Cost Analysis: Upgrading Your FA20 with Turbocharger Kits – $3,500 to $6,000

The Subaru FA20 engine, found in models like the BRZ, Toyota 86, and Subaru WRX (some generations), is prized for its lightweight construction and high-revving nature. For enthusiasts seeking substantial power gains, forced induction via a turbocharger kit is a popular route. However, moving from naturally aspirated to turbocharged power involves a significant financial commitment. This article delivers a detailed cost analysis of upgrading your FA20 with a turbocharger kit in the $3,500 to $6,000 range, breaking down what you get, hidden expenses, and long-term financial considerations.

Understanding the FA20 Turbocharger Kit Landscape

Turbocharger kits for the FA20 are not one-size-fits-all. They range from basic, entry-level setups to comprehensive, high-horsepower systems. The price range of $3,500 to $6,000 typically covers the core components needed for a reliable 300–400 wheel horsepower build, but the final cost depends heavily on the kit’s completeness, brand tier, and supporting modifications. Before diving into costs, it’s essential to understand the categories of kits available.

Standard Turbocharger Kits ($3,500 – $4,500)

These kits usually include the turbo manifold, a journal-bearing turbocharger (like a Garrett GTX or BorgWarner S200SX derivative), wastegate, blow-off valve, intercooler piping, and intercooler core. They often assume you already have a tune or will source one separately. Brands like Ft86 Speed Factory or AVO Turboworld produce well-regarded standard kits. These are ideal for enthusiasts on a budget who can handle some of the tuning and miscellaneous parts themselves.

High-Performance Turbocharger Kits ($4,500 – $6,000)

Moving up the price ladder, high-performance kits include ball-bearing turbochargers (offering faster spool and better durability), higher-quality intercooler cores, mandrel-bent stainless steel piping, and sometimes fuel injectors or a fuel pump. Companies like JDL Auto Design or Full Blown Motorsports are known for their premium FA20 kits. The extra cost translates to better power delivery, reliability, and often a more complete solution out of the box—meaning fewer additional parts to purchase.

Custom Turbocharger Kits ($5,500+)

Custom kits are a wildcard. They involve fabricating custom manifolds, piping, and turbo placement—often for a specific power goal (e.g., 500+ whp). These can exceed $6,000 quickly when you factor in custom fabrication labor, high-end billet turbos, and extensive engine management. For most enthusiasts, a well-chosen production kit is more cost-effective unless you have a specific build target that no off-the-shelf kit meets.

Detailed Cost Breakdown of a $3,500 to $6,000 Turbo Build

Let’s set a realistic scenario: you buy a mid-range kit for $4,500. The final out-the-door cost will be higher due to installation, tuning, and supporting modifications. Here is a transparent breakdown.

Component / Service Estimated Cost
Turbocharger Kit (base) $3,500 – $4,500
Professional Installation $600 – $1,200
ECU Tuning (custom dyno or remote) $400 – $800
Supporting Mods (fuel pump, injectors, boost controller, clutch) $800 – $2,500
Total Estimated Cost Range $5,300 – $9,000

As the table illustrates, the advertised kit price is just the starting point. The $3,500–$6,000 range for the kit itself often excludes the final tuning and supporting hardware that a reliable, driveable setup requires.

Installation Costs: DIY vs. Professional

Installing a turbo kit on an FA20 is a substantial job. Labor time ranges from 15 to 30 hours for a shop. At $100–$150 per hour, that’s $1,500–$4,500. However, most kits in this price range can be installed in 20–25 hours by an experienced shop, landing in the $600–$1,200 range if you find a shop with a flat-rate turbo install fee. DIY installation saves money but requires advanced mechanical skills, tools (including a lift or jack stands, torque wrench, and possibly a welder for minor fabrication), and the ability to troubleshoot boost leaks and oil lines. If you DIY, you can save $600–$1,200, but you assume all risk.

Tuning: The Non-Negotiable Investment

A properly tuned ECU is crucial for FA20 turbo builds. The stock ECU does not handle boost well without a custom tune. Options include:

  • OpenFlash Tablet (OFT) – around $500–$650 for the tablet and tune files from a tuner. Good for mild setups.
  • ECUtek – $1,000–$1,500 including license, cable, and tuning session. Preferred for higher power levels.
  • Custom dyno tuning – $400–$800 per session. The gold standard for safety and power.

Skimping on tuning is the fastest way to blow your engine. Expect to spend at least $500 for a reliable remote tune, and more for a shop tune.

Supporting Modifications – The Hidden Costs

To handle the added power, your FA20 will often require additional upgrades beyond the kit. These are often overlooked by first-time builders.

  • Fuel System: The stock FA20 fuel pump and injectors can support around 300 whp. For anything above that, you need a high-flow pump ($150–$300) and larger injectors ($400–$800).
  • Clutch: The stock clutch will slip under boost beyond 280 whp. A stage 2 or 3 clutch kit costs $400–$800. Expect to pay for installation ($300–$500) unless you do it yourself.
  • Intercooler and Charge Piping: Many kits include these, but upgrading to a larger core or better routing can add $200–$600.
  • Oil Cooling: Turbocharged FA20s run hot. An oil cooler kit ($300–$600) is highly recommended for track use or sustained boost.
  • Exhaust System: A full turbo-back exhaust (downpipe + catback) is often needed to reduce backpressure. Plan $500–$1,200.
  • Boost Controller: A manual boost controller ($30–$80) or electronic boost controller ($200–$400) to manage boost levels safely.

These supporting mods can easily add $1,500 to $3,000 to the total build cost, pushing a $5,000 kit into the $7,000–$9,000 range for a turnkey, reliable setup.

Factors Influencing Total Build Cost

Not every build is the same. Several variables affect the final price tag you’ll see on your invoice.

Brand and Quality

Established brands like GReddy or HKS command a premium due to rigorous R&D, fitment quality, and customer support. Their kits often include everything needed (fuel injectors, intercooler, full piping) and are well-tested, which reduces surprise costs. On the other hand, budget brands may offer a lower entry price but require more additional parts or fabrication.

Kit Completeness

A “complete” kit includes all plumbing, hardware, intercooler, wastegate, blow-off valve, and often a tune. A “basic” kit might only include a manifold, turbo, and downpipe. The less complete the kit, the more you’ll spend on ancillary parts. Read the kit description carefully: if it says “requires ECU tuning, fuel upgrades, and oil lines,” expect to spend significantly more.

Labor Rates and Location

Shop rates vary from $80/hour in rural areas to $200/hour in major cities like Los Angeles or New York. A lower labor rate can save hundreds, but ensure the shop has FA20 experience. Mistakes during turbo installation on an FA20 can lead to oil starvation, boost leaks, or engine damage — worth paying a bit more for a specialist.

Power Goals and Engine Health

If you’re aiming for 350 whp, you can often keep the stock fuel system and clutch. For 400+ whp, you’re looking at a built short block ($2,500–$4,000) because the FA20’s pistons and rods are weak at high boost. This can triple your budget. For the $3,500–$6,000 kit range, the realistic safe target is 300–350 whp on a stock block with good tuning.

Long-Term Financial Considerations

Buying the turbo kit is only the beginning. Owning a turbocharged FA20 comes with ongoing costs that affect your wallet over the life of the car.

Maintenance and Reliability

  • Oil Changes: Turbocharged engines require more frequent oil changes (every 3,000–4,000 miles) and high-quality synthetic oil ($8–$12 per quart).
  • Spark Plugs: Copper plugs for boosted builds need replacement every 15,000–20,000 miles ($30–$60).
  • Belt and Seal Wear: Increased heat and pressure can shorten the life of serpentine belts, crank seals, and gaskets. Budget $200–$400 yearly for incidental repairs.
  • Turbo Rebuild: Journal-bearing turbos may need rebuilding every 50,000–70,000 miles ($400–$800). Ball-bearing units last longer but are more expensive to replace ($1,200+).

A good rule of thumb: set aside $1,000–$1,500 per year for maintenance and unforeseen repairs on a turbo FA20 driven daily.

Fuel Efficiency

While cruising, a turbo can be efficient if kept out of boost, but the moment you step into the throttle, fuel consumption skyrockets. Expect 15–20% less average MPG compared to stock. If you daily drive 12,000 miles per year at $3.50/gallon, that’s roughly $200–$300 extra annually in fuel costs.

Insurance Implications

Modified vehicles, especially with forced induction, are considered higher risk. Many standard insurance policies will not cover aftermarket parts unless you have a stated-value policy or specialty insurer. Be prepared for a 10–30% increase in premiums, or even denial of coverage. Always disclose modifications to your insurer to avoid claim denial. Specialty insurers like Hagerty or Grundy offer agreed-value policies for modified cars, but they come with restrictions (limited mileage, storage requirements).

Resale Value

A turbocharged FA20 car can be a tough sell. Many buyers shy away from heavily modified vehicles due to reliability concerns. If you sell the car, you may recoup only 30–50% of the turbo kit investment. Keeping the stock parts and returning the car to stock before selling can maximize resale, but that adds time and hassle.

Budgeting for Your Build – A Step-by-Step Approach

To avoid financial surprises, follow this budgeting plan:

  1. Set a clear power goal. – 300 whp is achievable for $5,000–$7,000 total. 400 whp will cost $8,000–$12,000 including supporting mods.
  2. Select your kit first. – Research two or three reputable kits within your target price. Read owner forums and reviews.
  3. Add 20% to the kit price for unforeseen parts. – Hoses, fittings, gaskets, and odds and ends can quickly add $500.
  4. Get a comprehensive shop quote. – Ask for a written estimate that includes installation, tuning, and any recommended supporting upgrades.
  5. Budget for a clutch and fuel upgrades. – Even if you think you can delay them, you’ll eventually need them. Plan ahead.
  6. Set aside a contingency fund. – At least $1,000 for potential engine issues (e.g., a blown head gasket or ring failure).

Conclusion

Turbocharging your FA20 engine with a kit ranging from $3,500 to $6,000 is an exciting path to significantly more power, but it is not a simple purchase. The final cost of a reliable, driveable setup typically lands between $5,500 and $9,000 when installation, tuning, and supporting modifications are included. Beyond that, ongoing maintenance, fuel costs, insurance adjustments, and resale considerations should factor into your decision.

The best approach is to do thorough research, choose a kit from a reputable brand that matches your power goals, and work with a shop experienced with FA20 builds. With careful planning and a realistic budget, you can enjoy the thrill of a turbocharged FA20 without breaking the bank or compromising reliability. For further reading on FA20 turbo specifics, check out resources from FT86Club forums or tuning guides from Delicious Tuning.