2018 Yaris SE 5MT - T-Sport w/Valvematic!

[atomic_hoji]

Hello All!

I've loved my 2007 FJ Cruiser and had lots of good times with it, but we decided as the family has grown and everyone needs to be out and about to different places all the time that it's time to move on from the truck; seriously, the FJC rear doors are not small kid friendly.. After some serious reading (lots here on Yaris World) we've decided to stay in the Toyota family and have a 2018 Yaris SE 5MT on order - coming soon (soon'ish? Not soon enough!). Apparently SEs aren't common and neither are 5MTs, so have to wait for a build.

As there's no picture yet, posted a placeholder (with appropriate details blanked) for the time being..
-- Adam

EDIT (16-Oct-2017): It's here! Arrived last Saturday, been driving it this week - fun little ride. Engine pic to show the 1NZ before the swap; for reminiscing. When I paid for oil spray (we salt the heck out of our roads) I assumed it was underspray, not all-over-the-entire-body-of-the-car spray.

yaris_side_view.jpg
yaris_engine_before.jpg

EDIT (27-May-2018): Picture of the final engine bay after the 2ZR-FAE install.
yaris_engine_after.jpg

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Overall Swap Summary
This thread is a build as it progressed and has tidbits of information, discussion, etc.. through-out. I've included this brief summary as the short, to-the-point version noting what was needed to do the swap, but without discussion as to how it was completed.

Engine
A complete 2ZR-FAE from the wrecker including the main engine wiring harness, intake and exhaust manifolds, injectors and fuel system, ignition coils, all sensors, and ancillaries such as starter, A/C compressor, and alternator. The RH engine mounts - both the engine side bracket and the frame side mount - from a Scion xD were used as per the 2ZR-FE swaps already documented.

Cooling System
Radiator filler neck, and radiator and heater hoses from the Scion xD were used: inlet and outlet heater hoses, and upper radiator hose; lower radiator hose from the Yaris was retained, though is a tight fit on the 2ZR thermostat housing. The Yaris radiator was retained. A short piece of 30mm radiator hose is needed to connect the Scion xD filler next to the radiator. The hoses route much easier versus using the Yaris hoses and create space for the main engine harness to the new ECM location.

Exhaust
A 2012 Scion xD complete exhaust system was used, however it does not bolt up without modification. The main pipe is not long enough to reach the rear hanger on the Yaris so the pipe was cut and extended. The rear hanger bracket is in a different location and had to be cut and re-welded to match the Yaris location. The 2ZR-FAE exhaust manifold from the iM does not center in the Yaris exhaust hole so the manifold to main pipe connection is poor - a modified bolt-up method was used to clamp the two parts enough to stop exhaust leakage.

Intake
The Injen Cold Air Intake system for a Scion xD was installed, however, like the exhaust it requires modification. The shape of the 3rd gen. Yaris front-end means the CAI interferes with the LH headlight assembly and the bumper reinforcement. The CAI was cut and shortened to make a 'ram air intake' instead.

Ancillaries
Most of the ancillaries on the engine were retained and plugged in without modification. The A/C hoses from the Yaris were retained and matched the ports on the iM A/C compressor with a bit of finagling. Reinforced PVC hose was run between the vacuum pump and the brake booster as the 2ZR-FAE uses a separate vacuum pump; there is no OEM hose to use. Similarly, heater hose (to be replaced with PVC when canister is installed) was used to run the connection between the PCV port and the intake manifold.

Transmission
The C50 from the Yaris was used and generally unmodified - the Yaris back-up switch was removed and replaced with a iM style back-up switch to match the main engine wiring harness connector. Flywheel, clutch, and pressure plate from the 2ZR were already installed on the engine, so those were used in place of the Yaris setup.

Electrical & Wiring
The ECM was relocated from the RH side firewall to the LH side of the engine bay. Custom brackets were built to hold the Scion iM ECM in front of the battery location. The wiring was fished out of the Yaris harness and re-routed to the new location, and the iM engine harness is bent over the Valvematic box to mate at the new location. The engine to body connector was converted from 18-pin + 2 pin connector setup to match the Yaris' 26-pin connector. An additional connection to power the Valvematic system was also wired in. Modification to the fuel pump control system was made to run the fuel pump and an external cooling fan control setup was installed due to differences between the Yaris and iM ECM control methods.