Forge Motorsport inlet duct for Toyota GR Yaris I XP210

After speaking to numerous GR Yaris owners, Forge Motorsport developed an inlet duct for the Toyota GR Yaris. The product adds an attractive carbon-fibre inlet component to the engine bay and helps maintain lower intake air temperatures during dynamic driving, on the track or on a rally stage.

Using 3D scanning and CAD construction in SolidWorks, the development team optimised the size of the inlet duct, allowing it to capture a greater volume of uninterrupted cold air into the original airbox. Alongside CAD simulations, 3D-printed test parts were also used to determine the optimal size and geometry. This performance air intake part is considerably larger than the original and fits closely against the front bumper and airbox, minimising the effect of engine heat on it.

During track testing, the original duct caused a significant heat-soak effect on the intake air temperature, which therefore fluctuated considerably. Forge’s inlet duct lowered the intake air temperature while also keeping it more consistent. A more consistent temperature is important because high temperature peaks can cause the engine control unit (ECU) to reduce ignition advance and available power. The Forge design allows free airflow to the upper and lower airbox openings, while the original design does not direct air to the lower opening, and the upper opening is small and not fully sealed. The lower opening is particularly important for the performance of the Yaris GR. When the vacuum-operated flap is activated at full throttle, the Forge Motorsport inlet duct supplies cooler, directed air when the engine needs it most.

The data was recorded live by the passenger during a track test day. The vehicle was equipped with an upgraded intercooler, and the test took place over two consecutive five-lap runs: first with the original air intake and then with it for comparison. The intake air temperature dropped from 42 °C to 35–36 °C. With the original duct, temperatures of up to 45 °C were also recorded. Temperature fluctuation was significantly reduced when the secondary air intake was fed through the Forge Motorsport composite inlet.

The original design contains open sections, baffles and noise restrictors that disrupt airflow. The inlet duct is part of Forge’s Hi Flow series and supplies cold air to the airbox. The carbon-fibre version is made from prepreg carbon fibre in a 2×2 twill weave, formed in an autoclave using solid-block tooling and finished with a glossy gel coat providing UV protection.

Suitable for: Toyota GR Yaris I (XP210).

Approval

This part has no TÜV certification (ABE, TTG or Teilegutachten).

Compatible vehicles (manufacturer data)

Before ordering, check that the product matches your vehicle (model, year and engine). If in doubt, write to us — we will check for you.