How to Remove and Add a Turbo on a 500 Abarth

[texanbrit]

Step 16:
Disconnect wastegate supply line from actuator pump

wastegate supply line.jpg (53.56 KiB) Viewed 7894 times

Step 17:
Disconnect turbo pressure sensor hose (underneath where the intake connects to the turbo)

Step 18:
Remove oil supply line banjo bolts and remove oil supply line from vehicle
- (1) 17mm bolt
- (1) 19mm bolt

oil supply.png (40.55 KiB) Viewed 7894 times

[texanbrit]

Step 19:
Remove lower splash shield
- (6) 10mm bolts

Step 20:
Remove downpipe
- Remove upper o2 sensor – 22mm wrench
- Remove nuts that connect midpipe to downpipe - 12mm (usually)
- Remove V-Band Clamp that connects turbo to downpipe – 10mm

Step 21:
Remove oil return line from vehicle:
Remove the bolts from bottom of turbo (top of line)
- (2) T-27 Torx bolts

oil return line.png (114.22 KiB) Viewed 7893 times

Remove bolts from bottom of line:
- 1” Socket
- T-27 Torx bolt

[texanbrit]

Step 22:
Remove the heat shield that covers the exhaust manifold
- (2) 8mm nuts
- (1) 10mm nut (center)

manifold shield 1.png (35.81 KiB) Viewed 7892 times

manifold shield 2.png (35.52 KiB) Viewed 7892 times

manifold shield 3.png (34.55 KiB) Viewed 7892 times

Step 23:
Remove nuts securing the exhaust manifold. There are spacers behind the nuts. DO NOT LOSE THESE! You will reuse them. Discard the nuts and install new ones.
- (9) 13mm nuts

Step 24:
Remove the banjo bolt from the coolant supply hose at the front of the turbo
- (1) T-60 Torx Bolt

Step 25:
Remove the coolant return line from the back of the turbo. Remove Coolant Cap from Coolant Reservoir (to relieve pressure). Remove bolt from the other end of the coolant return line that connects to the coolant hard line. Now remove the coolant return line from the vehicle. Reinstall the Coolant Cap to the Coolant Reservoir.

Step 26:
- Remove the turbo and exhaust manifold assembly from vehicle. Remove exhaust manifold gasket

remove manifold.png (71.8 KiB) Viewed 7892 times

[texanbrit]

Step 27:
Separate the turbo from the exhaust manifold
- (4) 13mm nuts (use wrench)

separate turbo 1.png (78.75 KiB) Viewed 7892 times

separate turbo 2.png (77.15 KiB) Viewed 7892 times

separate turbo 3.png (130.77 KiB) Viewed 7892 times

Step 28:
Transfer Surge Valve (Also referred to as Diverter Valve) to NGEN Turbo. Now connect NGEN Turbo to exhaust manifold (make sure you transfer the gasket!). All four nuts need to be tight so there is not any exhaust leaks

transfer surge valve.png (118.12 KiB) Viewed 7892 times

Step 29:
Install new exhaust manifold studs into cylinder head. Make sure all studs are all the way back in. If not, oil will leak out! Here is a great video to watch on how to properly install exhaust studs:



Please note: You can reuse any stud that stayed in the head. However, make sure they are all the way in. Any studs that came out you should replace with new ones.

manifold studs.png (58.39 KiB) Viewed 7892 times

[texanbrit]

Step 30:
Install new exhaust manifold gasket
- Part No: 0050049871-001

new manifold gasket.png (111.3 KiB) Viewed 7892 times

Step 31:
Install new Oil Return Line Gasket on existing Oil Return line (if not replacing the Oil Return Line). Disregard this step if you are replacing the line.
- Part No: 04893442AA-001 (Gasket)

oil return gasket.png (104.54 KiB) Viewed 7892 times

Step 32:
Install coolant return line on to turbo with new crusher washers before placing turbo back in vehicle. Do not attempt to secure the other end of the coolant return line to the coolant hard line yet.
- Part No: 09001004

[texanbrit]

Step 33:
Place turbo loosely in vehicle and align on some or all of the studs. This gives you room to move the turbo while securing the coolant return line back to the coolant hard line (it is short). Once the line has been secured, you can set the turbo/exhaust manifold assembly on all studs.

Step 34:
Reinstall all of the spacers previously removed from Step 23 and install all new exhaust manifold studs. Just make sure they are snug. You will tighten them in the next step.

Step 35:
Tighten exhaust manifold nuts in this order:
- Tighten 1 – 9
- Retighten 1-4
- Retighten 1-9
DO NOT DISREGARD THIS STEP. It is very important that you follow this step 100%!

manifold tightening order.png (118.62 KiB) Viewed 7892 times

[texanbrit]

Step 36:
Reinstall Exhaust Manifold Heat Shield
- (2) 8mm Bolts
- (1) 10mm Nut (Center)

Step 37:
Install Oil Return Line (or reinstall existing Oil Return Line)
- (2) T-27 Torx Bolts to bottom of turbo (top of line)
- (1) 1” Bolt
- (1) T-27 Torx Bolt – To Oil Pan (bottom of line)

install oil return.png (106.87 KiB) Viewed 7892 times

Step 38:
Install Oil Supply Line to top of turbo with new crusher washers
- (1) 19mm Bolt
Part No: 68186475AA-001 (2 Total)

Step 39:
Reinstall Coolant Supply line with banjo bolt and new crusher washers to front of turbo
- (1) T60 Torx Bolt
Part No: 68186475AA-001 (2 Total)

[texanbrit]

Step 40:
Reconnect wastegate supply line to actuator pump, turbo pressure sensor hose and turbo surge connector to Diverter Valve (DV).

*** The installation of the NGEN Performance Turbo is now complete. The remaining steps are to put the rest of the vehicle back together. Before doing this, now would be a good time to make sure everything is secured and tight. It is a lot easier to access all of the bolts to the lines now instead of when the vehicle is back together. ***

Step 41:
Install intercooler hose to the bottom of the turbo and route to the front (EC FMIC Hose pictured). Make sure the clamp is tight.
- (1) 8mm hose clamp

Step 42:
Reinstall downpipe:
- Install upper o2 sensor – 22mm wrench
- Install nuts that connect midpipe to downpipe - 12mm (usually)
- Install V-Band Clamp that connects turbo to downpipe (don’t forget the gasket!) – 10mm

Step 43:
Reinstall turbo blanket/turbo heat shield and turbo bracket
- (3) 10mm bolts (blanket/shield)
- (2) 10mm nuts (blanket/shield)
- (3) 13mm bolts (bracket)

reinstall bracket and blanket.png (54.86 KiB) Viewed 7891 times

[texanbrit]

Step 44:
Reinstall intake

EC v4.1

step44.png (113.42 KiB) Viewed 7891 times

Step 45:
Reattach core support:
- Reinstall bolts at top of fender that secure the front core support - (4) 13mm bolts
- Remove the single bolt on the bottom, then reinstall the bottom bumper supports, then reinstall all bolts
(8) 15mm bolts (4 each side)

Step 46:
Reinstall crash bar with intercooler core
- (8) 15mm bolts

Step 47:
Reinstall intercooler hoses to intercooler core. Make sure the clamps are tight!
- (2) 8mm hose clamps

Step 48:
Reinstall battery and engine heat shield/factory airbox

[texanbrit]

Step 49:
Start the engine and let it idle for about 3-5 minutes. DO NOT REV IT AT THIS TIME. Oil will circulate through the turbo automatically. This is the time to check for leaks. Tighten and/or correct any areas that might be leaking (there shouldn’t be any leaks if all steps are followed). Now let the vehicle run for another 15-20 minutes. Rev the engine periodically during this time to make sure there is boost/vacuum. If everything checks out after running for 20 minutes, you can shut off the engine.

Step 50:
Reinstall lower splash shield
- (6) 10mm bolts

Step 51:
Reinstall headlights, front bumper and wheels. Installation is complete!
- (6) 10mm bolts (3 each side for headlight).
- (4) T-27 Torx Bolts up Top
- (3) T-27 Torx Bolts on bottom
- (2) Phillips head screws on bottom
- (6) Phillips head screws in inner fender (3 each side)
- (2) T-27 Torx Bolts (Bumper attaches to fender)
- Reconnect DRL, Fog Lights and Bumper Lights.
- Wheels (17mm Socket)

Congratulations! Now go drive your vehicle! We recommend performing the following break-in procedure:

1.) 1st 5 miles: 0-5psi boost
2.) 5-15 miles: 5-10psi boost
3.) 15-25 miles: 10-20psi boost
4.) 25+ miles: Full boost