164 3-litre 12V turbo - Alfa Romeo Forum
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(Post Link) post #1 of 1 Old 07-12-18 Thread Starter
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Join Date: Mar 2016
County: denmark
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164 3-litre 12V turbo

Alfa 164 3,0 12V turbo - simple kit with original parts!

Just sharing my turbo conversion project on my 1990 - 164 3,0 12V 5-speed manual Busso :-)
Aim is not biiig horsepower but to hear spooling and hissing from the turbo and feel that boost kicking in.

The idea is to take hardware parts from the 2-litre V6 TB engine. Simple, cheap and fun is my motivation :
- turbo TB2538 (wastegate std. spring gets 0,4 bar boost - around 5,5 PSI)
- silicone boost pipe and intake pipe (you have to do some DIY here for the boost side)
- exhaust manifolds (only front is needed)
- y-piece for turbo collector (bolts straight on the studs on the engine block)
- oil lines (turbo oil-in from front cylinder head oil plug)
- oil pan w. oil return hole
Extras if you want:
- inlet pipe w. blow-off (not really needed but makes it look more original)
- intercooler (havent installed yet - boost is low so maybe not really needed)
- clutch has been uprated to 440 Nm since the old was bad - new push type Sachs with organic plates and stronger springs

Other parts
- variable fuel pressure regulator (it will run quite ok with original fuel pressure regulator - but too lean above 5.000 rpm so no thrashing. Actually no misfiring has been detected so far)

It is born as a 3-litre 12 valve 184 BHP AR06412 engine. Approx. 260.000 km.
Dyno test in NA-mode showed 186 BHP and 260 Nm on the crank - spot on!

Installation was very easy since only the front exhaust manifold is needed.
Turbo y-piece bolts straight on to the engine block since the block already has the studs ready. Easy!
The rear exhaust pipe between collector and manifold need a cut and a pipe connector to close a gap of approx 20 mm. In this way you dont need to touch the rear manifold which is not easily accessible.

DIY: you must do some welding after the original turbo-downpipe. Not too difficult I guess.

How does it feel?
It feels greeeeaaaat Turbo spools up right from idle and the engine just feels bigger with an extra push around 2.500 rpm when boost peaks. Turbo is maybe too small for this engine but it actually pulls strongly right to the rev-limiter.
The original crispy respons and rev-happiness is kept and just combined with the elastic feeling from the turbo.
With 0,4 bar boost torque is around 350 Nm I guess (slipping clutch so no good dyno result yet) and skinny 205/65-16" front wheels cope quite well with it.
In cold or wet surface they will spin in second gear of course but in general the power is easy to handle. Give it third and you have strong power at any speeds.
The standard rear silencer is possibly killing 10-20 BHP - which I saw on a dyno before the clutch slipped. So an old 3" rear flow-through beast is installed just adding a deep tone the sound. It is not loud at all but backs up the extra grumpf I think.

This setup is so good I think that Alfa should have made the combo back in the days.

Total cost for me:
- TB turbo parts: 300 Euro
- variable fuel pressure regulator: 200 Euro
- Uprated clutch (incl. new clutch): 600 Euro
- misc. parts: 100 Euro
Total: 1200 Euro

Videos here:
Dyno with bad clutch and head gasket (fixed now)
Free exhaust - too loud - bad head gasket makes it smoke:

More coming when boost goes up :-)
Wish list:
- programmeable ECU
- bigger turbo
- diff with limited slip
- gearbox main bearing getting worn
Attached Images
File Type: jpg IMG_8321.jpg (61.5 KB, 3 views)
File Type: jpg IMG_6478.JPG (184.0 KB, 8 views)
File Type: jpg IMG_6448.JPG (107.3 KB, 3 views)
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12v , 164 , 3litre , turbo

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