Toyota Vios Turbo

Stage 2 Turbo Project - Golden Eagle Intake Manifold

Christmas just got better with the arrival of the intake manifold from Golden Eagle Manufacturing.

Thanks to GT Auto, as Golden Eagle's authorized dealer they've worked together to developed this intake manifold for my car.

This is still a prototype.

The design of this intake manifold is not final yet as we'll be testing it and to keep refining the design until we get it right.

So I guess you won't find this intake manifold up for sale anywhere yet but if you're the adventurous type and would like to give it a try please do get in touch with us.

Or if you're interested in getting one when its ready, you could get in touch with GT Auto to place an early pre-order and get a discount off the list price when its up for sale!

And to copycats out there, imitation is the sincerest form of flattery.

The intake manifold

We're quite impressed with the quality of the finishing

An peek into the inners of the intake manifold

The flange is made for the 60mm throttle body that we'll be using later

Stage 2 Turbo Project - Golden Eagle Head Gaskets

Now that we're using the 77mm over sized pistons from Ross Racing along with the newly sleeved engine block, we also got Golden Eagle to custom make these head gaskets for us as well.

They are multi-layered and is 1mm in thickness, just as we requested.

And Golden Eagle were kind enough to even threw in 2 steel tags for us as souvenirs!

Stage 2 Turbo Project - Golden Eagle Sleeves

Just as I was walking back from lunch with Toby and Thomas, we saw the DHL delivery truck parked right outside of GT Auto's shop.

I knew it had to be more goodies from Santa, and it turned out to be the engine blocks that we've long waited for.

We previously sent two engine blocks some time ago to Golden Eagle Manufacturing in California, USA as GT Auto is their authorized dealer in Malaysia.

Golden Eagle did a splendid job in getting the block bored and sleeved, the installation job was clean and neat and the new liners look very strong and sturdy.

Golden Eagle's HD sleeves comes with a lifetime warranty against cracking and is rated to withstand up to 1200 horsepower. The sleeves has a 500% increase in contact area compared to stock liners allowing better heat dissipation.

With them installed we should have a peace of mind and need not to worry about cylinder wall cracking when we get ready to crank up the boost later.

Both the engine block returned

Close up shot

O ring groove for the copper bus wire

Copper bus wire

Now that we have all these in hand, its about time we start preparing for the completion of the stage 2 turbo project as there are more goodies arriving.

Stage 2 Turbo Project - Autronic SM4

Yes we're ditching the Haltech Platinum Sport 1000 ECU for this big guy here.

The SM4 is currently the top of the line engine management offered by Autronic where GT Auto is currently the sole dealer for Malaysia.

Some of you might have heard about how this company got started as the founder Richard Aubert is also the co-founder for Motec before he formed Autronic.

The reason why we went with the Autronic SM4 is very simple, response time and VE (volumetric efficiency) tuning.

Nothing comes close to the response time the SM4 provides, not even Motec. Not to mention the amount of compensation algorithms and tables that is working behind the scene.

I know die hard Motec fans out there will beg to differ though, but thats what Toby of GT Auto commented after tuning both of them and I'm sticking with his advice.

Coming Soon - Suzuki Swift Turbo

A new project from GT Auto, check out www.swift-turbo.com for more updates in the future.

Ross Vios Turbo

We have a new member in our family, a 2008 model white Toyota Vios manual fitted with GT Auto's turbo kit belonging to Dr. Ross.

Recently completed in GT Auto, with the Garrett GT20 turbo the car pulled over 157 PS with over 22 kg-m of torque at the wheels at a mere 0.6 bar of boost.

And still this is all done with the exhaust silencer installed! Nothing beats the benefit of having a manual transmission for maximum torque delivery.

This new turbo kit from GT Auto features an improved design where the intercooler piping routes are much more shorter.

Not only the response is quicker now due to the faster build up turbo spool, the engine bay also looks much more cleaner and stealthier.

If there is anything that you would like to ask about this car, besides myself you may contact the owner directly at ross@viosturbo.com.

Besides the tuning of GT Auto, other highlights of the modifications includes the fitting of an E-Manage, AEM water/methanol injection kit, HKS SSQV III, Turbosmart Ultra-Gate38 external wastegate and the Wilwood Dynalite 4 piston brake kit.

Meanwhile, I'll let the pictures do the talking.

Power: 157.87 PS @ wheels

Torque: 22.79 kg-m @ wheels

Boost: 0.6 bar

When you see this sticker, you know whats under the hood

Would you believe that this 1NZ-FE is forced fed if we didn't tell you?

HKS SSQV III

AEM water/methanol injection nozzle

The Turbosmart Ultra-Gate 38mm external wasteagate

Wilwood Dynalite 4 pistons brake kit

Runstop rear conversion kit

M7 Super Street GT muffler with titanium tip

The AEM water/methanol tank

Body hugging buckets from SSCUS

Momo Tuner steering with Elevo quick release kit

Top right: GReddy Informeter Touch

Mid right: Shadow oil pressure and boost gauge

Lower center: Pivot 3-Drive, Pivot Speed Meter & Shadow Voltage Meter

Lower left: Apexi turbo timer

Stage 2 Turbo Project - ACT Clutch Kit

With the amount of horsepower projected by the stage 2 turbo kit, the stock clutch from the TRD Vitz RS Turbo transmission would not be sufficient to take on the new found torque ratings.

So we placed an order with ACT for a set of their 6 pad clutch kit and it took them more than 4 months to deliver it as they are currently on a long back order.

Featuring a 40% increase in clamp load, the kit is rated to have a torque capacity of around 300 Ft/Lbs or 40 kg-m at the crank.

ACT claims that the kit will still give the driver a stock to moderate pedal feel thanks to the spring centered disc design.

We hope it'll be able to cope with the new turbo kit or else we'll just have to stock a couple of the clutch kit on standby until we find a better one.

Meanwhile, here are some pictures for your viewing pleasure.

GT Auto's guest data entry clerk updating the clutch kit in the stock system

Close up shot of the box

Part number for you guys to refer in the future

Contents of the packaging

The pressure plate

The 6-pad spring centered disc

The release bearing

Stage 2 Turbo Project - Ross Racing Pistons & Crower Rods

Update (30/05/11): This set of pistons has been replaced with a custom set from Ross Racing as well with revised compression ratio and coated pistons crown.

If you are wondering why would I have another set of pistons and rods with me here, it is because we're actually building up two engines at the moment.

Engine one will be running CP forged pistons and Crower rods with custom regrind cams.

Engine two will be running Ross Racing pistons and Crower rods, together with the JUN 272 camshafts and Golden Eagle sleeves.

The major difference between the pistons from CP and the new Ross pistons is that they are custom made to 77mm with gas ports so that the rings will stay sealed when we rev the mutha f**ker over 8,000 RPM.

And with the new pistons we're also bringing up the engine displacement to 1.6 litre as well.

The items arrived today along with a whole bunch of others goodies while I was hanging around so here are some pictures for your viewing pleasure.

There are some rods from Oliver as well

The humor side of Ross Racing

Deep dish design

We did not teflon coat the piston skirts this round though

Notice those gas ports up there?

There is a reason why we stood with Crower rods

The individual packaging of the rods

You know their shot peening process is of quality when the surface looks like this

Stage 2 Turbo Project - JUN Auto Camshafts

Ever since JUN Auto's visit to GT Auto back in March 2009, JUN President Junichi Tanaka promised that they will immediately start researching parts for the 1NZ-FE engine when they return to Japan.

Well they made good their promise and released connecting rods for the 1NZ-FE engine back in April 2010. The news to the article can be found on their website here.

Now, as a result of partnership with GT Auto for the past few months they have now again developed parts for the 1NZ-FE engine.

This time its performance camshafts, and they come in 3 variations:

- 256 duration, 9.0mm lift (street spec)
- 272 duration, 9.5mm lift (NA spec)
- 272 duration, 10.5mm lift (turbo spec)

And best of all, VVT-i feature of the engine is retained even with the camshafts fitted.

Toyota Vios Turbo will be fitting in the 272 turbo spec camshafts as part of the stage 2 turbo project.

Stage 2 Turbo Project - GT Auto Fuel Rail

With the FIC fuel injectors in place, the stock fuel rail will no longer be sufficient to hold enough fuel supply to the new injectors.

GT Auto made this fuel rail for me and it is a direct plug and play to the cylinder head without any modifications required.

And best of all, it can be easily configured to fit both return or returnless fuel setup.

Just a note, besides my car they could also custom make the fuel for any car models.