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Abarth Turbo Upgrade: A $950 Boost Kit That Delivers 30 HP and Sharper Response
For Abarth owners chasing more power without a complete engine rebuild or a wallet-draining swap, the Abarth Turbo Upgrade offers a compelling solution. Priced at just $950, this boost kit promises a 30-horsepower increase and noticeably improved throttle response. It targets the heart of the 1.4-liter MultiAir turbo engine, refining the turbocharger system to unlock hidden performance while maintaining daily-driver reliability. This deep dive covers everything from the kit’s engineering to real-world driving impressions, installation details, and how it stacks up against other modifications.
What Exactly Is the Abarth Turbo Upgrade?
The Abarth Turbo Upgrade is an aftermarket performance kit engineered specifically for the Fiat 500 Abarth and its derivatives (including the Abarth 595 and 695 models). Rather than replacing the entire turbocharger unit, the kit typically includes a ported, modified, or upgraded turbo housing, a revised wastegate actuator, and matched components that optimize boost pressure and flow characteristics. This approach keeps costs low while delivering meaningful gains in both horsepower and torque.
The core philosophy behind the upgrade is to enhance the turbocharger’s efficiency—reducing backpressure, improving spool time, and allowing the engine to breathe more freely at higher RPMs. Many kits also come with a reflashed ECU or instructions for a tune, ensuring the air/fuel mixture and ignition timing align with the new hardware. The result is a more responsive, energetic power delivery that transforms the Abarth’s character without sacrificing reliability.
How It Works: The Science Behind the Boost
At its simplest, a turbocharger uses exhaust gases to spin a turbine, which forces more air into the engine. The stock Abarth turbo is designed for a balance of emissions, fuel economy, and performance. The boost kit removes some of those compromises by optimizing the compressor and turbine wheel geometry, increasing the wastegate spring pressure, and smoothing airflow paths. This allows the turbo to reach target boost sooner and maintain it longer across the rev range.
Typical upgrades involve:
- Port-matched intake and exhaust housings to reduce turbulence
- A stronger wastegate actuator to hold higher boost without creeping
- High-flow recirculation or blow-off valve to protect the compressor wheel
- Revised engine control unit (ECU) calibration to maximize the new hardware
These changes collectively unlock the latent capacity within the 1.4-liter MultiAir engine, which is already known for its responsive low-end torque.
Key Features of the Boost Kit
Every turbo upgrade kit varies slightly by manufacturer, but most share a core set of features that make them attractive to Abarth enthusiasts.
- Power Increase: Advertised gains of +30 horsepower at the wheels (some kits report up to +40 hp with a tune). Peak torque typically rises by 30–40 lb-ft, flattening the torque curve for stronger mid-range pull.
- Improved Throttle Response: The upgraded turbo spools faster, reducing lag from a stomp on the gas to actual acceleration. Drivers report a more immediate connection between the pedal and the engine.
- Plug-and-Play Installation: Most kits are designed for DIY installation with standard hand tools (socket set, wrenches, screwdrivers). No custom fabrication or machining is required.
- Robust Construction: Billet compressor wheels, CNC-machined housings, and billet wastegate actuators are common, ensuring durability under sustained high-load driving—track days included.
- Comprehensive Kit: Includes gaskets, o-rings, clamps, and installation hardware—no need to source extra parts.
Installation Process: What to Expect
For those with moderate mechanical experience, installing the Abarth Turbo Upgrade is a weekend project. Below is a detailed walkthrough of the steps involved. Always refer to the specific kit’s manual, but the general procedure remains consistent.
Tools and Preparation
- Socket set (metric, 8mm to 15mm)
- Torque wrench
- Flat-blade and Philips screwdrivers
- Jack and jack stands (or lift)
- Coolant (for refilling after removing the turbo water lines)
- Penetrating oil (for stubborn bolts)
Step 1: Disconnect the Battery and Drain Fluids
Begin by disconnecting the negative battery terminal. Drain the engine coolant (loosen the drain plug on the radiator) and remove the air intake tract. This clears access to the turbocharger.
Step 2: Remove the Stock Turbocharger
Disconnect the intercooler pipes, the exhaust downpipe (support the turbo when removing bolts), the oil feed and return lines, and the water lines. Carefully unbolt the turbo from the exhaust manifold. This step requires patience—exhaust bolts may be tight and can snap if forced. Use penetrating oil and a breaker bar.
Step 3: Install the Upgrade Kit
Transfer the oil line fittings and any gaskets from the old turbo to the new unit. Apply a thin film of anti-seize to the studs. Bolt the upgraded turbo to the manifold, tightening to manufacturer torque specs. Reconnect the oil and water lines, downpipe, and intercooler piping. Replace the wastegate actuator if included.
Step 4: Reconnect and Check
Reinstall the intake, refill the coolant, and reconnect the battery. Verify all clamps, hoses, and electrical connections are secure. Start the engine and check for oil or coolant leaks. Let the engine idle for a few minutes to warm up and burp the coolant system.
Step 5: ECU Calibration
If the kit includes a handheld tuner or requires a flash, follow the instructions to upload the new map. Some kits are “tune-free” for stock ECUs, but a custom tune will extract the maximum power.
Step 6: Test Drive
Take the car for a gentle test drive, gradually increasing load. Listen for unusual noises, check boost levels on a gauge, and feel for hesitation. After the first 50 miles, re-torque the turbo-to-manifold bolts as they may settle.
Performance Improvements: Real-World Results
On the dyno, the Abarth Turbo Upgrade typically shows the following gains compared to stock:
- Peak horsepower: +30 to +40 whp (e.g., from 160 whp to 190–200 whp)
- Peak torque: +30 to +45 lb-ft, with a flatter curve extending from 2500 to 5000 rpm
- Boost pressure: Increased from 18–20 psi stock to 22–25 psi, depending on tune
On the road, these numbers translate into tangible improvements. The car pulls harder from 2000 rpm, eliminating the slight hesitation common in stock turbos. The engine feels more eager to rev, and overtaking on highways requires significantly less lead time. During track sessions, the upgraded turbo maintains consistent boost through corners, allowing for earlier throttle application.
Drivability Comments
Many owners report that the power delivery retains a linear feel—not an abrupt surge that upsets the chassis. The extra torque at low RPM makes daily driving more relaxed; you can cruise in sixth gear without downshifting for moderate inclines. Combined with a sport exhaust and intake, the Abarth’s exhaust note also becomes more aggressive under boost.
Cost-Effectiveness of the Upgrade
At $950, the Abarth Turbo Upgrade represents one of the best horsepower-per-dollar ratios in the aftermarket. Consider the alternatives:
- Full standalone turbo kit: $2,500–$4,000 (requires custom piping, intercooler, fuel system upgrades)
- Cat-back exhaust: $400–$800 (single-digit hp gains)
- Cold air intake: $200–$400 (marginal power, mostly sound)
- ECU tune only: $400–$700 (limited gains without hardware)
By combining hardware and tune in a single kit, the upgrade offers immediate, verified gains without requiring a cascade of supporting mods. Labor costs for professional installation typically run $300–$500, but many enthusiasts install it themselves, saving that expense.
Comparing the Abarth Turbo Upgrade to Other Mods
It’s helpful to see how this kit stacks up against common performance modifications for the Abarth 500.
| Modification | Estimated Cost | HP Gain | Throttle Response Improvement | DIY Difficulty |
|---|---|---|---|---|
| Turbo Upgrade Kit | $950 | 30–40 hp | Significant | Moderate |
| ECU Tune (Stage 1) | $500 | 15–20 hp | Moderate | Easy |
| Exhaust + Downpipe | $800 | 5–10 hp | Minor | Moderate |
| Intercooler Upgrade | $400 | 0–5 hp (but consistent power) | None | Easy |
| Full Turbo & Built Motor | $5,000+ | 80+ hp | Variable | Expert |
For enthusiasts seeking a noticeable performance uplift without committing to a major project, the turbo upgrade is the sweet spot.
Customer Feedback and Community Reception
Across Abarth forums and owner groups, feedback for the $950 boost kit is overwhelmingly positive. A roundup of common comments:
- "Best mod I've done." — Many praise the transformation in drivability, noting the car feels significantly quicker in daily driving.
- "Installation was straightforward." — DIY reviews frequently mention clear instructions and minimal modification needed.
- "It's a huge upgrade for the money." — Value for money is a recurring theme.
- "No issues with reliability." — Long-term owners (20,000+ miles on the kit) report no turbo failure or engine problems when properly tuned.
- "Paired with a tune, it’s a riot." — Many recommend a custom tune for even more power (up to 210 whp).
Some critical notes appear as well: a few users had to shim the wastegate actuator for proper boost control, and others recommend upgrading the intercooler if the car is used for track days to prevent heat soak.
Potential Drawbacks and Considerations
No performance upgrade is perfect. Here are factors to weigh before purchasing.
- Warranty Impact: Installing an aftermarket turbocharger will almost certainly void the engine and powertrain warranty on a newish Abarth. Check local laws and dealer policies.
- Compatibility Verification: While the kit fits most 500 Abarth models (2012–2019), ensure the specific year and revision match the kit’s specifications. Some early models have different turbo flange patterns.
- Professional Installation Recommended for Some: Though DIY-friendly, those uncomfortable with turbo work or ECU calibration should budget for a shop’s labor.
- Supporting Mods May Be Needed: To fully realize gains and keep IATs low, a larger intercooler and high-flow intake are advisable. The kit may not include a tune, requiring an additional purchase ($300–$600).
- Emissions Compliance: The upgraded tune may not pass smog checks in strict states (California, New York) without a CARB EO number. Check local regulations.
- Increased Heat: More boost = more heat. Monitor oil and coolant temperatures during spirited driving.
Long-Term Reliability
Stock Abarth engines are robust up to about 230 whp on stock internals. The 30–40 hp gain from this kit stays well within that safe zone. However, consistent track use should include upgraded cooling and oil catch cans. Regular oil changes (every 3,000–5,000 miles) are critical when running higher boost.
Conclusion
The Abarth Turbo Upgrade at $950 delivers exactly what it promises: a substantial 30-hp gain, sharper throttle response, and a more exciting driving experience. By refining the factory turbocharger’s weaknesses, it elevates the Abarth from a peppy city car to a genuinely quick machine that holds its own on twisty roads and track days. Installation is accessible to moderate DIYers, and the upgrade’s value proposition makes it one of the most effective modifications available for the platform.
For owners looking to take the next step beyond an intake and exhaust, this kit is a logical, rewarding investment. Just ensure you address supporting mods, consider a tune, and respect the increased demands on maintenance. With those boxes checked, the Abarth Turbo Upgrade is a surefire way to unlock the true potential of your little Italian rocket.
Further reading: Check out owner reviews on the Abarth Forum, the product page on 500Madness, and Wikipedia’s Abarth 500 overview for broader context on the platform.