Toyota's rigorous testing process involves deliberately crashing GR performance cars to achieve perfection. This exclusive inside look at the Gazoo Racing facility in Japan reveals their unique development and construction methods.

Development teams, including Toyota Chairman Akiyo Toyoda (known as Morizo), push test vehicles to their absolute limits. During one test, a GR Yaris rolled due to a four-wheel drive system fault, leading to crucial software improvements that prevent similar issues in production models.

The GR facility employs a unique cell-based production method, unlike traditional assembly lines. This approach allows for greater flexibility and rapid implementation of improvements.

Key production features include:

• Ultra-precise measurements and tolerances
• Exact suspension mounting point alignment
• Custom-matched subframes for each vehicle
• Strict steering wheel position control
• Vehicle turntables to maintain precision

Each GR Yaris undergoes thorough quality testing before leaving the factory. Test drivers perform aggressive maneuvers to verify performance consistency, ensuring that every vehicle meets Toyota's exacting standards.

This meticulous attention to detail in both development and production explains why the GR Yaris has become such a respected performance vehicle, with each unit being virtually identical in terms of handling and performance.

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