The Toyota 86 (also known as the Subaru BRZ or GT86 in different markets) is a lightweight, rear-wheel-drive sports car that celebrates pure driving dynamics. With its horizontally opposed 2.0-liter boxer engine, the Toyota 86 offers a balanced chassis, precise handling, and an engaging driver experience. However, for enthusiasts hungry for more performance, the factory output of 200-228 horsepower (depending on model year and region) can feel limiting.
In this comprehensive guide, we’ll explore proven and effective ways to increase Toyota 86 horsepower, transforming it into a more potent driver’s car without compromising reliability or drivability. Whether you’re looking for subtle gains or a full-on performance build, this article provides all the information you need to make informed tuning decisions.
Understanding the Toyota 86’s Engine
Before diving into modifications, it’s essential to understand the heart of the Toyota 86: the FA20 engine.
The FA20 is a 1998cc flat-four boxer engine developed as a collaboration between Toyota and Subaru. It features direct fuel injection (DFI), a high 12.5:1 compression ratio, and a lightweight aluminum block. Designed for high-revving performance, the engine generates a linear power curve and revs up to 7,400 RPM.
While naturally aspirated and modest by modern turbocharged standards, the FA20 is robust and well-engineered, responding well to modifications. The high-quality internals, strong bottom-end, and compatibility with a wide range of upgrades make it an ideal candidate for performance tuning.
Basic Horsepower Upgrades for the Toyota 86
If you’re new to tuning or looking for budget-friendly ways to extract more power, there are several foundational modifications that can provide a modest but noticeable increase in horsepower.
1. Air Intake and Exhaust Upgrades
One of the most effective and cost-efficient ways to gain power is improving airflow into and out of the engine.
Upgrading to a cold air intake (CAI) can increase airflow efficiency, reduce intake temperatures, and slightly improve horsepower (typically 5-10 hp). A high-quality CAI like the Injen or K&N unit can make a real difference in throttle response and engine note.
On the exhaust side, a cat-back system or even axle-back system (depending on your budget) can reduce backpressure and improve exhaust flow. Brands like Megan Racing, Borla, and Fujita offer systems designed specifically for the Toyota 86. Horsepower gains from a full cat-back system range from 8-15 hp, depending on setup.
2. Engine Tuning via ECU Calibration
ECU tuning is one of the most impactful modifications you can make for the Toyota 86. The stock ECU has considerable conservative programming that limits the potential gains from intake and exhaust mods.
Using a flash tuner like the APEXi Power FC, Unichip, or Hondata Flashpro allows you to reprogram the ECU for a more aggressive fuel and ignition map. Companies like Top Secret, A’PEXi, and GReddy offer stage-specific tunes that pair with bolt-on modifications.
If you’re running only the intake and exhaust, a custom tune can extract an additional 10-15 hp. More advanced modifications (like forced induction or cams) will require more extensive tuning, but these will be discussed in later sections.
3. High-Flow Catalytic Converters
Factory catalytic converters restrict exhaust flow. Replacing them with high-flow units can reduce backpressure and improve engine breathing. Brands like Vibrant, Wicked Flow, and JBA offer high-flow cats that work well with the Toyota 86.
This change often pairs with custom ECU tuning and exhaust modifications for maximum gain. Expect gains of approximately 5-10 hp along with sharper throttle response.
Intermediate Modifications: Leveling Up Your Toyota 86 Performance
Once you’ve covered the basics, you can graduate to more involved modifications that offer greater horsepower increases. These upgrades typically require more investment and may alter daily driving characteristics.
1. Lightweight Pulley Installation
Replacing the factory crank and accessory pulleys with lightweight units reduces rotational mass and allows the engine to rev quicker. Companies like APS, UR, and Whiteline offer lightweight pulley kits specifically for the FA20 motor.
This mod alone usually adds around 5 hp and is often a complementary modification to other upgrades. The result is a more responsive engine that “feels” faster even on small boosts.
2. Lightweight Flywheel
A lighter flywheel, such as those from Exedy or OS Giken, removes rotational inertia from the drivetrain. This makes the car more snappy through gear changes and engine revving.
Installation of a lightweight flywheel may sacrifice some smoothness in idle and low RPM driving, but the payoff comes in sharper throttle response and performance feel. With proper tuning, it can yield 3-5 hp gains and makes the car more enjoyable to drive.
3. Oil Catch Can (OCC)
The FA20DPR engine (in later Toyota 86 models) uses direct injection, which can lead to carbon buildup on the intake valves due to lack of fuel washing over them.
Installing an oil catch can (OCC) system helps reduce this buildup and improves overall engine efficiency and longevity. While not a power-increasing mod on its own, maintaining clean intake runners and valves ensures optimal airflow over time—which indirectly helps preserve and maximize engine output.
4. Performance Cams
Upgrading to performance camshafts is one of the most effective internal modifications that can increase Toyota 86 horsepower.
Manufacturers like Toda, BC Racing, and COMP Cams offer cam profiles that provide increased valve duration and lift, optimizing the engine’s volumetric efficiency. On a stock bore and stroke FA20 engine, a good set of cams may provide 15–20 hp gains when combined with proper ECU tuning and upgraded valvetrain components.
Advanced Toyota 86 Modifications: Forced Induction and Engine Swaps
For those looking for substantial performance gains, forced induction and engine swaps are game-changers. These are advanced builds that typically require support from the entire drivetrain and suspension.
1. Turbocharging the FA20 Engine
The FA20 can handle forced induction, especially with engine internals reinforcement and proper tuning. Several companies offer bolt-on turbo kits:
- Gillett Engineering: Offers complete turbo kits that start around 250–350 hp depending on boost levels.
- The Complete Hub Garage (TCHG): Offers the FR-S turbo kit with great reliability and user-friendliness.
- Damond Motorsport: Known for affordable bolt-on turbo conversions and comprehensive kits.
While turbocharging can potentially deliver 300+ hp on the stock internals with conservative boost, pushing beyond that requires internal upgrades such as forged pistons, stronger rods, or even a bottom-end rebuild.
Turbos can generally be expected to offer anywhere from 200 hp to 600 hp, depending on tuning and supporting modifications. Turbocharged builds are ideal for those who want a streetable car with track-level performance.
2. Supercharger Installations
While fewer turnkey supercharger kits exist compared to turbo options, a supercharged Toyota 86 offers instant throttle response and a linear power delivery. Whipple and Edelbrock used to offer kits for similar platforms which can be adapted.
Supercharging is more expensive upfront than turbocharging but provides excellent tractability, especially in the city. Gains usually range from 250–300 hp with appropriate hardware.
3. Engine Swap: Toyota 2AR-FE or 4U-GSE
For extreme power or hybrid track/daily builds, swapping the FA20 with a different engine is an option.
- 2AR-FE Swap: Toyota’s 2.4-liter four-cylinder from the Camry or Rav4 offers more displacement, good reliability, and potential for forced induction. The larger displacement makes it easier to generate mid-300 hp figures with simple bolt-ons.
- 4U-GSE or 3S-GTE: Popular in drift circles, though swaps require extensive fabrication work. The 2ZZ-GE from the Celica is also popular, albeit rare today.
Engine swaps are not for the faint of heart—they require custom fabrication, mounts, wiring, and tuning. However, for performance junkies, the swap is a viable path to reliable high horsepower numbers.
Internal Engine Upgrades for Higher Horsepower and Reliability
When pushing the FA20 past 300 hp or aiming for longevity under high-stress environments like track days or drifting, internal upgrades become nearly mandatory.
1. Forged Engine internals
Forged pistons, rods, and crankshafts are the bedrock of high-performance engines. Companies like Wiseco and Manley offer forged pistons specifically for the FA20. Eagle Specialties supplies forged H-beam rods.
Investing in forged internals allows the engine to safely manage higher levels of boost or more aggressive cam timing, without the risk of catastrophic failure.
2. Head Porting and Valvetrain Enhancements
Ported cylinder heads and high-performance valve springs can help support increased airflow and rpm stability. Companies like CBRacing and Toyota Racing Development (TRD) offer improved valvetrain components, such as titanium retainers and upgraded valvetrain geometry.
Porting usually delivers improved flow characteristics, increasing top-end power without compromising streetability.
Drivetrain and Cooling Enhancements
Horsepower is useless if your car can’t harness it effectively. A well-rounded tuning plan includes upgrades to major drivetrain and thermal management components.
1. Limited-Slip Differential (LSD)
Toyota’s factory open differential hampers corner exits, often causing one tire to spin while the other remains still. Upgrading to an aftermarket limited-slip differential significantly improves traction and consistency.
Popular brands include:
- KAAZ
- OS Giken
- Exedy
- Toyota Racing TRD LSD
A mechanical or plate-type LSD is ideal for street and performance applications, while helical diffs like the Quaife offer street-friendly performance.
2. Upgraded Clutch and Flywheel
As power increases, the factory clutch quickly becomes a weak link. A dual-mass or single-plate upgrade from ACT or SPEC ensures the car maintains traction and reliability under higher torque.
Coupled with a lightweight flywheel, these upgrades improve throttle response and longevity.
3. Cooling Enhancements
Higher output and sustained driving increase the risk of overheating. Upgraded radiators (such as Mishimoto), oil coolers, and intercooler upgrades (for forced induction builds) can keep thermal conditions within safe limits.
Intercooler upgrades for turbo builds significantly improve power stability under repeated runs or long drives.
Conclusion: Make Your Toyota 86 Your Own
Boosting the Toyota 86 horsepower is both a science and a passion. Whether you’re chasing an extra 10 hp through simple bolt-ons or pushing toward 500 hp with engine swaps and forced induction, the 86 remains one of the most engaging entry-level tuning platforms available.
Here’s an overview of potential horsepower improvements based on the stage of tuning:
| Modification Stage | Estimated Horsepower (RWHP) | Focus |
|---|---|---|
| Street / Bolt-On | 220-240 hp | Intake, exhaust, tuning |
| Intermediate | 250-280 hp | Cold air intake, pulleys, OCC, cam upgrades |
| Forced Induction | 300-500 hp | Turbo or supercharger, internal upgrades, cooling |
| Engine Swap or Big Power | 350+ hp | New engine builds, extreme modifications |
Ultimately, your tuning path depends on your goals: daily driver, track tool, or drift machine. The best part of tuning the Toyota 86 is that customization can be as minimal or extreme as you desire, without compromising the essence of what makes it such a beloved sports car.
Whether you’re improving horsepower for weekend autocrosses or carving canyon roads with friends, the Toyota 86 is a platform that rewards passion and persistence. So start tuning, drive confidently, and make every horsepower count.
If you’re ready to begin your Toyota 86 build journey, start with your budget, define your driving goals, and build up accordingly. With the right approach, you’ll transform your 86 into a performance machine that’s both fun and formidable.
How can I increase the horsepower of my Toyota 86?
There are several effective ways to boost the horsepower of your Toyota 86, depending on your budget and performance goals. A popular starting point is upgrading the intake and exhaust systems to allow for better airflow. Cold air intakes and high-flow air filters can significantly improve engine efficiency, while aftermarket exhaust systems reduce backpressure and enhance both performance and sound.
For more substantial gains, consider forced induction options like adding a turbocharger or supercharger. These modifications can nearly double the car’s power output when combined with supporting upgrades such as an intercooler, upgraded fuel injectors, and a proper engine tune. Additionally, performance camshafts, lightweight flywheels, and ECU tuning are other options that can deliver noticeable horsepower improvements without compromising reliability.
Is a turbo upgrade worth it for the Toyota 86?
A turbo upgrade can be a highly rewarding modification for the Toyota 86, especially if you’re seeking significant horsepower gains. Factory models typically produce around 200 horsepower, but with a turbo system, outputs can easily surpass 300 horsepower. This type of modification is ideal for drivers who want more performance for track use or spirited driving without needing to switch to a different vehicle platform.
However, installing a turbo system is not a bolt-on upgrade and requires careful planning. Supporting modifications, including a stronger clutch, upgraded intercooler, reinforced internals, and a custom tune are essential for reliability. Additionally, the installation can be costly and requires expertise, but for the performance gains and the thrill of driving, many enthusiasts find the investment worthwhile.
How does ECU tuning affect Toyota 86 horsepower?
ECU tuning plays a crucial role in unlocking additional horsepower for the Toyota 86. By adjusting engine parameters like fuel delivery, ignition timing, and turbo boost (if applicable), tuning allows the engine to operate more efficiently and produce more power. A well-tuned ECU can improve throttle response, increase horsepower, and enhance overall drivability with no hardware changes other than perhaps an exhaust or intake system.
For best results, ECU tuning should be done by a professional or with reliable tuning software from a reputable provider. It’s also important to make sure that the car’s internal components can handle the increased stress of a performance tune. This upgrade is especially effective when paired with other power-enhancing modifications, leading to a cohesive and safe performance upgrade package.
What are some budget-friendly ways to increase Toyota 86 horsepower?
One of the most cost-effective ways to boost power is by installing a cold air intake and a cat-back exhaust system. These mods improve airflow into and out of the engine, allowing it to breathe more efficiently and generate slightly more power—typically around 10–15 extra horsepower. Additionally, upgrading to a performance throttle body can improve airflow and throttle response at a reasonable cost.
Another budget-friendly modification is a software ECU tune, especially if you already have some bolt-on upgrades. A tune can optimize the engine’s performance settings for the modifications you have, and some gains can be achieved for the cost of a few hundred dollars and a visit to a tuning shop. Finally, replacing the spark plugs with high-performance variants and using high-quality synthetic oil can also contribute to a modest yet noticeable improvement.
How does a limited-slip differential impact performance?
While a limited-slip differential (LSD) does not directly increase horsepower, it significantly improves how that power is delivered to the road. The Toyota 86 benefits greatly from an LSD because it helps maintain traction and balance during cornering and acceleration. This is especially useful in performance driving where power distribution becomes crucial for maintaining stability and speed.
Installing an LSD can result in faster lap times, better handling, and an overall more engaging driving experience. It’s a particularly valuable upgrade if you frequently drive on the track or in wet and slippery conditions. For those who are pushing the car’s performance limits—even without major horsepower upgrades—an LSD is one of the best handling upgrades available.
Do forced induction kits void the Toyota 86 warranty?
Yes, installing a forced induction kit, such as a turbo or supercharger, can potentially void the Toyota 86’s warranty, especially if the modifications affect engine components or lead to mechanical failure. OEM warranties typically cover parts and systems from the factory, and once you start altering engine components or increasing power substantially, Toyota or its authorized dealers may refuse to honor warranty claims for related repairs.
However, the Magnuson-Moss Warranty Act protects consumers from automatic warranty denial solely due to aftermarket parts unless the part directly caused the repair issue. That said, it’s important to speak with your dealership and understand the service policies before modifications are made. Many owners choose to wait until the factory warranty is close to expiring before undertaking such modifications.
What are the risks of increasing horsepower on my Toyota 86?
Boosting horsepower on your Toyota 86 can put additional stress on engine and drivetrain components, potentially reducing reliability and longevity if not done correctly. Internal parts like pistons, rods, and the crankshaft were designed to handle stock power levels, and exceeding those without upgrading the internals can lead to premature wear or catastrophic engine failure. This is especially true for significant power increases from forced induction or nitrous oxide.
To mitigate risks, it’s essential to work with experienced professionals, use high-quality parts, and consider supporting upgrades like cooling system enhancements, reinforced transmissions, and upgraded clutch systems. Regular maintenance becomes even more critical when running a modified engine. By taking these precautions, you can enjoy increased performance without sacrificing the reliability and long-term enjoyment of your Toyota 86.