SSP_861403.pdf

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Steering and Suspension
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Volkswagen of America, Inc.
Volkswagen Academy
Printed in U.S.A.
Printed 12/2004
Course Number 861403
©2004 Volkswagen of America, Inc.
All rights reserved. All information contained
in 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 any time without notice. No part
of this document may be reproduced,
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 permission to copy and
redistribute information should be referred
to Volkswagen of America, Inc.
Always check Technical Bulletins and the latest
electronic repair information for 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.
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Table of Contents
Introduction ................................................................................ 1
Course Introduction, Steering and Suspension
Front Axle ....................................................................................4
Front Axle, Half Shafts
Rear Axle ................................................................................... 10
Rear Axle
Steering .....................................................................................13
Steering System, Electro-Mechanical Power Steering,
Steering Wheels, Steering Column
Brake System ............................................................................ 19
Brake System, Brake Caliper Assemblies, Anti-Lock Braking
System ABS/ESP, Brake Pressure Sensor 1 G201, Optimized
Hydraulic Brake Servo (OHBS), ESP and CAN
Communication, Handbrake
Pedal Assemblies ......................................................................29
Pedal Assemblies, Clutch Position Sensor G476, Accelerator
Pedal Position Sensors G79 and G185
Service .......................................................................................34
Axle Geometry, Special Tools
New!
Important/Note!
This Self-Study Program covers the steering and suspension
system of the new Jetta!
This Self-Study Program is not a Repair Manual. This
information will not be updated.
For testing, adjustment and repair procedures, always refer
to the latest electronic service information.
i
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Introduction
Course Introduction
Volkswagen has set the standard in the
automobile industry for steering and
suspension technology by enhancing the
design of the new Jetta. Best in class
steering and suspension components
include: optimized front axle strut
suspension, multi-link rear suspension, new
electro-mechanical power steering and the
latest generation of ESP and brake assist
systems. All were developed to provide an
unmatched driving experience.
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