GR Yaris (Gen 2) Intermittent Misfire After Extended Driving - 2024 GR Yaris

Dogbone06

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Intermittent Misfire After Extended Driving - Heat Soak Related?

I've got an intermittent misfire issue that could have several causes. Hoping someone here recognises the exact symptoms and can point me in the right direction before I start throwing money at parts.

Background
Picked up the car in November 2025 and drove it 335 km from the dealer. Parked it for the winter and did the following engine-side mods:
  • Eventuri intake
  • Hand-built stainless exhaust without OPF
  • Airtec Stage 1 intercooler
  • Oil cooler sandwich plate with AN outputs
When the season started, the car ran fine for a while - until the first misfire appeared at around 2,000 km on the clock, still on the stock tune and stock ECU.

How It Happens
I had been cruising at 120 km/h on the highway for about two hours. Downshifted to 4th and went full throttle. It immediately started to misfire, so I backed off. I have a custom display showing misfires in real time, and it was occurring on cylinder 3.

On the Dyno
I already had a Syvecs ECU on order, so a few days later it went on the dyno. During the tuning session (done by Romain at RaceCal), everything ran fine for a few hours until the misfire came back. Romain checked the logs and found that the ECU was commanding maximum fuelling, so his first guess is the solenoid in the high-pressure fuel pump. We turned the car off, opened the hood, and let it cool for about 20 minutes. Started it back up and the misfires were gone. That's an expensive part to swap just to test a theory (around 2500€ in Sweden), which is why I'm posting here first.

The Pattern
Since then the misfires have appeared a few more times. It always happens after the car has been driven for an extended period, and specifically after holding the same speed for a long time. My theory is that something is heat-soaking over time and stops functioning properly.
Any input from someone who has experienced the same issue or has solid knowledge of these engines would be greatly appreciated.
 
You’ve done the easy stuff like swap plugs and coil packs?
Haven't done that but it will absolutely be the first thing to do as it's way cheaper. I doubt it's the coils tho since Romain saw in the log that the ECU was commanding maximum fuelling.
 
Haven't done that but it will absolutely be the first thing to do as it's way cheaper. I doubt it's the coils tho since Romain saw in the log that the ECU was commanding maximum fuelling.
Is it possible that the ECU adding fuel is a reaction to another issue, like knocking?
 
When you say "the ECU is demanding maximum fuelling", what are you looking at?

HPFP target? Injector duty? Something else?

The HP fuel rail target will go to max on even quite light throttle applications so I wouldn't think that has anything to do with it.

Would still put money on it being a coil :)
 
@VileQuenouille: Could perhaps be, I am unsure. But the car isn't knocking, the current tune is extreamly safe. We're only running 326bhp. Syvecs on this car is a tad overkill. I am certain that something gets heat soaked.

@Duke: That is an interesting idea, buying a coil is always a good thing. Having a spare is never bad. So I will for sure buy one and swap into Cyl 3. But Romain saying the HPFP makes me still think a little bit of that. I am not sure what value he was looking at. I plan to log it myself next time I drive the car so I can show it here.
 
You don't even need a spare, just swap the one on cyl 3 with another and see if the problem follows it. Takes 5 mins to swap them.
Absolutely, but I prefer to have one spare. Way back when, I was driving another fun car I had to a car event, and one coil pack gave up. Ruined that whole weekend for me. I should have one spare at all times. :rolleyes:
 
For anyone curious here is an HTML graph of the actual misfire event.

 
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Check the actual LPFP and HPFP pressures on the same pull...
 
Check the actual LPFP and HPFP pressures on the same pull...
There doesn't seem to be actual pressure for LPFP, but there is for HPFP.

I gave the full log as a CSV format to Claude, this is the outcome:
1780571247210.webp
 
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