Video: Daniel Beckinsale Photos: Ryan Lewis 


As soon as Toyota and Subaru announced that the 86/BRZ would come with a non-turbo engine, workshops across the world started formulating ways to add boost to the mix. One of those workshops was Castle Hill Performance, and they wasted no time at all in getting their turbo kit up and running. We went out there this week to film the tuning process!



Needless to say, we were impressed by the results this kit produced. There's some more development in the pipeline for the bolt-on package, but it is already showing extremely strong potential.



The Castle Hill Performance 86/BRZ turbo kit gives you everything you need. It will be offered as a drive in and drive out solution for any 86 or BRZ owner.



With the kit installed, the engine bay still looks factory. Black powdercoated piping keeps the turbo setup almost undetectable. It's even possible to retain the factory airbox with an optional bit of pipework.



Included in the package is a Garrett 2871 that lives right down next to the gearbox bellhousing. You can see the scavenger pump for the oil return line at the bottom of this shot.



A front mount intercooler is supplied which fits with almost no modification to the car. Sprayed black, you would never notice it.



Back underneath and the factory undertray is retained with the kit installed.



As far as management is concerned, the standard direct injection controller remains in the engine bay for the injectors in the heads.



Everything else is handled by Haltech. Our demo car was running a Platinum Sport 1000 and a GM flex fuel sensor, but those wanting to run only 98RON pump fuel can get the kit with a Haltech Sprint 500 ECU.



With the Haltech wired in the car made 163kW on 5.8psi with 98 octane pump fuel. Standard cat-back exhaust, standard injectors and fuel pump. The car made 103kW completely standard, and the aim was an extra 50kW on top of that with the turbo, so 163kW had us smiling.



For the ethanol tuning we swapped the port injectors to Siemens 60 pound items.



From factory the FA20 motor runs eight injectors; four in the heads for the direct injection, and another four in the intake manifold.



To run the extra boost on E85 that the Castle Hill team were aiming for, the standard port injectors weren't going to be enough.



Back on the dyno we drained out the 98 octane and filled up with Caltex E-Flex fuel. With the GM flex fuel sensor, the Haltech monitors fuel composition and can detect exact ethanol percentage on the fly, and adjust the tune to suit.



After a handful of runs to make sure it was all functioning as it should, we came away with our final result of 211kW! A massive improvement over the standard power output (shown in red).



Even better than we were hoping for. That power is more than double the standard output of the FA20, and the car drives like a totally new animal. If you want one of these kits, call the team at Castle Hill Performance and tell them who sent you!




UPDATE - The team at Castle Hill Performance just fitted a three-inch exhaust to this car and retuned it. This increased horsepower to 216kW at the wheels and made it sound a bit meatier. While the auditory improvement is a good thing, this proves that the standard system works pretty well.