Toyota GT86 ZN6

The most common GT86 problem. The front timing cover is sealed to the engine block with liquid gasket (RTV sealant) rather than a solid gasket. Over time, heat cycles cause the sealant to crack and shrink, allowing oil to seep out. The leak typically appears first at the cam plate (a small blanking plate on the rear of the cylinder head) or at the front timing cover gasket surface. The cam plate leak is a simple fix: an aftermarket billet aluminium cam plate with an O-ring seal replaces the factory stamped steel part for around €50-100 in parts. The front timing cover reseal is more involved but does not require engine removal. A specialist reseal including surface preparation, new sealant, cam seals, and fresh oil costs €400-600. If ignored, oil can drip onto the exhaust and create a burning smell, and prolonged low oil levels risk engine damage.

The OEM throwout bearing (clutch release bearing) has a poor design that has plagued the ZN6/ZC6 platform for its entire production run. The factory applies only a thin layer of grease that breaks down quickly under heat. Symptoms include a chirping, squealing, or grinding noise when pressing or releasing the clutch pedal. The throwout bearing carrier can show visible wear with as few as 3,000 km on the odometer. Toyota issued a revised bearing part number, but even updated OEM bearings have proven short-lived. Since replacing the throwout bearing requires gearbox removal, most owners combine it with a clutch replacement. Bearing-only replacement at an independent shop costs around €300-500 in labour plus €30-80 for the part. A combined clutch and throwout bearing replacement runs €800-1,200 at an independent shop. The noise itself is harmless until the bearing begins to seize, at which point clutch operation becomes stiff or inconsistent.

Toyota issued recall 18SMD-105 for GT86 models produced between 9 April 2012 and 24 May 2013. A manufacturing defect in the valve spring material causes fatigue strength to be lower than specification. If a valve spring fractures while driving, the engine may stall and potentially suffer valve-to-piston contact, destroying the cylinder head and possibly the block. The recall replaces all 16 valve springs with improved components. This is performed free of charge at any Toyota dealer. If the recall has not been completed, the risk of spring fracture increases significantly with age and mileage. If a spring does break before the recall is done and engine damage occurs, repair costs can reach €3,000-4,000 for a cylinder head rebuild or more for a replacement engine. Always verify recall completion on any 2012-2013 GT86 before purchase.

The FA20's flat-four layout means the oil pickup sits at the bottom of a relatively shallow sump. During sustained high-G cornering, particularly extended right-hand turns on track, oil can slosh away from the pickup, starving the connecting rod bearings. Shops specialising in FA20 rebuilds report that 9 out of 10 engines they receive have spun rod bearings. However, this statistic reflects engines already in for rebuilds, not the overall GT86 population. Documented stock engine failures from oil starvation are extremely rare on road-driven cars. Most failures involve track use, low oil levels, or modified engines. An engine rebuild with new bearings and crankshaft inspection costs €3,000-5,000 at a specialist. A complete replacement engine runs €5,000-7,000 installed. Prevention: always keep oil at the full mark, use quality 0W-20 oil, avoid sustained full-throttle below 2,500 rpm, and consider an aftermarket oil cooler and baffled sump if tracking the car regularly.

Like many Japanese cars, the GT86's subframes and underbody components have minimal factory corrosion protection. Surface rust on subframe welds and suspension mounting points is common on cars older than 5-6 years, especially in northern European countries that salt roads in winter. In most cases, the corrosion is cosmetic and can be arrested with professional underbody treatment (Dinitrol, Tectyl, or similar) costing €300-500. However, in severe cases where corrosion penetrates the structural metal of the subframe, replacement is necessary to pass inspection. A new front subframe costs €400-600 in parts, with around €400-600 in labour. Rear subframes are similar. Applying underbody protection proactively is strongly recommended for any GT86 that will see winter use.

The factory tail light gaskets on the GT86 are a known weak point. The gasket material is too thin and degrades over time, allowing water vapour and eventually liquid water into the tail light housing. This causes fogging, condensation, and in severe cases pooling water that can damage the LED elements. The headlights are similarly affected but less frequently. Toyota has replaced tail lights under warranty for many owners. Out of warranty, aftermarket neoprene gaskets (such as Gasket Ninja brand, specifically designed for the GT86/BRZ) provide a superior seal and cost around €20-30. New OEM tail light units cost €150-200 each if the internals are damaged. Headlight condensation is typically resolved by resealing with fresh silicone.