assemblies consistof a wheel hub and bearing that areattached to the strut pivot from the insidewith four bolts.

This design eliminates the need for bearingadjustments.

S321_020

S321_022

Key:

= Bonding Point to Body

SubframeControlArm

Wheel BearingAssembly

Page 10: The new Jetta Steering and Suspension

6

Front Axle

Suspension Strut

The suspension strut consists of a coilspring and a polyurethane dampener. Thehigh tensile steel coil spring is bent inwardat both ends. The polyurethane dampenerprogressively dampens suspension travel.

Upper Strut Mount

The upper strut mount is a bonded rubberbushing that separates the spring andshock absorber from the body. Thisdampening force is then absorbed by thevehicle chassis. This design eliminatespretension in the dampener mount,resulting in a smoother ride with less roadnoise.

The mount provides soft dampening in thedirection of suspension travel and a morerigid dampening of lateral forces.

Coil Spring

S321_039

S321_041

PolyurethaneDampener

Upper StrutMount

Page 11: The new Jetta Steering and Suspension

7

Front Axle

Swivel Mount

The swivel mount is connected to thesuspension strut by a clamp and attached tothe wishbone by a guide joint.

The wheel bearing assembly is attached toeither a bolted or integrated swivel mount,depending on the suspension design.

S321_043

S321_021

WishboneSuspension

Subframe

SuspensionStrut Swivel Mount

Clamp

BoltedConnections

WheelBearing

BrakeCarrier

BrakeCaliper

GuideJoint

Wishbone Assembly

The wishbone assembly connects thesubframe and the swivel mount.

Bolted Swivel Mount

Page 12: The new Jetta Steering and Suspension

8

Front Axle

Anti-Roll Bar

S321_134

Bonded RubberBushing

BearingMovementAbsorbed

Anti-Roll Bar

The tubular anti-roll bar is connected to thesuspension strut through a coupling rod in a1:1 ratio.

This design increases the degree of anti-rollby using the same bar diameter.

S321_045

CouplingRod

The anti-roll bar is mounted on thesubframe by two bonded rubber bushingsthat prevent movement with the anti-rollbar.

Instead of turning within the rubberbushing, the rotational movements of theanti-roll bar are absorbed by the mounts.

Strut

BondedRubberBushings

Subframe

Anti-Roll Bar

Page 13: The new Jetta Steering and Suspension

9

Front Axle

Half Shafts

The new Jetta uses short and long driveshafts. The shorter shaft on the left-handside is solid, whereas the longer shaft onthe right is of a hollow tubular construction.

On vehicles with higher powered engines,the shafts are the same length. This isachieved by using an intermediate shaftattached to the crankcase. This designeliminates pulling to one side (torque steer)during vehicle acceleration.

Left-HandHalf Shaft

S321_049

S321_048S321_046

IntermediateShaft

Intermediate ShaftRight-HandHalf Shaft

Page 14: The new Jetta Steering and Suspension

10

Rear Axle

Rear Axle

The rear axle suspension of the new Jettais a compact four-link design. Each sideconsists of three suspension links: lowerlink, track rod and upper link, and a trailingarm. This design greatly enhances stabilityand ride.

This suspension develops a slightundersteer during cornering. By altering thewheel position slightly, a self-steeringresponse or toe-in steering is achieved.

UpperLink

S321_171

BearingBracket

Steel Spring

Anti-Roll Bar

Subframe

Track Rod

Lower Link

Trailing Arm

Dampener

Toe Adjustment

CamberAdjustment

S861403_15

Page 15: The new Jetta Steering and Suspension

11

Rear Axle

S321_027

Wheel Carrier

S321_029

StubAxle

WheelBearing

Torque toYield Bolt

Subframe

The subframe is a welded steelconstruction assembly and is bolted directlyto the body.

Wheel Carrier

The wheel carrier is a forged steelassembly with a molded stub axle to mountthe wheel bearing.

Wheel Bearing and Hub Assembly

The wheel hub and wheel bearing form anassembly. The wheel bearing is connectedto the stub axle of the wheel carrier by atorque to yield bolt, which achieves thenecessary bearing preload but does notexceed it.

Page 16: The new Jetta Steering and Suspension

12

Rear Axle

Four-Link Suspension

Separate longitudinal and lateralconnections were added for the four-linksuspension of the new Jetta. Theadvantage of this suspension is that itenhances the Jetta’s handlingcharacteristics without sacrificing itscomfortable ride.

The trailing arm is no longer subjected tolateral forces such as those caused bycracks and grooves in the road surface. Thefour-link suspension absorbs these forces,allowing the vehicle to better maintain itsstability.

The following illustration shows the forcedistribution of the double wishbonesuspension of the previous Jetta.

S321_190

Lateral ForceLowerWishbone

UpperWishbone

Trailing Arm

LongitudinalForce

S321_018

LongitudinalForce

Trailing Arm

Lateral Force

Track Rod

Bottom Link

Top Link

Page 17: The new Jetta Steering and Suspension

13

Steering

Steering System

The electro-mechanical power steeringsystem of the new Jetta enhances thevehicle’s driving response by maintainingthe driver’s precise feel of the road. Asspeed changes, steering assist adapts.Road surface factors such as bumps andgrooves in the road are minimized as muchas possible.

Refer to SSP 892403 “new JettaElectro-Mechanical SteeringSystem” for additionalinformation.

Steering Wheel

SteeringColumn

IntermediateShaft

Electro-MechanicalPower SteeringAssembly

S861403_04

Page 18: The new Jetta Steering and Suspension

14

Steering

S321_137

SteeringPinion

S321_057

SteeringAngle Sensor

SteeringColumn

Steering ForceSensor

Control Module

Electric Motor

ToothedRack

Drive Pinion

Electro-Mechanical Power Steering

The new Jetta features an electro-mechanical power steering system. Thissteering system consists of a steeringassist pump and an electric motor with acontrol module that is installed on thesubframe. The steering assistance providedto the steering gear is similar to previousbelt-driven systems.

Electro-mechanical power steering providesassist depending on vehicle speed, steeringforce and steering angle.

The control module is located near theelectric motor and receives its data fromthe Drivetrain CAN-bus.

Refer to SSP 892403 “new JettaElectro-Mechanical SteeringSystem” for additionalinformation.

Page 19: The new Jetta Steering and Suspension

15

Steering

Steering Wheels

The standard steering wheel on the newJetta has three-spokes with a polyurethane(PU) covering. There is also a one-piece castmagnesium frame steering wheel with softleather covering available.

The airbag module is installed in thesteering wheel during manufacture and canonly be removed if the steering column isunlocked. An anti-theft feature preventsunauthorized removal of the driver airbag.

The cross sectional diagram below showsthe design of the multi-function steeringwheel.

Typical Steering Wheel Cross-Section

S321_196MagnesiumFrame

PU FoamCovering

Sheet Metal Plate

Leather Covering

Mounting for RightMulti-Function Switch

Leather Covering ofLeft Spoke Trim

Leather Covering ofRight Spoke Trim

Mounting for LeftMulti-Function Switch

S861403_05

Page 20: The new Jetta Steering and Suspension

16

Steering

Steering Column

The steering column features optional tiltand extension adjustments. The column canbe adjusted up and down by 2.0 in. (50mm)and in and out by 2.4 in. (60mm) toaccommodate individual driverrequirements or preferences.

Steering wheel adjustment is done througha multi-plate bundle consisting of ten steelplates; five plates in the horizontal plane forthe extension adjustment and five plates inthe vertical plane for the tilt adjustment.

Multi-Plate Bundlefor Tilt Adjustment

S321_084

Multi-Plate Bundle forExtension Adjustment

The steering column attaches to theinstrument panel by an aluminum bracket.

Page 21: The new Jetta Steering and Suspension

17

Steering

Clamping

Clamping action is performed by two rollersthat move up a ramp to lock the steeringwheel in the desired position. This forcesthe multi-plate bundle together by pressurefrom the thrust block.

Multi-Plate Bundle Released

Multi-Plate Bundle Locked in Position

S321_128

S321_126

Plates for ExtensionAdjustment

Thrust Block

Roller

Plates for TiltAdjustment

Ramp

Plates for ExtensionAdjustment

Thrust Block

Roller

Plates for TiltAdjustment

Ramp

Since gear teeth are not used in theclamping mechanism, component wear isnegligible.

Page 22: The new Jetta Steering and Suspension

18

Steering

Collision Features

To protect the driver, the steering columnand the intermediate shaft slide into eachother and disengage from the steering gearin the event of a head-on collision wherethe steering gear is forced toward thedriver.

The cradle and housing are connected by ashear plate. In the event of a crash, theshear plate moves as a result of the forceof the driver against the cradle.

The design of the shear plate providesprogressive travel depending on the forceapplied.

ShearPlate

S321_130

S321_173

Housing

Cradle

Page 23: The new Jetta Steering and Suspension

19

Brake System

Handbrake

FrontCaliperBrake Servo

BrakeLines

Rear Caliper

Brake Cable

ABS/ESPModule

S861403_03

Brake System

The newly designed braking system on thenew Jetta presents the driver with thelatest generation ABS/ESP combined withits state of the art power brake assistsystem.

Overview

Page 24: The new Jetta Steering and Suspension

20

Brake System

Brake Caliper Assemblies

All brake caliper assemblies are made ofnon-hazardous materials.

The front calipers are vented discs thatrange in size from 11.3 in. x 1.0 in.(288mm x 25mm) to 12.3 in. x 1.0 in.(312mm x 25mm) depending on model andoptions. The front calipers are also betterprotected from road debris, moisture andcorrosion by the addition of protectiveplates.

Rear Caliper

The rear brake calipers are solid discsthat range in size from 10.2 in. x .4 in.(260mm x 10mm) to 11.2 in. x .5 in.(286mm x 12mm) depending on model andoptions.

The calipers have been designed toimprove resistance to moisture andcorrosion and are mounted forward of therear axle center line like front axle calipers.This provides optimal brake performancefrom the rear calipers. S321_168

S321_158

Page 25: The new Jetta Steering and Suspension

21

Brake System

Anti-Lock Braking System ABS/ESP

The Continental/Teves MK 60 ABS/ESPfeatures:• Active wheel speed sensor

• Combined ESP-Sensor Unit G419 (yawrate/lateral acceleration sensor)

• The Brake Pressure Sensor 1 G201 ispart of the ESP module. In the past, thebrake pressure sensor was mounted onthe master cylinder

• New ESP warning lamp

S321_192

Page 26: The new Jetta Steering and Suspension

22

Brake System

Brake Pressure Sensor 1 G201

The Brake Pressure Sensor 1 G201measures the pressure applied at the brakepedal. To provide additional safety, thesensor sends two separate pressuresignals to the control module.

These two signals are sent at the sametime as opposite voltages. The controlmodule constantly compares the twosignals.

ABS Control Module J104 with Brake PressureSensor 1 G201

Electrical Contact

The brake pressure sensor communicateswith the ABS Control Module J104 throughfour contact springs. Two contacts supplypower and two send separate pressuresignals.

Brake Pressure Sensor

S321_060Brake Pressure SensorSpring Contacts

Page 27: The new Jetta Steering and Suspension

23

Brake System

Construction

The sensor operates by piezo resistanceusing the change in conductivity caused bydeformation. Four piezo resistive measuringelements are bridged together (5) on amembrane (6).

1. Measuring Chamber2. Piezo Resistive Thick Film Sensor Element3. Sensor Electronics and Signal Amplifier4. Contact Springs to ABS Control Module J104

S321_175

S321_176 S321_178

5. Piezo Resistive Measuring Bridge6. Flexible Thick Film Membrane7. Piezo Bridge Elements within Measuring Bridge

Function

As pressure (P) increases, the length of themembrane (6) and the imbedded piezoresistive measuring bridge (5) increases.This change in length alters the charge inthe piezo elements.

This change in the electrical charge of thepiezo bridge elements is proportional to thepressure applied. This charge is amplifiedand the signal is transmitted to the ABSControl Module J104.

The piezo resistive measuring elements areresistors made from semi-conductormaterial that functions much like abi-metallic strip.

Self-Diagnosis

The electronic control module monitors thepressure sensor’s output signals. If thesignals deviate beyond a specified range, afault is set by the control module.

Effects of Failure

If the pressure sensor fails, the ESPreduces its functions to ABS and EBD(electronic brake pressure distribution).

Page 28: The new Jetta Steering and Suspension

24

Brake System

Optimized Hydraulic Brake Servo(OHBS)

One method of providing brake assist is tosupply vacuum pressure to the brake servofrom the intake manifold. On gasolineengines with automatic transmissions, theavailable vacuum pressure can dropsignificantly under certain conditions (coldstarts). This limits brake assist.

S321_062Brake Pedal Pressure

Bra

ke P

ress

ure

Braking Assistance Using OHBS

Point of BrakeServo Actuation

Lower Vacuum Level (e.g. Cold Start)

Map Characteristicat 800 Mbar Vacuum

On previous brake assist systems, thenecessary vacuum was provided by anauxiliary unit, such as an electric vacuumpump.

The new Jetta uses its ESP hydraulics toprovide the necessary brake assist.

Page 29: The new Jetta Steering and Suspension

25

Brake System

Function

On the OHBS system, the loss of brakingassistance is offset with an active andcontrolled build-up of brake pressure fromthe ESP hydraulics. To provide this assist,pneumatic pressure in both chambers ofthe brake servo (BS) is measured. Thepressure difference is used to determinethe maximum amount of braking assistanceavailable. When the pressure in bothchambers is equal, the point of brake servoactuation has been reached and anyadditional increase in braking force is onlypossible by an increase in brake pedalpressure without assist.

The ABS Control Module J104 uses astored program to control the build-up ofbrake pressure, depending on the pressuredifference in the servo chambers. However,if the intake manifold vacuum is too low,actuation occurs even when brake pressurelevels are lower than the specified amount.

This occurs with a controlled build-up ofbrake pressure, initiated by the ESPhydraulics. When compared to conventionalbraking assistance, the driver does notnotice any difference in the force applied tothe brake pedal.

To enable the controlled build-up of brakepressure, new solenoid valves are used toswitch to the ESP controlled mode.

These valves are controlled by the amountof time that they are open, allowing theassist provided to be altered to meetchanging requirements.

Page 30: The new Jetta Steering and Suspension

26

Brake System

ESP and CAN Communication

The ESP Control Module J104 exchangesdata with other control modules of the databus on board diagnostic interface network,as shown in the diagram below.

J104ABS/ESP ControlModule

S861403_09

J533Data Bus On BoardDiagnostic Interface

Diagnosis Connection

J285Instrument Cluster ControlModule

J220Motronic EngineControl Module

J217Transmission ControlModule (TCM)

J527Steering ColumnElectronic SystemsControl Module

G85Steering Angle Sensor

J500Power Steering ControlModule

Drivetrain CAN-bus

Diagnosis CAN-bus

Instrument Cluster CAN-bus

Data Wiring

Page 31: The new Jetta Steering and Suspension

27

Brake System

Handbrake

The new design of the new Jetta handbrakereduces the space it requires in the centerconsole. This allows additional storagebehind the handbrake. The lever is pressurecast from magnesium, resulting in a weightsaving of more than 50% compared to thesteel mechanism.

S321_073

Page 32: The new Jetta Steering and Suspension

28

Brake System

The toothed part of the mechanism issecurely attached to the bearing bracket. Inthe released position, the pawl engages thetoothed part and locks the brake lever inposition.

When the release button is pressed, thepawl is pulled away from the toothed partand the brake lever is free to move.

S321_203

S321_201

Page 33: The new Jetta Steering and Suspension

29

Pedal Assemblies

Pedal Assemblies

The foot pedal assemblies have beenredesigned for the new Jetta. Accelerator,clutch and brake pedals are modulardesigns.

S321_087

Clutch Pedal withClutch Position Sensor

Clutch Position Sensor G476

Location

The clutch position sensor is attached tothe clutch master cylinder. This sensordetects clutch pedal movement.

Sensor Signal

When the clutch pedal is pressed:• The cruise control system is turned OFF

• The amount of fuel injected is reducedbriefly to reduce gear change jolts

S321_195

Page 34: The new Jetta Steering and Suspension

30

Pedal Assemblies

How It Works

The clutch master cylinder is attached tothe bearing bracket using a bayonet-typeconnector.

When the clutch pedal is pressed, theplunger moves the piston in the mastercylinder.

Clutch Pedal Not Pressed

When the clutch pedal is not pressed, theplunger and piston are in the rest position.The clutch position sensor sends a voltagesignal, which is two volts less than batteryvoltage, to the engine control module.

Clutch Pedal Pressed

When the clutch pedal is pressed, thepiston is pushed in the direction of theclutch position sensor. The front end of thepiston has a permanent magnet attached.

As soon as the permanent magnet passesthe switch point of the Hall effect sensor,the voltage signal that has been reducedzero to two volts is sent to the enginecontrol module. This signals the enginecontrol module that the clutch pedal hasbeen depressed.

S321_204Piston with PermanentMagnet

Pedal Travel

ClutchPositionSensor

PlungerBearing Bracket

Clutch MasterCylinder

S321_224

S321_226

Piston withPermanentMagnet

Piston withPermanentMagnet

Plunger

Plunger

Switch Point(Hall Effect Sensor)

Switch Point(Hall EffectSensor)

ClutchPositionSensor

ClutchPositionSensor Voltage Signal to

Engine ControlModule

Voltage Signal toEngine ControlModule

Page 35: The new Jetta Steering and Suspension

31

Pedal Assemblies

Accelerator Pedal withPosition Sensors G79 andG185

Accelerator Pedal Position SensorsG79 and G185

Both accelerator pedal position sensors arepart of the accelerator pedal module andoperate as inductive sensors without directcontact.

Advantages• No wear because sensors operate

without contact

• No kick-down setting necessarybecause the sensor is part of theaccelerator pedal module

Sensor Signal

The engine control module uses theaccelerator pedal position sensor signals tocontrol the amount of fuel injected into thecylinders.

Effects of Signal Failure

In the event of failure in one or bothsensors, a fault code is stored and theelectronic power control (EPC) warninglamp illuminates.

Also, convenience features, such as cruisecontrol and engine braking control aredeactivated.

Sensor Failures

If one sensor fails, the system will set itselfto the idle position. If the second sensor isdetected at idle within a specified period,the system will resume normal drivingmode.

If the accelerator pedal is moved to fullthrottle, engine speed will increase slowly.

If both sensors fail, the engine will only runat fast idle (maximum 1500 rpm) and willnot respond to input from the acceleratorpedal.

S321_217

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32

Pedal Assemblies

Pedal Assembly Design Features

The accelerator pedal module consists ofthe accelerator pedal, the pedal end stop,the mechanical components necessary toconvert rotational motion to linear motion,and both the Throttle Position Sensor G79and the Accelerator Pedal Position SensorG185.

The sensors are mounted on a circuit boardand each sensor consists of an exciter coil,three receiver coils, and electronics formonitoring control. For added safety, thetwo sensors function independently.

The mechanical components of theaccelerator pedal module convert leveragedrotational movement into straight linemotion.

Accelerator Pedal Not Pressed

A small metal plate is attached so thatwhen the accelerator pedal is actuated, it isbrought in line just short of the circuitboard.

Accelerator Pedal Pressed

S321_220S321_222

ExciterCoils

Area ofReceiverCoils

MechanicalComponents Small

MetalPlate

CircuitBoard

MechanicalComponents

SmallMetalPlate

CircuitBoard

S321_219

MechanicalComponents

Cover

CircuitBoard

SmallMetalPlate

Page 37: The new Jetta Steering and Suspension

33

Pedal Assemblies

How It Works

The pedal assembly electronics receivesfive volts and generates a high frequencyalternating voltage that produces analternating electro-magnetic field. This fieldaffects the moving small metal plate andproduces a second alternatingelectro-magnetic field around the smallmetal plate.

This location-dependent alternating fieldinfluences the receiver coils, producing analternating signal.

The strength of this alternating voltagedepends upon the position of the smallmetal plate. Different positions result indifferent coverage of the receiver coils bythe small metal plate.

The idle position results in the leastcoverage and the lowest inducedalternating voltage.

The full throttle position (kick-down onautomatic transmissions) coverage resultsin the greatest and the highest inducedalternating voltage.

Accelerator Pedal Signal

The accelerator pedal electronics set thealternating voltages of the three receivercoils at a common value, amplify them, andbring them together for processing. Afterprocessing, the result is converted to alinear voltage signal and transmitted to theengine control module.

KickdownArea

ExciterCoils

SmallMetalPlate

ReceiverCoils

S321_232

Diesel Direct Fuel Injection(DFI) Engine ControlModule (ECM) J248

Electronics forEvaluation

Electro-MagneticAlternating Fieldof Small MetalPlate

Electro-MagneticAlternating Fieldof Exciter Coil

S321_228

S321_230Small Metal Plateat Full ThrottlePosition

Small MetalPlate at IdlePosition

Accelerator Pedal Position

Sig

nal V

olta

ge in

Vol

ts

Accelerator Pedal Position Travel

FullThrottleStop

AcceleratorPedal EndStop

Page 38: The new Jetta Steering and Suspension

34

Service

S321_120

S321_118

S321_116

Axle Geometry

The new Jetta rear axle track and cambercan be set independently.

The track is adjusted by turning an eccentricbolt that joins the lower link and subframe.

The camber is adjusted by turning aneccentric bolt that joins the link to thesubframe.

To adjust the camber, use thefollowing required special tools:

• Shock Absorber Set T10001

• Ring Spanner T10179

Page 39: The new Jetta Steering and Suspension

35

Service

S321_200

Description Tool Application

T10179Ring Spanner

T10219 (1)Sleeve

T10219 (2) Drift

T10149 Support

T10238 Release Tool (1)T10240 Release Tool (2)

For adjusting camber on rear axle, use with shock absorber set T10001.

For replacing bonded rubber bushing on the front axle wishbone.

For adjusting unloaded position of bonded rubber bushings on the front and rear axles.

Release tool for accelerator pedal module, LHD (1) and RHD (2)

(1) (2)

(1) (2)

S321_114

S321_112

S321_194

S861403_02

Special Tools

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36

Knowledge Assessment

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:

– 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]

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