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10-12-2020, 04:52 AM | #73 | |
Drives: 2009 Base Hatch 2 Dr Auto Join Date: Dec 2008
Location: nj
Posts: 4,790
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Quote:
In my experience it’s best to heat rusted fasteners with a torch before trying to remove them. Heated up cherry red. Not often necessary to resort to EZ Out with that approach.
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Synthetic Oil: Its All In Your Head |
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10-12-2020, 12:17 PM | #74 |
Drives: 06 2ZR Turbo Yaris RS Join Date: Aug 2017
Location: Fredericton, New Brunswick, Canada
Posts: 2,384
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Yes, I agree. In this case it was nearly impossible to get anything on it as it was pretty corroded. My mechanic heats them up red hot, then uses an ice cube on the fastener and immediately removes it. Due to the difficult position and the fact that I had to become a contortionist just to get something on to turn the bolt shank, I couldn't coordinate heat, a removal tool attached while holding an inspection mirror in the other hand. Much of this job was done 'blind'. I feel thankful that I managed to drill and tap straight and the nut ended up flush to the manifold. If the engine had been out of the car, it would have been a quick job, I suspect. Live and learn. The next time, I'll know exactly what to do and hopefully it won't be in such an awkward and cramped position.
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2006 Yaris 5 Door RS 2ZR-FE (2011 Corolla 1.8L) Swapped, Automatic, T-28 Turbocharged (8 psi), HSD MonoPro Coilovers, DIY W/M Injection, custom 3" cold air intake, custom 2.5" exhaust, TRD rear sway bar, Penguin Garage 13mm spacers (rear), custom Civic front lip, full repaint, Android 6.0 7" touchscreen, Rockford Fosgate speakers, tweeters, NVX underseat subwoofer https://www.instagram.com/2zr_turbo_yarisrs/ |
10-12-2020, 02:52 PM | #75 |
Drives: 2009 Base Hatch 2 Dr Auto Join Date: Dec 2008
Location: nj
Posts: 4,790
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Yes things are a lot tighter these days when working on a car! I’m kind of thankful the car is I got to work on have a lot more space to do so. I would have a difficult time changing a water pump on my 09 Yaris. Even 10 years ago!
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Synthetic Oil: Its All In Your Head |
10-24-2020, 07:07 PM | #76 |
Drives: 06 2ZR Turbo Yaris RS Join Date: Aug 2017
Location: Fredericton, New Brunswick, Canada
Posts: 2,384
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Missed this. Yeah, I remember the old boats I drove; 69 Olds Cutlass, 70s Buick Century, 80s Crown Vic. You could practically stand in the bay beside the engine. Some day I might buy a classic car and work on it. I can only imagine how much easier it would be, space-wise.
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2006 Yaris 5 Door RS 2ZR-FE (2011 Corolla 1.8L) Swapped, Automatic, T-28 Turbocharged (8 psi), HSD MonoPro Coilovers, DIY W/M Injection, custom 3" cold air intake, custom 2.5" exhaust, TRD rear sway bar, Penguin Garage 13mm spacers (rear), custom Civic front lip, full repaint, Android 6.0 7" touchscreen, Rockford Fosgate speakers, tweeters, NVX underseat subwoofer https://www.instagram.com/2zr_turbo_yarisrs/ |
10-24-2020, 07:22 PM | #77 |
Drives: 06 2ZR Turbo Yaris RS Join Date: Aug 2017
Location: Fredericton, New Brunswick, Canada
Posts: 2,384
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More exhaust work...
I knew I had to replace the little donut at the back of the exhaust system. I got it unbolted and the old deteriorated donut removed. Man, it was stuck on there and it took a while to pry off all the little bits. I started up the car and still...exhaust leak! I plugged the exhaust with my hand and could hear exhaust coming out just above the flange. Dang...the little welded on shield had rusted through at the weld. Seen this before. I got it ground down. The rest of the metal around the hole is very thick and solid. I just slowly bent a small rectangular piece of old car hood into a curve in my vise. Got the patch welded on. When I bent the small shield over to have good welding access, I noticed that the other weld had also rusted through. I figured I'd weld that, then weld the shield back on after both patches were done. Ultimately, gave up on that idea. There's a large aluminum shield between that and the gas tank anyway. Painted with VHT flameproof ceramic paint. This should hold up for a good while. I would have just put the relatively new muffler I had on my '06 before the swap, but then recalled that I'd put that on my '08 LE before I sold it. Eventually, I'll pick up a Walker SS muffler from RockAuto, or, I'll keep my eyes open for a Megan or other performance muffler, if I can find a cheap one for sale. Car is coming along nicely. Went out for a nice drive in it today. Still have a few jobs left to do.
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2006 Yaris 5 Door RS 2ZR-FE (2011 Corolla 1.8L) Swapped, Automatic, T-28 Turbocharged (8 psi), HSD MonoPro Coilovers, DIY W/M Injection, custom 3" cold air intake, custom 2.5" exhaust, TRD rear sway bar, Penguin Garage 13mm spacers (rear), custom Civic front lip, full repaint, Android 6.0 7" touchscreen, Rockford Fosgate speakers, tweeters, NVX underseat subwoofer https://www.instagram.com/2zr_turbo_yarisrs/ Last edited by 06YarisRS; 10-25-2020 at 07:23 PM. |
10-27-2020, 03:31 AM | #78 |
Drives: Yaris 06 - 5dr hatchback Join Date: Aug 2015
Location: Birmingham, UK
Posts: 390
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Impressive job so far. Glad you managed to deal with that bolt. I just can't believe it was seized so bad. It's an aluminium block - I just don't understand what was holding it in like that. If anything it should have just removed the threads from the block.
What jobs are left to do on her?
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- Yaris 2006, 1.0, 5 door hatchback "Betty" - 240,000 miles UK to Nordkapp in a Yaris
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10-27-2020, 03:58 AM | #79 | |
Gen 3 > Gen 2
Drives: NCP131, F-150 Join Date: Jul 2019
Location: Red Deer, AB
Posts: 501
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Quote:
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2014 NCP131 5 Speed 2007 F150 4.2L 5 Speed 2013 Rav4 LE AWD Autotragic - Wife's |
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10-27-2020, 05:40 AM | #80 | |
Drives: 06 2ZR Turbo Yaris RS Join Date: Aug 2017
Location: Fredericton, New Brunswick, Canada
Posts: 2,384
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Quote:
Although every situation in unique, if I again ran into the same conditions, I would try in this order: 1) Try socket style bolt extractor. If that failed, 2) grind bolt flat and remove manifold. If the nub of shank wasn't enough, 3) weld a larger nub onto the protruding bolt shank, roughly shape to take a socket style extractor. What remains to be done: - passenger side axle boot, or axle replacement. I have a whole axle and may just do that. - Driver's seat slider assembly - Stuck hatch lock tumbler - despite having replaced an ebrake cable, rear brake job and and topping up fluid, I have a brake warning light on. Will have to troubleshoot that. I think the car has ABS, but no ABS light. I was thinking rear wheel ABS sensor plug corrosion, but not sure what the root cause is. I suppose I should check the ebrake switch. Ebrake and braking system function flawlessly with great pedal pressure etc. - Optional (as they're not that bad), rear axle to frame bushings. I have 2 new ones. I expect that will be a tough job getting them out. I have an air hammer and will attempt to walk them out. I know you bought a bushing remover and I may end up having to do that too. - Full repaint, though this will not happen this year. Plugging along slowly, but the car is coming along nicely. It will be pretty nice, solid and reliable when done. A lot of work! I undertook this for a few reasons: 1) it's an RS and 2) I've always wanted to buy a cheap (though good quality car) and tackle such jobs as welding/structural repair, and one that involved more than just simply bolting on parts that obviously needed to be replaced. This car, provided both! 3) everything from the rear axle forward is in pristine condition from a rust perspective. The owner had it rustproofed really well from the axle forward. A true learning experience and one that's honing my 'rebuild skills' to some degree. I would say that a car that needs this many repairs is on the far edge of projects that I'd be willing to take on again, though. Haha.
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2006 Yaris 5 Door RS 2ZR-FE (2011 Corolla 1.8L) Swapped, Automatic, T-28 Turbocharged (8 psi), HSD MonoPro Coilovers, DIY W/M Injection, custom 3" cold air intake, custom 2.5" exhaust, TRD rear sway bar, Penguin Garage 13mm spacers (rear), custom Civic front lip, full repaint, Android 6.0 7" touchscreen, Rockford Fosgate speakers, tweeters, NVX underseat subwoofer https://www.instagram.com/2zr_turbo_yarisrs/ Last edited by 06YarisRS; 10-27-2020 at 05:50 AM. |
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10-31-2020, 07:39 PM | #81 | ||
Drives: Yaris 06 - 5dr hatchback Join Date: Aug 2015
Location: Birmingham, UK
Posts: 390
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Quote:
Quote:
I used the air hammer to fold the lip out and then cut the lip off with the grinder. That meant I could get my bushing extractor on. It took an enormous amount of force. I actually damaged the M12 forcing screw in the kit. I would suggest adding heat to the metal sleeve with a propane torch. It might help them come out. Mine weren't in great condition. They were causing a "clunking" from the rear when I was braking. It was quite annoying. My rear shocks were dead as well. Also my rear axle was very rusty so I needle scaled, sand blasted it and painted it with Jotun 87. The amount of rust scale the air hammer and needle scaler chipped off it was shocking. It may well have rusted through somewhere if I hadn't treated it at the rate it was going. Seen as you have to drop the rear axle to do it you might as well clean it up. As for your brake light being on - I would sometimes get this if I was driving on a wet night when the roads had been salted. Near as I could figure out salt water was getting into and shorting out a connector somewhere because it would go away when the car dried out. The main culprit on mine was one of the rear ABS sensors. So I stuffed the connectors with vaseline to keep the water out and it seemed to cure the problem.
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- Yaris 2006, 1.0, 5 door hatchback "Betty" - 240,000 miles UK to Nordkapp in a Yaris
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11-01-2020, 12:34 PM | #82 |
Drives: 2 Yaris Hatchbacks Join Date: Dec 2006
Location: Montana
Posts: 44
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2 things about your RS Surprise Me!
This post has been great to follow! And the basic car you are working with looked great to begin with as well. But as a US-living guy, a couple things about your car surprise me, the fact that it has black mirrors (not body-colored,) and manual windows. I thought CDN RS spec cars came with upgrades to both these items? (Power Windows and Colored Mirrors.) And only CE/LE cars might have not? But your door panels look like they are original RS ones, the place where window switches go is correctly dark colored... I even wondered if a previous owner had "combined" an crunched RS interior with a LE pkg 3 door in good shape? I have an old online CDN 08 HB brochure that shows the original equipment for these cars, and thought that the 07 range was the same. Or am I totally wrong? Many years ago I bought some Canadian parts from a BC dealership and looked closely at a couple LE models (no RS on site,) and always thought that in Canada, I would quickly replace the mirror covers of an LE with US-sourced colored covers...
In any case, thanks for a fantastic post about rebuilding your car! And I hope you don't mind my intrusion. Again, Great Work so far! Last edited by Snappy; 11-01-2020 at 12:38 PM. Reason: understandability |
11-07-2020, 12:38 AM | #83 | |
Drives: 06 2ZR Turbo Yaris RS Join Date: Aug 2017
Location: Fredericton, New Brunswick, Canada
Posts: 2,384
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Quote:
My 2008 had the ABS light issued as well. A pin had actually corroded off. I clipped the ends off a sewing needle plugged it in, like you, applied grease and plugged the connector back in. Never had a problem again. I have a jumper for the OBD2 port, so I'll bridge the appropriate pins and get the code. If the pin or pins on the wheel speed sensor are gone, I'll order a wss and install it. Thanks for the insight and guidance!
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2006 Yaris 5 Door RS 2ZR-FE (2011 Corolla 1.8L) Swapped, Automatic, T-28 Turbocharged (8 psi), HSD MonoPro Coilovers, DIY W/M Injection, custom 3" cold air intake, custom 2.5" exhaust, TRD rear sway bar, Penguin Garage 13mm spacers (rear), custom Civic front lip, full repaint, Android 6.0 7" touchscreen, Rockford Fosgate speakers, tweeters, NVX underseat subwoofer https://www.instagram.com/2zr_turbo_yarisrs/ |
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11-07-2020, 12:46 AM | #84 | |
Drives: 06 2ZR Turbo Yaris RS Join Date: Aug 2017
Location: Fredericton, New Brunswick, Canada
Posts: 2,384
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Quote:
EDIT: I found this: https://www.autotrader.ca/research/t...power%20locks. Then there's this (though USA, I believe). It shows power locks, windows, A/C and a few other things as options. It does look like body colored mirrors were standard equipment. I wonder if the mirrors were replaced on my car. It had definitely been in a few fender benders. Both front fenders look like aftermarket ones. I was planning to pick up two at the U-Pull before painting the car. Or, what I have here is really a CE done up like an RS. I'm going to look on my insurance card. The policy links the VIN to a model and trim automatically. I'll post up the result after I check. Again, very intriguing. https://www.auto123.com/en/new-cars/.../2007/3-dr/rs/
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2006 Yaris 5 Door RS 2ZR-FE (2011 Corolla 1.8L) Swapped, Automatic, T-28 Turbocharged (8 psi), HSD MonoPro Coilovers, DIY W/M Injection, custom 3" cold air intake, custom 2.5" exhaust, TRD rear sway bar, Penguin Garage 13mm spacers (rear), custom Civic front lip, full repaint, Android 6.0 7" touchscreen, Rockford Fosgate speakers, tweeters, NVX underseat subwoofer https://www.instagram.com/2zr_turbo_yarisrs/ Last edited by 06YarisRS; 11-07-2020 at 01:22 AM. |
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11-07-2020, 02:01 AM | #85 |
Drives: 2 Yaris Hatchbacks Join Date: Dec 2006
Location: Montana
Posts: 44
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'08 Toyota Canada Brochure
I think I downloaded this from Toyota.ca back in 08.
(Split into 3 PDFs for size posting limits.) First Part: Last edited by Snappy; 11-07-2020 at 02:06 AM. Reason: Number of PDFs |
11-07-2020, 02:05 AM | #86 |
Drives: 2 Yaris Hatchbacks Join Date: Dec 2006
Location: Montana
Posts: 44
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'08 Toyota Canada Brochure
Second Part:
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11-07-2020, 02:06 AM | #87 |
Drives: 2 Yaris Hatchbacks Join Date: Dec 2006
Location: Montana
Posts: 44
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'08 Toyota Canada Brochure
Third Part:
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11-07-2020, 07:11 AM | #88 |
Drives: 06 2ZR Turbo Yaris RS Join Date: Aug 2017
Location: Fredericton, New Brunswick, Canada
Posts: 2,384
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Those are awesome! Thanks a lot. I downloaded them to my Yaris folder. I didn't know about those optional wheels and the performance exhaust. I love the slightly retro font. Haha.
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2006 Yaris 5 Door RS 2ZR-FE (2011 Corolla 1.8L) Swapped, Automatic, T-28 Turbocharged (8 psi), HSD MonoPro Coilovers, DIY W/M Injection, custom 3" cold air intake, custom 2.5" exhaust, TRD rear sway bar, Penguin Garage 13mm spacers (rear), custom Civic front lip, full repaint, Android 6.0 7" touchscreen, Rockford Fosgate speakers, tweeters, NVX underseat subwoofer https://www.instagram.com/2zr_turbo_yarisrs/ |
11-07-2020, 08:32 AM | #89 |
Drives: 06 Polar White 5dr, 13 Soul 4u Join Date: Oct 2008
Location: Georgetown, Ontario, Canada
Posts: 5,762
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There's too much RS in that car to be a lesser model converted with RS bits. I have the '07 brochure and it is not quite the same as '08.
The mirrors however are supposed to be body colour regardless of whatever option package the car was delivered with. Body colour mirrors is achieved by snapping coloured caps over base black mirrors is it not? Could be a factory oversight, or caps have been removed.
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11-07-2020, 07:06 PM | #90 | |
Drives: 06 2ZR Turbo Yaris RS Join Date: Aug 2017
Location: Fredericton, New Brunswick, Canada
Posts: 2,384
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Quote:
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2006 Yaris 5 Door RS 2ZR-FE (2011 Corolla 1.8L) Swapped, Automatic, T-28 Turbocharged (8 psi), HSD MonoPro Coilovers, DIY W/M Injection, custom 3" cold air intake, custom 2.5" exhaust, TRD rear sway bar, Penguin Garage 13mm spacers (rear), custom Civic front lip, full repaint, Android 6.0 7" touchscreen, Rockford Fosgate speakers, tweeters, NVX underseat subwoofer https://www.instagram.com/2zr_turbo_yarisrs/ |
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