Patrik's 2004 Toyota Yaris T-Sport Turbo

JapCarForum Cars, Cars, Cars! Project Cars Patrik's 2004 Toyota Yaris T-Sport Turbo

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Sparkystav
Administrator

14,683

08-04-2022, 12:59 PM

#21

Good research mate, I must admit when you said IHI I immediately thought of Subaru.

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

Sparkystav

08-04-2022, 12:59 PM #21

Good research mate, I must admit when you said IHI I immediately thought of Subaru.

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

phaebo
Senior Member

285

11-04-2022, 02:05 PM

#22

What kind of ecu is this thing running? Does it have its own unique toyota ecu? Or maybe some kind of your own blackboxes? Just wondering

phaebo

11-04-2022, 02:05 PM #22

What kind of ecu is this thing running? Does it have its own unique toyota ecu? Or maybe some kind of your own blackboxes? Just wondering

P.Lindblom
Posting Freak

821

18-04-2022, 11:02 AM

#23

phaebo What kind of ecu is this thing running? Does it have its own unique toyota ecu? Or maybe some kind of your own blackboxes? Just wondering

That's a very good question. I suppose it's got some kind of FCD. I might look into it Smile

A few days ago a large package arrived from the UK, containing a turbo Big Grin

I didn't have time to take a closer look at it until last night. The first thing I did was to remove the compressor and turbine housings to see if the were interchangeable. I thought the turbocharger from the Subaru had the same manifold flange, but I was wrong, so I swapped over the turbine housing from my Yaris turbocharger. It fit like a glove. Even the alignment pin was in exactly the right place.

Next up was the compressor housing. They turned out to be identical.
[Image: DSC_8839_fix.jpg]

To match my old turbo setup I needed to rotate the compressor housing slightly and fit the wastegate bracket. In order to do so I had to drill and thread four new holes. Fortunately two of the holes for the housing and one for the bracket matched, so I didn't even have to measure anything to figure out where to drill the new holes.
[Image: DSC_8832_fix.jpg]

I now have a working turbo, ready to be fitted to the Yaris. Check out the clearance, compared to that of my old turbo.
[Image: DSC_8855_fix.jpg]

Same thing in the turbine housing
[Image: DSC_8849_fix.jpg]

Here's a comparison pic. The old impeller was really worn:
[Image: turbine_comparison.jpg]

Unfortunately I don't know when I will have the time to fit it. It might have to wait until next weekend. By then all the bolts and gaskets I've ordered should have arrived as well. I've received a few already.
[Image: DSC_8844_fix.jpg]

I thought I might as well replace the drop links while the car is on jack stands. I'm also going to order a new set of tires.
[Image: DSC_8846_fix.jpg]

Edited 31-05-2015, 07:51 PM by P.Lindblom.

P.Lindblom

18-04-2022, 11:02 AM #23

phaebo What kind of ecu is this thing running? Does it have its own unique toyota ecu? Or maybe some kind of your own blackboxes? Just wondering

That's a very good question. I suppose it's got some kind of FCD. I might look into it Smile

A few days ago a large package arrived from the UK, containing a turbo Big Grin

I now have a working turbo, ready to be fitted to the Yaris. Check out the clearance, compared to that of my old turbo.
[Image: DSC_8855_fix.jpg]

Same thing in the turbine housing
[Image: DSC_8849_fix.jpg]

Here's a comparison pic. The old impeller was really worn:
[Image: turbine_comparison.jpg]

I thought I might as well replace the drop links while the car is on jack stands. I'm also going to order a new set of tires.
[Image: DSC_8846_fix.jpg]

Sparkystav
Administrator

14,683

18-04-2022, 01:31 PM

#24

Result with the turbo mate! Looks much better

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

Sparkystav

18-04-2022, 01:31 PM #24

Result with the turbo mate! Looks much better

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

P.Lindblom
Posting Freak

821

26-04-2022, 12:03 PM

#25

IT'S ALIVE!!!

Today I finally put everything back together. Before starting the car I disconnected the ignition coils and the oil return hose from the turbo to make sure the oil was pumped through it. After checking and rechecking every hose, nut and bolt I had touched I turned the key and the car started right away. I let it idle for a few minutes while looking for any leaks. Then I took it for a few test runs. Here's one of them:

[youtube]1uasGSm4kB0[/youtube]

I've driven plenty of ferraris and lamborghinis, but still this little Yaris puts a huge grin on my face. Partly because this was my first experience working on a turbo but mostly because it's so much faster than it looks :thumbup:

As soon as my new oil filter arrives I will change the oil, as I don't know when the last change was done. Last Friday a bunch of other stuff arrived, though.
[Image: DSC_8864_fix.jpg]

I received a short shifter kit from Hypersport
[Image: DSC_8865_fix.jpg]

Since my airbox was already removed it literally took five minutes to fit the short shifter and it works like a charm.

P.Lindblom

26-04-2022, 12:03 PM #25

Sparkystav
Administrator

14,683

26-04-2022, 12:21 PM

#26

Great news mate!
Starting the modding already lol

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

Sparkystav

26-04-2022, 12:21 PM #26

Great news mate!
Starting the modding already lol

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

DaveEdin
Posting Freak

5,657

29-04-2022, 02:29 AM

#27

Sweet little sleeper... :thumbup:

IS200 Sport - Sold
Mazda 6 MPS - Zoom Zoom!

Modifications
Completed:
Currently 280bhp/295lbft; 3" Meercat custom exhaust; KW Suspension; FMIC; SSP; HPFP; Custom Stainless Steel Dials - for the moment, the only set in the world!! (Till the group buy for MPSOC anyway :lol: )

In Progress:
E-Tuning remap ongoing via Cobb Accessport; Braided brake lines; Stubby aerial; Tinted repeaters and sidelights; 3 Port Boost Control Solenoid; 3" HTP Intake

DaveEdin

29-04-2022, 02:29 AM #27

Sweet little sleeper... :thumbup:

P.Lindblom
Posting Freak

821

03-06-2022, 10:06 AM

#28

I was just about to fit it when a hailstorm started
[Image: DSC_9051_fix.jpg]

A few days later, when trying to figure out where the presumed boost leak was I discovered there wasn't one. Unfortunately my "new" turbo had worn bearings. There was no play in the axle and the turbo worked like it should, but it didn't sound too good. Time to replace it a second time... yay.
[Image: DSC_9171_fix.jpg]

Oh, and if anyone's interested, here's the part number of the Yaris TS Turbo front lip: 76851-YW602
[Image: DSC_8970_fix.jpg]

I bought two VF19 turbos for £30 each and used a stethoscope to decide which one to use. This one looked a lot better than the last one I fitted.
[Image: DSC_9063_fix.jpg]

I cleaned all the ports on the turbo and while I was at it I also sandblasted and painted the bolts for the compressor housing
[Image: IMG_9749.jpg]

Then it was time to fit the turbo
[Image: DSC_9071_fix.jpg]

But not before making a turbo pyramid Smile

I got a bunch of new gaskets
[Image: DSC_9152_fix.jpg]

Here's where the oil feed line is connected to the engine block.
[Image: DSC_9157_fix.jpg]

I removed and cleaned the intake manifold
[Image: DSC_9174_fix.jpg]

These are the water cooling lines
[Image: DSC_9206_fix.jpg]

Fitted to the turbo
[Image: DSC_9210_fix.jpg]

New air filter
[Image: DSC_9382_fix.jpg]

I cleaned the intercooler as well as all the pipes and hoses before refitting everything. Yesterday I finally fitted the last few parts and primed the turbo before I started the engine. I got slightly worried when large amounts of smoke started coming from the exhaust. I started thinking the seals were blown in this turbo, but then I realized it could just be residual water left in the intercooler, so I let the car idle for like 15 minutes and sure enough the smoke disappeared after a while.

Today I took the car for a 100 mile drive and so far everything seems to be in order. The turbo is quiet like it should be and it's building boost. Neither the oil level nor the coolant level has dropped :thumbup:

Edited 16-07-2015, 07:47 PM by P.Lindblom.

P.Lindblom

03-06-2022, 10:06 AM #28

It's been a while since my last post, so I thought I'd give you an update.

The emblem I mentioned arrived as a nice surprise. Someone at the car breakers must have looked up my phone number and found my address. They removed the emblem from the rear hatch and mailed it to me as a gift. Next time I'm their neck of the woods I'll bring them a cake or something.
[Image: DSC_9045_fix.jpg]

[Image: DSC_9046_fix.jpg]

I was just about to fit it when a hailstorm started
[Image: DSC_9051_fix.jpg]

[Image: DSC_9060_fix.jpg]

A few days later, when trying to figure out where the presumed boost leak was I discovered there wasn't one. Unfortunately my "new" turbo had worn bearings. There was no play in the axle and the turbo worked like it should, but it didn't sound too good. Time to replace it a second time... yay.
[Image: DSC_9171_fix.jpg]

Oh, and if anyone's interested, here's the part number of the Yaris TS Turbo front lip: 76851-YW602
[Image: DSC_8970_fix.jpg]

I bought two VF19 turbos for £30 each and used a stethoscope to decide which one to use. This one looked a lot better than the last one I fitted.
[Image: DSC_9063_fix.jpg]

I cleaned all the ports on the turbo and while I was at it I also sandblasted and painted the bolts for the compressor housing
[Image: IMG_9749.jpg]

[Image: IMG_9750.jpg]

Then it was time to fit the turbo
[Image: DSC_9071_fix.jpg]

But not before making a turbo pyramid Smile
[Image: DSC_9203_fix.jpg]

I got a bunch of new gaskets
[Image: DSC_9152_fix.jpg]

Here's where the oil feed line is connected to the engine block.
[Image: DSC_9157_fix.jpg]

I removed and cleaned the intake manifold
[Image: DSC_9174_fix.jpg]

These are the water cooling lines
[Image: DSC_9206_fix.jpg]

Fitted to the turbo
[Image: DSC_9210_fix.jpg]

New air filter
[Image: DSC_9382_fix.jpg]

I cleaned the intercooler as well as all the pipes and hoses before refitting everything. Yesterday I finally fitted the last few parts and primed the turbo before I started the engine. I got slightly worried when large amounts of smoke started coming from the exhaust. I started thinking the seals were blown in this turbo, but then I realized it could just be residual water left in the intercooler, so I let the car idle for like 15 minutes and sure enough the smoke disappeared after a while.

Today I took the car for a 100 mile drive and so far everything seems to be in order. The turbo is quiet like it should be and it's building boost. Neither the oil level nor the coolant level has dropped :thumbup:

phaebo
Senior Member

285

03-06-2022, 10:58 AM

#29

nice job!! So first you only have a car with a broke turbo and then you have 4 turbos hahah. Hopefully this one will last a bit longer.

phaebo

03-06-2022, 10:58 AM #29

nice job!! So first you only have a car with a broke turbo and then you have 4 turbos hahah. Hopefully this one will last a bit longer.

ZAIS200
Senior Member

741

04-06-2022, 07:27 AM

#30

A lot of peeps are doing massive td04 turbo upgrades to the starlet gt i wonder how this compares and if a big turbo conversion is available on this thing?

ZAIS200

04-06-2022, 07:27 AM #30

A lot of peeps are doing massive td04 turbo upgrades to the starlet gt i wonder how this compares and if a big turbo conversion is available on this thing?