Saturday, January 9, 2016

2015+ Fiat 500 Abarth / 500 Turbo adapter kit installation.

My engine with factory intake removed.


Note the two disconnected hoses.  These were connected to the two hoses on the back of the airbox.  You're going to remove the hose with the male end.  This one connects to the Purge Valve in the center back of the engine.  The female (grey clip below) stays.

Using a screwdriver, pop open the retaining clip that held the two hoses together and set aside.
With a flat head screwdriver, gently open the bracket that holds this remaining hose and remove the hose.  Close the bracket and push the hose back towards the firewall.

Cable removed from retaining bracket and gently pushed back against the firewall between two hoses.  No cable ties necessary as it seems to stay there nicely.

This is the connector on the back of the airbox where the two hoses used to connect.  You need to remove this.  With a flat edge screwdriver, slightly cut away at the plastic cross piece holding it in place.  See picture above where I had to work the plastic off so it could come out.
Once removed, connect this valve to the female plug on the hose you left installed and pushed back against the firewall.  It should click right in.  Note the orientation above -- it's like an inverse "T".
Next, take the long hose from the 2015+ adapter kit WITHOUT the Y adapter and connect it to the purge valve.  This is the same valve you disconnected the male hose you removed.  Run it around the firewall to the left to the "T" you just placed into the female plug from the remaining hose.
Now cut the hose and connect to the connector facing the firewall.
Next, take the remaining piece of hose and connect it to the final connector that is facing forward and route it towards the front of the car but moving it under the hoses currently in place.  This hose will connect to the larger connector on the new intake.
Have a paper towel that's damp with a touch of dishwasher detergent.  Use it dampen the fittings.  Just a little will do.  Makes them VERY easy to install.
Attach the intake to the turbo and just lay it flat.  Note that the long hose (Mine is Red) that came with the 2.1 is already connected to the connector close to the filter and draped along the back over to the right.  This will connect to the PVC port over by the battery.  The airbox had a large hose connected to this port.  You can see the port in the lower right of the picture above.
There will be a small gap where the intake hose can go no closer to the turbo.  This is OK.
Going back to the airbox, there is sensor that is screwed in with a two torx screws. Unscrew the screws, remove the retaining clip and then gently remove the sensor.

Screw the retaining clip back onto the airbox where you removed the sensor using the two torx screws.  This will be good for safe keeping in the event you wish to revert to stock.


In the adapter kit there is a "T" connector attached to a short piece of hose.  Attach the sensor you just removed from the factory intake and push it into the end of the hose opposite of the "T" connector.  Then connect the electrical plug from wiring harness in the car to the sensor.  Lay the "T" end down under the hose coming from the intake to the PVC port in the location where you'll cut the large hose.

After figuring out the best position for the sensor and the "T", cut the hose and splice in the "T".


Run this hose the rest of the way and gently loop it around to the PVC port by the battery.  I used the retaining clip I removed from the intake box where the old PVC hose was connected.

This is how it should look when you're all done.  Note on the lower left the small and large hoses on the base of the intake just up from the turbo are now connected.  The Red hose in this picture comes from the connector closer to the new air filter and loops around along the firewall to the right, through the "T" with the sensor we removed from the airbox and into the PVC port.

Take the lid off the airbox by removing the three screws and remove the air filter.  Then place the box back in the car, affix the lid and screw it down with the filter removed.







LEFTOVERS!