14 - Section ST - Steering System

STEERING SYSTEM
SECnONST
CONTENTS
PRECAUTIONS ST- 2
PREPARATION ST- 3
ON-VEHICLE INSPECTION ST- 5
STEERING WHEEL AND STEERING COLUMN ST-10
POWER STEERING GEAR AND LINKAGE (Model PR26SE) ST-14
POWER STEERING OIL PUMP , ST-26
TWIN ORIFICE POWER STEERING SYSTEM ST-29
TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses ST-31
TWIN ORIFICE POWER STEERING SYSTEM -
Trouble Diagnoses (Without SUPER HICAS system) ST-32
TWIN ORIFICE POWER STEERING SYSTEM -
Trouble Diagnoses (With SUPER HICAS system) ST-42
SUPER HICAS SYSTEM ST-43
SUPER HICAS SYSTEM - On-vehicle Inspection ST-44
SUPER HICAS SYSTEM - Repair of Component Parts ST-48
SUPER HICAS SYSTEM - Trouble Diagnoses ST-60
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ST-97
When you read wiring diagrams:

• Read GI section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuil.
When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW FLOW CHART
IN TROUBLE DIAGNOSES".
PRECAUTIONS
• Before disassembly, thoroughly dean the outside of the

unit.
• Disassembly should be done in Ii clean work area. It is
important to prevent the Internal parts from becoming
contaminated by dirt or other foreign matter.
• When disassembling parts, be sure to place them in order
in a parts rack so they can be reinstalled in their proper
positions.
• Use nylon cloths or paper towels to clean the parts;
common shop rags can leave lint that might interfere with
their operation.
• Before Inspection or reassembly, carefully clean all parts
with a general purpose, non-flammable solvent.
• Before assembly, apply a coat of recommended A.T.F.* to
hydraulic parts. Vaseline may be applied to O-rings and
seals. Do not use any grease.
• Replace all gaskets, seals and O-rings. Avoid daml\ging
O-rings, seals and gaskets during installation. Perform
functional tests whenever designated.
*. Automatic transmission fluid
ST-2
PREPARATION
SPECIAL SERVICE TOOLS
Tool number
Description
Tool name
KV48100700 Measuring pinion rotating torque

Torque adapter
ST27160001 Removing steering wheel

Steering wheel puller
HT72750000 Removing ball joint

Ball joint remover
ST27091000 Measuring oil pressure

Pressure gauge
Shut-off valve
KV481 02500 Measuring oil pressure

Pressure gauge adapter
ST3127S000 Measuring turning torque

(DGG91030000
Torque wrench
(j)\;,1fC~=6=o
(!)HT6294000
Socket adapter
®--{J
(!)HT62900000
Socket adapter ®~
KV481 04400 Reforming teflon ring
Rack seal ring reformer
KV32101100 Removing and installing tube seat

Pin punch
ST-3
PREPARATION
COMMERCIAL SERVICE TOOLS
Tool name Description
Rear oil seal drift Installing rear oil seal
Pinion oil seal drift Installing pinion oil seal
Oil pump attachment Disassembling and assembling oil

R2110.83) Welding \1. \0.1.1' pump
11 10.43) di8.
40
11.57)
.....JJ/:r-~12
'4!l~.~10.47)
,<' .;.'
<i'\~.
Unit: mm On) SST481 A
ST-4
ON-VEHICLE INSPECTION
Checking Steering Wheel Play

• With wheels in a straight-ahead position, check steering
wheel play.
Steering wheel play:
35 mm (1.38 in) or less
• If it is not within specification, check steering gear assem-
bly when front suspension and axle, steering gear assem-
bly and steering column are mounted correctly.
Checking Neutral Position on Steering Wheel

O.K. N.G.
Pre-checking
• Make sure that wheel alignment is correct.
Wheel alignment:
Refer to section FA for S.O.S.
• Verify that the steering gear is centered befcre removing
the steering wheel.
Checking
l- T.:.:
-"SS:.c ' O.:.::J48 1. Check that the steering wheel is in the neutral position
when driving straight ahead.
2. If it is not in the neutral position, remove the steering wheel
and reinstall it correctly.
3. If the neutral position is between two serrated teeth, loosen
tie-rod lock nut and move tie-rod in the opposite direction
by the same amount on both left and right sides to compen-
sate for error in the neutral position.
Front Wheel Turning Angle

1. Rotate steering wheel all the way right and left; measure
turning angle.
Turning angle of full turns:
Refer to section FA for S.O.S.
2. If it is not within specification, check rack stroke.

Rack stroke "L":
Refer to S.O.S.
I
I-~
58T3078
ST-5
Checking Gear Housing Movement

1. Check the movement of steering gear housing during
stationary steering on a dry paved surface.
• Apply a force of 49 N (5 kg, 11 Ib) to steering wheel to check
the gear housing movement.
Turn off ignition key while checking.
Movement of gear housing:
± 2 mm (± 0.08 in) or less
2. If movement exceeds the limit, replace mount insulator
after confirming proper installation of gear housing clamps.
Adjusting Rack Retainer

• Perform this driving test on a flat road.
1. Check whether vehicle moves in a straight line when
steering wheel is released.
2. Check whether steering wheel returns to neutral position
when steering wheel is released from a slightly turned
(approx. 20°) position.
• If any abnormality is found, correct it by resetting adjusting
screw.
Checking and Adjusting Drive Belts

Refer to section MA for Drive Belt Inspection.
Checking Fluid Level

Check fluid level.
Fluid level should be checked using "HOT" range on dipstick at
fluid temperatures of 50 to 80°C (122 to 176°F) or using "COLD"
range on dipstick at fluid temperatures of 0 to 30°C (32 to 86°F).
CAUTION:
• Do not overfill.
• Recommended fluid is Automatic Transmission Fluid
''DEXRON™,, type.
SST280B
ST-6
Checking Fluid Leakage

Check the lines for improper attachment and for leaks, cracks,
damage, loose connections, chafing or deterioration.
1. Run engine at idle speed or 1,000 rpm.
Make sure temperature of fluid in oil tank rises to 60 to 80"C
(140 to 176"F).
2. Turn steering wheel right-to-left several times.
3. Hold steering wheel at each "lock" position for five seconds
and carefully check for fluid leakage.
CAUTION:
Do not hold the steering wheel In a locked position for more
than 15 seconds.
4. If fluid leakage at connectors is noticed, loosen flare nut
and then retighten.
Do not overtighten connector as this can damage O-ring,
washer and connector.
Bleeding Hydraulic System

1. Raise front end of vehicle until wheels clear ground.
2. Add fluid into oil tank to specified level. Meanwhile, quickly
turn steering wheel fully to right and left and lightly touch
steering stoppers.
Repeat steering wheel operation until fluid level no longer
decreases.
3. Start engine.
Repeat step 2 above.
• Incomplete air bleeding will cause the following to occur.
When this happens, bleed air again.
a. Generation of air bubbles in reservoir tank
b. Generation of clicking noise in oil pump
c. Excessive buzzing in oil pump
While the vehicle is stationary or while turning the steering
wheel slowly, fluid noise may occur in the valve or oil pump.
This noise is inherent in this steering system, and it will not
affect performance or durability of the system.
ST-7
Checking Steering Wheel Turning Force

After turning
360° 1. Park vehicle on a level, dry surface and set parking brake.
2. Start engine.
3. Bring power steering fluid up to adequate operating tem-
perature. [Make sure temperature of fluid is approximately
60 to 80°C (140 to 176°F).]
Tires need to be Inflated to normal pressure.
4. Check steering wheel turning force when steering wheel
has been turned 360° from the neutral position.
SST1088
Steering wheel turning force:
39 N (4 kg, 9 Ib) or less
5. If steering wheel turning force is out of specifications, check

rack sliding force to detect condition of steering gear
assembly.
a. Disconnect steering column lower joint and knuckle arms
from the gear.
b. Start and run engine at idle to make sure steering fluid has
reached normal operating temperature.
c. While pulling tie-rod slowly in the ± 11.5 mm (± 0.453 in)
range from the neutral position, make sure rack sliding
force is within specification.
SST090B Average rack sliding force:
Without HICAS
Average value _ (Max.value + Min. value) 206 - 265 N (21 - 27 kg, 46 - 60 Ib)
1/ 2
With HICAS
~ - "" 201.0 - 250.1 N (20.5 - 25.5 kg, 45.2 - 56.2 Ib)
..
c
- 11 - Maxi mum value
d. Check sliding force outside above range.
Maximum rack sliding force:
• Mini mumvalu8 Not more than 39 N (4 kg, 9 Ib) beyond above
•
u value
Ie
6. If rack sliding force is not within specification, overhaul
-11.5
steering gear assembly.
11.5 Rack It.oke
{-GA531 Neuuel (O.4531-
SST117A position Unit: min lin)
ST-8
Checking HydraUlic System

Before starting, check belt tension, driving pulley and tire
pressure.
1. Set Tool. Open shut-off valve. Then bleed air. (See "Bleed-
ST27091000 ing Hydraulic System".)
2. Run engine.
Make sure temperature of fluid in tank rises to 60 to 80"C (140 to
176"F).
WARNING:
Warm up engine with shut-off valve fully opened. If engine is
started with shut-off valve closed, oil pressure in oil pump will
increase to relief pressure, resulting in an abnormal rise in oil
temperature.
L~==:':.-L Low-pressure
- . : Direction of oil flow ho. 3. Check pressure with steering wheel tully turned to left and
right positions with engine idling at 1,000 rpm.
CAUTION:
Do not hold the steering wheel in a locked position for more
than 15 seconds.
Oil pump maximum standard pressure:
7,453 - 8,042 kPa (74.5 - 80.4 bar, 76 - 82 kg/em',
55T834
1,081 - 1,166 psi)
4. If oil pressure is below the standard pressure, slowly close
shut-ott valve and check pressure.
• When pressure reaches standard pressure, gear is dam-
aged.
• When pressure remains below standard pressure, pump is
damaged.
CAUTION:
Do not close shut-off valve for more than 15 seconds.
5. If oil pressure is higher than standard pressure, check oil
pump flow control valve.
6. After checking hydraulic system, remove Tool and add fluid
as necessary, then completely bleed air out of system.
ST-9
STEERING WHEEL AND STEERING COLUMN
Steering tube assembly
Steering wheel
"'~ 24·29
~A ·3.0. 17· 2/2)~~~Cf~
~: N·m (kg-m, ft-tb}

Lower joint
SST3118
Removal
STEERING WHEEL
• Remove screw from rear of steering wheel and pull out
horn pad.
SST312B
• Remove steering wheel with Tool.
SST313B
Installation
Ell
STEERING WHEEL
When installing steering wheel, apply multi-purpose grease to
entire surface of turn signal cancel pin (both portions) and also
to horn contact slip ring.
SST112B
ST-10
Installation (Cont'd)
iOU. portion7 / STEERING COLUMN
• When installing steering column, fingertighten all lower
bracket and clamp retaining bolts; then tighten them se-
L. ~ •
curely. Do not apply undue stress to steering column.
When attaching coupling joint, be sure tightening bolt faces
#f cutout portion.
CAUTION:
After installing steering column, turn steering wheel to make
sure it moves smoothly and that the number of turns from the
Lower joint straight forward position to left and right locks are equal.
SST800A
Be sure that the steering wheel is in a neutral position when
driving straight ahead.
Disassembly and Assembly
SteeronglOCkY
assembly
~combonallon
switch assembly
Jacket tube
assemblv . }~
Jacket tube
bracket insulator
Snap,;ng~ .r>.
~~13.16 11.3 ·1.6.

/
.:
9 ·121 •
Column shaft assembly
!~
/
~ 12.4·3.0,17·22)
24-29 ~
~ Lower joint
.-4' N'm [kg-rn, ft·lbl
88T3148
ST-11
Disassembly and Assembly (Cont'd)
• To remove combination switch, insert a suitable tool be-
tween mating portion. Lift switch bracket and pull it out.
SSTS02B
• When disassembling and assembling, unlock steering lock

with key.
• Install O-ring CD before inserting shaft into jacket tube.
Ensure that rounded surface of snap ring faces toward
bearing when snap ring is installed.
SST428A
• Install snap ring on upper shaft with box wrench.
_ _ _ Upper shaft
SST770A
•a) Steering lock
~
Break self-shear type screws with a drill or other appropri-
ate tool.
b) Install self-shear type screws and then cut off self-shear
type screw heads.
iSelf-shear screw
SST742A
ST-12
Inspection
• When steering wheel can not be rotated smoothly, check
the steering column for the following matters and replace
damaged parts.
a. Check column bearings for damage or unevenness. Lubri-
cate with recommended multi-purpose grease or replace
steering column as an assembly, if necessary.
b. Check steering column lower shaft for deformation or
breakage. Replace if necessary.
• When the vehicle is involved in a light collision, check
SST3158
steering column length "L," and steering column lower
shaft length "L 2 " . If it is not within specifications, replace
steering column as an assembly.
Steering column length "L,":
745.9 - 747.5 mm (29.37 - 29;43 in)
Steering column lower shaft length "L.":
L.H.D.
280.6 - 282.2 mm (11.05 - 11.11 in)
R.H.D.
314.6 • 316.2 mm (12.39 - 12.45 In)
ST-13
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Removal and Installation
~24.29
-
12.4 ·3.0. 17 . 221
Gear housing mounting bracket Rack mounting insulator
/cotter
~ 29 • 49 (3.0 • 5.0, 22 • 36)...( plnO
.~~' \; @
Gear and J inkage

assembly
Front
~ 88·108 19.0· 11.0,65·801
~, Nen Ikg-m. tt-lb!

SST317B
• Detach tie-rod outer sockets from knuckle arms with Tool.

HTI2750000
SST783A
• Install pipe connector.

G) Low-pressure side
~: 36·40 N'm (3.7 • 4.1 kg·m, 27 • 30 fl·lb)
® High-pressure side
~: 30· 35 N'm (3.1 • 3.6 kg·m, 22 • 26 fl·lb)
ST-14
Removal and Installation (Cont'd)
• Observe specified tightening torque when tightening high-
pressure and low-pressure pipe connectors. Excessive
tightening can damage threads or damaged connector
O-ring.
• The O-ring in low-pressure pipe connector is larger than
that in high-pressure connector. Take care to install the
proper O-ring.
, ..-c Pin hole • Initially, tighten nut on tie-rod outer socket and knuckle arm
.;-~
to 29 to 49 N'm (3 to 5 kg-m, 22 to 36 ft-Ib). Then tighten
further to align nut groove with first pin hole so that cotter
pin can be installed.
CAUTION:
Tightening torque must not exceed 49 N'm (5 kg-m, 36 ft-Ib).
S$T824A
• Before removing lower joint from gear, set gear in neutral

(wheels in straight-ahead position). After removing lower
joint, put matching mark on pinion shaft and pinion housing
to record neutral position of gear.
• To install, set left and right dust boots to equal deflection,
and attach lower joint by aligning matching marks of pinion
shaft and pinion housing.
ST-15
<;
~
®
~~~
~
<\_ ~ Cl ~ ~ toJ 16 - 21 (1.6 • 2.1. 12 - 15)
~ ~ Rear housing cover
I'lEll~ \
r
Rear housing assembly
toJ 7 - 12 (0.7 • 1.2. 5.1 - 8'7)~~'

'~." ! \,
Solenoid velve>~ CiJ) 0

J
r
0
O-ring~ ~,
toJ (4.0 - 6.0. Adjusting screw ~ Ell ring ~

29 • 43) ~~ Spnng Pinion'
washer~1f Il ~ Spr.ing disc assembly lEI
Qj O-nng~\
toJ 20 • 26 (2.0 • 2.7. 14 • 20) Shim~~
~
~/Pinion oil seaJ~ElI
Washer <, ~ ~ ____
Spring seat ~. ---
, :::5:;" -------
Retainer '-0\\ ·-.-v1l1
Cylinder tube
Rack oil seal ~~
Pnl20 _ 26 (2.0 - 2,7. 14 - 20) ~
r.,-.. Rack seal
~
ring ~
End cover assembly --;ifm@~iJllll'"" Gear housing
toJ 59 - 74 (6 - 7.5, 43 - 54) Center housing
~, '\ EO
Rack assembly ~!
O-rjng~
Lr -!toJ
Cotter pin
29 _ 49 Tie-rod
Boot band\
~~'0
~
Boot clamp
@"" (3.0 • 5.0. \ ~ Steering gear spacer
~
<Sl . 22 - \36) Tie-rod i~er ;::::,;
toJ 78 - 98 (8.0 • 10.0, 58 - 72)

toJ 78 - 98 (8.0 • 10.0. 58 - 72)
Tie-rod
Do not disassemble.
toJ: Ncm (kg-m, tt-Ib)

SST552B
ST-16
Disassembly
KV48100700 1. Prior to disassembling, measure pinion rotating torque.
Record the pinion rotating torque as a reference.
• Before measuring, disconnect cylinder tube and drain fluid.
• Use soft jaws when holding steering gear housing. Handle
gear housing carefully, as it is made of aluminum. Do not
grip cylinder in a vise.
ST3127S000
2. Remove pinion gear.
Be careful not to damage pinion gear when removing pinion
SST320B seal ring.
3. Remove tie-rod outer sockets and boots.

4. Loosen tie-rod inner socket by prying up staked portion,
and remove socket.
5. Remove retainer.
6. Remove pinion assembly.
SST881
7. Drill staked portion of cylinder end cover with drill of 2 to 2.5

mm (0.079 to 0.098 in) diameter, until the staking is elimi-
nated.
SST450A
8. Remove gear housing end cover assembly with Tool.

9. Draw out rack assembly.
SST081B
10. Remove rack seal ring.

• Using a heat gun, heat rack seal to approximately 40'C
Rack seal
(104·F).
ring • Remove rack seal ring.
• Replace rack seal ring and O-ring with new ones.
Be careful not to damage rack.
SST0828
ST-17
Disassembly (Cont'd)
11. Remove center bushing and rack oil seal using tape
wrapped socket and extension bar.
Rack oil seal Do not scratch Inner surfaces of pinion housing.
center bushing
Extension bar
29 mm socket
SST472A
Inspection
Thoroughly clean all parts In cleaning solvent or automatic
transmission fluid ''DEXRON™,, type, and blow dry with com-
pressed air, If available.
BOOT
Check condition of boot. If cracked excessively, replace it.
RACK
Thoroughly.examine rack gear. If damaged, cracked or worn,
replace it.
PINION ASSEMBLY
• Thoroughly examine piruon gear. If pinion gear is
damaged, cracked or worn, replace it.
• Inspect bearings to see that they roll freely and are free
from cracked, pitted, or worn balls, rollers and races.
Replace if necessary.
TIE-ROD OUTER AND INNER SOCKET

• Check ball joint for swinging force.
~=~
Tie-rod outer ball Joint:
4.61 - 46.09 N
(0.47 - 4.7 kg, 1.04 - 10.36 Ib)
~Munn~~0 Tie-rod inner ball Joint:
8.8 - 78.5 N
=9 ~
SST3338
(0.9 - 8.0 kg, 2.0 - 17.6 Ib)
• Check ball joint for rotating torque.

ST3127SOOO Tie-rod outer ball Joint:
0.29 - 2.94 N'm
(3.0 - 30.0 kg-em, 2.6 - 26.0 In-Ib)
Tie-rod Inner ball Joint:
1.0 - 8.8 N'm (10 - 90 kg-em, 8.7 • 78.1 In-Ib)
SSTIS1A
ST-18
Inspection (Cont'd)
• Check ball joint for axial end play.
Tie-rod outer ball joint:
o mm (0 in)
Tie-rod inner ball joint:
o mm (0 in)
• Check condition of dust cover. If cracked excessively,
replace it.
Axial end
play
58T334B
CYLINDER TUBES
Check cylinder tubes for scratches or other damage. Replace if
necessary.
Assembly
1. Using a heat gun, heat rack seal ring (made of Teflon) to
approximately 40·C (104·F) and install it onto rack with your
hand.
~Rack ...1,ing
SST0838
• Using Tool, compress periphery of rack seal ring (made of

Teflon) to position and secure it on rack.
KV481 04400 Always insert the tool from the rack gear side.
Position and
secure seal.
SST084B
2. Insert rack oi I seal.

• Place plastic film into rack 011 seal to prevent damage by
rack teeth.
• Always remove plastic film after rack 011 seal is positioned
properly.
c--.~ • Make sure lips of rack 011 seal face each other.
Film
~
Rack oil seal
SST201A
ST-19
Assembly (Conl'd)
3. Install center bushing and rack oil seal with rack assembly.
4. Insert rack oil seal and end cover assembly to rack then
tighten end cover assembly.
Rack oil seal
End cover assembly
55T3218
2·3mm
5. Fasten cylinder end cover assembly to gear housing by
10.08· .12 in} staking.
End cover
Gear
assembly
housing
$ST0738
6. Set rack gear in neutral position.

Rack stroke "L":
Refer to S.O.S.
58T3078
Suitable
tool
• Gear housing
7.
•
Coat seal lip of oil seal with multi-purpose grease and
install new pinion oil seal to pinion housing with a suitable
tool.
Make sure lip of oil seal faces up when installed.
<'. Oil seal

Rack assembly "<;
88T3228
ST-20
Assembly (Cont'd)
8. Install pinion bearing adjusting shim(s).
Gear housing
• Whenever pinion assembly, gear housing and rear housing
are disassembled, replace shim(s) with new ones. Always
use the same number of shim(s) when replacing.
SST074B
9. Install pinion seal ring on pinion gear assembly.

• Using a heat gun, heat pinion seal ring to approximately
40°C (104°F) before installing it onto pinion gear assembly.
• Make sure pinion seal ring is properly settled in valve
groove.
88T3238
10. Apply a coat of multi-purpose grease to needle bearing

Gear housing
roller and oil seal lip before installing pinion assembly in
gear housing.
Needle bearing
SST0758
11. Install pinion assembly to pinion housing.

Be careful not to damage pinion oil seal.
SST3248
12. Apply a coat of multi-purpose grease to rear oil seal lip

Rear oil seal
before installing rear housing.
SST3258
ST-21
Assembly (Cont'd)
13. Install rear cover cap so that protrusion of rear housing
cover is positioned as shown in figure at left.
Be careful not to damage worm ring and all seal.
58T326B
14. Install solenoid valve.
SST3168
15. Install diaphragm spring at retainer.

• Always install retainer, spring washer and diaphragm
spring in that order.
• Make sure convex end (painted white) of diaphragm spring
faces outward when installing.
16. Install retainer spring and adjusting screw temporarily.
88T0878
CAUTION:
Ensure steering gear spacer is installed with rubber side facing
rack.
• Attach lock plate ® to side rod inner socket (D.
• Insert steering gear spacer ® to rack @.
• Apply locking sealant to inner socket threads @.
Screw inner socket into rack @ and tighten to specified
torque.
• Stake lock plate at two places.
88T3278
17. Install steering gear spacer ® to lock plate ®.
ST-22
Assembly (Cont'd)
18. Tighten outer socket lock nut.
Tie-rod length "L":
ReIer to S.O.S.
~' L $1 1 Jf------'Y
SST0938
19. Measure rack stroke.

Rack stroke "L":
ReIer to S.O.S.
SST3078
20. Before installing boot, coat the contact surfaces between

boot and tie-rod with grease.
SST3298
21. Install boot clamps.

• To install, wrap boot clamp around boot groove twice.
Tighten clamp by twisting rings at both ends 4 to 4-1/2 turns
with screwdriver while pulling with a force of approx. 98 N
(10 kg, 22 Ib).
• Install boot clamps so that they are behind the steering gear
housing when steering gear is attached to the vehicle. (This
l"'J:::::::i===FJ LesS then will prevent interference with other parts.)
42 111111
(1.65 Inl
(e oth
sides)
center
of retainer
ST-23
Assembly (Conl'd)
• Twist boot clamp in the direction shown in figure at left.
98 N (10 kg, 221bl
SST440A
• After twisting boot clamp, bend twisted and diagonally so it

does not contact boot.
SST1268
Adjustment
lock nut
Apply sealant. Adjust pinion rotating torque as follows:
1. Set gears to Neutral without fluid in the gear.
2. Coat the adjusting screw with locking sealant and screw it
in.
3. Lightly tighten lock nut.
4. Tighten adjusting screw to a torque of 4.9 to 5.9 N'm (50 to
'.' ,."".
....... ""V-~'" 60 kg-em, 43 to 52 in-Ib).
5. Loosen adjusting screw, then retighten it to 0.05 to 0.20 N'm
Adjusting screw (0.5 to 2 kg-em, 0.43 to 1.74 tn-Ib),
58T0898
6. Move rack over its entire stroke several times.
7. Measure pinion rotating torque within the range of 180·
KV48100700 from neutral position.
Stop the gear at the point of maximum torque.
8. Loosen adjusting screw, then retighten It to 4.9 N'm (50
kg-em, 43 in-Ib).
9. Loosen adjusting screw by 60· to 100·.
SST320B
10. Prevent adjusting screw from turning, and tighten lock nut
to specified torque.
SST557A
ST-24
WER STEERING GEAR AND LINKAGE (Model PR26SE)
Adjustment (Cont'd)
11. Measure pinion rotating torque.
V48100700 Within 100· from the neutral position:
Average rotating torque
0.8 - 1.3 N'm (8 - 13 kg-em, 6.9 - 11.3 in-Ib)
Maximum torque deviation
0.4 N'm (4 kg-em, 3.5 in-Ib)
Except for above measuring range:
Maximum rotating torque
ST3127S000 1.9 N'm (19 kg-em, 16 in-Ib)
Maximum force deviation
SST3'OB 0.6 N'm (6 kg-em, 5.2 in-Ib)
'-------+-----== • If pinion rotating torque is not within specifications, readjust
it by starting from procedure 4. If pinion rotating torque is
sti II out of specifications after readjustment, replace steer-
ing gear assembly.
12. Check rack sliding force on vehicle as follows:

a. Install steering gear onto vehicle, but do not connect tie-rod
to knuckle arm.
b. Connect all piping and fill with steering fluid.
c. Start engine and bleed air completely.
d. Disconnect steering column lower joint from the gear.
e. Keep engine at idle and make sure steering fluid has
reached' normal operating temperature.
f. While pulling tie-rod slowly in the ±11.5 mm (±O.453 in)
range from the neutral position, make sure rack sliding
SST090B force is within specification.
. Average rack sliding force:
Averagevalue _ (Max. value + Min.value) Without HICAS
/ 2 206 - 265 N (21 - 27 kg, 46 - 60 Ib)
~
~ -r- With HICAS

Maxi mum value
.
c
- ..L - 201.0 - 250.1 N (20.5 - 25.5 kg, 45.2 - 56.2 Ib)
g. Check sliding force outside above range.
•
- Mini mum value Maximum rack sliding force:
u Not more than 39 N (4 kg, 9 Ib) beyond above
• value
• If rack sliding force is not within specification, readjust by
-11.5 11.5 Rack Itt ok.
(-0.463) N.~t~al (0.453)-- repeating adjustment procedure from the beginning.
SST717A position Unit: mm linl • If rack sliding force is still out of specification after read-
justment, gear assembly needs to be replaced.
ST·25
POWER STEERING OIL PUMP
Disassembly and Assembly

Connector bolt ~ 49 -&9 (5.0 - 7.0, 36·51)
Copper washer t) ~
Connecter ~ 69 -78 17.0 -8.0,51 - 581
Do not disassembly. ~ 54 -68 (5.5 -6.9,40· SO)\
O-dng ~ 1'1 Pulley
\ Control valve
~~ ~
\ Spdng
~14 -18
,
11.4 -1.8, 10 -13)
~"-- Snap rmg

0
t)
.> ~~_ ~, 1 Drive shaft
A~· Ci 0 '" ali seal ~I'l
O-dng~1'l I »> g~ ~ ~ JonthoU"ng
V c> ~q ... " I

"''''\''' Wavewashe, 12_8
;;27_ 3 -3.6,
5
O·nng (Inner] ~ 1'1 20 - 26)
O-';ng 10ute"~1'l •
Front side plate ~
Vane ~
\ Rotor ' .
e:1' \
Pin
Gaske::"tiil Sub-bracket
Rear housing
~, N,m {kq-m, tt-tbl
\ ~ 31 ·4213.2 ·4.3, 23 ·31) SST3318
Pre-disassembly Inspection
Disassemble the power steering oil pump only if the following
items are found.
• Oil leak from any point shown in the figure,
• Deformed or damaged pulley.
• Poor performance
SST1288
ST-26
Disassembly
CAUTION:
• Parts which can be disassembled are strictly limited.
Never disassemble parts other than those specified.
• Disassemble in as clean a place as possible.
• Clean your hands before disassembly.
• Do not use rags; use nylon cloths or paper towels.
• Follow the procedures and cautions in the Service Manual.
• When disassembling and reassembling, do not let foreign
mailer enter or contact the parts.
• Remove snap ring, then draw drive shaft out.

Be careful not to drop drive shaft.
[ } - - - Extension bar
~_~~~~~orive shaft
SST010B
• Remove oil seal.

Be careful not to damage front housing.
• Remove connector.
Front houling Be careful not to drop control valve.
SST036A
Inspection
Inspect each component part for wear, deformation, scratches,
and cracks. If damage is found, replace the part.
ST-27
Assembly
Assemble oil pump, noting the following instructions.
• Make sure O-rings and oil seal are properly installed.
• Always install new O-rings and oil seal.
• Be careful of oil seal direction.
• Cam ring, rotor and vanes must be replaced as a set if
necessary.
• Coat each part with AT.F. when assembling.
SST038A
• Pay attention to rotor direction.

Rear housing side Front housing side
Punchmark
SST289A
• When assembling vanes to rotor, rounded surfaces of

Vane vanes must face cam ring side.
Faces inside
Flat portion
Round portion
SST843A
• Insert pin ® into pin groove CD of front housing and front

side plate. Then install cam ring ® as shown at left.
t Front houling side

-....::~CS;~ 'I RIO' housingside
SST497A
ST·28
TWIN ORIFICE POWER STEERING SYSTEM
Hydraulic Circuit
Steering gear assembly

r-----------------,
i Rotary valve
,
J
,
,I
I
I
,,: Power cylinder
Speed sensor
I
Reservoir I
I
Solenoid valve
tank Pump I
rr-r-: I
I
I
I
I
I
I
I
I
I
I
I
I
Control unit
,I ,
~------------------~
SST630B
Schematic
Without SUPER HICAS
(Refer to SUPER HICAS Schematic IGNITION SWlTCH
for models equipped with SUPER HICA$.) ON or START
CHECK
CONNECTOR
FUSE FUSE
@ 0
To stop lamp
STO? LAMP
SW! TCH
n
U
101m @
ITI:!:liI3l1M65'
*
@ ~m~lNG
SOLENOID
lZlliJ VALVE
POWER STEERING
~~
, --:°"1
3 ELECTRIC@
CONTROL UNJ T r SPEED-
OMETER
INHIBITOR
SWITCH
VEHICLE
SPEED
~ ,A/T model SENSOR
NEUTRAL PARKING CLUTCH
@:M/T model SWI TCH BRAKE SWITCH
@(ill)I SWITCH
§)~ m:'l@ SST5548
ST-29
0' 'ii ~
COMBINATION METER
FUSE BLOCK
(Refer- to "'POWER SUPPL Y ROUTJ NG'"
;t ~
16 To stop lamp
in EL section.) h~
18 • ., III
3 112
C- - llC:C
IGNITION SWI TCH u ® ~~ilI
E~r START
en I I B i l::c :D
~~ G -:::!±!lI1111~ g~~2~CTOR ~:E
G 1"0
§ ffH"fEi1] ~<§ l>
51!i !II
< «
_ " w
.,:>.
• PaNER STEERING 56::1
r- ••
V~G J® C[JoNTROL
UNIT ii :i!z
r-+---::±:!: .s; 0 I':
Yll S -
(@)@
~i
RIB ' • o
POWER (Brown) G"
STEERING %I
SOLENOID W =n
VALVE ev
r::==:J--..i), &- "V '" sm
~~B I ~
o """
:;' "0
(Eng I ne room harness) =:;' o
harness)
t/)
II Ia
C
~
m
iii' %I
~ @. Ia t/)
.
III -I
I , , - - 1 / " U -rm CLUTCH ""
~ m
A/1 ~ B ~~SWITCH~ 3 m
%I
(Black)
Z
III -e
, <-e
_, ;a_, 1lI-<-e
Q
8® @ SHORT t/)
~ I:: YIPU -o:J r;o- Y/PU.., CONNECTOR
@)~@)~ ~® YIP U -un t:J.j-----l ®
(Blue) U;
FUSE BLOCK
~£
Un RELAY BOX)
@~®~ ~® -e III
~.,~rARKING iii
III ,-e ,.., ;a,..,-e T/PU-{lJ] ~~:~~5H i:
(Refer to "'POWER • • •
SUPPLY ROUTING" ~
c;=::;:;> 0
in EL section.)
@)~
~':~~8 ®i!i@)
@ 11 BODY ® :,lVT model
I _~. --P.J. ~NEUTRAL GROUND
l. ~Y/G-.-ID~SWITCH ® :M/T model
(Jl
(Jl VEHICLE
@)~@) 9
BODY I ~1/. e-==eSPEED
L SENSOR
;ec
In
GROUND (A t ternator harness)
~
'"
~~'O' " On,,", " - '.."''''''·'~,"C-~,-''''''''''''''''

TWIN ORIFICE POWER STEERING SYSTEM - Trouble Diagnoses
Precautions
BEFORE DIAGNOSING THE POWER STEERING SYSTEM,
ENSURE THAT:
Vehicle stopped
a. Power steering components (gears, oil pump, pipes, etc.)
are free from leakage, and that oil level is correct.
b. Tires are inflated to specified pressure and are of specified
size, and that steering wheel is a genuine Nissan pari.
c. Wheel alignment is adjusted properly.
d. Suspension utilizes the original design, and is free of
modifications which Increase vehicle weight.
Vehicle in operation
a. Understand the trouble symptoms.
b. Engine is operating properly.
PRELIMINARY KNOWLEDGE HELPFUL IN CONDUCTING

Steering force during
fail-safe control ~
DIAGNOSES
t Steering force
during full turns __--f-
,----"=::
The power steering system is a twin orifice type, which uses a
vehicle-speed sensing, electronic control design. Valve sensi-
tivity is controlled in response to vehicle speed to achieve
optimum steering effort. When a vehicle-speed signal is not
175 entered into the power steering control unit for approximately
(109) 10 seconds during normal operation (see NOTE below), a
o 50 100 150 200 fail-safe system activates to maintain the steering effort at a
(01 (311 (621 (93) 11241 level similar to that experienced during high-speed operation.
Vehicle speed km/h IMPH)- SST338B
More precisely, if a foot-brake signal, parking-brake signal
and/or transmission position signal (N or P-range signal on
automatic transmission models and a neutral or clutch signal on
manual transmission models) are not entered, the power steer-
ing system is held in a "fail-safe" control state. When this
happens, a symptom referred to as "heavy steering during
stationary turns" sometimes occurs.
NOTE:
Normal operation refers to a driving condition In which the foot
brake pedal and parking brake lever are released, the shill
lever is in any position other than "P" or uN" (automatic
transmission models), the shill lever set in any position except
uN" (manual transmission models) and the clutch pedal Is not
depressed.
ST-31
- Trouble Diagnoses (Without SUPER HICAS system)
Diagnostic Procedure 1
SYMPTOM:
Heavy steering operation during stationary turns
START
'-----!-----
1) CHECK STOP LAMP SIGNAL.
Turn ignition switch "ON" (with
engine OFF), release foot brake
pedal and parking brake lever.
Set shift lever to any position
except "P" and "N" on auto-
matic transmission models or
set shift lever to any position
except "N" on manual transmis-
sion models. and ensure clutch
pedal is released.
- Depress brake pedal and mea- ~I Go to 2).

SST563B sure voltage between solenoid
valve terminals of "check" con-
nector.
- fIIo,malnop lomp .... ,tel>
- - - - Mollun"uon·,ng .tQplemp .... ,tch
Ignition .....\Ch ON
~OO,
1J •
b,ake d/lp,KSed
4.4 ·6.6V
,
:
11.o.,.5v--
Awrox. 10 _. I
SST340B
Time
Voltage:
4.4 - 6.6 volts (constant)
.•. O.K.
Outside the above range or
Yoltage fluctuations
... N.G.
~N.G.
••IG::,O.::tO::..::5)~.
Check if terminal voltage drops !-,O:.;.:.;K:.; 'L -.J
to 1 - 1.5V range approx. 10 sec- I
onds after ignition switch is
turned ON.
No change (outside 4.4 - 6.6V
range) ... O.K.
Voltage drop ... N.G.
~N.G.
@
ST·32
Diagnostic Procedure 1 (Cont'd)
m @
lEffi~ ~ i) 00 m •
Check if stop lamp switch signal N.G. Malfunctioning stop lamp switch
G is present at power steering system
ill control unit.
~ YES (12 Yolts - Brake pedal
depressed.) ... O.K.
NO (0 Yolts) .., N.G.
"=" !O.K.
SST5568
Ensure that power steering con-
[!] trol unit connector is connected
~ BBHm
-, properly.
Ei
eJ G
TV!
!
After ignition switch is turned N.G. Malfunctioning power steering
00 '--~ ~
"ON", depress brake pedal and
measure voltage between sole-
naid valve terminals of "check"
control unit.
~ ~
SST5638
connector.
4.4 - 6.6 Yolts (constant)
•.• O.K.
Voltage fluctuations
.•. N.G.
!O.K.
Check if heavy steering opera- ~I Go 10 4). I

tion occurs during stationary
turns.
YES ... N.G.
NO (Lighter steering opera-
tion) ... O.K.
!O.K.
END
ST·33
m m
~
-.
EEE:HfE 2) CHECK PARKING BRAKE
SIGNAL.
I-'0~.~K,""11~G~0~t~0":3~)'
I
J
eo G
[YJ
Release foot brake pedal and
apply parking brake lever.
00 --~
Measure voltage between sole-
noid valve terminals of "check"
~
connector.
- - Normal parking b'ol<e sw"~,,
~
- - - - __ u.lfuncliOtlingPOrk'ng
IgnitiOn ...it<:h ON bike .....ilCh
SST5648 '.,king brak' oPPlied
f 1
IJ
4.4-6.6V
>
I AppnoK.l0_. . 1
SST340B
Y/PU
Tome
Vollage:
4.4 • 6.6V (constant)
.•. O.K.
Outside the aboye range or
yollage fluctuations
••• N.G.
Check if terminal voltage drops 1-0::;.,,-K::"1...G:::O-.:tO':...:::5~). .J

to 1.0 - 1.5V range approx. 10 I
seconds after ignition switch is
turned ON.
No change (outside 4.4 • 6.6V
renge) .., O.K.
Vollage drop ... N.G.
Check if parking brake switch N.G. Malfunctioning parking brake

signal is present at power steer- system
ing control unit.
YES (0 YOnS - Perking brake
applied.)
NO (12 Yolts) ... N.G.

trol unit connector is connected
properly.
ST-34
[I
~ EEEi!ffi]
-IV G
[I
,
Turn ignition switch ON and ap- N.G. Malfunctioning power steering

ply parking brake lever. control unit
!Vi Measure vo'ltage between sole-
00 .!.....2
naid valve terminals of "check"
connector.
~
Voltage:
4.4 - 6.6 volts (constant)
~
••• O.K.
55T564B
Voltage t1uctuatlons
... N.G.
!O.K.
Check if heavy steering opera- ~IGOt04). I
turns.
YES ... N.G.
NO (Ughta, stae,lng ope,a·
tlon) ... O.K.
lO.K.
END
ST-35
f:.1 f:.1
~ EHHH:EJ
-.
3) CHECK NEUTRAL POSITION
SIGNAL.
O.K. Depress clutch pedal (MIT
model) and move shift lever to
G Release parki og brake lever. "P" (AIT model).
ED -
00
Move shift lever to Neutral (AIT Measure voltage between 501e-
~
and MIT models). Measure volt- nord valve terminals at "check"
'--~ age between solenoid valve ter- connector.
minals of "check" connector. Voltage:
--No,mal pas<hon ,....i,ch N.G. 4.4 • 6.6V (constant) .., O.K.
- - - - - Mal'"nelioning po$ition .....iICh
-
~
Igni,ion swilCh ON Outside the above ,ange or
SS15658 IOSition ....iICh ON
• I
~ I 4.4 ·6.6V
voltage Iluctuations ... N.G.
(;] ,,, O.K.
E&tE9[iti) ~ App<ol<. 10_. I

Tim~
"1.0.1.5\,--
SST3.0B
Y/L ~
Voltage:
[Y] 4.4 • 6.6V (constanl)
~ ... O.K.
Go to 4).
Outside Ihe 4.4 • 6.6V range

or Voltage fluctuations
~
... N.G.
SST5588
J.~ N.G.
Check if terminal voltage drops O.K.. I Go to 5).
to 1.0 - 1.5V range approx. 10
seconds after ignition switch is
turned ON.
No change (outside 4.4· 6.6V
range) ... O.K.
Vollage drop ... N.G.
(;] LN.G
Check if position switch signal is N.G. Malfunctioning position switch

present at power steering eon- system
trol unit.
VES (0 volls, when posilion
switch is ON) ... O.K.
NO (4 • 5 volls) ... N.G.
L°.K.
properly.
r
©
ST-36
[t
~
-.
EEHiHm [t ©
•
Turn ignition switch ON, depress N.G. Malfunctioning power steering
ED G
TVl
clutch pedal (MIT model) and
move shift lever to "P" (AIT
control unit
00 ~
model).
Measure voltage between sole-
noid valve terminals of "check"
~
connector.
Voltage:
SST565B
4.4 • 6.6V (constant) ... O.K.
Voltage fluctuations •.. N.G.
~O.K
Check if heavy steering opera- ~I Go to 1).
I
turns.
YES ..• N.G.
tion) ••. O.K.
~OK.
END
4) CHECK POWER STEERING N.G. Malfunctioning power steering

SOLENOID VALVE FOR solenoid valve
PROPER OPERATION.
Disconnect solenoid valve con-
nector.
Apply voltage between connec-
tor terminals (on solenoid valve
side) and touch solenoid valve
to ensure that it vibrates.
(Vibration is felt after applied
voltage is removed.)
Yes ... O.K.
No ••• N.G.
O.K.
• Adjusting steering gear as-

sembly adjust screw
• Malfunctioning steering gear
assembly
• Malfunctioning oil pump
ST-37
m
N.G.
G/Y
SST559B Ii) OK
r="-------''---------,
Measure solenoid valve resis- N.G. Malfunctioning solenoid valve
tance. f--~ system
nector, and measure resistance
between connector terminals (on
solenoid valve side.)
Resistance:
4 - 6 ohms ••• O.K.
Gohms or Inflnlle ... N.G.
O.K.
properly.
Check if heavy steering opera- N.G. Malfunctioning power steering

tion occurs during stationary control unit
turns.
YES ... N.G.
NO (Lighter steering opere-
lion) ... O.K.
OK
END
ST-38
s Diagnostic Procedure 2
~ EEmm
-,
ID
G
SYMPTOM:
Light steering operation during high-speed driving
Raise rear wheels off ground
rn and start engine.
~ ~ m 1
Measure voltage between 501e- O.K.
~
noid valve terminals of "check" ©
connector while driving vehicle
SST565B
from 0 to 100 km/h (0 to 62
MPH).
Iil Voltage:
I~I Y/G o km/h (0 MPH):
4.4 - 6.6V ... O.K.
[iti) rn 100 km/h (62 MPH):
1.6 - 2.6V ... O.K.
,-~---, Constant voltage ... N.G.
1N.G.
~
Check speedometer for proper N.G. Malfunctioning vehicle speed
SST560B operation. sensor or speedometer
YES ... O.K.
[;] NO ... N.G.
1 O.K.
~IEEEEtS~
[;]
N.G.
CIMET === Check A.S.C.D. and vehicle Check if vehicle speed signal is
£) speed-sensing door lock for

proper operation.
present at speedometer.
Disconnect speedometer from
TVl Y/G
YES ... O.K. vehicle to facilitate work. Aecon-
E'...+
~ NO ... N.G. nect wiring. Measure voltage
between speedometer terminals
O.K.
while driving vehicle at very
~
SST5618 slow speeds.
1 volt (Min.) and 5 volts (Max.)
are alternately repeated ...
O.K.
No voltage is present ... N.G.
Iil O.K. N.G.
Check if vehicle speed signal is N.G.
present at power steering con-
trol unit.
Malfunctioning
While driving at very slow
speedometer
speeds, connect power steering
unit connector. Measure termi-
nal voltage.
1 volt (Min.) and 5 volts (Max.)
are alternately repeated
... O.K.
No voltage is present ... N.G.
10 K
Ensure that power steering con- Improper connection between
trol unit connector is connected speedometer and power steer-
properly. iog control unit
~
ST-39
TWIN ORIFICE POWER- STEERING SYSTEM
r.:I
~
®
+
Y/G Measure voltage between sole- O.K. Check if steering operation is
noid valve connector terminals heavy during high-speed driv-
of "check" connector while driving.
ing vehicle from 0 to 100 km/h (0 YES ... O.K.
+ - to 62 MPH). NO.o.N.G.
Voltage:
N.G. O.K.
okm/h (0 MPH):
4.4 - 606V ••• O.K.
100 km/h (62 MPH): END
SST560B
1.8 - 2.8V ... O.K.
No yollage variations •..
NoG.
14----.-<c
N.G.
Ii
Measure solenoid valve resis- Disconnect solenoid valve con-
tance. nector.
Disconnect solenoid valve con- Apply voltage between connec-
nector, and measure resistance tor terminals (on solenoid valve
between connector terminals (on side) and touch solenoid valve
solenoid valve side). to ensure that it vibrates.
N.G.
Resistance: (Vibration is felt after applied
4 - 6 ohms .•. O.K. voltage is removed.)
o ohms or infinite •.. H.G. Yes O.K.
No N.G.
O.K.
N.G. O.K.
Malfunctioning power steering
control unit Malfunctioning
solenoid valve

sembly adjust screw
assembly
ST-40
Control Unit Inspection Table

The standard values (voltage), measured with an analog tester
in contact with the control unit terminal, are shown below:
Terminal No. Application Standard value
1 Power Approx. 12V

2 Ground OV
1 volt (min.) and 5 volts
(max.) are alternately re-
3 Vehicle speed sensor input
peated when vehicle is
driven at very slow speeds.
Pressed: Approx. 12V

4 Stop lamp switch input
Released: OV
OV (clutch engaged and
shift lever in "N")
... MIT models
5 Neutral switch input OV (selector lever in "N" or
"P") .., AIT models
4 - 5V (except for the
above)
Applied: OV
6 Parking brake switch input
Released: Approx. 12V
Power steering solenoid

o km/h 4.4 - 6.6V
7 100 km/h 1.8 - 2.8V
valve output
Fail-safe 1.0 - 1.5V
Performance of Controller
1.1
5
•en 1.0
e
•c.
E
• 0.8
;-
S
0
0
0.6
0.5
0.25 t--t---t----t-------------=
0.1
12 17) 30 1191 50 (31) 175 (109)
o 50 (31) 100 150 200

(62) (93) (124)
Vehicle speed km/h (MPH)
SST3498
ST-41
- Trouble Diagnoses (With SUPER HICAS system)
SYMPTOM:
Heavy steering operation during stationary turns or light steer-
ing operation during high-speed driving.
I START I
~ !
Check in self-diagnosis mode. O.K.
Refer to page ST-70. _
IN.G.
Repair malfunctioning part de-
tected by self-diagnosis.
Refer to "SUPER HICAS SYS-
TEM" - Trouble Diagnoses,
Diagnostic Procedures 5 to 12.
DATA 111j~nT0R
ACTII)E TEST
rcu PART flur"lBER Check for heavy steering opera-
tion during stationary turns or
light steering operation during
SST4768 high-speed driving
YES .•. N.G.
tion; Stationary turns.
Heavier steering opera-
tion; High.speed driving.)
... O.K.
lOK
1 END 1
~ ~ ~
IllSClIlMECT
CHECK POWER STEERING SO- N.G. Malfunctioning power steering

LENOID VALVE FOR PROPER solenoid valve
OPERATION.
nectar.
Apply voltage between connec-
tor terminals (on solenoid valve
side) and touch solenoid valve
to ensure that it vibrates.
(Vibration is felt after applied
voltage is removed.)
Yes O.K.
No N.G.
O.K.

sembly adjust screw
assembly
ST-42
SUPER HICAS SYSTEM
HICAS Component Parts Location
HICAS solenoid valve
Control unit
Steering
angle sensor
~-.
--:::::::::7-~ ~ Fail-safe valve
Power steering
solenoid
Power
cylinder
SST604B
System Diagram
Control unit
Vehicle speed sensor
Steering angle Power

sensor cylinder
bcent.,;ng
~ sp"ng
~
~
t ' i.. ..'-
'- Fail-safe
',~,
valve
Power steering
solenoid
SST451B
ST-43
SUPER HICAS SYSTEM - On-vehicle Inspection
Checking Fluid Level

Maintain the fluid level so that the lower surface of the float is
maintained between the "L" and "H" marks on the gauge rod.
The fluid level should be checked when the engine is stopped
~==*O.K. and the fluid temperature is normal.
CAUTION:
• Do not overfill.
• Recommended fluid is Automatic Transmission Fluid
"Dexron TM" type.
SST3738
Checking Fluid Leakage

Check lines for proper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
Fluid leakage should be checked for when the oil temperature is
normal with the engine idling.
SST60SB
Lines parallel to Measuring Rear Toe-in

center line of body
Measure distance "A" and "B" at the same height as hub
center.
Total toe-in:
A - B: 0 • 4 mm (0 - 0.16 in)
28: 0' - 22'
Refer to "SUPER HICAS" in section RA.
Front
"'<?'-.-' Toe-in = A - B
**
SFA2:MA 6 TaUI toe-in Ingle = 26
ST-44
Inspection of HICAS System Operation

CAUTION:
Ensure that shift lever is set to "P" (A/T model) or "Neutral"
(MIT model) before checkin~CAS system operation.
When CONSULT is used: \j)
1. Have a helper sit in the drfver's compartment and raise
vehicle.
(Use a two-pole lift or a center pole lift so that the four
wheels are free to rotate.)
2. Connect CONSULT unit to diagnosis connector and start
engine,
3. Touch "START" on CONSULT display.
4, Touch "HICAS", "ACTIVE TEST" and "SIMULATED DRIVE"
in that order,
5, Touch "START" when MAIN SIGNALS display is reversed .

• SIMULATED DRIVE TEST.
~ SELECT M5NIT5R ITEM
MAIfI SIGNALS
SELECTI5N FR5M MENU
START
SST3758
6. Touch "START."
• ACTIVE TEST. [J
After simulated drive condition has continued for 5 minutes, it
DRIVE HIGH SPEED will automatically cancel and CONSULT unit will then show
C[oI~DITWN
======= M5NIT5R ======= "TEST IS INTERRUPTED TO AVOID OIL TEMP. RISE" display.
STEERING ANG R II" To cancel this mode during self-diagnosis, simply touch
HICAS S5L RO.58A "CANCEL".
P5WER STR S5L 1.05A
CANCEL
SST3778
ST·45
Inspection of HICAS System Operation (Cont'd)
7. Operate engine at speeds greater than 2,000 rpm, and turn
0
steering wheel 180 in one direction from the neutral
position. Measure extension value of one power cylinder
rod and retraction value of the other. Then, turn steering
0
wheel 180 in the other direction from the neutral position,
and measure extension value of one cylinder rod and
retraction value of the other. Determine strokes of respec-
tive power cylinders by adding (measured) extension and
retraction values.
Measure rod strokes In as short a period of time as possible.
SST37BB Standard stroke:
'------------------' When turned to the right
2.6 mm (0.102 in)
When turned to the left
2.6 mm (0.102 in)
Total stroke
5.2 mm (0.205 in)
4 sec. When CONSULT is not used: @

1. Have a helper sit in the driver's compartment and raise
vehicle.
(Use a 2-pole lift or a center pole lift so that the four wheels
R.H. are free to rotate.)
L.H. 2. Set HICAS system in self-diagnosis mode.
(1) Turn ignition switch "OFF".
(2) Set shift lever to "P" or "N" position (A/T model), or
"Neutral" position (MIT model).
Time (3) Turn ignition switch "ON".
SST445B (4) Immediately start engine.
0
(5) Turn steering wheel from left to right (at least 20 from the
neutral position) 5 times or more, then depress foot brake
pedal at least 5 times all within 10 seconds after ignition
switch has been turned "ON".
0
3. Set steering wheel to a point approximately 10 from the
neutral position and check to ensure that rear wheels turn
to the left and right alternately.
ST-46
Inspection of HICAS System Operation (Cont'd)
0
steering wheel 180 in one direction from the neutral
Neutral pO,ition position. Measure extension value of one power cylinder
rod and retraction value of the other. Then, turn steering
0
wheel 180 in the other direction from the neutral position,
and measure extension value of one cylinder rod and
retraction value of the other. Determine strokes of respec-
tive power cylinder rods by adding (measured) extension
and retraction values.
Measure rod strokes in as short a period of time as possible.
L- .:::SS:.:.T3:.:.7::::J68 Standard stroke:
When turned to the right
2.6 mm (0.102 In)
When turned to the left
2.6 mm (0.102 in)
Total stroke
5.2 mm (0.205 In)
Do not depress foot brake pedal during operation check.
otherwise the operation will be stopped.
Bleeding Hydraulic System

Before bleeding air from the HICAS system, be sure to bleed air
from the power steering system.
Refer to "SUPER HICAS SYSTEM - Repair of Component
Parts".
ST-47
SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder
~~39. 49 (4.0 - 5.0, 29 • 36)
~ l)
~@
~
i:(. r~
II
.: (8.6 • 11, 62 - 80)
~ 45 • 60 (4.6 - 6.1, 33 • 44)

A: Nm (kg·m, ft-tbl
88T6078
REMOVAL
• Detach power cylinder lower links from axle housing sock-
ets with Tool.
• Disconnect oil pipes from power cylinders and remove

power cyl inders.
CAUTION:
Plug openings of oil pipes and power cylinders to prevent entry
of foreign particles after removal.
INSTALLATION
1. Before installing power cylinder on suspension member,
wipe power cylinder bracket and mating surface of suspen-
sion member. Using the left side of the bracket as a
reference point, locate the right side (oblong hole side) and
install power cylinder.
CAUTION:
¢JLH R.H.¢ a. To prevent entry of foreign particles, clean oil pipes and
connectors using dry compressed air.
b. Ensure that your hands are clean and free from foreign
88T6098
particles when connecting 011 pipes.
ST·48
Power Cylinder (Cont'd)
2. Install power cylinders and oil pipes.
3. After installing lower link assemblies, check toe-in to en-
sure that it is within specifications. If it is not within
specifications, perform proper adjustments.
Refer to "SUPER HICAS" in section RA.
BLEEDING HYDRAULIC SYSTEM

Before bleedlnq.air from the HICAS system, be sure to bleed air
from the power steering system.
CAUTION:
Ensure that shift lever is set to "P" (A/T model) or "Neutral"
(MIT model). M
When CONSULT Is used: '-.iJ
1. Connect CONSULT unit to diagnosis connector on body
side.
2. Have a helper sit in the driver's compartment and raise
vehicle.
Use a two-pole lift or a center pole lift so that the four wheels
are free to rotate.
3. Start engine.
• SIMULATED DRIVE TEST. 4. Touch "START" on CONSULT display. (Display will then
~ SELECT MGNITGR ITEM change.)
MAIH SIGHALS
5. Touch "HICAS", "ACTIVE TEST", "SIMULATED DRIVE"
and "START" in that order.
SELECTIGN FRGM MENU Before touching "START", ensure that MAIN SIGNALS display
is reversed.
6. Touch "START".
STA,:T
SST375B
ST-49
0
steering wheel 180 to the right from the neutral position.
Loosen right power cylinder bleeder valve to bleed air, then
retighten. Return steering wheel to the neutral position.
0
steering wheel 180 to the left from the neutral position.
Loosen left power cylinder bleeder valve to bleed air, then
retighten. Return steering wheel to the neutral position.
9. Repeat steps 7. and 8. until there are no air bubbles in fluid.
While bleeding air from power cylinders, never allow fluid
level to drop below inlet port of reservoir tank (by adding
fluid as required).
10. Touch "CANCEL" on CONSULT display and turn ignition
switch OFF.
When CONSULT is not used: ®

1. Have a helper sit in the driver's compartment, and raise
vehicle.
Use a two-pole lift or center pole lift so that the four wheels are
free to rotate.
2. Set HICAS system in self-diagnosis mode.
(2) Set shift lever to "P" or "N" position (AIT model), or
SST4178
(3) Turn ignition switch "ON".
(4) Immediately start engine.
0
(5) Turn steering wheel from left to right (at least 20 from the
0
3. Set steering wheel within 10 from the neutral position.
Ensure that rear wheels turn to the left and right alternately.
4. Operate engine at idling speed, and turn steering wheel
0
180 to the right from the neutral position. Loosen right
power cylinder bleeder valve to bleed air, then retighten.
Return steering wheel to the neutral position.
5. Operate engine at idling speed, and turn steering wheel
0
180 to the left from the neutral position. Loosen left power
cylinder bleeder valve to bleed air, then retighten. Return
steering wheel to the neutral position.
6. Repeat steps 4. and 5. above until there are no air bubbles
in fluid. While bleeding air from power cylinders, never
allow fluid level to drop below inlet port of reservoir tank (by
adding fluid as required).
7. Turn ignition switch OFF to complete self-diagnosis opera-
tion.
ST.50
DISASSEMBLY AND ASSEMBLY
Air bleeder
~ Stroke stopper EI
V
fI? ttJ.l& - 8
(0.& • 0.8. 4.3 • 5.8) Inner socket ~
Dust boot
e;~~ ~~:::.,:
ttJ.l 37 - 48
(3.8 - 4.7. 27 - 34)
--, l~.,
ttJ.l 49 - 89 (5.0 - 7.0.
38 - 51)
Boot clamp ~
1c
or---L.
L~
Boot band
Outer link
ttJ.l . Nsm (kg-m. ft-Ib)
SST610B
Power cylinder assembly cannot be disassembled. When it is

malfunctioning. replace power cylinder as an assembly.
DISASSEMBLY
1. Remove clamps from left and right dust boots. and move
dust boots toward outer links.
2. Attach wrenches to left and right ball joint sockets. and turn
in directions that loosen lower links. Remove one of loos-
ened lower link assemblies.
SST611B
3. Loosen stroke stopper lock nut from which lower link

assembly was removed. and remove stroke stopper.
~ , ..
Width ICrOIl fla" :JftJJ
Stroklstopper SST386B
ST·51
• While attaching a wrench to "width across flats" section of
e rod end from which stroke stopper was removed, remove
the other lower link assembly.
SST6128
ASSEMBLY
1. Install stroke stopper and lock nut on the lower link assem-
bly to be assembled.
SST388B
2. Apply Locktite to inner ball joint thread. Attach a wrench to

"width across flats" section of piston rod (located on the
other side) to prevent rod from turning. Install lower link
assembly.
SST613B
3. After installing stroke stopper and lock nut on the other

lower link assembly, install lower link assembly. Attach a
wrench to inner ball joint (to prevent it from turning), tighten
inner socket to specified torque.
Inner socket:
~: 78 - 98 N'm (8 • 10 kg-m, 58 - 72 ft·lb)
SST6148
Lock nut 4. If stroke stopper was moved during removal of lower link,
LOJ 49 - 69 Nem adjust it after installation, as described below:
(5.0 • 7.0 kg-m, 36 - 51 fl·lb)
(1) Loosen lock nut which secures stroke stopper.
2.9 - 3.1 mm (2) Turn stroke stopper until clearance between inner ball joint
(0.114 - 0.122 In)
and stroke stopper is 2.9 to 3.1 mm (0.114 to 1.122 in) on
each side.
(3) Tighten lock nut securely.
Lock nut:
~: 49 - 69 N'm (5.0 • 7.0 kg-m, 36 • 51 ft-lb]
(4) Recheck clearance between inner ball joint and stroke
S$T391B stopper on each side.
ST-52
5. Install dust boot using new boot band and clamp.
• Apply a coat of grease to grooves at boot location.
SST392B
ST-53
Oil Pump
Connector bolt
~69.78
f7.0 . 8.0. 51 ·581
~ V·35 (2'8'3'6'20'2B1~
Lo.,;n g
~rI
Front bracket
~Corls:::~ O.,lng ~~,. •
~ 0 •
Pulley
~ snap.,ng~
• • '\ Drive shaft ~ 14 .18 fl.4 ·1.8. 10 .131
Rotor~ r
011 seal ~ rI ~
c ~~~. Front housing Y'fT T~ Stopper bracket
.. ~ Wave washer .. ~~DJ.
~ ~~ ~ O-ring (Inner) t)~ ~..~.
~ ~",\ O-ring (Outer) t)~.. .<, _ .
v< Spring
. ~~. .> ~rI ~>~

. . Front side plate Suction pipe '
.> O·.,ng I Control valve
s:
Pm,.. 1.:9J&. " /"'"
Cam ring O-ring {Inner] ~~~ ~. 1 .
.. Vane - '/
Gasket ~ U 12
Cam ring \" Q Connector bolt
~ 31·42 ,,()
Wavewasher
f7.0 • 8.0.
51 .58)
(3.2·4.3,
, ... ~ O-ring (Outer) t) ~ Copper washer
23·311
~ \ Rear Side plate ~ rI
\ \
!S i Aotor
Pm
Gasket ~ rI
Rear housing
~ : N·m (kg-m, ft·lbl
SS13938
PRE-DISASSEMBLY INSPECTION
Disassemble the power steering oil pump only if the following
items are found.
• Oil leak from any point shown in the figure.
• Deformed or damaged pulley.
Procedures for disassembly and assembly are the same as
those for the power steering oil pump.
5$13948
ST-54
Disassembly
CAUTION:
• Paris which can be disassembled are strictly Ii"lited. Never
disassemble paris other than those specified.
• Disassemble in as clean a place as possible.
• Clean your hands before disassembly.
• Do not use rags; use nylon cloths or paper towels.
• Follow the procedures and cautions in the Service Manual.
• When disassembling and reassembling, do not let foreign
matter enter or contact the paris.
1. Remove connector.
Be careful not to drop control valve.
Be careful not to confuse main side with sub side.
SST3958
2. Remove rear housing.

3. Remove center housing.
4. Remove cam ring, rotor and other parts from center hous-
ing (sub side).
5. Remove cam ring, rotor and other parts from front housing
(main side).
Be careful not to confuse main side with sub side.
SST401B
6. Remove snap ring, then draw drive shaft out.

Be careful not to drop drive shalt.
Drive shaft
SST399B
ST·55
Disassembly (Cont'd)
7. Remove oil seal.
Be careful not to damage front housing.
SST400B
Inspection
If any of the following parts are scratched or damaged, replace
oil pump assembly.
• Mating surfaces of front housing and cam center housing
• Mating surfaces of rear housing and cam center housing
• Front housing bushing (at drive shaft support location)
• Flow control valve
• Drive shaft
• Rotor
Assembly
Assemble oil pump in the reverse order of disassembly, noting
the following instructions.
• Before installation, coat the O-rings and oil seal with A.T.F.
• Make sure O-rings and oil seal are properly installed.
• When assembling vanes to rotor, rounded surfaces of
vanes must face cam case side.
• Always install new O-rings and oil seal.
• Be careful of oil seal direction.
1. Press oil seal into front housing and apply grease to sealing
lips.
Press
2. Press shaft assembly into front housing and install snap
ring.
SST4038
ST-56
Assembly (Cont'd)
3. Install component parts on front housing in the order
indicated below:
O-ring Valve washer
1) O-ring x 2
2) Wave washer
Center housing
3) Side plate
4) Rotor [thickness: 16.25 mm (0.6398 in) (main side); 13 mm
(0.51 in) (sub side)]
5) Vane
6) Pin
7) Cam ring [thickness: 16.25 mm (0.6398 in) (main side); 13
mm (0.51 in) (sub side)]
4. Place packing on front housing and position center housing
on the packing. In the manner similar to step 3. above,
install component parts on front housing (sub side).
Gasket
CAUTION:
• Ensure that O-rings are positioned properly.
• Ensure that vane is installed with curved side facing cam
Front housing
ring.
• Use cam, rotor vane as original single unit.
• Ensure that control valve moves smoothly.
88T4048
Rear housing side Front housing side

• Pay attention to rotor direction.
Punchmark
SST2B9A
• Pay attention to cam ring direction.
SST2058
ST-57
HICAS Solenoid Valve and Fail-safe Valve

• Do not loosen lock nut which secures solenoid since HICAS
solenoid fair-safe valves are of types that should not be
disassembled.
• If any part is found to be malfunctioning, always replace as
a valve assembly.
SST405B
SST406B
• Whenever tubes are disconnected, check tube seat for

scratches or damage. A scratched or cracked tube seat may
cause oil leakage. Replace it using pin punch.
SST3978
HICAS solenoid valve Fail-safe valve

Part No. 49528-31 P10 49528-52L10
A (dia.) mm (in) 1.5 (0.059) 6.5 (0.256)
__4+0-- A (dlo.1
SST4078
Steering Angle Sensor

• Ensure that steering angle sensor bolts are secure and
tight.
• If any part of steering angle sensor is malfunctioning,
replace steering angle sensor assembly.
ST-58
Steering Wheel
O.K. N.G.
CHECKING NEUTRAL POSITION
• Check that the steering wheel is in the neutral position
when driving straight ahead at a speed of at least 70 km/h
(43 MPH).
• If it is not in the neutral position, remove the steering wheel
and reinstall it correctly.
• If the neutral position is between two serrated teeth, loosen
tie-rod lock nut and move tie-rod in the opposite direction
SST104B by the same amount on both left and right sides to compen-
sate for error in the neutral position.
ST-59
SUPER HICAS SYSTEM - Trouble Diagnoses
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair 5T-61
Symptom Chart 5T-62
Preliminary Check 5T-63
Component Parts and Harness Connector Locations 5T-66
Circuit Diagram for Quick Pinpoint Check 5T-67
Wiring Diagram 5T-68
Self-diagnosis (When CONSULT is used) 5T-70
Self-diagnosis (When CONSULT is not used) 5T-73
Diagnostic Procedure 1 5T-76
Control Unit Inspection Table 5T-96
ST-60
How to Perform Trouble Diagnoses for Quick

and Accurate Repair
WORK FLOW
CHECK IN <Reference item
LISTEN TO CUSTOMER
COMPLAINTS AND CONFIRM.
INVESTIGATE ITEMS RELATED Symptom Check

TO EACH SYMPTOM. (See page ST-62.)
r-----~
Fluid level and leakagecheck

BASIC INSPECTION (See page ST-63.)
Self-diagnosis Preliminary
PERFORM SELF-DIAGNOSIS (See page ST·lO.) check
1--------- PERFORM REAR WHEEL ACTION
I CHECK Rear wheel action check
I ,-----
I (See page ST-64.)
I ,
I
I
I
I INSPECTION ON THE Diagnostic Procedures 1 to 4
BASIS OF EACH (See pages ST-l6 to B5.)
SYMPTOM
Self-diagnostic item
INSPECTION ON THE Diagnostic Procedures 5 to 12

BASIS OF EACH MAL· (See pages ST·B6 to 95.)
I
I FUNCTION
I
I
I
I
I
I
I
I REPAI R/REPLACE
I
I
I
I
l !'!..~.
FINAL CHECK
CHECKOUT
ST·61
Symptom Chart
DIAGNOSTIC TABLE
Preliminary
PROCEDURE Diagnostic Procedure
Check
REFERENCE PAGE (ST-) 63 63 64 76 77 79 80 86 88 89 90 91 92 94 95
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i5
No warning lamp comes on when ignition switch is turned "ON" a a
Warning lamp comes on when engine is funning a a a a a a a a a a a a a
Abnormal noise is emitted. a a a a
Vehicle behavior is unusual (due to malfunctioning HICAS system.) a a a a a a a a a a a a
System is not set in self-diagnosis mode. a
Self-
diagnosis Diagnosed part CONSULT indication
code No.
HICAS solenoid valve (RH) oUI- HICAS SOLENOID-R

1
put is not present. (ABNORMAL SIGNAL]
a
HICAS solenoid valve (lH) oUI- HICAS SOlENOID-L
2
put is not present. (ABNORMAL SIGNAL]
a
Pall-sate valve output is not FAIL-SAFE VALVE
3
present. [ABNORMAL SIGNAl]
a
J1 Power steering solenoid output POWER STEERING SOL
"5
0
4
is not present. [ABNORMAL SIGNAL]
a
e
.
.2
0
e: 5
Vehicle speed signal is not
present.
VEHICLE SPEED SENSOR
[NO SIGNAL] ('a)
CAR SPEED SENSOR
a
0>
~ [SIG-SUDDEN TURN] ('b)
.'"
'0
....
6
STEERING ANGLE SEN
[NO ANG SIGNAL] ('a)
STEERING ANGLE SEN
Steering angle sensor input is [NO NEUT SIGNAL] Cob)
not present. STEERING ANGLE SEN
a
[NEUT SIG-360" OFF] (-c)
7 STEERING ANGLE SEN
(NEUT SIG-30" ON] ('d)
Parking brake (AT) or clutch

8
switch (MT) input is not present.
- a
Inhibitor switch (AT) or neutral
9
switch (MT) input is not present.
- a
ST·62
Preliminary Check
CHECK 1
Checking fluid level and fluid leakage
....-::~~=* O.K. Refer to "SUPER HICAS SYSTEM - On-vehicle Inspection" on
page ST-44.
SST3738
SST605B
CHECK 2
Perform self-diagnosis.
Refer to "Self-diagnosis" on page ST-70.
SST4768
ST-63
Preliminary Check (Cont'd)
CHECK 3
• SIMULATED DRIVE TEST.
Perform rear wheel action check.
~ SELECT MGHITGR ITEM
MAIt1 SIGNALS When CONSULT is used: 00
SELECTIGH FRGM MEHU
1. Have a helper sit in the driver's compartment, and raise
vehicle.
(Use a two-pole lift or a center pole lift 50 that the four
STAF~T wheels are free to rotate.)
2. Connect CONSULT unit to diagnosis connector and start
SST3758
engine.
3. Touch "START" on CONSULT display.
4. Touch "HICAS", "ACTIVE TEST" and "SIMULATED DRIVE"
in that order.
5. Touch "START" when "MAIN SIGNALS" display is re-
versed.
6. Touch "START" .
• ACTIVE TEST. [] Aller simulated drive condition has continued for 5 minutes, it
DRIVE HIGH SPEED will automatically cancel and CONSULT unit will then show
CON[) ITIGH "TEST IS INTERRUPTED TO AVOID OIL TEMP RISE" display. To
======= MGHITGR =======
STEER IHG At1G R 11' cancel this mode during self-diagnosis, simply touch
HICAS SGL RO.58A "CANCEL" .
PGWER STR SOL 1.05A
CAt-..JCEL
SST377B
7. While running engine at speeds greater than 2,000 rpm, turn

steering wheel 180' to the left and right from the neutral
position. Ensure that rear wheels steer in response to
rotation of steering wheel.
ST·64
Preliminary Check (Cont'd)
When CONSULT Is not used:
1.
®
Have a helper sit in the driver's compartment and raise
vehicle.
(Use a 2-pole lift or a center pole lift so that the four wheels
are free to rotate.)
2. Set HICAS system in self-diagnosis mode.
(2) Set shift lever to "P" or "N" position (A/T model). or
L- S::Se.-T4e.-17:.::JB (4) Immediately start engine.
(5) Turn steering wheel from left to right (at least 20' from the
pedal at. least 5 times all within 10 seconds after ignition
3. Set steering wheel to a point approximately 10' from the
neutral position and check to ensure that rear wheels turn
to the left and right alternately.
SST4778
ST-65
Component Parts and Harness Connector

Location
HICAS warning lamp

CONSULT connector
Power cylinder
Power steering solenoid
Fail-safe valve
Steering angle sensor Oil pump
88T6158
ST-66
-
IGNITION SWITCH BATTERY -I

ONorSTART I
® : R.H. drive model I
FUSE
FUSE~ 1 rusE~ FUSE~ f/)
@ c:
'V
m
@ STQPlAMP ®l :D
0
STEERING @ :::c
811115 32 7 16
ANGLE sm~ (;
SENSOR e
To stop lamp
»f/)
(i) @ @
C1£' ::K To E.C.C.S. co Init f/)
COli NECTOR ~ I o:::;"
(Engine T.p.m.)
n -<
f/)
@ro ',
. l c
16 a 4 11 s ;:;: ....
• 2 7
IIt. m
" 101-- c
.
1 3:
ii
JOINT 17 I-- co
123.4567 17 • 18111
~ HICAS CONTFKX. UNIT • II 1011 131415 II 22 23 2•
@ III
rtEfE~@) 6 . 241-- 3
. .....I
5. El:i=I 0
0' c
17
L 16 8 22 23
CD
14 1.
..0
2. C
!lL- ELECTRIC
c_.
n
_.
III
SPEED-
OMETER
U~~ ~@ :I\" co
S~ ::I
:!! 0
EIiH!E P R N 0 2 1 ::I In
--0- CD
In
r- ",
" ,. 1
::I
•a " ~ @ @
@ @ @ @ (")
~ • ;U g!'"
Is i ~
r-v •
•r ~ ~ ~o ;E: '-f' ;E:
-
:t'
CD
~ <@
~ @l
il ~rr @ i
@> INHIBITOR @ -.L@
VEHICLE """"".., -'- _L -
SPf:=ED - -- - -=
-_ SENSOR -= -= -= -= POWER HICAS
-= "" NEUTRAl PARKING HICAS HICAS
HICAS ~e BRAKE ClIJTQi FALSAFE STEERING SOlENOID
SWITCH VALVE
~ OILtEVEl SWITCH SWITCH SOLENOID SOlENOID
ill SWITCH VAlVE VAlVE
~GD G)@S)I E>~ me ~e<D ~s ~E>

s®
INHIBITOR
r
SWITCH STEERING ;:t
COMBINATION METER WARNING LAMP ANGlE
~ SENSOR !=l
VEHICLE I14TOf1OfTT
SPEED ~. SPEeo-
ELECTRIC 4
s::
SENSOR ! "~ ~"18 ~'
, 17 OMETER 1<1 HICAS 7 ®: A1Tmod&l o
' U FUSEBLOCK lQl: MIT model
c
4 (Refer to "POWERSUPPLY
m
~ : ROUTl~G· in EL_section.) _ EEmf1] ~ ffim3 l;;
•
~ ~
@'W
~
®<f? <;1;l @ I ~ ..NlmN SWITCH II @ EHfflll@
.~ ! '" ,ONorSTART ~~(§ rEEEW3 @
o r- ~~ ID
o .~ .§~.~ en
HICAS c:
M' CONTROL
.
H~~r
~~ UNIT "Cl
ECTOR
y
m
, M
L..-
L- ----
---n"
I
I IIII ~ I
~~ :II
~ .... !B air- ~ ID ---11M no' G .. " .. , ------tt---:l
I :::I:
== ~, :~" =t:t:J=-J
~9" aN II II I I I
__ ---.J @V@ (Main 10:
harness)
®l$l$l® ~®
~ _ (Blue)
@)1'tJ--L(
~
en
~' :§
M
~, -<
en
:::J
lQ -I
en Tn Tobub
m
k relay
C s::
(Brown)
iii'
_ _ r -~~~ I I I IIII I lQ
(Engineroom
~ I
harness) Dl -I
3
. ..
o
BATTERY I c
CT
- CD
-M'
c
iii'
",- lQ
~
:::J
~ '" To stop lamp
o
1/1
• CD
[ill @ (Blacl<)
L.l111.lil111@ 1/1
• 1 1 1 .... ~li) Qg!aOl ~"'~ HICAS
mIIi! I II @ (Body harnessNo. 2) ~ES~~
FUSEBLOCK @CQ:) <P@c::D@) .. ~ (Body VALVE
(In RELAY BOX) I harneSs).aJ B ..fh~
(Refer 10~ POWER
L - - WIG ~ --H3CI WIG --F WIG -0 'CJ---t::::::::
SUPPlY ROUTING"
in El section.)
Ililll~@ fi """" r= • """
~ ~~ ~ ~
@@ @ ~ JOINT @<§)
BOOY CHECK OONNEClOR BODY @~M@
HICAS GROU<D OONNECTOR GROUND
HICAS Oil LEVEL POWER
~
~
i8~
SOLENOID SWITCH STEERING BOOY
VALVE SOLENOID GROUND
'" VAlVE
STEERING
;Jl
COt.l3lNAnoN METER WARNING LAMP ANGLE J:
SENSOR
VEHICLE NEUlRAl !='
SPEED SWITCH SPEED- 18" 6
SENSOR "~ ElECTRIC ~" ~ i:
17 0ME1ER 14 HICAS 7 @, Afrmodel
iQI, wr model
oc
E!Effi1]~ ~ m
r-
CIl
~ ~
@ew
~
®<f?
;r ..... -<,.... mg
@) EEEm!ilJ ~ <§J rEHW3 § ) Et@il(§)
o ~ g~ 1Il
o >~ O~~m~
HICAS U)
l: III M A I , - CONrnOl c:
--~
H~· I, 1000NECTl]A UNIT
W.
W. -- "V
, L- - - , VW - m
I I I I ~'" c...'::
~,.... !~,....
" ~ '"
I --
L - - --111M 110' G .. ::D
~9A ON r-r- " :::I:
(Main
r-''''''
®l$ l$J@ @) ~ ow '
harness)
___
~® (Blue) ~----- g
@ - r-'w
(Engine room U)
harness)
-I.,
OR· - -
,
G
:e (/)
W
" ~ ~
r- Ge .... , ~
.3: ~
. - i8I2: ea -I
U) 1
rn I I
~~'@ •" • m
(Black) 0 117 C s:::
~
CO
•
j1 ® m'
~ ea
>-@-y,
@!l~PARKING DI
:JID~: -en BRAKE -I
8 <§) SWITCH
. .I
BATIERY
3 o
I I§) nfOnl ST': LAMP ( ') C"
-- e
"• ::BI ~SWITCH o CD
1-.., ~
r- L@-, nfOnl ~CH -
",-
mr • ::BI
<§)
~SWITCH .....a: cm'
ea
(Brown) I I r ~
~ ,. r= I To stop lamp
I III o
...
~JI~ "'" !II
I 80' g.oI CD
ITO ® 1 I m ~!" R-g"l:I" (Body HICAS !II
2.0 o hamess) FAILSAFE
FUSEBlOOK
.f mm
co
s.~
iiJ
of
SOlENOID
VALVE
(In RElAY BOX)
@)@ Q>@<J;l@) ®ii Q Q
(Refer '0 - POWER w"
SUPPLYROUTING- -F~,,:9~
in EL section.) ®@ 1Il @)
CHECK CONNEClOR BODY
@)@
u JlJt~
BODY
CONNEClOR GROUND
-I I ®ii@)
HICAS GROUND
HICAS OIL LEVEL POWER
18~
SOLENOID SWITCH STEERING
BODY
GROUND
VALVE SOlENOID
I VALVE
~ SELECT DIAG MODE

Self-diagnosis (When CONSULT is used)
SELF-DIAG RESULTS • Start engine.
• Touch START (on CONSULT display).
DATA MONITOR • Touch HICAS.
ACTIVE TEST • Touch SELF-DIAG RESULTS.
ECU PART NUf1BER
85T4128
• Self-diagnostic results are shown on display.

• SELF-DIAG RESULTS I[J Refer to Table on page ST-71.
FAILURE DETECTED
**** NO FAILURE ****
PRIHT
• SELF-DIAG RESULTS I[J

FAILURE DETECTED
HICAS SOLENOID-L
[ABNORMAL SIGNAL]
PRIHT
55T4138
l~ SELECT NAG ~10DE [J! For reference:

Recording input/output signals using data monitor function
SELF-DIAG RESULTS • Start engine.
DATA I'IONITOR • Touch START (on CONSULT display).
ACTI I.!E TEST • Touch HICAS.
• Touch DATA MONITOR.
ECU PART t-!UtlBER
58T4148
• Check to ensure that the ALL SIGNALS display is reversed.

I~ SELECT MONITOR ITEM I Touch START. Refer to Table on page ST-72.
, ALL SIGfiALS
SELECTION FROM MENU
1==
55T4158
ST-70
Self-diagnosis (When CONSULT is used) (Cont'd)
• Touch RECORD to record data.
Ensure that ON-OFF signal is produced when signal is entered
from each sensor while monitoring.
CAF: SPEm Okfl1.·!-r To cancel data recording during operation, touch CANCEL.
STEEPHfG AIlG L :3 11
HEUTPAL SIG o If
STOP LAI'1P '31.<1 OFF
PKB.···CLUTCH SI.,I oH
HEUTPAL SI.,J o II
WG F:EU Ut·~DEP 1500
HIeAS SOL PO.DOA
POI.,JEP ";TP SOL 1.05A
PECOF'[1 I
1\·~lmHHIP '::-,110 FAIL EJ
FAILSAFE/U n H
FAILSAFE flotf
WARNING LAI'1P OFF
F:EC::UF;O
SST4168
Self-diagnosis items
Diagnostic item Description Remarks
·"**NO FAILURE**** • No failure has been detected.
VEHICLE SPEED SENSOR • No vehicle speed signal is entered after vehicle has been
[NO SIGNAL] Cal operated.
VEHICLE SPEED SENSOR

• Vehicle speed signal abruptly changes during operation.
[SIG-SUDDEN TURN] ('b)
STEERING ANGLE SEN • Steering angle has not been changed while driving at a
[NO ANG SIGNAL] ('a) speed of at least 60 km/h (37 MPH).
STEERING ANGLE SEN • Neutral (ON) signal is not entered after vehicle has been
[NO NEUT SIGNAL] ('b) driven.
STEERING ANGLE SEN • Neutral (ON) signal is not entered even after steering
0
[NEUT SIG-360' OFF] ('e) wheel has been turned at least 360 •
STEERING ANGLE SEN • Neutral (ON) signal is continually shown at steering angle
[NEUT SIG-30· ON] ('d) of at least 3D'.
FAILSAFE VALVE • Output terminal voltage is abnormal due to broken or
[ABNORMAL SIGNAL] shorted HICAS fail-safe valve circuit.
HICAS SOLENOID-R • Output terminal voltage is abnormal due to broken or

[ABNORMAL SIGNAL] shorted HICAS solenoid valve (RH) circuit.
HICAS SOLENOID-L • Output terminal voltage is abnormal due to broken or
[ABNORMAL SIGNAL] shorted HICAS solenoid valve (LH) circuit.
POWER STEERING SOL • Output terminal voltage is abnormal due to broken or

[ABNORMAL SIGNAL] shorted power steering solenoid valve circuit.
ST-71
Self-diagnosis (When CONSULT is used) (Cont'd)
Data monitoring items
0: Standard
6.: Optional selection
Monitor item selection

Item Remarks
All items Item menu
Vehicle speed sensor (km/h) 0 f', -

Abnormal value is shown before straight-
Steering angle sensor (deg) 0 f', ahead position ("0") is set and after battery
is disconnected and reconnected.
Neutral signal
(ON-OFF display)
0 f', -
Stop lamp switch signal
(ON-OFF display)
0 f', -
Parking brake/Clutch switch Clutch switch signal for MIT model and
0 f',
(ON-OFF display) parking brake switch signal for AfT model.
Neutral switch Neutral switch signal for MIT model and In-
0 f',
(ON-OFF display) hibitor relay (N or P) signal for AIT model.
Engine rpm Engine speed greater thanlless than 1,500
0 f',
("OVER 1,500" or "UNDER 1,500" is shown.) rpm is shown.
Controlled current flow from control unit to

(R/L) (A)
0 c: HICAS solenoid valve and direction of cur-
rent control are shown.
Controlled current flow from control unit to

Power steering solenoid valve (A) 0 f',
power steering solenoid valve is shown.
Fail-safe valve ON (when connected) or OFF (when discon-

0 f',
(ON-OFF display) nected) is shown.
NON (fail-safe valve ON) referring to

Fail-safe system "normal" conditioner CUT (fail-safe valve
0 f',
(CUT-NON display) OFF) when in "fail-safe" condition are
shown.
Warning lamp Illumination control of control- unit's HICAS

0 f',
(ON-OFF display) warning lamp is shown.
Voltage measured with voltage probes is

• Voltage (V) - f',
shown.
Value measured with pulse probes is

shown.
• Pulse (rns, Hz or ) - f', If pulse cannot be measured, "#" is down.
"#" is also shown at left of final data until
measurement results are determined.
ST-72
SUPER HICAS SYSTEM -. Trouble Diagnoses
Self-diagnosis (When CONSULT is not used)

SELF-DIAGNOSIS PROCEDURES
1. Input starting conditions for self-diagnosis.
(2) Set shift lever to "P" or "N" position (A/T model), or
(4) Immediately start engine.
(5) Turn steering wheel from left to right (at least 20· from the
2. Input self-diagnosis item.
(1) Depress and release foot brake pedal.
(2) Turn steering wheel from left to right (at least 20·) from the
neutral position.
(3) (MIT model)
Depress clutch pedal and move gear shift lever to any
position other than Neutral and return to Neutral. Release
clutch pedal.
(A/T model)
Disengage and engage parking brake lever. Move shift
lever to any position other than Neutral or Parking and
return to Parking.
(4) Move car at least 3 meters (10 ft) forward and proceed at an
indicated speed of at least 2 kmlh (1 MPH) in self-diagnosis
mode.
3. The self-diagnosis mode will then appear in the "HICAS"

warning lamp.
When all systems are normal:
HICAS warning lamp flashes at 0.25-second intervals.
55T4178
ST-73
Self-diagnosis (When CONSULT is not used) (Cont'd)
When there is a system malfunction:
Example: When ® HICAS solenoid valve LH, @ power steer-
ing solenoid valve and ® vehicle speed sensor have
experienced a malfunction.
The warning lamp displays abnormal mode (1 sec. ON).
E1 If fail-safe system was operated (fail-safe valve is operat-
ing) when ignition switch was turned OFF for the last time,
fail-safe items will be displayed in numerical order in
modes indicated. After all items are displayed, display is
repeated again.
• To change the display mode to E1 , turn OFF ignition switch
aller mode I5J is displayed.
• When battery charge is insufficient, mode I5J is displayed.
Indicator 0.1 sec. Displav repeats until

(Normal key switch is turned
----+ Diagnosis starts
mode OFF or after acproxt-
10 times 1 sec. (Abnormal mode dlsplavs.I I disptavs.I - maretv 5 minutes have
ON ~- r-t- r-t-
(
I passed.
OFL
- - '-- '-- 2 sec. e ach for
CD through ®
5 sec.
5/1 ® ® @ ®
®\~:T' Parking A/T.-"
brake Inhibitor
HICAS HICAS Steering
Power Vehicle Steering sensor sensor
solenoid solenoid Fail-safe neutral
Diagnosis part steering speed angle
position
MIT. MIT.
valve valve valve solenoid Clutch Neutral
sensor sensor
R.H. L.H. valve
sensor
sensor sensor
SST418B
ST-74
Self-diagnosis (When CONSULT is not used) (Cont'd)
(5) If fail-safe system was not operated when ignition switch was
turned OFF for the last time, display will show self-diagnosis
results in numerical sequence in modes indicated below. After all
self-diagnosis results are shown, display is repeated again.
Display repeats until
I_
key switch is turned
Indicator 0.1 sec. OFF or after approxi-
~o';;;'"
rnatetv 5 minutes have
-
ON Diagnosis starts 1 sec. (Abnormal mode disptevs.I
passed.
<, 1 ( displavs.)
I
OFF 2 sec. each for

CD through ®
5 sec. 5 sec.
A/T:
Parking A/T:
Steering brake Inhibitor
HICAS HICAS Steering
power Vehicle neutral sensor sensor
solenoid solenoid Fail-safe angle
Diagnosis part steering speed position MIT: MIT:
valve valve valve solenoid sensor sensor sensor Clutch Neutral
R.H. L.H. valve sensor sensor
SST4198
CANCELING THE SELF-DIAGNOSIS FUNCTION

There are three methods for canceling the self-diagnosis func-
tion, as described below:
• The self-diagnosis system is canceled by the turning igni-
tion switch "OFF".
• After self-diagnosing has been operated for approximately
5 minutes, the self-diagnosis system will be automatically
canceled.
• The self-diagnosis system is canceled by a vehicle speed of
30 km/h (19 MPH) or over.
ST-75
SYMPTOM:
No warning lamp comes on when ignition switch is turned
"ON" .
I- - -START
-----
m L
CHECK WARNING LAMP N.G. Check and repair wiring.
POWER SUPPLY.
SST4178 1) Turn ignition switch "ON".
2) Measure voltage across
warning lamp connector ter-
minal®i and ground.
Voltage:
OR
Approximately 12V
O.K.
'----ktJ+ r_u.
IReplace warning lamp.
SST488B
ST-76
;;f-J ~~j I
SYMPTOM (A):
Warning lamp comes on during operation.
START
I~
I
W~:~
,,\\ II r.i.1 I
Check in self-diagnosis mode.
"=='-/" i'~
Refer to page ST-70.
\
<. SST4178
1
Repair malfunctioning part de-
tected by self-diagnosis.
O.K .. 1 END
I
r.i.1
00 @~
Refer to Diagnostic Procedures
5 to 12.
~ :3ElECT DI AG 1'1:;1[';:
:3ElF -(j I HI':; RESULT:o
O! <::-~/
'_:1 =:=J !NG
NHA 11(iNIH::'F-' Check connectors for improper O.K .. 1 END

I
~
~"~~
ACTIl)E TE:3T contact.
scu OO§~
I~
PH!':T NUt'18ER
~ I \ I' !NG
I Check steering neutral position.
'" SST4768 Refer to page ST-59.
ST·77
SYMPTOM (8):
Warning lamp comes on when ignition switch is turned ON;
however, it does not go out after engine start.
START
CoAT A MtiN IT0R
ACTIUE TEST
ECIJ PART NUMBER
Check in self-diagnosis mode. OK No engine rpm signal is en-
Refer to page ST-70. teredo
SST476B L - - - - - - r - - - - , - - - '
Warning lamp
~========~ remains ON
N.G.
Check rear wheel action. No No power is supplied to control

Left and right rear wheels are unit.
turned in response to rotation of
steering wheel.
Yes
Insufficient oil quantity.
Replace fluid level sensor (on A
reservoir tank) if warning lamp

remains on during engine oper-
ation.
ST-78
SYMPTOM:
Abnormal noise occurs.
START
Disconnect HICAS solenoid f-Y,",e",s-J1~~~~~--,

Noise stops. ---.l
valve connector and check noise I
55T6188 for changes.
'------,---------'
No
Bleed air from hydraulic system.

Noise occurs in any system
other than HICAS.
N.G.
,- l Locate and repair.
Replace control unit.
N.G.
END
IReplace HICAS solenoid valve.
55T4408
ST-79
1~Ci)(6)~Y
SYMPTOM:
Vehicle behavior is abnormal. (Vehicle sways or jerks.)
, if e-; ~==
i'll. START
I
~.
I
\ B ...I
O.K. END
Check steering wheel neutral
I I
m
• SST4758
position for misalignment and
steering angle sensors for
looseness.
I.~ ,,_.-.-:g ,~ ';c~~~ m !NG.
Check in self-diagnosis mode. N.G. Repair malfunctioning system

I SElF-(:olHI~ RESULTS I / Refer to page ST-7Q. detected by self-diagnosis.
I Refer to Diagnostic Procedures
'I~
NilA r11:;NIHiR
O.K.
~~
t ACTIUE TE~T I \
\\11 5 to 12.
I teo PART 1~1I~18EJ:::
I
I I Check static HICAS characteris-
I t "- tic performance.
SST476B Refer to flow chart A on page
ST-81.
~
Check dynamic HICAS charac-
teristic performance.
Refer to flow chart B on page
ST-84.
ST·80
~ A. Static HICAS characteristic performance check
I\!SSELECT 1)[;::',;; l'f':IC,;o-TI

:_J~J/ I START
~
3ElF-['Ii'lG RESIJU:~'
~
00
,~
I ['ATA r1(jt-HT(i~: ~
Set CONSULT in ACTIVE
!~
;::,CTIUE TE:3T
ecu F'ART rlUI·18ER.
~\"~
OO~
~ TEST mode.
I I ~ /I \\' OR
I I
<,
@ ~
Set self-diagnosis mode.
SST4768
El ~
m • Run engine at a speed of less
Neutral position" than 2,000 rpm.
• Turn steering wheel approxi-
A \§ St,oke -.r- mately 180' to the left or right.
~
taI"~,
~ I
Hili -.'-,
CHECK POWER CYLINDER
STROKES.
~I END
I ®
Each stroke from neutral

position:
SST378B
2,1 - 3.1 mm
(0.083 - 0.122 in)
[i]
r------', ~i3 [i] IN.G

l'
I ~. I Replace HICAS soienoid valve.
I
~
CHECK RESISTANCE OF HICAS N.G.
22~, 23)
SOLENOID VALVE.
Stop engine and disconnect HI-
CAS solenoid valve.
lQl Measure resistance between
HICAS solenoid valve connector
::.........:
SST441B·
terminals@and @ , and @.
Resistance
4·6n
~OK
ST-81
• ACTIVE TEST.
DRIVE HIGH SPEED I

CONDITION
== = MONITOR
STEERING ANG R180°
== =
HICAS SOL RO.95/\
POWER STR SOL 1.05A
CANCEL ISST304C
!-~0~--1 CHECK HICAS OIL PUMP RE-

LIEF PRESSURE.
I
• Cancel self-diagnosis mode.
: --<' ~@""b. : High·
I ~ I I pressure • Check HICAS oil pump relief
LI ...JI hose
_
pressure with engine running
~ .. "HICA~ at a speed of more than 2.000
~ \.\.SolenoldP rpm .
.... :0... _ ~ Relief pressure:
l' l' Tonk More than 5,884 kPa
(58.8 bar, 80 kg/em', 853
.00
Low-pressure
~ : Direction of oil flow hose SST478B psi)
lO.K.
@~ CHECK OIL PRESSURE AT FAIL-
11'0 SELECT ['1"03 ""DE 01

I SELF-DrAG RESULTS I
= = "'.~\./ M SAFE VALVE.
~ TEST mode.
I DATA MONITOR I
~
III~ ~
OR
~
I
1 .moE TEST
ECU PART NI)~lBER -- , 1\\'
II1II
Set self-diagnosis mode.
I I
I 1 "--""_---
SST4768
ST-82
Shut-off
valve is
closed t!1 ~
• Run engine at a speed of N.G. Replace HICAS solenoid valve.
more than 2,000 rpm and turn
Bleeder steering wheel approximately 1:1
valve = =---=-1:..
z z:
180' to the left and right. CHECK POWER CYLINDER
• Check oil pressure at bleeder STROKE.
valve of power cylinder. Each stroke from neutral posl-
Oil pressure: tion:
Power cylinder SST6198 More than 3,923 kPa 2.1 - 3.1 mm
(39.2 bar, 40 kg/em', 569 (0.083 - 0.122 In)
psi) Refer to page ST-48.
Neutr.1 position
O.K. N.G. O.K.
r- 1 Replace power cylinder. Replace fail-

safe valve.
®
85T3788
ST-83
B. Dynamic HICAS characteristic performance check
START
r
CHECK PIPING AND CONNEC-
TIONS. ALSO BLEED AIR FROM
HYDRAULIC SYSTEM.

TEST mode.
ACTII)E TEST
OR
EL:U F'ART NUI1E;ER
fU\ Set in self-diagnosis
~ mode.
S$T476B L- .--- ----'
~============~
Run engine at a speed of more
than 2,000 rpm.
O.K. 1 END _
N.G.
SST3788
ST-84
Replace HICAS solenoid valve.
CHECK POWER CYLINDER OK 1 END ----"

STROKE.
• After replacing HICAS sole-
noid valve, check power cylin-
der stroke.
SST3788 Each stroke from neutral posi-
tion:
More than 1.6 mm
(0.063 in)
N.G.
1 Replace power cylinder.
ST-85
m Diagnostic Procedure 5
~
SYMPTOM:
System is not set in self-diagnosis mode.
( q,ff
~.~ I START
I
m 1
~t#t ~~
CHECK CONNECTOR CONTINU- O.K. Poor connector connection
ITY
Disconnect steering angle sen-
SST4468
sor connector and control unit
IS) connector, and reconnect them
[i] i~MiJtU TCiR 1:~tlO FAIL Q firmly. Conduct self-diagnosis.
CA.: SPEW
STEE.:Hli3 AI·jG L 8 11
Okm/h ® IS) LNG
NEUT.:AL SI G o II CHECK STOP LAMP IN- N.G. Malfunctioning stop lamp switch
STOP LAI'lP SI...I OFF
PKB/CLUTCH SI.'
NEUTRAL :,1.,1
ENG REtJ
HICAS SeiL
o t·j
(I H
Ut-tC'ER 1500
PO.OOA
® !
PUT SIGNAL.
Set CONSULT in DATA
MONITOR mode.
system
P(jl,JER STR SOL 1.05A ON-OFF display
I RECOF:D
i~MeiN !TOR i;:~tKi FAI L LJ

I ® _
OR
Check that stop lamp in-
put is present at control
unit connector terminals
FAILSAFE/I) (i I·j
FAILSAFE NiJtj @ and @.
I~ARtH NG LAI1P (iFF Brake ON:
Approximately 12V
Brake OFF:
OV
[i] LO.K
I F'EI-npo
.... "-' "-" ., I CHECK STEERING NEU- O.K. - I Replace control unit.
TRAL POSITION SENSOR
IS)
SST4468
® ~
INPUT SIGNAL.
Set CONSULT in DATA
MONITOR mode.
~i)OO ® ® ON-OFF display

OR
Check that steering neu-
HmHEI Iffim tral input is present at

control unit connector
RIB B terminals 0 and @
when steering wheel is
TV! turned to the left and
~
+ right at least 20° from the
SST6348
neutral position.
Neutral position:
[i]
~ i)@a ® Approximately 5V
When turned at leasl 20·:
OV
II 0
7~ Iffim
LIW
B
t·
@
G
ill
~~
SST635B
ST-86
CHECK STEERING NEUTRAL O.K. Repair or replace harness be-

B
POSITION SENSOR OUTPUT tween control unit and steering
lcdiEJ SIGNAL.
Check that steering neutral out-
put is present at steering angle
angle sensor.
L/W
sensor connector terminals (j)
and@when steering wheel is
+ turned to the left and right at
SST449B least 20° from the neutral posi-
tion.
Neutral position:
Approximately 5V
When turned at least 20°:
OV
N.G.
131 CHECK STEERING ANGLE ~I Replace steering angle sensor. I

SENSOR POWER SUPPLY.
1\ I • 1\ 1) Turn ignition switch
I~ 2 I I I 1\ "ON".
GIY
steering angle sensor
connector terminal @
and ground.
Voltage:
Approximately 12V
SST450B Ii CHECK STEERING ANGLE
SENSOR GROUND CIR-
CUIT.
B
I\ • I
II 1\
Check continuity between
steering angle sensor con-
nector terminal@and
ground.
Continuity should exist.
Check and repair power supply

harness or ground harness.
SST420B
ST-87
SYMPTOM:
HICAS solenoid valve (left and right) output is not present.
O.K. I Poor connector connection
N.G.
CHECK RESISTANCE OF LEFT N.G. I Replace HICAS solenoid valve.

AND RIGHT HICAS SOLENOID
VALVES (on solenoid side).
1) Disconnect HICAS solenoid
valve connector.
2) Measure resistance between
58T4228 HICAS solenoid valve connec-
tor terminals@and@, and
@
Resistance:
4·6n
O.K.
CHECK RESISTANCE OF LEFT O.K. I Replace control unit.

AND RIGHT HICAS SOLENOID
VALVES (on control unit side).
1) Disconnect control unit con-
nector.
85T6368 2) Measure resistance between
body connector terminals @
and@,and@.
Resistance:
4 - 6Q
N.G.
Repair or replace harness be-

tween control unit and
HICAS solenoid valve.
ST·88
1m Diagnostic Procedure 7
~
SYMPTOM:
Fail·safe valve output is not pres ent.
~~.r ~ I START
I
m I
t» ~~ CHECK CONNECTOR CONTlNU-
lTV.
~I Poor connector connection
SST424B Disconnect fail-safe valve con-
nector and control unit connec-
iii tor, and reconnect them firmly.
Oil i5(@3 Conduct self-diagnosis.
1N.G .
~ iii
~
CHECK RESISTANCE OF FAIL- N.G. I Replace fail-safe valve.
SAFE VALVE (on fail-safe valve
side).
TID 1) Disconnect fail-safe valve
connector.
2) Measure resistance between
SST425B
connector terminals @and
[!1 DlSCDNII(CT
@.
~
~ E8 @a Resistance:
13·170
~
10 K.
~
[!1
24
CHECK RESISTANCE OF FAIL- O.K. I Replace control unit.
B SAFE VALVE (on control unit
WIG
side).
LID 1) Disconnectcontrol unit con-
'-~t-- nector,
SST637B 2) Measure resistance between
body connector terminals
@ and@.
Resistance:
13·170
1 N.G.
Repair or replace harness

between control unit and fail-
safe valve.
ST·89
m '"
?if IV
SYMPTOM:
Power steering solenoid valve output is not present.
I START
I
~~ ~~ ~ SST4278
m L
CHECK CONNECTOR CONTINU-
ITY.
Disconnect power steering sole-
~I Poor connector connection
I
noid valve connector and control
Ii) unit connector, and reconnect
~i500
them firmly. Conduct 5e11-
diagnosis.
<tB Ii] !N.G
CHECK RESISTANCE OF N.G. Replace power steering 501e-

POWER STEERING SOLENOID naid valve.
TQi VALVE (on solenoid side).

1) Disconnect power steering
~
solenoid valve connector.
SST428B 2) Measure resistance between
solenoid valve connector ter-
[!] minals@and @.
~ i5~ Resistance:
4 - 6Q
~ tHHHm [!] !OK
B B/y~f CHECK RESISTANCE OF ~I Replace control unit.

I
POWER STEERING SOLENOID
VALVE (on control unit side).
Till 1) Disconnect control unit con-
nector.
'-'----" SST6388 2) Measure resistance between
body connector terminals@
and@.
Resistance:
4·6Q
!NG
Repair or replace harness be-

tween control unit and power
steering solenoid valve.
ST-90
SYMPTOM:
Vehicle speed signal Is not present.
I!trr~
I START
I
m r .I Poor connector connection
ITY.
O.K.
I
SST430B Disconnect control unit connec-
tor and reconnect it firmly. Con-
Ii) duct self-diagnosis.
{~NG!HTCiR l:,IKi FAIL [;]
CAR SPEED
STEERHlG AIlG L
Okrl'1/h
.:,11
® Ii) ING
~I
,~
NEUTRAL SIG oN CHECK CONTROL UNIT Replace control unit.

I
SHiP LAI'lP SI,.I OFF INPUT SIGNAL.
PKB""CLUTCH SI.~ e II 1) Raise rear end of vehi-
11EUTRAL '=:1.,.1 I) t·f
E!-IG RE\.I UNDER150!) cle so that rear wheels
HICAS ',OL PO.OOA
POl,JER STR SOL
I F:ECOF:D
1.05A
I
® rotate freely.
2) Set CONSULT in DATA
MONITOR mode.
Vehicle speed display
{:,NONITOR {',NO FAIL LJ (km/h)
FAILSAFE/I) ,,1 !-I
FAILSAFE OR
!-IG!·I
1,IARIHt1G LAI'lP OFF
@ Measure voltage varia-
tions between control
unit connector term i-
nals@and @while
slowly rotating rear
wheels by hand.
PECOPD Voltage must change
between 0 and 5V.
SST41Sa
IN.G
Ii) Repair or replace harness be-
00 ®
lDNCT
~ £) tween speed sensor or control

unit and speedometer.
1EfmI:H1B I~ Y/B
B
[YJ
'--~
SST6398
ST-91
SYMPTOM:
Steering angle sensor input is not present.
~r14
~ II
m
START
1
CHECK CONNECTOR CONTINU- O.K. I Poor connector connection
ITY. I
SST430B
Disconnect control unit connec-
Ii) duct self-diagnosis.
1:'~10NIT0R J:::rtKi FAIL
CAR SPEE[)
STEERHlt3 At·lt3
[J
Okrfl." h
:::11
00 Ii) iN.G.
L
NEiJTRAL SIt3 e tl . CHECK CONTROL UNIT O.K . I Replace control unit. I
STOP LAHP SI.,_I OFF INPUT SIGNAL.
PKB/CLUTCH SI.•.I Ci H
I1EUTRAL SI..) o II 1) Turn ignition switch
EIlt3 REV
HIeAS SOL
P0~JER STR SGL
Ut·l[.'ER1500
PO.OOA
1.05A 00 -
"ON".
2) Set CONSULT in DATA
MONITOR mode.
I RELOFTI I Steering angle deg.
Neutral signal ON-OFF
1~,~1131'1 I Ti3R ,:::,110 FAIL EI OR
FAILSAFE/I) (1 II
FAILSAFE
1,IARtH Nt3 LAMP
1·1011
OFF
@ Measure voltage varia-
tions between control
unit termlnals<l). @
and @ , and ® when
steering wheel is
slowly turned to the left
and right at least 20·
I F:ECUF:D I from the neutral posi-
tion.
SST416B
Do not turn steering
wheel quickly.
Ii) Voltage must change
® ~i)OO
from 0 to at least 5V.
1~1rn:m!~
UW
IN.G.
(i
CHECK STEERING ANGLE SEN- O.K. Repair or replace harness be-
i RIG
I
I
I
UG
SOR OUTPUT SIGNAL.
1) Turn signal switch "ON".
2) Measure voltage variations
tween control unit and steering
angle sensor.
I
I
I ,I [Y] between steering angle sen-
I~_~....
sor connector terminals ®'
- +
SST640B @and@.and@.
Voltage must change from 0
(i ~---~ to at least 5V.
RIG I
~
B
""irnl \j 1 NG.
COllET
£) ~'
UW-
\
UG
I
@
00 TV!
~
SST641B
ST-92
I;]
RHEI
G/V
f1ti)
I;]
,
CHECK STEERING ANGLE

~I Replace steering angle sensor. I
lli SENSOR POWER SUPPLY.
1) Turn ignition switch
+
~
.i:'- "ON".
00 ~
steering angle sensor
connector terminal@
SST4348
and ground.
[Ii" Voltage:
Approximately 12V
~I
B
f1ti) II CHECK STEERING ANGLE
SENSOR GROUND CIR'
CUlT.
TIl] Check continuity between
steering angle sensor ter-
~
- minal @ and body
metal (ground).
Continuity should exist.
~
SST435B
iN.G.
Repair or replace power supply

harness or ground harness.
ST-93
SYMPTOM:
Parking brake Input Is not present.
~r14 ~ m
START
i
lTV.
O.K.. 1 Poor connector connection
I
I!I [;]
duct self-diagnosis.
f,MOfHTOR
CAR SPEE[:o
STEERIHG Aim
l;,IW FAIL
Okm.····h
L 811
® I!I
!N.G.
I1EUTRAL SI G II o CHECK CONTROL UNIT O.K.• 1 Repiace control unit.

I
STOP LAI'IP SI.•.I OFF INPUT SIGNAL.
PKB/CLUTCH SI.o.I H o
HEUTRAL SI,)
EI1G REV
HICAS SOL
H o
Um)ER1500
RO.OOA
POI.•.IER STR SOL 1,05A
® Set CONSULT in DATA
MONITOR mode.
ON-oFF display
I RECORD
,:~r11]H !TOR }~rtlO FAIL ~
I ® OR
Measure voltage varia-
nons between control unit
terminals@ and @when
FAILSAFE/V o 1·1 parking brake is
FAILSAFE I·WII
I,IARH I HG LAI1P (iFF engaged.
Voltage:
OV -+ Approxlmetaly 5V
i N •G .
I RECOFm I Check parking brake switch and

harness.
SST416B
I!I .......
[1t £) ®
ImmHB IrnIQ
Y/PU B
00 NJ
~
SST6428
ST-94
fa Diagnostic Procedure 12
SYMPTOM:
Inhibitor switch input is not present.
~~
~ I
fa
START
1
ITY.
O.K. ....I Poor connector connection
I
Ii! ,~:,r'IOH I TOR l:::~tK' FAIL [;]
duct self-diagnosis.
CAR SREED Okm,-·"h

:;:1I
® Ii!
lNG
STEERHIG AI'IG
I1EUTRAL ';:113
STOP LAI-IP Sl•.1
L
I] tl
OFF
CHECK CONTROL UNIT O.K. IReplace control unit. I
INPUT SIGNAL.
PKB/CLUTCH ~;I.,J o 1·1 Set CONSULT in DATA
1·IEUTRAL ~;I.,.1 I) II
EHG FEI.}
HICAS ~:;OL
PCil.,.IER STP SOL
UHCoER1500
PO,OOA
1.05A ® MONITOR mode.
ON-OFF display
OR
I FECOF:D I @ Measure voltage varia-
tions between control- unit
~
=
,':,111:11'1 I TOR ,':,IW FAIL
terminals <ill and@ when
FAILSAFE/I.} oH shift lever is moved from
FAILSAFE I·WII
I.~ARHWG LAI'lP OFF P to any other position.
Voltage:
OV ~ Approximately SV
IN.G
I FECOFD I Check inhibitor switch and har-

ness.
SST416B
Ii! colIEr
~ £) ®
IEBfiEHB 100Q
Y/L B
~ NJ
10+' -""
~
SST6438
ST-95
Control Unit Inspection Table

The standard values (voltage) measured with an analog tester, in contact with the control unit terminal,
are shown below:
Terminal No. Application Standard value

1 Service support elK input -
2 Service support RX output -
Key switch ON: Approximately 12V
3 IGN power supply
Key switch in other position: OV
4 Battery Approximately 12V
5 E.G.C.S. revolution signal -
Rear wheel rotating

6 Vehicle speed signal
OV - - greater than 5V (approx.), intermittent
7 Steering neutral position sensor Approximately 5V (Neutral position)
8 Resistance of power steering solenoid valve 4- an
9 Service support TX output -
10 Ground OV
Brake ON: Approximately 12V
11 Stop lamp switch signal
Brake OFF: OV
Parking brake engaged (AIT)!
13 Parking brake signal
clutch disengaged (MIT): Approximately 12V
Shift lever in any position other than
14 Inhibitor signal
Parking: Approximately 5V
Steering wheel turned

15 Steering angle sensor-1 signal
o_ _ Approximately 5V, intermittent
16 Steering angle sensor-2 signal -

17 Ground OV
18 Resistance of fail-safe valve 13 - 17!l
Ignition switch ON: Approximately 12V
19 IGN power supply
Ignition switch in other position: OV
20 HICAS warning lamp -

22 Resistance of HICAS solenoid valve (R.H.) 4- an
23 Resistance of HICAS solenoid valve (L.H.) 4- 6n
24 Ground OV
1 2 3 0 4 5 6 7 17 0 18 19
8 9 10 11IX 13 14 15 16 20 1X122 23 24
55T6328
ST-96
SERVICE DATA AND SPECIFICATIONS (S.O.S.)
General Specifications
Australia Europe
Applied model Without With
SUPER HICAS SUPER HICAS
Steering model Power steering
Steering gear type PR26SE
Steering overall gear ratio 16.9 16.7
Turn of steering wheel
2.7 2.7
(Lock to lock)
Steering column type Collapsible
Inspection and Adjustment

GENERAL STEERING GEAR AND LINKAGE
Steering wheel axial play Steering gear type PR2.SE

0(0)
mm (in)
Tie-rod outer ball joint
Steering wheel play
35 (1.38) or less Swinging force 4.61 - 46.1
mm (in)
(at cotter pin hole) N (kg, Ib) (0.47 - 4.7, 1.04 - 10.4)
Movement of gear housing
±2 (±O.08) or less Rotating torque 0.29 - 2.94
mm (in)
Nm (kg-cm, in-Ib) (3.0 - 30.0, 2.6 - 26.0)
Axial end play mm (in) 0(0)
Tie-rod inner ball joint
STEERING COLUMN
8.8 - 78.5
Swinging terce" N (kg, Ib)
(0.9 - 8.0, 2.0 - 17.6)
Steering position R.H.D. L.H.D.
Rotating torque 1.0 - 8.8
Steering column length "L 1 "
745.9 - 747.5 (29.37 - 29.43) N·m (kg-cm, in-Ib) (10 - 90, 8.7 - 78.1)
mm (in)
Axial end play mm (in) 0(0)
Steering column lower
314.6 - 316.2 28D.6 - 282.2 Tie-rod standard length "L"
shaft length "L 2 "
(12.39 - 12.45) (11.05 - 11.11) 155 (6.10)
mm (in) mm (in)
..: Measuring point
SST3048
SST3158
Rack
_ __ stroke
__ "L"
_ _ _ _m_m_(i_n) 1 59.5--,--_-,--
(2.343) _
SST307B
ST-97
SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Inspection and Adjustment (Cont'd)
POWER STEERING POWER CYLINDER LOWER LINK
(SUPER HICAS)
Without With
Applied model SUPER SUPER Power cylinder lower link
HICAS HICAS ball joint
Retainer adjustment
SWinging force" N (kg, Ib) 2.9 - 41.2
Adjusting screw (0.3 - 4.2, 0.7 - 9.3)
Initial tightening torque Axial end play mm (in) 0(0)

4.9 - 5.9 (50 - 60, 43 - 52)
Nrn (kg-em, in-tb) Power cylinder lower link
309.5 (12.19)
Retightening torque standard length "L" mm (in)
0.2 (2, 1.7)
after loosening Stroke mm fln) 3.0 (0.118)
Tightening torque after ': Measuring point
4.9 (50, 43)
gear has settled
Returning angle degree 60' - 100'

Pinion gear preload without gear
oil Nm (kg-cm, in-Ib)
Within 100· from the neutral
position
0.78 - 1.27
Average rotating torque
(8.0 - 13.0, 6.9 - 11.3)
Maximum torque deviation 0.4 (4, 3.5)
SST4868
Except above range
Maximum rotating torque 1.9 (19, 16)
Maximum torque deviation 0.6 (6, 5.2)
Rack sliding force N (kg, Ib)
Under normal operating
oil pressure
Range within ± 11.5 mm 206 - 265 201.0 - 250.1
(± 0.453 in) from the neutral (21 - 27, (20.5 - 25.5,
position 46 - 60) 45.2 - 56.2)
Not more than 39 (4, 9)
Except above range
beyond above value
Steering wheel turning force
(Measured at one full turn from
39 (4, 9) or less
the neutral position)
N (kg, Ib)
Fluid capacity (Approximate)
1.3 (1-118) 2.0 (1-3/4)
e (Imp qt)
Main:
7,649 - 8,238
(76.5 - 82.4,
7,649 - 8,238 78 - 84,
Oil pump maximum pressure (76.5 - 82.4, 1,109 -1,194)
kPa (bar, kg/cm2 , psi) 78 - 84, Sub:
1,109 - 1,194) 6,375 - 6,865
(63.7 - 68.6,
65 - 70,
924 - 995)
ST·98

14 - Section ST - Steering System

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14 - Section ST - Steering System

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STEERING SYSTEM

When you read wiring diagrams:

• Before disassembly, thoroughly dean the outside of the

SPECIAL SERVICE TOOLS

KV48100700 Measuring pinion rotating torque

ST27160001 Removing steering wheel

HT72750000 Removing ball joint

ST27091000 Measuring oil pressure

KV481 02500 Measuring oil pressure

ST3127S000 Measuring turning torque

KV32101100 Removing and installing tube seat

COMMERCIAL SERVICE TOOLS

Tool name Description

Rear oil seal drift Installing rear oil seal

Pinion oil seal drift Installing pinion oil seal

Oil pump attachment Disassembling and assembling oil

Unit: mm On) SST481 A

Checking Steering Wheel Play

Checking Neutral Position on Steering Wheel

Front Wheel Turning Angle

2. If it is not within specification, check rack stroke.

Checking Gear Housing Movement

Adjusting Rack Retainer

Checking and Adjusting Drive Belts

Checking Fluid Level

Checking Fluid Leakage

Bleeding Hydraulic System

Checking Steering Wheel Turning Force

5. If steering wheel turning force is out of specifications, check

Checking HydraUlic System

Steering tube assembly

~: N·m (kg-m, ft-tb}

• Remove steering wheel with Tool.

Disassembly and Assembly

~~13.16 11.3 ·1.6.

Column shaft assembly

• When disassembling and assembling, unlock steering lock

• Install snap ring on upper shaft with box wrench.

•a) Steering lock

Removal and Installation

Gear housing mounting bracket Rack mounting insulator

Gear and J inkage

~ 88·108 19.0· 11.0,65·801

~, Nen Ikg-m. tt-lb!

• Detach tie-rod outer sockets from knuckle arms with Tool.

• Install pipe connector.

• Before removing lower joint from gear, set gear in neutral

toJ 7 - 12 (0.7 • 1.2. 5.1 - 8'7)~~'

Solenoid velve>~ CiJ) 0

toJ (4.0 - 6.0. Adjusting screw ~ Ell ring ~

toJ 78 - 98 (8.0 • 10.0, 58 - 72)

toJ: Ncm (kg-m, tt-Ib)

3. Remove tie-rod outer sockets and boots.

7. Drill staked portion of cylinder end cover with drill of 2 to 2.5

8. Remove gear housing end cover assembly with Tool.

10. Remove rack seal ring.

TIE-ROD OUTER AND INNER SOCKET

• Check ball joint for rotating torque.

• Using Tool, compress periphery of rack seal ring (made of

2. Insert rack oi I seal.

End cover assembly

6. Set rack gear in neutral position.

<'. Oil seal

9. Install pinion seal ring on pinion gear assembly.