The Toyota 86’s FA20 engine benefits greatly from a good set of headers, which help flatten its torque curve. Finding the Best Header For Toyota 86 is a common goal for owners who want to unlock more power and a better sound without breaking the bank. This guide will walk you through the top options, installation tips, and what to expect after the swap.
Headers are one of the first performance upgrades many 86 owners consider. They replace the restrictive factory exhaust manifolds, allowing the engine to breathe more freely. This can lead to gains of 10-15 horsepower at the wheels, plus a noticeable improvement in throttle response.
Why Upgrade Your Toyota 86 Headers?
The stock headers on the 86 are designed for emissions and noise control, not performance. They are heavy and have small, uneven-length tubes that create backpressure. This hurts power, especially in the mid-range where the FA20 feels flat.
Aftermarket headers use larger, equal-length tubes. This design improves exhaust scavenging, which pulls more air out of the cylinders. The result is a smoother torque curve and a higher peak power output. You also get a more aggressive exhaust note.
Key Benefits Of Header Upgrade
- More horsepower and torque across the rev range
- Improved throttle response and engine sound
- Reduced engine bay heat compared to stock cast iron
- Weight savings (stock headers are heavy)
- Better fuel economy under normal driving (if tuned)
Best Header For Toyota 86
When searching for the Best Header For Toyota 86, you have several excellent choices. The right one depends on your budget, power goals, and whether you need to pass emissions tests. Below are the top contenders, broken down by type.
1. JDL Auto Design EL Header
JDL is widely considered the gold standard for 86 headers. Their equal-length (EL) design is a masterpiece of engineering. It uses thick 304 stainless steel and mandrel-bent tubing for maximum flow.
This header is known for its strong mid-range torque gains. It also pairs well with a tune, producing a very linear power delivery. The build quality is exceptional, with CNC-machined flanges that seal perfectly.
Pros
- Excellent build quality and fitment
- Strong torque gains in the mid-range
- Works well with stock or aftermarket exhausts
- Available with or without a catalytic converter
Cons
- Higher price point (around $1,000+)
- Long wait times due to custom fabrication
2. Tomei Unequal Length Header
If you want the classic Subaru rumble, the Tomei UEL header is your best bet. It uses unequal-length tubes to create that iconic sound. It is lighter than stock and offers good power gains, especially in the low-end.
This header is a popular choice for daily drivers who want a more exciting exhaust note. It is also well-made and fits without issues. The power gains are slightly less than a good EL header, but the sound makes up for it.
Pros
- Produces the classic Subaru boxer rumble
- Good low-end torque improvement
- Lightweight and durable construction
- Reasonable price (around $700-$800)
Cons
- Slightly less peak power than EL designs
- Can be louder and drone on the highway
3. Gruppe-S UEL Header
The Gruppe-S UEL header is a budget-friendly option that still delivers good results. It is a copy of the Tomei design but made with slightly thinner materials. It offers similar sound and power gains for a lower price.
This is a great choice for beginners or those on a tight budget. The fitment is generally good, but some users report needing to adjust the hangers. It is a solid entry-level upgrade.
Pros
- Very affordable (around $400-$500)
- Good sound and power gains
- Lightweight compared to stock
Cons
- Thinner metal may crack over time
- Fitment can be slightly off
- Less consistent build quality
4. Perrin EL Header
Perrin is another well-respected brand in the 86 community. Their EL header is designed for maximum flow and power. It features a unique collector design that helps with exhaust scavenging.
This header is a bit louder than some other EL options, but it offers excellent top-end power. It is also available with a high-flow cat for those who need to pass emissions. The build quality is very good.
Pros
- Strong top-end power gains
- Available with high-flow cat
- Good build quality and fitment
Cons
- Can be loud with a catback exhaust
- Mid-range torque is not as strong as JDL
Equal Length Vs. Unequal Length Headers
This is the biggest decision you will make. Equal-length (EL) headers have tubes that are all the same length. This design optimizes exhaust flow for maximum power. The sound is more like a Honda or a high-revving four-cylinder.
Unequal-length (UEL) headers have tubes of different lengths. This creates the classic Subaru rumble because the exhaust pulses are uneven. UEL headers sacrifice a small amount of top-end power for a more aggressive sound.
Which One Should You Choose?
- Choose EL if: You want maximum horsepower and a smooth powerband. You plan to track the car or go forced induction later.
- Choose UEL if: You want the iconic Subaru sound and a more exciting daily driving experience. You are not chasing every last horsepower.
Installation Guide For Toyota 86 Headers
Installing headers on a Toyota 86 is a moderate DIY job. It takes about 4-6 hours for a first-timer. You will need basic hand tools, jack stands, and patience. Here is a step-by-step guide.
Tools And Parts Needed
- New headers (obviously)
- New exhaust gaskets (copper or multi-layer steel)
- New header studs and nuts (optional but recommended)
- Socket set (10mm, 12mm, 14mm, 17mm)
- Ratchet and extensions
- Breaker bar
- Penetrating oil (like WD-40 or PB Blaster)
- Jack and jack stands
- O2 sensor socket
- Anti-seize compound
Step 1: Preparation
Park the car on a level surface and let it cool completely. Disconnect the negative battery terminal. Jack up the front of the car and secure it on jack stands. Remove the under-engine splash shield.
Step 2: Remove The Stock Headers
Start by spraying the header bolts and O2 sensors with penetrating oil. Wait 10 minutes. Unplug the O2 sensors and remove them from the stock headers. Use a 14mm socket to remove the header-to-engine bolts. There are 6 bolts on each side. Use a 12mm socket to remove the header-to-midpipe bolts. Carefully lower the stock headers out from the bottom of the car.
Step 3: Install The New Headers
Apply anti-seize to the new header studs. Install the new exhaust gaskets on the engine side. Lift the new headers into place from the bottom. Start all the bolts by hand before tightening. Torque the header-to-engine bolts to 25 ft-lbs in a criss-cross pattern. Torque the header-to-midpipe bolts to 30 ft-lbs.
Step 4: Reinstall O2 Sensors
Apply anti-seize to the O2 sensor threads. Reinstall them into the new headers. Make sure the wiring is routed away from heat sources. Reconnect the O2 sensor plugs.
Step 5: Final Checks
Double-check all bolts are tight. Reinstall the under-engine splash shield. Lower the car. Reconnect the battery. Start the engine and check for exhaust leaks. Listen for any ticking sounds that indicate a leak at the gaskets.
Tuning Your Toyota 86 After Header Install
Installing headers without a tune will still give you some power gains, but you are leaving performance on the table. The stock ECU will not adjust the fuel and timing curves to take full advantage of the increased flow. A tune is highly recommended.
A proper tune can add another 10-15 horsepower on top of the header gains. It also smooths out the torque curve and can improve throttle response. Many owners use an OpenFlash Tablet or an ECUTek tune for this purpose.
What To Expect After Tuning
- Peak horsepower gains of 20-25 whp
- Much flatter torque curve, less dip at 3,500 RPM
- Improved throttle response and drivability
- Better fuel economy under normal driving
Emissions And Legal Considerations
Headers that remove the catalytic converters are not legal for street use in many areas. They will cause a check engine light and fail emissions tests. If you need to pass smog, look for headers with a high-flow catalytic converter option.
Some headers, like the JDL and Perrin, offer catted versions. These still flow much better than stock but keep the check engine light off. They are more expensive but worth it for street-driven cars.
Frequently Asked Questions
Will Headers Void My Toyota Warranty?
Yes, installing aftermarket headers can void your powertrain warranty. The dealer may deny claims related to the engine or exhaust system. Check your local laws and your warranty terms before installing.
Do I Need A Tune With Headers On A Toyota 86?
While not strictly required, a tune is highly recommended. Without a tune, you will only see about half the potential power gains. The car may also run lean, which can cause engine damage over time.
How Much Horsepower Do Headers Add To A Toyota 86?
With a proper tune, expect 20-25 wheel horsepower gains. Without a tune, you might see 10-15 wheel horsepower. The torque curve will also improve significantly.
Are UEL Or EL Headers Better For The Toyota 86?
It depends on your goals. EL headers make more peak power and have a smoother powerband. UEL headers make a better sound and have slightly better low-end torque. Choose based on your priorities.
Can I Install Headers Myself?
Yes, if you have basic mechanical skills and tools. It is a moderate difficulty job that takes 4-6 hours. If you are not comfortable, a shop can install them for around $300-$500 in labor.
Final Thoughts On Choosing Headers
Upgrading your headers is one of the best mods you can do for a Toyota 86. It wakes up the engine and makes the car more fun to drive. The Best Header For Toyota 86 depends on your budget and what you want from the car.
If you want the absolute best performance and build quality, go with JDL. If you want the classic Subaru sound, Tomei is the way to go. For a budget option, Gruppe-S works well. And if you want a good all-around EL header, Perrin is a solid choice.
Remember to pair your headers with a tune for the best results. Also, consider your local emissions laws when choosing between catted and catless options. With the right headers, your 86 will feel like a completely different car. The throttle response will be sharper, the power will be smoother, and the sound will be more exciting. It is a mod that truly transforms the driving experience.
Take your time researching and choose the header that fits your needs. The 86 community is full of helpful people who can share their experiences. Once you make the swap, you will wonder why you did not do it sooner. The car feels more alive and responsive, making every drive more enjoyable.
Whether you are a weekend warrior or a daily driver, headers are a worthwhile investment. They are one of the few mods that give you both power and sound improvements. Just make sure you do the install properly and get a tune to unlock the full potential. Your 86 will thank you for it.