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(Post Link) post #1 of 66 Old 31-01-12 Thread Starter
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My GTV TS Turbo Project

Hello all!

I got my gtv (a childhood dream for me) a couple of weeks back, and i thought i would share it with you guys!

It's a 1.8 twin spark in blue with tan leather with ~48k miles on the clock. The first owner had spent litteraly a small fortune on it: Novitec Turbo kit, Novitec dampers/Eibach springs, Brembo 4pot kit, ph3 nose, cup body kit, autodelta diffuser, quad exhaust, the lot! A couple of pictures:

http://i212.photobucket.com/albums/c...DSC_5561_1.jpg
http://i212.photobucket.com/albums/c...DSC_5563_1.jpg
http://i212.photobucket.com/albums/c...V/DSC_5568.jpg
http://i212.photobucket.com/albums/c...V/DSC_5569.jpg

The bad news is that the last 5 years it's barely done 500 miles in total, and the last two i bet it hadn't moved an inch. Alfas tend not to like that, so i had all kinds of niggles to sort out.

A few words on the turbo kit. It is, hands down, the most appalling conversion/upgrade i've seen on my entire automotive life. The plumbing on the intake is the wrong size, no other word for it, by some 20mm, and they used a maf casing with a sensor on it as an extension (they probably lacked a piece of ally pipe). The exhaust is simply horrid from end to end, chopped up stock manifold to fit the turbocharger, 52mm downpipe (that's nearly the stock sizing of the NA engine, to put it into perspective), and the rest of the system is as if it's bent, put toghether and welded by a retarded ape. To top it all off, novitec probably weren't able to remap the all-new (back then) stock ECU, so they downgraded it, and the replacement came from one of the very early 156 1.6. Although it seems they weren't all that able to remap that one either, because it does about 10mpg... It downright amazes me that despite all these, it goes like the clappers, and i can only imagine the potential it has when everything is sorted out.

There's a lot of work to be done on the car, so if you're interested i'd be more than happy to keep this thread alive with updates!

Cheers
Steve

Last edited by spresv; 27-08-12 at 19:38.
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(Post Link) post #3 of 66 Old 31-01-12 Thread Starter
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It's already gone
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Cant wait for the updates..
Good luck.

Last edited by FLATRON; 25-10-12 at 12:52.
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hope these updates include pictures and sounds clips too
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Engine and turbo pics please
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(Post Link) post #7 of 66 Old 01-02-12 Thread Starter
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Of course they will include pictures

This is the current state of the car. Novitec shoved the turbo very low down, under the air con compressor, making all the plumbing even more of a pain. The only thing written on the turbo is "Schwitzer", it looks about the size of a t25 unit.

http://i212.photobucket.com/albums/c...V/DSC_5681.jpg
http://i212.photobucket.com/albums/c...V/DSC_5678.jpg

Anyone noticed the HUGE oil cooler?

You can also see the exhaust in all of it's magnificense.

http://i212.photobucket.com/albums/c...V/DSC_5544.jpg
http://i212.photobucket.com/albums/c...V/DSC_5550.jpg
http://i212.photobucket.com/albums/c...V/DSC_5536.jpg

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comedy exhaust setup and that oil cooler you'd thought to be an intercooler
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I checked that while taking the pics, only difference is the intercooler is a bit thicker, they really are the same size

Think about this though, we may be laughing now but novitec used to charge the best part of 6 grand for this piece of [email protected] tuning. Not only that, but they were (and still are) thought of as a respected tuning company... And i hear the autodelta turbo conversions were no better.
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well here's my exhaust and coverting was nowhere near as expensive as the novitec and AD ones

http://i246.photobucket.com/albums/g...10at202949.png
http://i246.photobucket.com/albums/g...a/513a54c1.jpg
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(Post Link) post #11 of 66 Old 01-02-12 Thread Starter
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You don't have to tell me, my tig and mig are waiting for me, tell the bloke who actually paid for all these
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I want to get a tig as I want to make my own stuff from now on

I wouldn't pay £50 let alone £6000 for that!
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(Post Link) post #13 of 66 Old 05-03-12 Thread Starter
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Just a couple of updates. The fueling problem would be a pain in the a$$ to fix with the stock ecu, plus i needed a couple of new sensors, a fpr etc, so i bit the bullet and went for a standalone. Megasquirt DIYPNP it is, plus a wideband innovate O2 sensor.

http://i212.photobucket.com/albums/c...V/DSC_6104.jpg
http://i212.photobucket.com/albums/c...223_000527.jpg

In other news, the car developed a shocking heavy knocking noise when the turbo kicked in on 1st and 2nd. I thought it was a shot inner CV joint, which i replaced, but while i was at it i realised it wasn't the joint, but the gearbox. The previous owner somehow managed to damadged the underside of the car, with evicence of parts being replaced. All was well, apart from a nasty chip on the gearbox casing, but it wasn't really deep, so they helicolied it and sent it off. Somehow, without hitting anything, another big chunk chipped off, all 3 threads of the lower mount were shot and it's no longer tightly fastened, hence the knocking.

http://i212.photobucket.com/albums/c...224_135716.jpg

So, a replacement gearbox was found. And since i'm going into all the trouble, i had a full race paddle clutch come my way, for good measure.

http://i212.photobucket.com/albums/c...V/DSC_6101.jpg
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Jeez, what did the previous owner do to the gearbox, he/she must have dropped the wheel off a high kerb or driven into some kind of speedhump with the gearbox side wheel in the lower ridge and the gearbox banged into the ramp face? Anyways, car looks good spresv, and i wish you luck sorting out that Novitech mess, i think they used to be in F1?
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(Post Link) post #15 of 66 Old 05-03-12 Thread Starter
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Thanks mate, i really have no clue myself how it might have happened. Novitec in F1? They wouldn't last 10 seconds, let alone a full race/season
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Let us know how you get on with the megasquirt
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(Post Link) post #17 of 66 Old 05-03-12 Thread Starter
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Of course i will ECU is assembled and ready, i'm gonna plug it in the next couple of days, calibrate the sensors etc, and start the mapping.
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Really thinking of getting a motec for my replacement engine as they're getting cheaper.
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Nice car.
I must agree the turbo setup really looks cheap but if it works it work.
Personally I will change the outlet from the turbo to a nice 3 inch pipe.
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To be fair.. we don't know who installed that turbo.

I doubt it was Novitec just because their reputation would be shot if they made something like that... and it isn't. It's more likely someone had the components shipped and then fitted them themselves or with the help of a local mechanic..

Ralf S.
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(Post Link) post #21 of 66 Old 06-03-12 Thread Starter
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@turbonutters: Thanks! I won't bother with any of that on the current setup mate, when i have the cash, i'll throw away both the manifold and downpipe and fabricate new quality ones, with the turbo to follow.

@Ralf S.: It's pretty obvious that a bucketload of cash was spent on the car, so it doesn't make any sense he would cheap out on the conversion, or lie about it for that matter. Anyway, I've spoken to the previous owner about this, and he did what any regular customer would do, found out the Novitec dealer, phoned them up and booked the car in, paid the price and got it back "tuned". So, either Novitec was a bit sh1tty then, and all their conversions were like that, or they should be more carefull about their dealers. That said, i've found a couple of pics on the net of other novitec conversions, and all the piping etc looks remarkably like mine.
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Currently looking for a new bigger car and have come across something called AEM water methanol kits. There is an Impreza on Ebay with one fitted. Would this work on a GTV Turbo ??
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You pay them for the added performance and your car is proof that it work.
Personally I don’t like the look of it but they gave the previous owner what he wanted performance and not a show car.

But it should be pleasing to the eye as well. Not that this is perfect

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Quote:
Originally Posted by neilied View Post
Currently looking for a new bigger car and have come across something called AEM water methanol kits. There is an Impreza on Ebay with one fitted. Would this work on a GTV Turbo ??
Yes it will
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Is that nose a Phase 3 conversion or did the Phase 3 come in 1.8TS in Greece??

That will be a nice car when you have spruced it up
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