Toyota Ae86 Turbo Kit Installation Guide: Achieve 150+ Hp with Garrett Gt28r

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The Toyota AE86 is a legendary car, known for its lightweight design and exceptional handling. Many enthusiasts seek to enhance its performance, and one of the most effective ways to do so is by installing a turbo kit. In this guide, we will walk you through the installation of a turbo kit using the Garrett GT28R turbocharger, which can help you achieve over 150 horsepower.

Understanding the Garrett GT28R Turbocharger

The Garrett GT28R turbocharger is a popular choice among AE86 owners due to its reliability and performance. This turbo is capable of producing significant power gains while maintaining a relatively quick spool time. Here are some key specifications:

  • Compressor Wheel Diameter: 60mm
  • Turbine Wheel Diameter: 53mm
  • Maximum Boost Pressure: 1.5 bar (22 psi)
  • Suitable for: 1.6L to 2.0L engines

Required Tools and Materials

Before starting the installation, ensure you have the following tools and materials ready:

  • Socket set
  • Wrenches
  • Screwdrivers
  • Torque wrench
  • Boost gauge
  • Turbo kit (including Garrett GT28R)
  • Oil feed and return lines
  • Intercooler and piping
  • ECU tuning software

Preparation for Installation

Before you start the installation process, it is crucial to prepare your workspace and the vehicle. Follow these steps:

  • Ensure the car is parked on a level surface.
  • Disconnect the battery to prevent any electrical issues.
  • Remove the existing intake and exhaust components to make space for the turbo kit.
  • Drain the engine oil and coolant to prevent spills during installation.

Installing the Turbo Kit

Now that you have prepared the vehicle, you can begin the installation of the turbo kit. Follow these steps carefully:

  • Step 1: Install the turbocharger onto the exhaust manifold. Ensure that the gaskets are properly placed to avoid leaks.
  • Step 2: Connect the oil feed line to the turbo. Make sure it is secure and free from kinks.
  • Step 3: Install the oil return line, ensuring it has a downward slope for proper drainage.
  • Step 4: Attach the intercooler and piping to the turbocharger. Ensure all clamps are tight and secure.
  • Step 5: Connect the intake system to the turbo, ensuring a good seal.
  • Step 6: Reinstall any removed components and ensure everything is in place.

Tuning the Engine

After the installation of the turbo kit, tuning the engine is essential to achieve optimal performance. Here are the steps to follow:

  • Install a boost gauge to monitor boost levels.
  • Use ECU tuning software to adjust fuel maps and ignition timing.
  • Set the boost pressure to a safe level, ideally around 1 bar (14.5 psi) for initial tuning.
  • Test drive the vehicle and monitor for any issues.

Testing and Final Adjustments

Once the tuning is complete, it’s time to test the vehicle. Follow these steps:

  • Start the engine and let it idle for a few minutes.
  • Check for any oil or coolant leaks.
  • Take the car for a test drive, gradually increasing the throttle.
  • Monitor the boost gauge and ensure it is functioning correctly.
  • Make any necessary adjustments to the tuning based on performance.

Conclusion

Installing a turbo kit on your Toyota AE86 using the Garrett GT28R turbocharger can significantly enhance its performance, allowing you to achieve over 150 horsepower. By following this guide and ensuring proper tuning, you can enjoy the exhilarating experience of driving a turbocharged AE86.