$35 Electric Power Steering with Fail-Safe - No eBay module and no caster issues!!! - Ford Mustang Forums : Corral.net Mustang Forum
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post #1 of 36 Old 10-20-2016, 08:11 PM Thread Starter
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$35 Electric Power Steering with Fail-Safe - No eBay module and no caster issues!!!

It has been a while since I posted on this forum. I am not making or selling anything. I have posted this on couple of other forums and this is not for everyone.

Some of you have manual steering and I though you might like to see how added electric assisted power steering in my 1964 Falcon. Some of you may have come across the Saturn Vue conversions but I think I have found even cheaper and better alternative with no caster issues!

My testing shows that most Japanese branded cars and SUV with electric steering works in Fail-Safe mode if the control unit (ECU) is disconnected from CAN BUS. The effort in Fail-Safe mode feels just right like my 2013 Honda Civic. Not too much and not too little. Just like Hydraulic Steering, if the Electric Assisted Steering completely fails, the steering is back to completely manual mode maintaining car control.

The biggest advantage of using EPS from Toyota, Nissan and Kia/Hyundai is that the EPS works in Fail-Safe. The ECU for the column is mounted remotely and cab be disconnected and removed. The EPS from Saturn Vue and Chevy Cobalt has the ECU that cannot be disconnected and must be de-soldered for remote mount. More importantly there is no Fail-Safe and a 3rd party eBay module is needed in order for it to work. Additionally , people have reported that with after market eBay module, the Saturn EPS does not self center the steering wheel coming out of a turn. You have to make constant corrections. No center feel.

Below is the list of Car that I know of that has Fail-Safe Electric Steering. Only 3 wire connection. Ignition On, Power and Ground to the Steering ECU. That's it !

2004-2009 Toyota Prius
2009-2013 Toyota Corolla
2006-2011 Toyota Yaris - (With ABS)
2007-2009 Nissan Versa
2009-2012 Nissan Cube
2012-2014 Kia Soul

ECU Part Numbers:

2004-2009 Toyota Prius 89650-47102
2009-2013 Toyota Corolla 89650-02300
2006-2011 Toyota Yaris - (With ABS) 89650-52120 / 52050
2007-2009 Nissan Versa 28500-EM30A / 991-30303
2009-2012 Nissan Cube 28500-1FC0B / JL501-000932
2012-2014 Kia Soul B2563-99500 / 4PSG1312 / FPSG1312

The output shaft on Toyota is little larger than the rest and therefore the Borgeson 312500, 11/16 36 X 3/4 smooth bore weldable coupling should fits nicely. This couple fits the others as well. The Kia EPS is the biggest and appears to be most heavy duty. The Prius & Corolla EPS are very easy to find at salvage yards so this is the best bet. I picked up these EPS for testing for $35 each at my local pic-a-part

Note: As with any modification, there are risks. This post is intended to show how I did my modification. Use it at your own risk!

Waid

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post #2 of 36 Old 10-20-2016, 08:12 PM Thread Starter
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General Information

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File Type: jpg 1 Corolla Prius.jpg (209.9 KB, 222 views)
File Type: jpg 2 Prius Yaris.jpg (135.7 KB, 195 views)
File Type: jpg 3 Prius Yaris.jpg (122.6 KB, 182 views)
File Type: jpg 4 Cube Versa.jpg (112.7 KB, 176 views)
File Type: jpg 5 Cube Versa.jpg (127.1 KB, 168 views)
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post #3 of 36 Old 10-20-2016, 08:13 PM Thread Starter
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More general information
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File Type: jpg 6 Kia Soul.jpg (133.5 KB, 121 views)
File Type: jpg 7 ECU.jpg (138.1 KB, 120 views)
File Type: jpg Saturn Vue 1.jpg (102.5 KB, 112 views)
File Type: jpg Saturn Vue 2.JPG (100.1 KB, 113 views)
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post #4 of 36 Old 10-20-2016, 08:15 PM Thread Starter
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Wiring Diagrams. Only 3 wires are needed. Power, Ground and Ignition On
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File Type: jpg 2007 Yaris.jpg (144.8 KB, 118 views)
File Type: jpg 2008 Versa.jpg (67.1 KB, 86 views)
File Type: jpg 2009 Toyota Prius.jpg (128.8 KB, 208 views)
File Type: jpg 2010 Nissan Cube.jpg (104.3 KB, 75 views)
File Type: jpg 2014 Kia Soul.jpg (50.4 KB, 65 views)
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post #5 of 36 Old 10-20-2016, 08:16 PM Thread Starter
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My upper steering shaft and column tube
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File Type: jpg 1 Upper Steering Shaft.jpg (200.4 KB, 274 views)
File Type: jpg 2 Upper Steering Shaft.jpg (202.0 KB, 266 views)
File Type: jpg 3 Upper Steering Column.jpg (154.3 KB, 141 views)
File Type: jpg 4 Upper Steering Column.jpg (171.0 KB, 137 views)
File Type: jpg 5 Upper Steering Column.jpg (179.3 KB, 140 views)
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post #6 of 36 Old 10-20-2016, 08:17 PM Thread Starter
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More upper steering shaft and column tube
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File Type: jpg 6 Upper Steering Column.jpg (174.2 KB, 134 views)
File Type: jpg 7 Back Bracket.jpg (123.5 KB, 126 views)
File Type: jpg 8 Prius Mounted.jpg (95.7 KB, 142 views)
File Type: jpg 9 Versa Mounted.jpg (102.8 KB, 150 views)
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post #7 of 36 Old 10-20-2016, 08:18 PM Thread Starter
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My lower steering shaft for Rack and Pinion
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File Type: jpg 2 Lower Shaft.jpg (233.1 KB, 110 views)
File Type: jpg 3 Lower Shaft.jpg (231.6 KB, 107 views)
File Type: jpg 4 Complete.jpg (202.8 KB, 115 views)
File Type: jpg 5 Lower Bearing Support.jpg (153.1 KB, 116 views)
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post #8 of 36 Old 10-20-2016, 08:19 PM Thread Starter
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In order to convert my hydraulic power steering rack to manual, I took the valve out, removed the sleeve and tack welded the input shaft to the pinion shaft.
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File Type: jpg 9 Rack.jpg (69.9 KB, 102 views)
File Type: jpg 11 Rack.jpg (74.9 KB, 99 views)
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post #9 of 36 Old 10-20-2016, 08:21 PM Thread Starter
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YouTube Videos:

DIY Electric Power Steering 1 - EPS with Fail Safe

DIY Electric Power Steering 2 - Bench Test

DIY Electric Power Steering 3 - Mounting Options

DIY Electric Power Steering 4 - In Car Test
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post #10 of 36 Old 10-20-2016, 09:24 PM
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Garage
That's awesome! Subbed for later research.

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post #11 of 36 Old 10-21-2016, 01:47 PM
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Dude this is awesome. I have the Vue / Ebay setup in my 68 Mustang. Yeah it's better than manual, but it has all the issues you mention. On center steering feel is terrible.

I might have to do another swap, would give me a reason to put in a tilt column

*Edit

I see you posted this over on VMF too, strong work!
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post #12 of 36 Old 10-21-2016, 04:59 PM Thread Starter
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Quote:
Originally Posted by Beau M View Post
Dude this is awesome. I have the Vue / Ebay setup in my 68 Mustang. Yeah it's better than manual, but it has all the issues you mention. On center steering feel is terrible.

I might have to do another swap, would give me a reason to put in a tilt column

*Edit

I see you posted this over on VMF too, strong work!
Tilt will be hard to do.

Since you already have Vue setup, and Vue has same torque censor as Prius, get a ECU from a Prius and just plug in Ignition On, Battery and Ground. Your center/caster issue should go away!

Waid
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post #13 of 36 Old 10-22-2016, 06:52 AM
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Can you elaborate a bit more on the ecu need - I'm missing something as I thought "fail-safe" mode meant a failure of the ecu to control the steering unit, therefore no ecu was needed.....

Michael Yount - Charlotte, NC - 82 Volvo 242 - 6.2L; '17 Mazda3; '16 CrossTrek
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post #14 of 36 Old 10-22-2016, 09:13 AM Thread Starter
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Originally Posted by Michael Yount View Post
Can you elaborate a bit more on the ecu need - I'm missing something as I thought "fail-safe" mode meant a failure of the ecu to control the steering unit, therefore no ecu was needed.....
There are actually two Fail-Safe. If the steering ECU lose connection with CAN BUS (communication with cars engine computer, ABS, traction control, etc...), the steering ECU goes in to a Fail-Safe mode and provides a fixed level of steering assist instead of variable assist.

The 2nd Fai-Safe is manual steering. If the steering ECU lose power or burns up, the steering gear box will still operate in complete manual mode. This is just like if you lose power steering fluid in hydraulic power steering.

Waid
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post #15 of 36 Old 12-27-2016, 05:45 PM
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Thanks for the excellent information. I just picked up a column from a 2009 Prius. However, I was not able to get a matching ECU for it. I went to another salvage yard and they had a 2008 Scion Cube and I got the ECU from it. I suspect that uses the same column as the Yaris. From what you said earlier, it sounds like I can mix and match the column and the ECU. Can you please confirm?

Andrew
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post #16 of 36 Old 12-27-2016, 07:21 PM
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How 'bout we adopt the term "CCU" -- COLUMN control unit....at least that will help be from continuing to be confused....

Michael Yount - Charlotte, NC - 82 Volvo 242 - 6.2L; '17 Mazda3; '16 CrossTrek
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post #17 of 36 Old 12-27-2016, 07:22 PM Thread Starter
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Originally Posted by andrewb70 View Post
Thanks for the excellent information. I just picked up a column from a 2009 Prius. However, I was not able to get a matching ECU for it. I went to another salvage yard and they had a 2008 Scion Cube and I got the ECU from it. I suspect that uses the same column as the Yaris. From what you said earlier, it sounds like I can mix and match the column and the ECU. Can you please confirm?

Andrew
2008 Scion Cube? Nissan makes the Cube !

2004-2009 Prius uses same Power Steering ECU. All Scion don't use same steering column. If the Prius connectors fit the Scion Power Steering ECU then it should work. You can bench test it and confirm. Post some pics so I can see what you are talking about.

Waid
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post #18 of 36 Old 12-27-2016, 07:48 PM
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Originally Posted by waid302 View Post
2008 Scion Cube? Nissan makes the Cube !

2004-2009 Prius uses same Power Steering ECU. All Scion don't use same steering column. If the Prius connectors fit the Scion Power Steering ECU then it should work. You can bench test it and confirm. Post some pics so I can see what you are talking about.

Waid
Waid,

Actually I was wrong. So I have the controller from a Scion xD and the part number is 89650-52240.

The plugs are exactly the same as the Prius controller.

Andrew
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post #19 of 36 Old 12-27-2016, 07:55 PM Thread Starter
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From looking at eBay pics of the Scion Steering ECU, it appears to be almost identical to the Prius. If the Prius connector fits, the Ignition On is Pin 6. All you have to do is provide +12 Power, Ground and Ignition On. I would bench test it first. Remove the electric motor from the column for safety. Lock down the output shaft on a vice and turn the input shaft. The electric motor should turn depending on which way you move the steering input shaft.

Waid
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post #20 of 36 Old 12-28-2016, 01:20 PM
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Waid,

Do you have any more pictures of how you dealt with the upper portion of the column? I see that you made a collar to adapt your stock upper column to the Prius motor. What I am looking for is some pointers on how you removed the stock Pruis upper column. Did you just cut it off? Did you remove the snap ring at the very top and the stock upper tubes slides off?

Thanks in advance.

Andrew
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post #21 of 36 Old 12-28-2016, 10:09 PM Thread Starter
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Waid,

Do you have any more pictures of how you dealt with the upper portion of the column? I see that you made a collar to adapt your stock upper column to the Prius motor. What I am looking for is some pointers on how you removed the stock Pruis upper column. Did you just cut it off? Did you remove the snap ring at the very top and the stock upper tubes slides off?

Thanks in advance.

Andrew

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post #22 of 36 Old 12-29-2016, 01:33 PM
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Big Hammer!
Thank you!

Why did you not try to keep the upper portion of the column collapsible? It seems that it would be possible to do that.

Andrew
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post #23 of 36 Old 01-04-2017, 12:55 AM
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Very interesting and cool. Love to see this kinda old school ingenuity with affordable junkyard parts. Would be cool to see someone with a foxbody and manual rack try this. If I didn't already have a new pump and rack I might have tried it myself.
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post #24 of 36 Old 01-04-2017, 08:36 AM
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Is this more of a comfort/ease modification? Seems that you'd lose a lot of road feel with this type of deal but I haven't confirmed the validity of that thought. I assume this is probably one of the more common concerns and has probably been answered a million times. :P
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post #25 of 36 Old 01-04-2017, 11:05 AM
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Is this more of a comfort/ease modification? Seems that you'd lose a lot of road feel with this type of deal but I haven't confirmed the validity of that thought.
I agree. Steering feel is going to be a major factor here. One of the reasons I'm swapping to an 03-04 cobra steering rack is due to how these cars feel in terms of steering.

Converting to electric assist is an awesome concept, but I really would need to drive one and see how much feedback and feel you get out of it before deciding.

Kudo's on the innovation however. Always great to see new tech being retroactively applied.

Mike
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post #26 of 36 Old 01-05-2017, 06:50 PM Thread Starter
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Almost all new cars and truck have electric assisted steering that is either column assist or rack assist.

This is 2016 Mustang GT. The problem with this type is that all sensitive components are subjected to the environment and more likelihood of failure. With column assist, its all protected inside the car. This is why Toyota only uses column assist as far as I know!

Waid
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C7 Corvette.
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post #28 of 36 Old 01-07-2017, 09:29 PM
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I'd like to try one in a more performance oriented application, such as an SN95 rack in a fox, or even an SN95. The stock fox 20:1 rack feels sloppy even when everything is new, just because it's a slower ratio. The stock 15:1 feels "ok" (fox original), but is overboosted. An SN rack has a much better feel than any of the aformentioned, but adapting EPS to it doesn't seem like a great idea. Ideally, EPS would would assist a manual rack, because of the obvious fact that a power rack with no hydraulic assist is tough to deal with. But the manual racks have a slower ratio do they not?

On that note, I wonder. I wonder if there's an economical way to adapt a 12v electric hydraulic pump that could assist a power rack? But I personally don't see a need for it, just bolt the brackets on and run a traditional engine driven pump and be done with it for simplicity's sake, but I am thinking out loud here...for those guys who want to get rid of the engine driven pump......
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post #29 of 36 Old 02-10-2017, 01:47 PM
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Waid,

I don't see a lower tube in any of your photos or videos. Did you ever make a lower tube that attaches to the Prius steering unit? I am getting close to starting this project in my 67 Cougar and just looking for some ideas. Right now I am thinking that a simple flange will work that gets bolted to where the original Prius attaching bracket was attached.

Andrew
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post #30 of 36 Old 02-10-2017, 03:29 PM Thread Starter
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Waid,

I don't see a lower tube in any of your photos or videos. Did you ever make a lower tube that attaches to the Prius steering unit? I am getting close to starting this project in my 67 Cougar and just looking for some ideas. Right now I am thinking that a simple flange will work that gets bolted to where the original Prius attaching bracket was attached.

Andrew
I did not use a lower tube. The upper part of the column is supported by the the little original u-strap mount. The lower part of the column supported by the steering shaft and the bearing at the firewall. The Prius steering case is also held in place by little bracket for anti-torque - to prevent movement of the motor when the steering assist is provided.

Waid
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post #31 of 36 Old 02-10-2017, 06:41 PM
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I did not use a lower tube. The upper part of the column is supported by the the little original u-strap mount. The lower part of the column supported by the steering shaft and the bearing at the firewall. The Prius steering case is also held in place by little bracket for anti-torque - to prevent movement of the motor when the steering assist is provided.

Waid
This seems very flimsy to me. The column tube needs to be anchored at the dash and at the firewall. Doesn't the column sort of wobble around at the top?

Andrew
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post #32 of 36 Old 02-10-2017, 07:19 PM Thread Starter
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This seems very flimsy to me. The column tube needs to be anchored at the dash and at the firewall. Doesn't the column sort of wobble around at the top?

Andrew
My column is anchored at the dash and at the firewall and is sturdy. This is absolutely no movement in my column and happy with it.

Waid
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post #33 of 36 Old 02-13-2017, 03:15 PM
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I started collecting some parts for my Prius EPS swap into my 1967 Cougar. Not much to show for now, but I got a steel collar from McMaster Carr. It will be used as a basis for attaching the upper Cougar column to the EPS unit.





If anyone is interested in the full build thread, it can be found here:

1967 Cougar build (over 700 pictures and videos))

**Trigger warning: If you are sensitive to non-Ford engines in Ford vehicles, proceed with caution**

Andrew
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post #34 of 36 Old 03-05-2017, 03:17 PM Thread Starter
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Tested one more EPS / ECU that works in fail-safe/limp home mode with fixed level of assist. 2008-2011 Scion XD

2008-2011 Scion XD It's almost identical to Prius. The Prius, Yaris and Scion Xd ECU share same exact plug and works with each other.

ECU Part Numbers that function in fail-safe / limp-home mode:


2004-2009 Toyota Prius 89650-47102
2009-2013 Toyota Corolla 89650-02300
2006-2011 Toyota Yaris - (With ABS) 89650-52120 / 52050
2006-2011 Toyota Yaris - (Non-ABS) 89650-52070 & 520140
2007-2009 Nissan Versa 28500-EM30A / 991-30303
2009-2012 Nissan Cube 28500-1FC0B / JL501-000932
2012-2014 Kia Soul B2563-99500 / 4PSG1312 / FPSG1312
2008-2011 Scion XD 89650-52A10
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post #35 of 36 Old 10-26-2017, 11:17 PM
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can you help me , I recently bought a unit of a toyota corrolla 995-12500 and buy the ucu 89650-12850 but it does not work connected according to the diagrasmas of waid, the ecu makes a click sound but it still does not work and where I live it is very difficult to find this type of parts, corolla eps unit will work with a toyota yaris ecu 89650-52050?, I check all the connections, wires and voltages everything seems to be OK except the pin 5 of the p10 connector which should have between 7.5 vol and 8.5 volt but not the has, this could be the cause of non-operation of the system this system I need to adapt it to a vehicle of a disabled person, please I need your help
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