Aygo Tuning

"Aygo everywhere"

The Aygo is a good car tuning project to play with as it is small and light.

Being so small means that you feel the benefit of even the slightest modifications.

It shared much with the Peugeot 108 and Citroen C1

  • 1.0 L 1KR-FE I3 (KGB40) 68bhp 93 N⋅m (69 lbf⋅ft) at 3,600 rpm
  • 1.2 L EB2DT I3 (PAB40) 82bhp 130 N⋅m (96 lbf⋅ft) at 1,750 rpm

Originally built as an economical city car the car naturally appeals to young drivers seeking lower insurance premiums and as such has quite a cult following now.

The Aygo is a good car tuning project to execute. The key to Aygo tuning is getting your choice of modification right you can waste loads of money if you do it wrong.


Tuning tips and articles

Handling/Suspension upgrades

Many Aygo owners uprate the handling of their cars with modified suspension parts as a priority, this will certainly increase your enjoyment of the car.

Fully adjustable suspension allows you to fine tune the handling of you Aygo radically benefiting your drive.

We would go to a maximum drop of 29mm - 37 mm on most models. You risk rubbing on the arches if you go lower than this.

Engine tuning Transmission tuning Care care Intake & exhaust mods Improve handling Forums

The Aygo is good proposition as a first car and if you are prepared to invest some time and money it can be made into a great Tuning project.

The original car was not built for the track so handling has been compromised for comfort. TorqueCars recommend your fist mod is to fit uprated suspension and lower the car by 29-37mm. Larger drops will look quite silly and need extensive work to keep the geometry in alignment.

Turning our attention to the Aygos engine we need to get a bit more power out of the top end and increase the mid range torque. On such a light car even small increases in power can make a noticeable difference.

Turn the humble Toyota Aygo from an urban eco transport into a real urban warrier with just a few mods.

There was not a great deal of engine choices on the Aygo but the Toyota engineers showed the world what could be done with the Aygo Crazy - their Aygo tuning project. Now in it's second generation, the original concept has been further improved and tweaked with more than just a few styling mods.

Toyota Aygo Tuning modifications.

Your aim when tuning should be a nice flat torque curve and a wide power band. One of the best mechanical mods you can do is to fit a fast road cam.

There is a nice supercharger kit from TTS (there are also others around which we have yet to appraise) which will double your power and retain the cars economical, drivable nature in traffic to a large degree. Kits come with all the parts you need to set the car up, mapping is also highly recommended allowing you to get the full benefit of the supercharger.


A supercharger kit for the Aygo will cost quite a lot of money but there really is no other simple way to get as much of a power hike and it really does transform the car.

Stage 1 mods: Suspension upgrade (drop 29-37mm), Alloy wheels, Remap, Lighter flywheel, Panel air filter, Sports exhaust.

Stage 2 mods: fuel pump upgrades, Power/Sport clutch, Fast road cam, high flow fuel injector, Ported and polished head.

Stage 3 mods: Internal engine upgrades (pistons/head/valves), Sports gearbox, Adding or upgrading forced induction (turbo/supercharger), Engine balancing, Competition cam.

A supercharger kit will offer you a phenomenal power gain and due to the small engine it will retain much of the fuel economy your bought it for!

Uprated injectors will enable you to supply sufficient fuel to the engine and will only really be needed if you have added forced induction. Uprate the fuel pump to cope with the extra fuel requirements of your tuned Aygos uprated injectors.

Toyota Aygo Intake and Exhaust Tuning.

Breathing mods are usually next up. You need to unrestrict the airflow into the engine as much as possible and a cotton panel air filter will help this. Sports exhausts balance the flow of air through the engine. But if your exhaust is too large, ie it is over 1.8 inches bore, you will lose a lot of the flow rate and lose power on your Aygo, completely stuffing it's performance.

Panel filters made from cotton make a slight difference to top end power, so are useful for motorway cruising adding a little more go and will slightly improve economy depending on how you drive it.

Gas flowing the head will allow you to maximise your air/fuel delivery rates. Leave this to a professional though with a proper flow bench and machine tools.

Toyota Aygo Wheel modifications.

The benefits of alloy wheels include a lower unsprung weight and more efficient brake cooling. Large Aygo alloy wheels can decrease performance. If you get big alloy wheels you will be changing your final drive ratio. Although some people have gone larger we would stick to a 15 inch rim size as the maximum with 45 profile tyres, any more will cause scraping, especially if you have 4 occupants.

If you decided to fit some 15's you would need to fit wheel spacers of around 10mm and obviously longer wheel nuts on the front wheels to maintain the turning circle and prevent fouling on the bodywork whilst turning. At the rear there are issues, the petrol tank filler pipe is prone to rub on wider wheels. The top priority is to relocate this pipe and fix it out of the way.

The second issue with the rears is that using spacers will push the wheels into the bodywork, so you can't use spacers. (This information is based on the 4 door model, we assume the 3 door is still similar and subject to the same issues, notes.)

For more information on Tuning your Aygo please join us in our friendly forum where you can discuss Aygo tuning options in more detail with our members. It would also be worth reading our unbiased Toyota tuning articles to get a full grasp of the benefits and drawbacks of each modification before you start buying tuning items.

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Your Constructive comments on this article

One Response to “Tuning the Toyota Aygo.”

  1. shaun maxfield says:

    Fantastic Aygo piece -thanks so much.
    I am waiting for Toyota to produce Aygo FR 1500 mid engined little hotty – in honour of a designer who died is it happening?

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