Torque Cars

Volvo S40 2.0d tuning project

Discussion in 'Volvo' started by Greg1990, 8 April 2019.

  1. Greg1990

    Greg1990 Tuner

    Messages:
    52
    From:
    Pontefract
    Car:
    S40 2.0D SE sport
    Hi everyone..I have a Volvo S40 2.0d 2007..done the usual mods ie custom map,dpf/egr delete,full stainless exhaust and K&N panel filter pushing just over 180BHP..Just had an hybrid turbo made and a “drifting” friend reckons he’ll get a Skyline GTR Intercooler behind the grill with all the space that’s there.Has anyone done the similar?..just wondering if the injectors will need uprating and/or the clutch?..All advice much appreciated..
     
  2. TCJBOLDIE

    TCJBOLDIE Torque King

    Messages:
    4,779
    From:
    Brisbane
    Car:
    JB Starion
    Hi and welcome Greg|B

    It seems that you have done all the right things so IMO the clutch should be fine IF it is handling the power ATM so when it fails then upgrade to a better clutch.

    Does the car have a stock intercooler and if it does have you ever had it internally cleaned as over time there can be a build up of oil film residue in the tubes that will reduce the IC's ability to transfer heat and the air temps at the outlet will be higher leading to less power.Fitting a larger IC will help reduce the air temps and cold inlet manifold air = more power.

    Re bigger intercoolers surface area is more important than thickness.
     
  3. Greg1990

    Greg1990 Tuner

    Messages:
    52
    From:
    Pontefract
    Car:
    S40 2.0D SE sport
    Thanks for your reply..We are ditching the stock Intercooler in favour of a much larger one to compliment the hybrid turbo.My cars stock power was only 136BHP and were hoping to achieve in the region of 250BHP with the new mods?..The clutch is coping well with the current 180BHP but it has done 130,000 miles and we are anticipating it may start slipping with an extra 70BHP?...Then there’s the injectors to consider,are we going to need bigger ones to cope with all that extra power?..It’s a voyage of discovery as I can’t find anyone who has done similar mods to their S40 2.0d for any hands on advice?..
     
  4. obi_waynne

    obi_waynne Administrator Staff Member Moderator

    Messages:
    41,202
    From:
    Deal, Kent UK
    Car:
    A3 1.4 TFSI 150 COD
    You will IMO need bigger injectors for this. Stock injectors on these flow ok up to around 200bhp, beyond this they can top out, and you'll get it running lean or flat spots. It might be worth uprating the fuel pump as well just to be on the safe side.
     
  5. Greg1990

    Greg1990 Tuner

    Messages:
    52
    From:
    Pontefract
    Car:
    S40 2.0D SE sport
    Thanks for your advice Wayne..just keep getting conflicting opinions,some say they won’t deliver enough fuel and some say they are good for 250BHP+?...I’m sure we’ll find out when we get her on the dyno..What bigger injectors do I ask for if needed,any ideas?...or will my “mapper” know that?...
     
  6. obi_waynne

    obi_waynne Administrator Staff Member Moderator

    Messages:
    41,202
    From:
    Deal, Kent UK
    Car:
    A3 1.4 TFSI 150 COD
    A new injector can do amazing things, as they get older though they drop off significantly. That's why the manufactures under specify the capabilities, to cope with them as they start to wear out. You need to be using a maximum of 85% of an injectors rated flow rate for safety IMO.

    To get the injector size you'll need to know the power output, this gives the amount of air being pushed in, then it's a calculation with the air.fuel ratio tables to get your injector size.
    NB: Injectors are rated in cc (not cylinder capacity)

    https://www.deatschwerks.com/fuel-calculators/fuel-injector-calculator is a handy rough rule of thumb calc.
     
    Lunchmoney likes this.
  7. Greg1990

    Greg1990 Tuner

    Messages:
    52
    From:
    Pontefract
    Car:
    S40 2.0D SE sport
    Thanks again Wayne...Seems I’ll have to wait until we get her on the dyno to ascertain what’s needed?..I’ll keep you all posted..Just had a look at that injector calculator site,it won’t let me select diesel as the fuel type?..lol..
     
    Last edited: 9 April 2019
  8. Greg1990

    Greg1990 Tuner

    Messages:
    52
    From:
    Pontefract
    Car:
    S40 2.0D SE sport
    Well all that waiting is finally over!..she’s off to the dyno tomorrow...booked in at 10:00...:)
     
  9. Greg1990

    Greg1990 Tuner

    Messages:
    52
    From:
    Pontefract
    Car:
    S40 2.0D SE sport
    The results are bittersweet!...195BHP!...the map sensor is only a 2 bar one and the hybrid turbo is maxing it out..looking at the graph from the new map and old map it is over 40BHP increase from 3,800RPM and carries on all the way to the red line..looking to find a 4 bar map sensor to let that turbo do its stuff..the journey carries on..lol
     
    Lunchmoney likes this.
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