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Looks like I may have found the issue - air getting into the fuel line at the union with the injection pump. I’d re-used the fuel pipe from the filter to the IP when I refitted it after the recon work and it clearly wasn’t up to the job. Not bad enough to stop the car running and driving at...

.. trace attached showing rpm and fuel rail pressure. The latter fluctuates wildly...

.. just been out on another test run - same symptoms and interestingly, same OBD error codes : ECM-0002 Fuel volume control valve - Faulty signal ECM-089 Fuel pressure control valve : Faulty signal The fuel volume control valve is attached to the injector pump - though I'm struggling to find...

Thanks Greg, Paskal. Still experiencing quite serious issues - to the extent that I may have to abandon my plans to take the car to Europe the week after next which is a real shame... As a reminder : - Fuel injection pump and fuel injectors completely refurbished by the same guy who did...

Thanks Greg Just come back after the logging run. Car was seriously black smoking under any power - plumes of it coming out when you floored it. Clearly an overfuelling (?) issue.. We did a couple of 3rd gear pulls with wide open throttle and repeatedly at about 3,100rpm the engine struggled...

Thanks - I stand corrected.. I have a S40 II so obviously won’t have this issue. HP injector pump has been reconditioned (by the same guy that did yours) - as have injectors. Fuel distribution line (from filter to injector pump) is original - so one scenario might be air bubbles being drawn...

Thanks Greg - I definitely plan to get up to Leeds though this will need to wait until after the Summer. I’m taking the car on a road trip across Europe in as week’s time and don’t have time to travel up there before we head off.. The car has a stage 3 HDI Tuning map - and runs really well up...

Can anyone recommend a diesel tuner / rolling road in the Bristol area? I’m running out of time to get the car properly sorted and am having a few sensor / fuelling related issues with the stage 3 map that I’m using..

Thanks - will give that a try..

On a separate note - Induction System Upgrades. I’m currently running the stock S40 air cleaner and pipework from the air intake duct back to the (cylinder type) air filter assembly. Silicon pipe upgrades from the air cleaner onwards. Thinking about how this can be improved - any suggestions...

I’m going with an HDI Tuning remap - which is configured around an upgraded fuel pressure sensor. Sent the ECU off yesterday - looking forward to seeing the results..

Found the details I needed :

.. I quoted the wrong part number above (this is the uprated MAP sensor). The fuel rail pressure sensor Bosch part no is 059130758 - any help with the pin out schema welcome..!

Fuel Pressure Sensor Upgrade - Pin out schema. Hi everyone, I’ve finally got the S40 into a state where I’m ready to have the ECU remapped. Ahead of this I’ve installed an updated 3.1 bar MAP sensor and now want to install an uprated fuel rail pressure sensor (Bosch part no : 0281 006 059). I...

Thanks for this - really helpful ! I’ve posted a longer response but its awaiting moderator approval..

Thanks for this - really helpful suggestions. - My injectors and turbo getting the ‘Greg‘ treatment (refurb and hybrid rebuild respectively) - Gravity intercooler on the shopping list - Exhaust suggestion sounds great - Will look into hdi tuning - sounds like a sensible approach though will...

Sounds like the way to go. I’m based in Bristol so it might be a bit of a trek to get to your mate’s place…. There’s a good rolling road / bespoke exhaust place quite near to me that I‘ve used for my my classic car tuning projects so might give them a try for the exhaust and an an initial base...

Thanks - this is very helpful. Sounds like I need to re-think… So - I’d welcome anyone’s thoughts on the optimum performance exhaust for the 2.0D? The ’spec’ for the car is the following: - the car’s a 2007 S40 model - it’s being prepped for a ‘fast road’ pan-European road trip (2,500...

Exhaust Question… Will a 2WD T5 exhaust (from the cat exit flange backwards) fit a 2.0D with minor modification? I know the rear valance will need altering to accommodate the twin pipes.. Thinking of going down this route rather than having one made up for the car..

Intercooler Hard Pipes : Anyone know if the T5 hard pipe kits that are available can be tweaked to fit the 2.0d? Is this a cheaper route than getting a bespoke set made up? Or just replacing with 'good' silicon pipes designed for the car..?

Exhaust question - Can an S40 T5 exhaust like the one below be made to fit the 2.0d? I'd rather avoid a full bespoke build - and could re-use this exhaust on a c30 T5 project that my son is considering as a future project. Obviously the rear valance will need modifying or replacing... This...

Thanks for documenting so much of the journey Greg - I'm not sure I'd have known where to start were it not for this forum thread. I'm a very experienced mechanic, but a rookie when it comes to diesel engines - all my tuning projects thus far have been on petrol cars (my diesel experience to...

Thanks Greg

Hello everyone - I’ve just joined this forum as I’m heavily modifying a 2007 S40 2.0d for fast road / occasional track day use. I’m planning to do most of the mods outlined in this thread (not Nitrous Oxide…). One question - do I need to upgrade the TCV to deal with higher boost pressures...