General Fiat Stilo Abarth 2.4L 20v Turbo!

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General Fiat Stilo Abarth 2.4L 20v Turbo!

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Nov 2, 2006
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I'm coming to the end of my turbo conversion of my Stilo Abarth and all major alterations have been completed, I was thinking it would be pretty easy, but for a novice, it was a big learning curve.

Some might say why bother! It has been said just stick the 2.0L 20V Turbo lump in the Stilo! Which I could, but that's not what I wanted to do, I wanted a Fiat Stilo 2.4L 20V Turbo Abarth, which is how I think it should have come out of the factory??

I wanted to keep this a completely OEM (Original Equipment Manufacturers), so it's taken some effort with cross referencing part-numbers between the Coupe 2.0L 20v Turbo and the Stlio.

I need help now, I notice that the 2.4 Stlio shares the same injectors as the normally aspirated coupe 2.0 20v and the 20v turbo's are different. Should I then fit the 20v Turbo injectors?

Another problem is the waste-gate electronic control solenoid as fitted as standard on the Coupe Turbo, it connects to the injector circuit unit, which I can't! so can I disregard this solenoid and fit a dump valve? If so, are there any that don't make a loud noise??
 
:eek: you are a god if you pull this off :worship:

how much has it cost you if you don't mind me asking and did you do the work yourself or did you get someone else to do it?

oh and is it a selespeed or manual?

Sorry I don't know the answers to your questions I'm just excited someone has managed to turbo the 2.4 20v lump :D :D :D
 
:eek: you are a god if you pull this off :worship:

how much has it cost you if you don't mind me asking and did you do the work yourself or did you get someone else to do it?

oh and is it a selespeed or manual?

Sorry I don't know the answers to your questions I'm just excited someone has managed to turbo the 2.4 20v lump :D :D :D

A lot of the parts can be sourced secondhand with a few modifications, but I wanted it all new!! Oh, except the turbo, I bought this secondhand and reconditioned it.

It's not cheap if you want to do it all new, and you will need a decompression spacer which was £150.00, the sump is over £200.00, exhaust manifold £300.00, oil cooler radiator and take-off with pipes £350.00 etc. I will post a complete listing of what was needed and the cost when I have finished the project. So far I've done all the work myself, although being a novice on all new cars, I did do an apprenticeship at Fords for the first 5 years of my working life, but that was when MK3 Cortina were all the rage, giving away my age now!!
 
What have you done with regards to the suspension and brakes? as I heard that you need some monster brakes/suspension to keep all them horses in check.

I've put on Brembo 4 pot caliper's with cross drilled ventilated discs on the front and standard size rear discs, but crossed drilled to match the front with 'Red Stuff' pads, mainly just for the colour!

Suspension is Koni adjustable all round
 
Are you aware that the conrods are dancing along the crank shaft? They won't be able to take the torque you will see with the turbo. When we took the engine apart for the 2.4 performance tuning development, we were quite shocked to see that much float considering that the engine had been developed to be in the Delta Integrale that Mr. Agnelli finally killed.
 
Are you aware that the conrods are dancing along the crank shaft? They won't be able to take the torque you will see with the turbo. When we took the engine apart for the 2.4 performance tuning development, we were quite shocked to see that much float considering that the engine had been developed to be in the Delta Integrale that Mr. Agnelli finally killed.

This is why I didn't even bother to answer this post as many think they can do it and never explore the strength of the internals of an engine before they attempt these things ..I also know the chassis of the stilo is incapable of putting that much power down onto the tarmac as is the coupe and you will need better that just a set of struts and springs and more like a full suspension revamp ..no doubt your gearbox will sooner or later blow its self apart with the extra torque the high boost will be giving it ..all these things have already been done by the Greek lads all be it not on the abarth but a 1.6 turning out 227bhp and 5 gearboxes later will give you a hint of whats to come :)
 
as is the coupe

I agree with the rest of the stuff mentioned, as its not designed for a turbo, but the coupe is... :confused:

Ok when they are running 400bhp + (which the 2.4 turbos are) then yes the chasis cant put that power down in the corners, but most FWD cars cant put down huge amount of bhp anyways.

Ross
 
I thought you meant the car fell apart or something.... :D

But yes people arent experienced enough to deal with the power.... i got caught out last night in the wet weather. Tried to turn 45degrees at a junction and i kept going straight. Only doing 25mph but still reminds ya to keep alert.

Anyways, back on topic. If the original pistons are being kept, have you checked out how much heat, boost etc they could handle?

Ross
 
I'm more concerned that you've come this far with the project yet don't understand the difference between the waste-gate control solenoid and a dump-valve. :cry:
 
This is why I didn't even bother to answer this post as many think they can do it and never explore the strength of the internals of an engine before they attempt these things ..I also know the chassis of the stilo is incapable of putting that much power down onto the tarmac as is the coupe and you will need better that just a set of struts and springs and more like a full suspension revamp ..no doubt your gearbox will sooner or later blow its self apart with the extra torque the high boost will be giving it ..all these things have already been done by the Greek lads all be it not on the abarth but a 1.6 turning out 227bhp and 5 gearboxes later will give you a hint of whats to come :)

I have explored in great detail (Part numbers) what parts are shared with all the Fiat, Lancia range etc. You will find that the crank bearing part numbers are the same for the Stilo Abarth and Coupe Turbo, the Coupe Turbo uses the same crank as a normally aspirated Bravo, Marea, Lancia Thesis, Kappa, Lybra. The Inlet camshaft are the same for both the Abarth and Coupe Turbo. but the exhaust is a different part number and the Abarth shares it with the normally aspirated Coupe, so I guess the exhaust camshaft will have to be changed? the oil pumps are the same part number for both engines; The Coupe Turbo camshaft bearings are the same as the MAREA BZ GAMMA`99 (1999-2002), which shares both inlet and exhaust camshafts as the Stilo Abarth; don't see why the gear box won't cope, what would be your technical reason with this gearbox not coping?

The Koni uprated suspension has got to be better than the production suspension for both the Abarth and Coupe, so what would be your technical reason be why the Koni would not work?

The Abarth compression ratio has been lowered to 8.3:1 and the Coupe Turbo is 8.5:1 so the power will not be far off what the standard production Coupe Turbo was?

Gear box and transmission are not far off - Coupe is 5 speed with a top gear ratio of 0.91:1, the Abarth is the same; Coupe final drive ratio is 3.11:1, the Abarth is 3.56:1
 
I'm more concerned that you've come this far with the project yet don't understand the difference between the waste-gate control solenoid and a dump-valve. :cry:

I'm asking for advice, I thought going on this forum would be helpful, but all I seem to be getting is negative results!!

I tell you what I think it is then! The solenoid controls the actuator on the turbo which in turn opens the waste gate on the exhaust side to let the excess pressure from the inlet side when the throttle is closed?

I thought a 'dump' valve did the same but with the wiring into the control unit not needed?

If I'm wrong, then so be it, but I'm looking for advice and not negative feedback!
 
Lol..... Originally Posted by h2ypr
I thought you meant the car fell apart or something....

But yes people arent experienced enough to deal with the power.... i got caught out last night in the wet weather. Tried to turn 45degrees at a junction and i kept going straight. Only doing 25mph but still reminds ya to keep alert.

Anyways, back on topic. If the original pistons are being kept, have you checked out how much heat, boost etc they could handle?


Ross

How much heat, boost etc are they meant to handle, the Coupe Turbo uses the same pistons as a normally aspirated MAREA BZ GAMMA`99 (1999-2002), so why do you think the Abarth pistons would not cope, this was manufactured as a normally aspirated engine same as the MAREA BZ GAMMA`99?
 
How much heat, boost etc are they meant to handle, the Coupe Turbo uses the same pistons as a normally aspirated MAREA BZ GAMMA`99 (1999-2002), so why do you think the Abarth pistons would not cope, this was manufactured as a normally aspirated engine same as the MAREA BZ GAMMA`99?

are you sure thats N/A Marea? sounds like one of the Brazillian Turbo Marea's to me
 
How much heat, boost etc are they meant to handle, the Coupe Turbo uses the same pistons as a normally aspirated MAREA BZ GAMMA`99 (1999-2002), so why do you think the Abarth pistons would not cope, this was manufactured as a normally aspirated engine same as the MAREA BZ GAMMA`99?

I have never heard this. As bulldog says, its probably the turbo marea, which is basically the same engine. :D

Ross
 
I have never heard this. As bulldog says, its probably the turbo marea, which is basically the same engine. :D

Ross

Sorry my mistake, looking further in the parts catalogue, this is for the Brazilian Turbo.

So I will have to fit forged pistons? and forged con rods? if so that's no problem, someone just tell me where I can purchase them.
 
Pistons and conrods try here..
http://www.forgedpistons.co.uk/Products/Products.asp?type=dept&DepartmentID=7


And going back to the suspension and why apex alone wont hack it is quite simply the stilo abarth doesn't corner well because of the weight up front and you are going to need more that just a set of shocks and springs to get the power down to the road ..anti roll bars are not available in uprated form for the car and the only way you will get enough torsional stiffness will be to fit a roll cage inside the car..basically you will need to set the car up as if its going to be used for track use to get the car to handle the power well and we all know that its not practical to do it with the roads we drive on today as the car will hop skip and jump all over the road if you set the suspension up this way :)
 
Speak to Guy Croft if you're after fordged pistons & conrods for a Fiat. He might also be able to offer some real world advice on your project http://www.guy-croft.com/

Yeah he's good but hes MEGA expensive. Also you need 2.4 pistons and rods. Barbz at TI had to get them specially made AFAIK. I could ask where he got them from if u want?

Ross
 
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