My Subaru BRZ Transformation: The $2,500 FA20 Power Package Experience

The Subaru BRZ has earned its reputation as a driver’s car through its lightweight construction, perfect 50:50 weight distribution, and rear-wheel-drive layout. Yet for many owners, the factory 200-horsepower FA20 engine leaves them wanting more. After two years of ownership, I finally made the decision to invest in a comprehensive FA20 Power Package priced at $2,500. This article documents my complete experience, from installation through months of real-world driving, to help fellow BRZ enthusiasts decide if this upgrade is right for them.

Before diving into the details, it’s worth noting that the FA20 engine found in the BRZ and Toyota 86 is a free-revving 2.0-liter flat-four that responds exceptionally well to modifications. While the platform is known for its handling, the power package addresses the one area where the BRZ leaves some owners wanting more: straight-line grunt and mid-range torque.

What the FA20 Power Package Actually Includes

Understanding exactly what you’re getting with the FA20 Power Package matters when evaluating the $2,500 price tag. This isn’t a single component but rather a coordinated system of upgrades engineered to work together. The package consists of three main components that complement each other for optimal results.

High-Performance Cold Air Intake System

The intake system replaces the restrictive factory air box with a larger-diameter intake tube and a high-flow panel filter. This allows the engine to breathe more freely, reducing restriction at higher RPMs. The intake is designed to pull cooler air from outside the engine bay, which helps maintain consistent power output even during extended driving sessions. The sound change is immediately noticeable, with a more pronounced induction note that makes the flat-four engine sound more aggressive without being intrusive during highway cruising.

Cat-Back Exhaust System

The exhaust component replaces everything from the catalytic converter back to the tips. It features larger-diameter piping, mandrel bends for smooth flow, and performance mufflers designed to reduce back pressure. The exhaust system saves approximately 12 pounds compared to the factory setup. The sound character shifts from the relatively muted stock exhaust to a deeper, more purposeful note that really comes alive above 4,000 RPM. Importantly, the system includes a Helmholtz resonator to eliminate drone at cruising speeds, making it livable for daily driving.

ECU Tune and Calibration

The most critical component of the package is the custom ECU calibration. The stock engine control unit runs conservative fuel and timing maps to meet global emissions and fuel economy targets. The tune optimizes these parameters for the upgraded intake and exhaust, advancing ignition timing and adjusting air-fuel ratios. The calibration also improves throttle response by remapping the pedal-to-throttle-body relationship, eliminating the slight delay present in the factory calibration. This tune is specifically developed for the FA20 Power Package components, not a generic off-the-shelf map.

Installation: What to Expect

I opted for professional installation at a shop specializing in Subaru performance, though experienced DIYers could certainly tackle this job. The shop charged $400 for labor, bringing the total investment to $2,900. The installation took approximately four hours from drop-off to completion, including dyno time for final confirmation of the tune.

Step-by-Step Installation Overview

The process begins with the exhaust system, which requires disconnecting the factory exhaust from the catalytic converter flange. The old system comes out in one piece, and the new system goes in with new gaskets and hardware. The intake installation involves removing the factory air box, installing the new intake tube and heat shield, and reconnecting the mass airflow sensor. Finally, the ECU tune is loaded through the OBD-II port using a handheld programmer that comes with the package.

Tools You Will Need for DIY Installation

  • Socket set with 10mm, 12mm, 14mm, and 17mm sockets
  • Torque wrench capable of 30-80 ft-lbs
  • Breaker bar for stubborn exhaust bolts
  • Jack stands or a hydraulic lift
  • Penetrating oil for exhaust fasteners
  • Oxygen sensor socket (if reusing factory sensors)

Common Installation Pitfalls to Avoid

Several owners have reported issues with exhaust fitment if the system is not properly aligned before tightening. It’s essential to loosely install all exhaust components, then tighten from the front to the rear while checking clearance against the chassis and heat shields. The intake system should be checked for secure fitment around the MAF sensor, as any air leaks downstream of the sensor will cause the engine to run lean. If installing yourself, plan for five to six hours to allow for unexpected challenges, especially if your car has significant mileage and the exhaust hardware is corroded.

Measurable Performance Gains

My baseline dyno runs before installation showed 197 horsepower and 151 lb-ft of torque at the wheels on a Dynojet dynamometer. After the Power Package installation, the car produced 238 horsepower and 178 lb-ft of torque at the wheels. This represents a gain of 41 horsepower and 27 lb-ft of torque, which translates to roughly a 20 percent improvement in power output. More importantly, the torque curve is significantly fatter in the mid-range, where the FA20 often feels flat from the factory.

Peak Power vs. Area Under the Curve

While peak numbers make for good headlines, the real-world driving experience is shaped by the shape of the torque curve. The factory BRZ makes peak torque around 6,400 RPM, but the power package moves that peak lower to 4,800 RPM while also increasing torque throughout the entire rev range. This means you don’t need to wring the engine to redline to feel the benefits. From 3,500 RPM to 6,500 RPM, the engine pulls stronger and more consistently, making everyday driving more engaging and reducing the need for downshifts on highway on-ramps.

Quarter-Mile and Acceleration Testing

To quantify the real-world impact, I conducted before-and-after acceleration tests using a VBox GPS datalogger. The factory BRZ ran the quarter-mile in 14.6 seconds at 96.3 mph. After the Power Package, the same car ran 13.8 seconds at 102.1 mph. The 0-60 mph time improved from 6.2 seconds to 5.4 seconds. These numbers align with what other FA20 Power Package owners have reported on forums like FT86 Club and Subaru BRZ Forum, confirming that the gains are consistent and repeatable across different vehicles.

Driving Experience: Beyond the Numbers

Performance figures only tell part of the story. The way the car feels during daily driving, canyon carving, and track use matters more to most enthusiasts. The FA20 Power Package fundamentally changes the character of the BRZ without ruining what makes it special. The car still loves to rev, and its handling remains sharp and communicative, but it now has the power to back up its aggressive stance.

Daily Driving and Commuting

For daily use, the improved mid-range torque makes the biggest difference. The BRZ no longer requires constant downshifting to maintain momentum up hills or when passing slower traffic. The throttle response improvement is immediately noticeable, with the engine feeling more eager to rev with even light pedal inputs. The exhaust note is more present but not fatiguing, and there is no drone at highway speeds thanks to the Helmholtz resonator design. Cold starts are louder than stock, so consider that if you leave for work early in the morning.

Spirited Back Road Driving

On twisty roads, the FA20 Power Package transforms the BRZ into a genuinely quick car. The added power allows you to carry momentum through corners and accelerate harder on exit. The chassis balance remains excellent, and the car still rotates predictably when you lift off the throttle or trail-brake into corners. The BRZ’s standard limited-slip differential does an excellent job putting the extra power down, though aggressive corner exits on uneven pavement will still produce gentle oversteer. The improvement in power-to-weight ratio takes the BRZ from a momentum car to one that can genuinely intimidate heavier, more powerful machines in the twisties.

Track Day Performance

On track, the FA20 Power Package shines in sustained driving. The intake system maintains consistent intake air temperatures even during 20-minute sessions, and the exhaust system does not heat-soak the cockpit. The power gains translate to faster lap times, with my best lap at Motorsport Track Days improving by 2.3 seconds on a 1.7-mile circuit. The car is now fast enough that upgrading the brake pads to a more aggressive compound is recommended, as the increased entry speeds will push standard pads beyond their limits. The stock tires also become more of a limiting factor, as the added power can overwhelm the factory Prius-spec rubber more easily.

Fuel Economy Reality Check

Fuel economy was a concern before installation, as many enthusiasts assume that adding power means sacrificing efficiency. The reality is more nuanced. During mixed driving, my average fuel economy went from 28.5 mpg to 27.8 mpg, a negligible decrease of 0.7 mpg. On highway trips, the difference was even less, with the car recording 33.1 mpg before and 32.6 mpg after the upgrade. The ECU tune optimizes the air-fuel ratio for the specific hardware, and the engine is actually more efficient at part throttle because it can operate at a more optimal volumetric efficiency point. The fuel economy decrease only becomes significant if you spend extended periods at wide-open throttle, which is expected with any performance upgrade.

Cost Analysis and Value Proposition

At $2,500, the FA20 Power Package sits at an interesting price point in the BRZ modification ecosystem. A single turbocharger kit for the FA20 starts around $4,500 and requires additional supporting modifications that push the total cost well above $7,000. Individual bolt-on parts purchased separately totaling the same components would cost approximately $1,700 for the intake, $1,200 for the exhaust, and $800 for the tune, totaling $3,700. The Power Package saves you $1,200 compared to buying components individually, and everything is designed to work together from the start.

Comparison to Other Modifications

Many BRZ owners consider headers as a first modification. Headers alone can add 15-20 horsepower for around $800 but often require a tune to realize the full benefit. The FA20 Power Package includes the tune, meaning you get more power and a more complete solution for a reasonable premium. Supercharger kits offer 60-80 horsepower gains but cost $5,000-$6,000 and add complexity and weight. The power package represents a balance of cost, reliability, and performance that works well for a daily driver that sees occasional track use.

Long-Term Reliability and Ownership Considerations

I have now driven 18,000 miles with the FA20 Power Package installed. The car has been completely reliable with no check engine lights, no oil consumption increase, and no drivability issues. The intake filter requires cleaning every 15,000 miles, and the exhaust system has shown no signs of cracking or corrosion. The ECU tune is CARB-compliant, which matters if you live in California or other states with strict emissions testing. The package does not void the factory warranty when installed by an authorized dealer, though individual dealer policies may vary.

What Other Owners Are Saying

Online communities provide valuable perspective on long-term ownership. On the FT86 subreddit, owners consistently report satisfaction with the FA20 Power Package, with the most common complaint being the temptation to drive the car harder than before. The consensus among experienced owners is that this package offers the best power-per-dollar ratio for naturally aspirated FA20 builds, and that the car remains reliable with normal maintenance schedules.

Final Verdict After Six Months of Ownership

The FA20 Power Package has transformed my Subaru BRZ from a car I enjoyed into a car I genuinely love driving every day. The power increase is meaningful without being overwhelming, and the improved throttle response and sound make every drive more engaging. The installation process was straightforward, the cost is reasonable for the results, and the long-term reliability has been flawless. If you own a BRZ or Toyota 86 and find yourself wanting more power without sacrificing the car’s essential character, this package delivers exactly what it promises.

The $2,500 investment has extended my relationship with the car, delaying the temptation to trade it for a more powerful platform. The BRZ with the FA20 Power Package now feels like a complete sports car rather than a compromised enthusiast vehicle. For anyone considering this upgrade, I would recommend it without hesitation, provided you have realistic expectations about the gains. The car will not transform into a Corvette killer, but it will become a significantly more capable and entertaining version of itself.