Professional Documents
Culture Documents
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
ST-2
PREPARATION
Tool number
Description
Tool name
Shut-off valve
ST-3
PREPARATION
ST-4
ON-VEHICLE INSPECTION
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.
I
I-~
58T3078
ST-5
ON-VEHICLE INSPECTION
ST-6
ON-VEHICLE INSPECTION
ST-7
ON-VEHICLE INSPECTION
ST-8
ON-VEHICLE INSPECTION
ST-9
STEERING WHEEL AND STEERING COLUMN
Steering wheel
"'~ 24·29
~A ·3.0. 17· 2/2)~~~Cf~
Removal
STEERING WHEEL
• Remove screw from rear of steering wheel and pull out
horn pad.
SST312B
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
STEERING WHEEL AND STEERING COLUMN
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.
SteeronglOCkY
assembly
~combonallon
switch assembly
Jacket tube
assemblv . }~
Jacket tube
bracket insulator
Snap,;ng~ .r>.
.:
9 ·121 •
!~
/
~ 12.4·3.0,17·22)
24-29 ~
~ Lower joint
.-4' N'm [kg-rn, ft·lbl
88T3148
ST-11
STEERING WHEEL AND STEERING COLUMN
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
SST428A
_ _ _ Upper shaft
SST770A
~
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
STEERING WHEEL AND STEERING COLUMN
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)
~24.29
-
12.4 ·3.0. 17 . 221
/cotter
~ 29 • 49 (3.0 • 5.0, 22 • 36)...( plnO
.~~' \; @
SST783A
ST-14
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
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
ST-15
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
<;
~
®
~~~
~
<\_ ~ Cl ~ ~ toJ 16 - 21 (1.6 • 2.1. 12 - 15)
~ ~ Rear housing cover
I'lEll~ \
r
Rear housing assembly
r
0
O-ring~ ~,
~
~/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 ;::::,;
ST-16
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
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.
SST881
SST450A
SST081B
SST0828
ST-17
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
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 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)
SSTIS1A
ST-18
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
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
Position and
secure seal.
SST084B
~
Rack oil seal
SST201A
ST-19
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
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
55T3218
2·3mm
5. Fasten cylinder end cover assembly to gear housing by
10.08· .12 in} staking.
End cover
Gear
assembly
housing
$ST0738
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.
ST-20
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
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
88T3238
Needle bearing
SST0758
SST3248
SST3258
ST-21
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
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
SST3168
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
ST-22
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Assembly (Cont'd)
18. Tighten outer socket lock nut.
Tie-rod length "L":
ReIer to S.O.S.
~' L $1 1 Jf------'Y
SST0938
SST3078
SST3298
• 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
POWER STEERING GEAR AND LINKAGE (Model PR26SE)
Assembly (Conl'd)
• Twist boot clamp in the direction shown in figure at left.
98 N (10 kg, 221bl
SST440A
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.
ST·25
POWER STEERING OIL PUMP
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)
t)
.> ~~_ ~, 1 Drive shaft
A~· Ci 0 '" ali seal ~I'l
O-dng~1'l I »> g~ ~ ~ JonthoU"ng
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
POWER STEERING OIL PUMP
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.
[ } - - - Extension bar
~_~~~~~orive shaft
SST010B
• 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
POWER STEERING OIL PUMP
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
SST289A
Flat portion
Round portion
SST843A
SST497A
ST·28
TWIN ORIFICE POWER STEERING SYSTEM
Hydraulic Circuit
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)
~
'"
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.
ST-31
TWIN ORIFICE POWER STEERING SYSTEM
- 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.
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
TWIN ORIFICE POWER STEERING SYSTEM
- Trouble Diagnoses (Without SUPER HICAS system)
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.
!O.K.
END
ST·33
TWIN ORIFICE POWER STEERING SYSTEM
- Trouble Diagnoses (Without SUPER HICAS system)
Diagnostic Procedure 1 (Cont'd)
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.
ST-34
TWIN ORIFICE POWER STEERING SYSTEM
- Trouble Diagnoses (Without SUPER HICAS system)
[I
~ EEEi!ffi]
-IV G
[I
,
Diagnostic Procedure 1 (Cont'd)
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
tion occurs during stationary
turns.
YES ... N.G.
NO (Ughta, stae,lng ope,a·
tlon) ... O.K.
lO.K.
END
ST-35
TWIN ORIFICE POWER STEERING SYSTEM
- Trouble Diagnoses (Without SUPER HICAS system)
Diagnostic Procedure 1 (Cont'd)
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.
SST3.0B
Y/L ~
Voltage:
[Y] 4.4 • 6.6V (constanl)
~ ... O.K.
Go to 4).
(;] LN.G
L°.K.
Ensure that power steering con-
trol unit connector is connected
properly.
r
©
ST-36
TWIN ORIFICE POWER STEERING SYSTEM
- Trouble Diagnoses (Without SUPER HICAS system)
Diagnostic Procedure 1 (Cont'd)
[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
tion occurs during stationary
turns.
YES ..• N.G.
NO (Lighter steering opera-
tion) ••. O.K.
~OK.
END
ST-37
TWIN ORIFICE POWER STEERING SYSTEM
- Trouble Diagnoses (Without SUPER HICAS system)
Diagnostic Procedure 1 (Cont'd)
m
N.G.
G/Y
SST559B Ii) OK
r="-------''---------,
Measure solenoid valve resis- N.G. Malfunctioning solenoid valve
tance. f--~ system
Disconnect solenoid valve con-
nector, and measure resistance
between connector terminals (on
solenoid valve side.)
Resistance:
4 - 6 ohms ••• O.K.
Gohms or Inflnlle ... N.G.
O.K.
Ensure that power steering con-
trol unit connector is connected
properly.
ST-38
TWIN ORIFICE POWER STEERING SYSTEM
- Trouble Diagnoses (Without SUPER HICAS system)
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
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
- Trouble Diagnoses (Without SUPER HICAS system)
Diagnostic Procedure 2 (Cont'd)
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 driv- ing.
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
ST-40
TWIN ORIFICE POWER STEERING SYSTEM
- Trouble Diagnoses (Without SUPER HICAS system)
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)
SST3498
ST-41
TWIN ORIFICE POWER STEERING SYSTEM
- Trouble Diagnoses (With SUPER HICAS system)
Diagnostic Procedure 1
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.
NO (Lighter steering opera-
tion; Stationary turns.
Heavier steering opera-
tion; High.speed driving.)
... O.K.
lOK
1 END 1
~ ~ ~
IllSClIlMECT
ST-42
SUPER HICAS SYSTEM
Control unit
Steering
angle sensor
~-.
--:::::::::7-~ ~ Fail-safe valve
Power steering
solenoid
Power
cylinder
SST604B
System Diagram
Control unit
HICAS solenoid valve
bcent.,;ng
~ sp"ng
~
~
t ' i.. ..'-
'- Fail-safe
',~,
valve
Power steering
solenoid
SST451B
ST-43
SUPER HICAS SYSTEM - On-vehicle Inspection
SST60SB
Front
"'<?'-.-' Toe-in = A - B
**
SFA2:MA 6 TaUI toe-in Ingle = 26
ST-44
SUPER HICAS SYSTEM - On-vehicle Inspection
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
SUPER HICAS SYSTEM - On-vehicle Inspection
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)
ST-46
SUPER HICAS SYSTEM - On-vehicle Inspection
Inspection of HICAS System Operation (Cont'd)
4. Operate engine at speeds greater than 2,000 rpm, and turn
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.
ST-47
SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder
~ l)
~@
~
i:(. r~
II
.: (8.6 • 11, 62 - 80)
88T6078
REMOVAL
• Detach power cylinder lower links from axle housing sock-
ets with Tool.
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
SUPER HICAS SYSTEM - Repair of Component Parts
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.
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
SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder (Cont'd)
7. Operate engine at speeds greater than 2,000 rpm, and turn
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.
8. Operate engine at speeds greater than 2,000 rpm, and turn
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.
ST.50
SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder (Cont'd)
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
SST610B
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
~ , ..
Width ICrOIl fla" :JftJJ
Stroklstopper SST386B
ST·51
SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder (Cont'd)
• 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
SST613B
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
SUPER HICAS SYSTEM - Repair of Component Parts
Power Cylinder (Cont'd)
5. Install dust boot using new boot band and clamp.
• Apply a coat of grease to grooves at boot location.
SST392B
ST-53
SUPER HICAS SYSTEM - Repair of Component Parts
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
~ 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
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
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
SUPER HICAS SYSTEM - Repair of Component Parts
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
5. Remove cam ring, rotor and other parts from front housing
(main side).
Be careful not to confuse main side with sub side.
SST401B
Drive shaft
SST399B
ST·55
SUPER HICAS SYSTEM - Repair of Component Parts
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
SUPER HICAS SYSTEM - Repair of Component Parts
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
SST2B9A
SST2058
ST-57
SUPER HICAS SYSTEM - Repair of Component Parts
SST405B
SST406B
SST3978
__4+0-- A (dlo.1
SST4078
ST-58
SUPER HICAS SYSTEM - Repair of Component Parts
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
Diagnostic Procedure 2 5T-77
Diagnostic Procedure 3 5T-79
Diagnostic Procedure 4 5T-80
Diagnostic Procedure 5 5T-86
Diagnostic Procedure 6 5T-88
Diagnostic Procedure 7 5T-89
Diagnostic Procedure 8 5T-90
Diagnostic Procedure 9 5T-91
Diagnostic Procedure 10 5T-92
Diagnostic Procedure 11 5T-94
Diagnostic Procedure 12 5T-95
Control Unit Inspection Table 5T-96
ST-60
SUPER HICAS SYSTEM - Trouble Diagnoses
LISTEN TO CUSTOMER
COMPLAINTS AND CONFIRM.
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
CHECKOUT
ST·61
SUPER HICAS SYSTEM - Trouble Diagnoses
Symptom Chart
DIAGNOSTIC TABLE
Preliminary
PROCEDURE Diagnostic Procedure
Check
.-'" N
-,e N .
on
"" 00
,e ,e ,e ,e "',e ,e ,e ,e ,e e, ,e
'" 0> ~ ;:: ~
c '" '"c
c '" -e
~
-e -e
-e -c
~e c ~
-e
"c "c -ec c -oc "c
~ ~
-c
~ ~ ~ ~ ~ ~
~ ~ ~ c c u c c
s:
c
s:
u
~
c e e e e e e e e e e e e
. . .
SYMPTOM 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0.
~ ~
~
c
e
c
~
c
U
~
U
~
U
~
U
~
u
~
.2 c
~
.2 u
~
c
~
c
:; .2
.~
0 0 0 0
.~ .~
0 0 0 0 0 0 0 0
c c c c c c c c c c c c
0> 0> 0> 0> 0> 0> 0> 0> 0> 0> 0> 0>
~ ~
£ Q. Q.
~
0
~
0
~
0
~
0
e
0
~
0
~
0
e
0
~
0
~
0 0
~ ~
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.
.'"
'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)
ST·62
SUPER HICAS SYSTEM - Trouble Diagnoses
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
SUPER HICAS SYSTEM - Trouble Diagnoses
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
ST·64
SUPER HICAS SYSTEM - Trouble Diagnoses
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.
(1) Turn ignition switch "OFF".
(2) Set shift lever to "P" or "N" position (A/T model). or
"Neutral" position (MIT model).
(3) Turn ignition switch "ON".
L- S::Se.-T4e.-17:.::JB (4) Immediately start engine.
(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".
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
SUPER HICAS SYSTEM - Trouble Diagnoses
CONSULT connector
Power cylinder
Power steering solenoid
Fail-safe valve
Steering angle sensor Oil pump
88T6158
ST-66
-
@)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
SUPER HICAS SYSTEM - Trouble Diagnoses
85T4128
PRIHT
PRIHT
55T4138
58T4148
1==
55T4158
ST-70
SUPER HICAS SYSTEM - Trouble Diagnoses
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.
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.
ST-71
SUPER HICAS SYSTEM - Trouble Diagnoses
Self-diagnosis (When CONSULT is used) (Cont'd)
Data monitoring items
0: Standard
6.: Optional selection
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.
ST-72
SUPER HICAS SYSTEM -. Trouble Diagnoses
55T4178
ST-73
SUPER HICAS SYSTEM - Trouble Diagnoses
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.
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
SUPER HICAS SYSTEM - Trouble Diagnoses
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.
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
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
ST-75
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 1
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
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 2
;;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
I~
PH!':T NUt'18ER
~ I \ I' !NG
I Check steering neutral position.
ST·77
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 2 (Cont'd)
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.
Yes
ST-78
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 3
SYMPTOM:
Abnormal noise occurs.
START
N.G.
END
55T4408
ST-79
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4
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.
Refer to page ST-59.
'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
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4 (Cont'd)
~ A. Static HICAS characteristic performance check
~
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.
Refer to page ST-70.
SST4768
El ~
m • Run engine at a speed of less
Neutral position" than 2,000 rpm.
• Turn steering wheel approxi-
~
taI"~,
~ I
Hili -.'-,
CHECK POWER CYLINDER
STROKES.
~I END
I ®
~OK
ST-81
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4 (Cont'd)
• ACTIVE TEST.
CANCEL ISST304C
.00
Low-pressure
~ : Direction of oil flow hose SST478B psi)
lO.K.
@~ CHECK OIL PRESSURE AT FAIL-
ST-82
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4 (Cont'd)
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.
85T3788
ST-83
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4 (Cont'd)
B. Dynamic HICAS characteristic performance check
START
r
CHECK PIPING AND CONNEC-
TIONS. ALSO BLEED AIR FROM
HYDRAULIC SYSTEM.
~============~
Run engine at a speed of more
than 2,000 rpm.
O.K. 1 END _
N.G.
SST3788
ST-84
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 4 (Cont'd)
ST-85
SUPER HICAS SYSTEM - Trouble Diagnoses
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
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
I RECOF:D
[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.
ill
~~
SST635B
ST-86
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 5 (Cont'd)
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.
B
I\ • I
II 1\
Check continuity between
steering angle sensor con-
nector terminal@and
ground.
Continuity should exist.
ST-87
SUPER HICAS SYSTEM - Trouble Diagnoses
Diagnostic Procedure 6
SYMPTOM:
HICAS solenoid valve (left and right) output is not present.
N.G.
N.G.
ST·88
SUPER HICAS SYSTEM - Trouble Diagnoses
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.
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.
ST·89
SUPER HICAS SYSTEM - Trouble Diagnoses
m '"
Diagnostic Procedure 8
?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.
!NG
ST-90
SUPER HICAS SYSTEM - Trouble Diagnoses
m Diagnostic Procedure 9
SYMPTOM:
Vehicle speed signal Is not present.
I!trr~
I START
I
m r .I Poor connector connection
CHECK CONNECTOR CONTINU-
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
,~
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
00 ®
lDNCT
1EfmI:H1B I~ Y/B
B
[YJ
'--~
SST6398
ST-91
SUPER HICAS SYSTEM - Trouble Diagnoses
m Diagnostic Procedure 10
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-
tor and reconnect it firmly. Con-
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
SUPER HICAS SYSTEM - Trouble Diagnoses
I;]
RHEI
G/V
f1ti)
I;]
,
Diagnostic Procedure 10 (Cont'd)
00 ~
2) Measure voltage across
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.
ST-93
SUPER HICAS SYSTEM - Trouble Diagnoses
m Diagnostic Procedure 11
SYMPTOM:
Parking brake Input Is not present.
~r14 ~ m
START
i
CHECK CONNECTOR CONTINU-
lTV.
O.K.. 1 Poor connector connection
I
SST430B Disconnect control unit connec-
tor and reconnect it firmly. Con-
I!I [;]
duct self-diagnosis.
f,MOfHTOR
CAR SPEE[:o
STEERIHG Aim
l;,IW FAIL
Okm.····h
L 811
® I!I
!N.G.
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!I .......
[1t £) ®
ImmHB IrnIQ
Y/PU B
00 NJ
~
SST6428
ST-94
SUPER HICAS SYSTEM - Trouble Diagnoses
fa Diagnostic Procedure 12
SYMPTOM:
Inhibitor switch input is not present.
~~
~ I
fa
START
1
CHECK CONNECTOR CONTINU-
ITY.
O.K. ....I Poor connector connection
I
SST430B Disconnect control unit connec-
tor and reconnect it firmly. Con-
Ii! ,~:,r'IOH I TOR l:::~tK' FAIL [;]
duct self-diagnosis.
IN.G
Ii! colIEr
~ £) ®
IEBfiEHB 100Q
Y/L B
~ NJ
10+' -""
~
SST6438
ST-95
SUPER HICAS SYSTEM - Trouble Diagnoses
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)
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)
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