Upgrading a Subaru BRZ with the MAPerformance Turbo Kit is one of the most effective ways to unlock serious horsepower and transform the car’s character. The kit is engineered to deliver reliable, substantial power gains while maintaining drivability, but the installation process demands careful preparation, the right tools, and a methodical approach. Rushing through the job or overlooking critical details can lead to leaks, poor performance, or even mechanical damage. This guide provides a comprehensive walkthrough of the essential tools, preparation steps, and installation tips you need to achieve a clean, professional-grade result in your own garage.

Essential Tools for a Successful Install

Having the correct tools on hand before you begin is non-negotiable. Missing a ratchet extension or a specific socket size will stop your progress dead. Beyond the basics, a few specialty items will make the job faster and safer. Gather the following before you roll your BRZ onto jack stands:

  • Metric socket set (3/8-inch and 1/2-inch drive) – Sizes from 8mm to 19mm cover nearly every fastener on the kit. A deep-well socket on the 14mm and 17mm is helpful for turbo oil drain bolts.
  • Metric combination wrenches – Especially 10mm, 12mm, 14mm, and 17mm. Ratcheting wrenches save significant time in tight engine-bay spaces.
  • Torque wrench (1/2-inch drive) – Critical for head studs, manifold bolts, and banjo fittings. Never rely on “feel” for turbocharger mounting bolts; under-torque causes leaks, over-torque strips threads.
  • Oil filter wrench – The kit requires removing the factory oil cooler and filter housing. A strap-style or cap wrench prevents slipping.
  • Scissors or a sharp utility knife – For trimming intercooler piping and silicone couplers to exact length. A clean cut prevents boost leaks.
  • Heat gun or industrial blow dryer – Softens silicone couplers and hoses for easier installation over metal piping. It also helps remove stubborn factory hoses.
  • Zip ties in multiple sizes – For securing vacuum lines, wiring, and loose harnesses away from hot exhaust components.
  • Shop towels and brake cleaner – Oil and debris on mating surfaces will cause leaks. Keep everything surgically clean.
  • Safety glasses and mechanic’s gloves – Turbo installations involve sharp edges, hot surfaces, and corrosive fluids. Protect yourself.
  • Jack and jack stands (or a lift) – You need safe, level access to the underside for oil drain and intercooler piping.
  • Coolant bleeder tool or funnel – For bleeding the cooling system after reinstalling the radiator and filling coolant.

Additionally, consider borrowing or buying a turbocharger oil feed line adapter kit if your BRZ has an engine build or aftermarket oil pan, though the MAPerformance kit includes the necessary fittings for a stock FA20. A battery terminal puller and trim removal tools for disconnecting plastic engine covers will also make the job less frustrating.

Pre-Installation Preparation

Before you turn a single bolt, take the time to thoroughly prepare both your workspace and your vehicle. Many installers run into trouble because they skip these foundational steps.

Read Every Word of the Instructions

The MAPerformance manual included with the kit is detailed and includes important torque specs, banjo bolt orientation diagrams, and routing paths for vacuum lines. Do not rely on memory or YouTube videos alone. Read the manual front-to-back at least once, then keep it open on a clean table nearby during the entire install.

Organize Your Hardware

Open the turbo kit box and lay out all components. The MAPerformance kit comes with pre-assembled oil lines, gaskets, and fasteners in labeled bags. Confirm nothing is missing against the parts list. If you find discrepancies, contact MAPerformance support before starting.

Prepare the Vehicle

  • Park on a clean, flat concrete surface. Gravel or asphalt will make jacking unsafe and can allow debris into the engine bay.
  • Let the engine cool completely (at least three hours after a drive). Hot coolant burns, and hot exhaust manifold studs are brittle and prone to snapping.
  • Disconnect the negative battery terminal and secure it away from the post. This prevents accidental short circuits while working near the starter or alternator.
  • Remove the engine undertray and front bumper support beam (if required by the intercooler setup).
  • Drain the engine oil and coolant. The kit includes a replacement oil filter adapter, so a fresh oil change is mandatory anyway.

Evaluate Your Tuning Path

The MAPerformance Turbo Kit will push the stock FA20 well beyond its factory fuel and ignition limits. You must have a plan for engine management. Options include an open-source tune using software like ECUtek, a Cobb Accessport with a custom MAPerformance OTS map, or a standalone ECU. Contact a reputable tuner before you install the turbo to schedule a remote or dyno calibration. Do not start the engine without a proper tune – running a modified engine with unadjusted timing and fuel can cause immediate detonation.

Step-by-Step Installation Overview

While the full procedure is dozens of steps, understanding the major phases helps you plan the timeline (expect 15–25 hours if you are experienced, longer if it is your first turbo install). Below we break down each major phase with practical tips.

Phase 1: Removing the Factory Exhaust and Intake

Start by removing the stock header, catalytic converter, and front pipe. The MAPerformance turbo manifold replaces the header. You will also remove the plastic intake tube, air box, and MAF housing. Tip: Soak oxygen sensor threads with penetrating oil the night before – they seize easily. Use a proper O2 sensor socket to avoid stripping.

Store all removed fasteners and brackets in labeled bags. You will reuse several factory bolts for the turbo manifold and wastegate bracket.

Phase 2: Installing the Turbo Manifold and Oil/Coolant Lines

The turbo manifold bolts directly to the cylinder heads using the provided gaskets and studs. Critical: Use a torque wrench and follow the sequence in the manual (tighten from the center outward). The oil feed line connects to a port on the block (normally capped), while the drain line routes into the oil pan or a dedicated drain adapter. MAPerformance supplies a -10AN drain fitting that requires drilling and tapping a return hole in your oil pan if you choose not to use their pre-drilled adapter. If you are uncomfortable drilling the pan, have a shop do it or purchase a pre-drilled aftermarket pan. A poorly aligned drain causes premature turbo seal failure.

Similarly, the coolant lines connect to the engine’s cooling system. Bleed the system carefully after the install – air pockets cause the turbo to overheat.

Phase 3: Mounting the Turbocharger and Wastegate

Bolt the turbo to the manifold, using new gaskets. The MAPerformance kit brackets hold the turbo steady while you tighten the V-band clamp. Do not reuse old V-band clamps – the kit includes new ones. Set the wastegate actuator to the proper spring pressure (often 6–8 psi for street use). Check that the wastegate arm moves freely before tightening the cotter pin.

Phase 4: Intercooler and Charge Piping

The front-mount intercooler (included with the kit) mounts behind the front bumper. You will need to cut or remove part of the crash beam and bumper support. MAPerformance provides templates, but measure twice. Improper bumper trimming leads to a misaligned intercooler that can contact the radiator. Use the heat gun to soften the silicone couplers, then tighten T-bolt clamps evenly. Rule of thumb: clamps should be snug enough that a screwdriver cannot easily rotate the coupler, but not so tight that you tear the silicone.

Phase 5: Reassembly and Electrical

Reinstall the intake piping, MAF sensor, and air filter (the kit may use a cone filter). Wire the supplied boost controller (if equipped) according to the diagram. Secure all wiring away from the exhaust manifold with zip ties. Double-check the wastegate vacuum source – it must come from a port that sees intake manifold pressure, not boost pre-throttle.

Post-Installation Checks and Tuning

With everything bolted together, take an hour to perform a meticulous inspection before starting the engine.

  • Oil and coolant levels: Fill with fresh 5W-30 (or recommended weight) and top off coolant. Crank the engine with the ignition fuse removed for 10 seconds to prime the turbo oil lines before first start.
  • Boost leak test: Use a DIY boost leak tester (a PVC cap with a schrader valve) to pressurize the system to 15 psi. Listen for hissing or use soapy water on all couplers and joints. Fix any leaks immediately.
  • Check for exhaust leaks: Start the engine and idle. Feel around the turbo manifold and downpipe with your hand (carefully – hot after a minute). A puffing sound indicates a gasket leak. Tighten bolts or replace gaskets as needed.
  • Test wastegate function: With the car on jack stands, manually open the wastegate with a vacuum pump (if pneumatic) or watch the actuator rod move. The wastegate must open and close smoothly.

First Start and Initial Tune

If you are using a Cobb Accessport, flash the MAPerformance base map (provided with the kit) before starting. Let the engine idle until it reaches operating temperature (about 5 minutes). Watch for oil pressure light to turn off quickly (within a few seconds). Check for drips under the car. Do not rev the engine aggressively on the base map – it is only for initial break-in and can be used to drive gently to the dyno tuner. Alternatively, if you have a remote tune, follow your tuner’s instructions for data-logging pulls.

Common Mistakes and How to Avoid Them

  • Insufficient oil drain slope: The turbo drain must have a constant downhill angle with no dips. If the drain is at a steep angle or has a low point, oil pools in the turbo and causes smoke. Use a flexible -10AN hose and route it straight down.
  • Overtightening banjo bolts: Banjo bolts for oil and coolant lines require low torque (typically 15–20 lb-ft). Overtightening crushes the copper washers and distorts the banjo fitting, causing leaks. Always replace crush washers with new ones each install.
  • Ignoring heat management: The turbo and downpipe generate immense heat. Wrap or coat the downpipe in heat-resistant wrap, and ensure brake lines, wiring, and ABS modules are at least 2 inches away from any hot surface. Use heat shield material for nearby sensitive components.
  • Skipping the intercooler position check: After mounting the intercooler, close the hood and check clearance. Many first-time installers find the intercooler pushes the hood slightly open or rubs the radiator fan shroud. Adjust the brackets before final tightening.
  • Forgetting to update the tune for higher boost: The base map might limit boost to 6 psi. If you plan to run higher boost (8–12 psi) on a built engine, you must have a tuner adjust the wastegate duty cycle and fuel tables. Running the base map above its target boost can cause lean conditions.

Performance and Reliability Considerations

The MAPerformance Turbo Kit is capable of 300–350 whp on pump gas with proper fueling upgrades (injectors, fuel pump). However, for long-term reliability, consider upgrading the clutch (the stock clutch slips around 280 whp) and installing an oil cooler if you track the car. The factory FA20 oil system can be pushed to high temperatures under sustained boost. Many owners also upgrade engine mounts to reduce drivetrain slop and protect the turbo from vibration fatigue.

Finally, invest in a good set of gauges – at minimum, boost pressure, oil pressure, and wideband air-fuel ratio. Watching these real-time alerts you to problems before they become catastrophic.

Conclusion

Installing the MAPerformance Turbo Kit on the Subaru BRZ is a rewarding project that dramatically transforms the car’s performance. Success depends on thorough preparation, using the correct tools, and following a disciplined installation sequence. To learn more about the kit and its options, visit MAPerformance’s official site. For community support and build logs, the FT86Club forum is an excellent resource. And when you are ready for tuning, consider reaching out to a recognized tuner like Delicious Tuning for a custom calibration. Take your time, work clean, and enjoy the results every time you push the throttle.