Volvo S40 2.0d tuning project

Mk2volvos40derv

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Mk2 volvo s40 2.0d
What psi have you made on the 3.1 bar map?

& helpfull info for those who don't want to buy a expensive "upgrade" map sensor, i found it's just the map sensor from 2.2d engine found in ford/jag etc so a fraction of the price
 

Greg1990

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I’m not sure of the exact amount of boost that I’m doing?..will find out on Thursday when she’s on the dyno although I’m sure he said we were close to maxing it out?..the map sensor I’m using is an upgrade for the Ford Fiesta/focus 1.6 TCDI..it’s a direct fit other than having to shave a little ridge off the plug with a razor blade...I was pulling my hair out trying to find a 4bar sensor that would be a direct fit.like you say,a custom sensor can be installed but you then need to fit an adapter to the intake ..too much pissing about for my liking..
 

Mk2volvos40derv

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I never said anything about a custom sensor! I'm saying instead of people getting ripped off buying a "upgrade" from a tuning company just just buy the actual part, part number is 079800-7661, as you'll notice on nb styling website they take there photo's in a way that does'nt show the part number, i've made 245hp on this sensor & cost me £25 from tms
 

Greg1990

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Sorry..thought you were on about a map sensor bigger than 3.1 bar?....you’re running just under 2bar of boost then?...you’re doing exceptionally well to be getting 245BHP..I’ve got a hybrid turbo made by AE turbo’s in Normanton with a 56ml Turbine wheel,Nissan skyline GTR upgrade intercooler which covers the entire front of the car,full stainless exhaust,dpf/egr delete and K&N filter..I’m getting 220BHP..Just fitted a Snowperformance methanol/water injection kit so going to see what extra that has given her on Thursday...
 

Greg1990

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S40 2.0D SE sport
I'm doing pretty much the same thing as you guys
I've got a s40 d4204t with following engine mods
Full custom 2.5" exhaust
Demon motorsport gt1756 hybrid turbo
Direnza focus st alloy intercooler
2.5" intercooler pipes
Egr delete
Ram air Induction kit
Creation motorsport catch can
Focus st hardrace engine mounts

I'm booked in for mapping on a rolling road this saturday & wondering if anyone has found the best map sensor for achieving around 250hp? Got a short space of time to find 1 & if you've found any other components that will let go around this power? What other things should i be buying? bought the car standard 2 month ago so it's been a rush from 1 part to another,
Any advice on parts needed is apreciated tia
How did you get on with the dyno results?..
 

Greg1990

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The car has been running exceptionally well with the new methanol injection kit..Been toying with the idea of adding nitrous!..Any opinions?..lol..
 

Moosebus50

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London
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Volvo v50 2.0d
Been on the dyno today...239BHP and 435ftlb of torque..pretty happy with the results.. :)
Hi their, im currently in the stage of going hybrid, turbo is getting send off next week currently running 182bhp 412nm, i have a couple of questions if thats okay, first one was how do you no the stock fueling is good for 300 plus and also whats it like now compared to a stock turbo remap and how come you used meth, did the turbo max out at 220, thankyou, ben
 

TCJBOLDIE

Torque King
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Brisbane
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JB Starion
Even Lewis Hamilton has to abide by the road rules that apply equally to pros and amateurs when out and about on public roads.

Not trying to start WW3 just reminding people that the laws apply to everybody regardless of their level of skill and experience.

PS am old enough to be your "dad"
 

Greg1990

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Pontefract
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S40 2.0D SE sport
Even Lewis Hamilton has to abide by the road rules that apply equally to pros and amateurs when out and about on public roads.

Not trying to start WW3 just reminding people that the laws apply to everybody regardless of their level of skill and experience.

PS am old enough to be your "dad"
Sorry dad..lol..and I’m 48 :)
 
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Greg1990

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S40 2.0D SE sport
Hi their, im currently in the stage of going hybrid, turbo is getting send off next week currently running 182bhp 412nm, i have a couple of questions if thats okay, first one was how do you no the stock fueling is good for 300 plus and also whats it like now compared to a stock turbo remap and how come you used meth, did the turbo max out at 220, thankyou, ben
I was around the same sort of power you’re running with the stock turbo,the hybrid added around an extra 30 or so BHP.Its not so much maxing the turbo out but AE Turbo’s told me to expect around 220-230BHP..the maf sensor is the weak link.i could only manage to find a 3.1bar sensor that was a direct fit and I’m maxing that out..the methanol kit was added as an extra boost to reliability as it cools the inlet charge down even further and improves emissions and MPG..It also added a further 19BHP and around 40-50ftlb of torque...the car is now 239BHP with 435ftlb(not newton metres) of torque..she runs sweet as a nut and even the stock clutch is coping with it!..the reason I know that the stock fuel pump is good for 300+BHP is because I was having fuelling issues and I thought the stock pump wasn’t up to the job so in my search for an alternative I came across a company called AP Diesels who unbelievably have a race car that uses the same engine that’s in my car.he told me that my fuel pump was faulty as he was running over 300BHP with no problems..I sent my pump to them which they then rebuilt and now I have no fuelling issues whatsoever!..and the difference between the stock turbo map and what she is now with the hybrid is incredible..my friend has got the same car with just a good dyno map with no other mods and it’s ridiculous how easily I just pull away from him,it’s like he’s got the handbrake on!..lol..
 
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Mk2volvos40derv

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Mk2 volvo s40 2.0d
How did you get on with the dyno results?..
I went to Joe at krypto Mapping in Dundee for a proper custom map and made 200hp & 437nm at only 15psi but the power and revs have been limited by a possible fuel problem, just hits a big power cut and drops everything back after 4k rpm, never had enough time up in Dundee to come up with a proper solution so planning a return trip,

I'm going to assume that the hpfp maybe isn't keeping up very well now because from 1.5k - 3.5k rpm I can't see anything behind me for my healthy black smoke screen then smoke clears up before hitting it's boost/fuel cut so changing as much on the fuel side as I can,
changing the standard fuel filter for a high flow aftermarket one aswell as genuine hpfp and lpfp replacements then back up to Dundee for round 2 and get boost up a bit more until we're back around 250hp and 500-550nm and able to hold boost into it's redline!

I've also had to set up a custom breather system as I've found that these engines breath a bit heavy for the standard system once more boost is added,
Will keep you updated and any input on my fuelling issue would be appreciated as the obd is telling me nothing!

.
 
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Greg1990

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S40 2.0D SE sport
I went to Joe at krypto Mapping in Dundee for a proper custom map and made 200hp & 437nm at only 15psi but the power and revs have been limited by a possible fuel problem, just hits a big power cut and drops everything back after 4k rpm, never had enough time up in Dundee to come up with a proper solution so planning a return trip,

I'm going to assume that the hpfp maybe isn't keeping up very well now because from 1.5k - 3.5k rpm I can't see anything behind me for my healthy black smoke screen then smoke clears up before hitting it's boost/fuel cut so changing as much on the fuel side as I can,
changing the standard fuel filter for a high flow aftermarket one aswell as genuine hpfp and lpfp replacements then back up to Dundee for round 2 and get boost up a bit more until we're back around 250hp and 500-550nm and able to hold boost into it's redline!

I've also had to set up a custom breather system as I've found that these engines breath a bit heavy for the standard system once more boost is added,
Will keep you updated and any input on my fuelling issue would be appreciated as the obd is telling me nothing!

.
I’m smiling reading your post..I had a chronic black smoke issue with my first map but that was a crappy generic map off a laptop!..I also had issues with power cutting above 4000RPM,the power would cut and “engine system service required “ would pop up on the dash but that would reset itself after a mile or so of driving..turned out that the solenoids in the pump were faulty..had the pump rebuilt at AP Diesels which cured that,mine now pulls like a freight train all the way to the redline and the methanol kit just extenuates that!..give Danny a call on 01784 437228,tell him Greg told you to call him..you don’t need an uprated fuel filter..use a MAN or MAYLE,not a CROSSLAND!..those 2 flow just fine...I’m running 28PSI of boost and I’m having a small issue regarding the engines breathing,getting a bit of excess oil blowing past the front seal of the turbo?..I’d appreciate a bit more info regarding your custom breather?..
 
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Mk2volvos40derv

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I thought it would be the pump so will get that changed 1st, I'll be replacing fuel filter with a exile motorsport filter with an fittings as I've already got a few spare ones sitting for my other cars.
I never had that problem, mine was blowing crankshaft seals,
For The breather system I've got a huge 1.2l baffled catch can with 2 x 32mm breathers, I've blanked off the pipe going into the air intake and ran a hose in it's place to the can + the hose from the front of the valve cover and the crank case all ran into the baffled tank,
I had to buy a alloy battery tray to move the battery slightly to fit the catch can in the bay
All equals better breathing and no oil going in my intake and no extra air getting sucked in after the maf sensor so in theory it will help greatly with its fuel/air mix
 

Greg1990

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S40 2.0D SE sport
Thanks for the info..any chance you could post a picture showing how and where you’ve run the hoses + the catch can..cheers.. :)
 

Moosebus50

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London
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Volvo v50 2.0d
I was around the same sort of power you’re running with the stock turbo,the hybrid added around an extra 30 or so BHP.Its not so much maxing the turbo out but AE Turbo’s told me to expect around 220-230BHP..the maf sensor is the weak link.i could only manage to find a 3.1bar sensor that was a direct fit and I’m maxing that out..the methanol kit was added as an extra boost to reliability as it cools the inlet charge down even further and improves emissions and MPG..It also added a further 19BHP and around 40-50ftlb of torque...the car is now 239BHP with 435ftlb(not newton metres) of torque..she runs sweet as a nut and even the stock clutch is coping with it!..the reason I know that the stock fuel pump is good for 300+BHP is because I was having fuelling issues and I thought the stock pump wasn’t up to the job so in my search for an alternative I came across a company called AP Diesels who unbelievably have a race car that uses the same engine that’s in my car.he told me that my fuel pump was faulty as he was running over 300BHP with no problems..I sent my pump to them which they then rebuilt and now I have no fuelling issues whatsoever!..and the difference between the stock turbo map and what she is now with the hybrid is incredible..my friend has got the same car with just a good dyno map with no other mods and it’s ridiculous how easily I just pull away from him,it’s like he’s got the handbrake on!..lol..
Okay mate thankyou for replying, thats awesome news, and okay so technically you could run more without meth if the where a better map sensor, maybe 4 bar, im curious how much info did you manage to get off the bloke who is running over 300bhp. Maybe worth an ask what their using in terms of map sensor, turbo and i presume the internal arnt stock, if they are thats awsome, obviously depends weather they want to tell us haha
 

Greg1990

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S40 2.0D SE sport
You can always run more power at a cost!..the meth kit is a fairly cheap reliable way of adding a bit more..I’m not sure if the race car has forged internals but I do know he is running a big turbo with stock injectors and stock fuel pump..ring AP Diesels on 01784 437228..ask for Vaun,it’s his race car...regarding the map sensor,a 4bar one is easy to come by but you then have to mess about fitting an adapter ..the best uprated direct fit I could find was a 3.1bar..with that I’m getting a good solid 2bar of boost which is plenty..
 

Moosebus50

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Volvo v50 2.0d
You can always run more power at a cost!..the meth kit is a fairly cheap reliable way of adding a bit more..I’m not sure if the race car has forged internals but I do know he is running a big turbo with stock injectors and stock fuel pump..ring AP Diesels on 01784 437228..ask for Vaun,it’s his race car...regarding the map sensor,a 4bar one is easy to come by but you then have to mess about fitting an adapter ..the best uprated direct fit I could find was a 3.1bar..with that I’m getting a good solid 2bar of boost which is plenty..
Okay mate cheers, and i spoke with danny today, what a awesome bloke so helpful and answered all my questions, definitely going with them for my pump rebuild
 

Greg1990

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S40 2.0D SE sport
Okay mate cheers, and i spoke with danny today, what a awesome bloke so helpful and answered all my questions, definitely going with them for my pump rebuild
Good stuff..Danny is a top bloke and that’s why I had them rebuild my pump for all the reasons you’ve stated..you should have mentioned my name as I was only speaking to him yesterday..Vaun who owns the race car is also a top bloke,he was giving me some great advice how to squeeze more power out of the 2.0d engine..it was him that told me it’s a Peugeot engine!..I thought it was a Ford?..lol..I was having serious fuelling issues above 4000RPM,the car would cut the power which led me to believe the pump wasn’t man enough for the power the hybrid was developing..when I got it back from AP and onto the dyno we had absolutely no issues with fuel delivery anymore or since..Glad to help..that’s what this forum is all about..Best £50 you’ll ever spend for a years subscription :)
 

Moosebus50

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Volvo v50 2.0d
Yes its a fantastic forum, i was searching long and hard until i came across this, and yes i mentioned your name he said he spoke to you recently, did you tap the methanol into the intake before the map sensor ? And yeah he gave me some great information regarding fuelling on this engine and that if needed they can bore out the nozzles on the stock injectors but obvs im not looking to run that much power that it will be needed, he couldent give me a price on the pump yet as they need to look at it first but just so i dont run into any issue, think im going to buy a second hand pump send it to him and then fit it, just due to the amount of people that seem to have issues with them it seem like a good thing to do before tuning.
 

Greg1990

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S40 2.0D SE sport
Yes..the injection point is before the map sensor...they charged me £210 to rebuild the pump and I also had them rebuild my injectors at £120 each..not cheap but I was safe in the knowledge that I wouldn’t be having any further fuelling issues...here’s a few pics of the methanol setup..1349C8E8-4213-433C-8AAE-4825023A02F8.jpegBF4F2CAD-521B-4F17-9F60-C90BE3D04B25.jpeg9A8F601A-61A8-4BE9-BA8B-2BCBF77354FE.jpeg
 

Moosebus50

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Volvo v50 2.0d
Yes..the injection point is before the map sensor...they charged me £210 to rebuild the pump and I also had them rebuild my injectors at £120 each..not cheap but I was safe in the knowledge that I wouldn’t be having any further fuelling issues...here’s a few pics of the methanol setup..View attachment 8186View attachment 8187View attachment 8188
Okay mate thats spot on, are they custom hard pipes or are they of the shelf of a different car
 

Greg1990

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S40 2.0D SE sport
Everything is custom..hand made by mate who specialises in making one off stainless exhausts..most people opt for an intercooler that’s for the MK2 Focus ST as they are more or less a direct fit but we went for a much larger Nissan skyline GTR upgrade which didn’t need to much fabrication work..it covers the full width of the car and is visible from the bottom of the bumper grill upto behind the bonnet grill..
 
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