[MR2] MR2 MkII PS Light Question

[alkirab at earthlink.net]

1-25-09
10:30 AM, PST
Hi folks, Quick question regarding PS light on '93 MkII NA

This morning, first time ever, while starting '93 MkII NA, no power steering boost & PS light came on solid on dash readout.
I shut ignition off and attempted restart...no electrical response...no lights, no crank...nothing on first try.  Then tried On/Off with key 3 times (I did not try to start it only reset the power)... and all systems then went  normal...PS returned: no warning lights.  Sounds classic, but there were no codes!   Read on:  

Checked PS reserve fluid in frunk...which was right at the correct "cold" line.  Next, jumpered terminals at diagnostic connector in engine bay...PS light did normal 2 flashes/sec without space, no 1.5 sec delay, nor 4 second pause, just constant normal 2 flashes /sec. continuously.  Checked all 4 brushes in PS motor...all had good concave curve and 5/16 carbon brush length remaining.
Cleaned male pins on PS motor's two connectors and reseated connectors.  Pulled PS ECU to bench and checked all connectors.  While PS ECU was on bench, I tested PS relay and verified operation w/12 volt bench power supply; polarized voltage to coil operates relay normally & contact resistance =0.1 to 0 ohms on numerous tries.  Cleaned both connectors and reinstalled PS ECU & Relay assembly to frunk.  Next wire-brushed hardware and & placed heavy star washers both sides (under) ground connectors at left side frunk, right side frunk, and negative battery cable-to-chassis bolt located behind PS motor (PITA).  Finally checked voltage at battery at 12.1 volts (3 year old gel-cell).  As it was still under full replacement, I replaced battery with fresh Optima Red Top (harder to fit in battery box without custom bracketry).  All looked good...then it happened again...one start...no PS boost, light on, engine starts, still no PS, restart, all systems on including PS boost??.....and again no PS code.  BGB only addresses troubleshooting if a PS code is present.  Schematic shows ignition lock key and one fuseable link in series.  Has anyone seen this before?  I'm off to get some epoxy paint for the now re-formed battery hold- down bar (Optima is shorter even with their supplied snap-in riser platform in place).  Also... anybody had luck in reforming the positive battery terminal, it's got a 90 degree downward bend that won't allow it fit onto the inset spacing of the + term on the Optima Red Top?

Colin
'93 MkII NA
Steel Mist Gray
Stock w/48,500 original