Turbo Project Yaris TS 1.8L

[CASTREX]

I've decided to start this thread here because the Forced Induction Section is filled with "Can I turbo the Yaris?" threads... And this would be of most interest for the 1.8L owners anyway.

The Project: Low boost turbo set up. (5psi-8psi) This is my DD after all and I want to keep it on the safe side. This will be a BUDGET build, but I won't cheap out on the critical parts.

I've been picking up random parts over the last few months and by now I probably have about 70% of the parts I will need.

The goal: 200Whp

My mind is not set yet in a lot things, that's why I'm starting this thread, to hear other members opinions and suggestions.

I would like to Thank TAMAGO, BAttleVersionTC and Caliyaris... all boosted members who have been pointing me on the right direction as this will be my first time doing something like this.

So far this is the plan:

Fuel: TC OE Injectors (370cc). I havent been able to find the cc rate of the OE injectors on the 1.8L engine but my guess is they should be around 270cc-300cc so it looks like the 370cc from the TC would be a good option.

Management: AEM FIC. I already have the ECU pin out for the Yaris TS and it happens to be 99% the same as the pin out on the 1.5 Yaris. The only difference is the extra camshaft sensor for the double VVT-i All the other locations are the same. I'm counting on the help from 2 other memembers who have installed a FIC on a Yaris.

Manifold: SS LOG Style with the turbo at the bottom. Similar placement as the TT manifold or the Revhard cast mani.

I already have the tees, elbows and turbo flange. I only need the engine flange and up to the solder. It looks like the flange pattern for the 2ZR engine is the same as the 1ZZ and JGS Precision offers a flange for the 1ZZ so I will try it.

Downpipe I have no idea. I believe 2.5" should do. I will have to see the final placement of the turbo to think about the DP. I know a guy who has an exhaust shop and is pretty handy.

The intercooler: As much as I would like to keep the routing as short as possible, it looks like the easiest and cheapest will be a regular FMIC. The TS has a nice lower grill that should provide very good air flow.
A regular FMIC will probably require more piping and the routing of the turbo to intercooler pipe over the engine. Ala greddy style. I find the pipe over the engine a little ugly, but would simplify things so....

The Pipes 2.25" diameter seems like a good compromise. Looking into some silicone hoses to use instead of some sections of the piping to make things easier.

The Turbo: Looking for usable power and nice torque figures. The Garret GT28RS "Disco Potato" is at the top of my list followed by a T3 super 60.
However initially I intend to use a GT25 that I have on hand. The idea would be to run it @5 psi to work out the bugs and the tuning. Once I got the car running smoothly the upgrade will come to a larger turbo.

Wastegate: The boost would be controlled by a Tiaal 38mm. The WG came with a 8psi spring. I need to get a 5psi for the initial set up.

Blowoff valve Any random unit should do the trick. I would like to have it re-circulated. For the sleeper factor :evil:

Gauges: AEM UEGO and random Boost Gauge. Perhaps oil/water temp.


So what do you think? Comments, questions?

Finally a pic of the future victim:

[Morgan]

... the Forced Induction Section is filled with "Can I turbo the Yaris?" threads...

yes, how many more times can we beat a dead horse? :iono: (but my favorite threads involve running "low boost, w/no engine management")

but the project sounds quite interesting, good luck to you!

Just curious but have you looked into water/methanol injection? Could definitely help in any forced induction application and be an extra layer of safety since you wanted this project to stay your DD, just a thought.

[CASTREX]

yes, how many more times can we beat a dead horse? :iono: (but my favorite threads involve running "low boost, w/no engine management")


:bellyroll:


And yeah I have concidered a Meth Injection system... I know it works wonders! But we would have to wait and see how the tuning goes, AFR's, EGT's and such to determine if the Meth would help.

[Morgan]

should/if/when I get up to a dyno, I want to really see if the methanol is really helping out powerwise... but being in Florida its almost a must with a no intercooler set up

[CASTREX]

In the case of the Blitz SC I doubt the meth would provide big power gains. If anything at all it would be because of the drop in the intake temps. The biggest benefit would be the prevention of detonation that other people has reported...

However, if you were able to properly tune (pull some timing and lean out the mixture) the car to make the most out of the METH... that would be another story!

Have you concidered ditch the blitz black box and install a FIC? or some other tuning system?

[andries]

Seems to be a very nice project.

But, somtimes I have problems to get te power of my "stock" 1.8 on bad or wet roads.
How wil it be with 200HP on the weels?

[CASTREX]

Seems to be a very nice project.

But, somtimes I have problems to get te power of my "stock" 1.8 on bad or wet roads.
How wil it be with 200HP on the weels?

Getting traction on a wet road on any hi powered car would be dificult... is not like this is a Yaris problem...
But yeah, depending on how bad (read how fun) it gets a LSD would follow... Can't really tell how long would the oe clutch hold up the task neither... is all wait and see..:biggrin:

[scape]

I think ~180hp is more attainable as a DD for this setup; good luck, this looks to be interesting!

[Zefoxe]

Do this with gusto Castrex :) I'm eagerly waiting for some results.

This is some info I received from Ian @ FSR:
The stock intake manifold did not test well under boost. Up to 10 psi it was ok, past that, it was very stressed (you pressurize it and do a vibration test to see if there are any weak spots). Because our intention was to run very high boost eventually with a built engine, we wanted to take care of that restriction right away. Using helmholtz natural frequency tuning, we got the runner lengths just right to make for a really nice powerband that still had a large enough plenum to prevent cavitation at high RPM. With the short stroke of the motor, we were going to spin it high and wanted the intake/cams to match that. As you can see, we are dead nuts serious about real performance, no fluff!

We didn't modify the firewall. Because we custom built the turbo manifold to clear. We are also running a 3" downpipie and 38mm external wastegate for maximum performance and boost control. It all fits fine; fitting the turbo was the tight part.

All accessories are in tact and working like stock. The car as around 1000 miles on it with the turbo, to and from shows. It was a blast to drive and really woke up with the boost, but like I said, we only had two days with it, so no tuning was possible.

The battery was moved when we got it. We are only responsible for the turbo system and a few other small things, like good brakes and KW suspension.

If you have any other questions, let me know or you can call me at the shop.

Ian


Should hit him up for some more info

[CASTREX]

Good info! I will contact them when the time comes...

My car won't see more than 10psi anytime soon so the Intake Manifold is not a concern.

I wonder if they could duplicate the turbo manifold and downpipe...

Are there any pictures of their set up?

[Zefoxe]

Theyre thrown around somewhere on Scionlife, but that forums has been a you know what lately to navigate crashing all the time :\

[Zefoxe]

http://www.pasmag.com/index.php?option=com_content&task=view&id=1133
google ftw

[CASTREX]

Quick update, NON turbo related.

Some idiot going in reverse hit my car this moring on my works parking lot.

No big deal as he had insurance, but still is such a bummer... I take so much care of this car...:frown:

He gave a good scratch to the front bumper and broke the pasenger side headlight and foglight.

As my car is a TS and only a handfull of them out there, the dealer obviously does't have any body parts in stock. That means 4-5wks from Japan for the bumber and lights.:cry:

On the good side, once on the bodyshop I will finally get to paint and install a Seibon hood and the RS rear spoiler that I've had under my bed for months...:cool:

[CASTREX]

Some pics:

GT25R / Tial 38mm WG / SS manifold pieces

AEM FIC / 2AZ-FE Injectors (370cc)

TRD roller stopper (don't want the turbo banging the firewall, do I?)

[eTiMaGo]

my my my, this is starting to get interesting :biggrin:

[CASTREX]

small update.

received the engine flange, and radius plate from JGS today. Also a new Bosch diverter valve...

The manifold is going to the welder next week and then I'm on the look for an exhaust shop who can make the downpipe...

[eTiMaGo]

arriba arriba! :biggrin:

Indeed a real Speedy Gonzalez you'll have there when you're done :thumbsup:

[hatchbackkid82]

PURA VIDA!!!!!!!!:biggrin:

[CASTREX]

arriba arriba! :biggrin:

Indeed a real Speedy Gonzalez you'll have there when you're done :thumbsup:

:laughabove:

Yeah... some instruction for the welder... I drop the parts today at a shop. They've never done anything like it before. I hope they don't mess up! :biggrin:



PURA VIDA!!!!!!!!:biggrin:


Pura vida amigo!!

[cali yaris]

I don't agree at all about the intake manifold. Chris Rado and I both run stock plastic manis up to 25 psi on the tC's. Art runs 18 psi on his xB (1.5L) and I intend to run mine up to 20 psi with it.

I know a custom mani would make more power, and our stock ones have their limits. But I wouldn't worry about it at anything less than an extreme tune.

[CASTREX]

If anyone comes out with some forged internals for this engine on the next year or so... then perhaps I would worry about the manifold...

:rolleyes: ***dreaming***


In the mean time... after the turbo, upgraded clutch and LSD are coming...


I'm getting really excited...! and really broke... :cry:

[y75]

look this German tuning.....
Pura vida,
Què tal en Costarica?

[CASTREX]

^^^
Todo bien en Costa Rica!


And yeah, that's the TRC kompressor kit... looks hot. But the price tag is crazy insane!!... :eek: (Over $10K I believe)

The budget for my project will probably end up in 1/4 of the cost of the TRC kit including the tuning... And I'm shooting for an output similar to what their kit produces...

[Kongo-Otto]

TRC is just selling this kit and transferring the car to Switzerland.

http://www.bemani.ch

Bemani built this kit. There was even a limited Yaris TS Compressor Edition for sale in Swiss which you could buy at your local Toyota dealer.

[Zefoxe]

kaaz lsd?

[youngxlos]

very nice project, good luck!

[CASTREX]

kaaz lsd?

Actually looking for a Toyota helical LSD. Much less maintenance than the clutch style kaaz...

But we will see... first things first.:wink:

[constantin]

I wish you all the best and lots of RESPECT for what you are trying to accomplish. I think it's one of the hardest cars to try tuning. Keep up the good work. :thumbup:

[y75]

^^^
Todo bien en Costa Rica!


And yeah, that's the TRC kompressor kit... looks hot. But the price tag is crazy insane!!... :eek: (Over $10K I believe)

The budget for my project will probably end up in 1/4 of the cost of the TRC kit including the tuning... And I'm shooting for an output similar to what their kit produces...

Sure, the price is very insane,but have the warranty:bellyroll:, no està muy barato:thumbup:

[cruz-gsr]

q envidia

[Zefoxe]

Btw do you think you can ask ur shop to keep a blue print of ur manifold setup? That way some of us can purchase it ready to go?

[CASTREX]

Btw do you think you can ask ur shop to keep a blue print of ur manifold setup? That way some of us can purchase it ready to go?

Shop? Blue prints??? :laugh: no prints here!!! All manual.. old fashion cutting and welding.

But really no need for any prints!

You can get a Stage2 JGS manifold for a 1zz
http://jgsturbo.com/index2.html

The downpipe will still have to be a custom job from a serious exhaust shop... when you are doing the downpipe just take the stage 2 manifold and have them weld the radius plate and the turbo flange on the position that you want.

This is how my manifold will look: (probably not as clean and nice but you get the idea) this is turbo toyotas design for the 1nz-fe

[CASTREX]

PROJECT UPDATE:

Good and BAD news today.


Good news first: Received my cheap CXracing intercooler today along with an universal set of alum bends...
Looks great for the price!


Bad news:
Major set back for the project. At least 4 weeks delay.

Longstory short: One of the tranny shifter cables broke...
Looks like one of the rubber protective boots near the tranny linkeage pulled back a little. This caused a misaligment of the cable and put it in contact with some metal part.:frown:
The worst part is that the dealer doesn't have the cable in stock and that means 22-30 days from Japan. :cry:

[eTiMaGo]

yikes.. Shifter cable can't be that big, no way they can express mail it over?

[Zefoxe]

no chance of getting it from us or canada?

[CASTREX]

Well the dealer will cover it under warranty so they need to order it. I could get it in 1 wk from the US probably but it is a $350 part... so I will wait for them to buy it.

Can't get too pushy on the dealer either because i have not taken the car to their scheduled maintenance... and even though non of them could have prevented this from happening they have some grounds to argue with me...

On the other side... some good news. I got the AE86 back today. My mech had to replace the main and rod bearings and polish the crank after the car developed a rod knock a few weeks ago. So at least I have a car... :wink:

[andries]

@Castrex

What is a AE86 ?

[TheRealEnth]

@Castrex

What is a AE86 ?

im surprised you haven't heard of it. The AE86 is the chassis code of the toyota corolla from 1983 to 1987. It was a lightweight vehicle with a good amount of hp(and it was rear wheel drive) =) SO it became very popular to work with. and it spread like wildfire in motorsports. Its pretty much our car with a more power weighing a bit less... and of course RWD ^_^. Initially stardom followed. When Initial D came out (a manga that was created about Shuichi Shigeno about a kid who races... very popular in the automotive/tuner scene) The AE86 was the main characters car. It made the AE86 get much more publicity to the newer scene of drivers. Thus far its held as an amazing car.

[eTiMaGo]

http://images.google.com/images?hl=en&source=hp&q=toyota+ae86&gbv=2&aq=f&oq=&aqi=

:wink:

[CASTREX]

This is she.... another ongoing project and future turbo build up as well...

...hard to do donuts on a Yaris you know!!! :bellyroll:

http://i445.photobucket.com/albums/qq175/castrex/HachiRecienllegada26Enero09002.jpg

http://i445.photobucket.com/albums/qq175/castrex/HachiRecienllegada26Enero09006.jpg

[andries]

Oke, thanks.
I didn't no that.
The Yaris is my first Toyota and and I have not so engrossed myself in the other, especially older models.
BTW
It looks very good.

A lot of Toyota models here in Netherlands have the same name as yours at the other side of the ocean but they look different.

Jou can take a look on www.toyota.nl (http://www.toyota.nl) for the models available overhere.