Volvo S40 2.0d tuning project

[Greg1990]

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

 

[Greg1990]

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..

 

[Mk2volvos40derv]

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!

.

 

[Greg1990]

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?..

 

[Mk2volvos40derv]

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]

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]

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]

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]

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]

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]

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]

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..

 

[Moosebus50]

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]

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..

 

[Moosebus50]

Okay mate, yeah i currently have a standard focus st intercooler but ive ordered at stage 2 airtec intercooler and will be getting new hoses from d088 intercoolers as they have direct upgrade hoses for the 2.0d engine, regarding the hardpipes ive bought spare ones to send of to make larager new ones as they look fairly restrictive, spoke to AET turbos and they said they can build one, speced to a 1756 with all the gaskets and hardware for £679 inc vat and postage which seems like a decent price, dont even have to send them a standard one, they build one for that price, happy days.

Regarding engine mods currently have

Srj ejr delete
Standard st intercooler
Pipercross panel filter
Stage 1 remap 182hp 412nm

Mods for hybrid tune

Srj ejr delete
Pipercross panel filter
Airtec stage 2 intercooler
1756 hybrid turbo
Do88 hoses, custom hard pipes
3.1 bar map sensor
Custom turbo back exhaust(straight pipe)
Heat wrap down pipe
Reflective wrap for the hard pipes

Possible catch can set up due to reading about them breathing heavily.

Think thats all i should need ?

 

[Greg1990]

AE Turbo’s built mine..it was £595 in April but I picked it up as I only live 7 miles away...have you not had the DPF chopped out?...you’ll basically have the same mods as me when you’re finished...I opted for the K&N panel filter but I’m sure they are the same...I’ve got a custom stainless exhaust and at first went straight though with no silencer..sounded awful so we put a single box in the middle and now it sounds awesome under full throttle but subdued when just driving around normally...

You’ve probably seen my stats further up the thread...she doing 239BHP with 435ftlb(not newton metres)of torque..she’s pretty rapid..lol

 

[Moosebus50]

AE Turbo’s built mine..it was £595 in April but I picked it up as I only live 7 miles away...have you not had the DPF chopped out?...you’ll basically have the same mods as me when you’re finished...I opted for the K&N panel filter but I’m sure they are the same...I’ve got a custom stainless exhaust and at first went straight though with no silencer..sounded awful so we put a single box in the middle and now it sounds awesome under full throttle but subdued when just driving around normally...

You’ve probably seen my stats further up the thread...she doing 239BHP with 435ftlb(not newton metres)of torque..she’s pretty rapid..lol

Okay mate and mines the model that didnt come with a dpf so i dont have to mess about their and yeah i did look at the k&n filter but i heard the maf doent like the oil the filters have in them, and yeah i have considered leaving the rear box in place i did have it so it had no silencer but still had the cat and i didnt like the noise it made. Is yours 2.5" from the turbo back, as i have just though about doing either 2.5 or 3" decat and leaving the rest of the exhaust stock diameter

 

[Greg1990]

Mines 2.5” from the turbo back...my pal who builds the exhausts says you only need 3.0” if you’re running over 500BHP!...

 

[TCJBOLDIE]

Sorry dad..lol..and I’m 48

That's the same age as my youngest child

There is a bit more power to be gained if an even larger turbo dump pipe can be fitted as am sure you know that turbos love as close to zero back pressure as possible.

People often make statements re exhaust diameters without hard evidence.so you may find this interesting.

http://www.superstreetonline.com/how-to/engine/modp-1102-exhaust-test-tech/

 

[Greg1990]

You started young then.. anything above 3.0” in diameter isn’t popular as you can’t bend the pipes in a pipe bender. Each bend has to be created by cutting the pipe into sections then tig welding them back up..laborious and expensive..

 

[TCJBOLDIE]

My exhaust system in my old car was formed using mandrel bends which is to my mind way better and less labor intensive and expensive than using the lobster back method you described. Press bending reduces the efficiency / diameter of any exhaust system.

https://www.google.com.au/search?sxsrf=ACYBGNTAv7snrkJ2TyVtAbLTd18OIMm98g:1576099273609&source=hp&ei=yV3xXerdIrnE4-EPxauNsAQ&q=mandrel+bends&oq=mandrel&gs_l=psy-ab.1.2.0i131i67j0i67l8j0.764.5050..10356...1.0..0.189.1168.0j7......0....1..gws-wiz.......35i39j0i131.UJ2XfsnmLhc

Lobster back welding pics for clarification

https://www.google.com.au/search?q=lobster+back+welding&sxsrf=ACYBGNSRXWhJMog9CEvnZu0dQIs9HQYCVQ:1576099594892&tbm=isch&source=iu&ictx=1&fir=ubVLn6IbNmlnWM%3A%2CxlEoTlAFMbCOqM%2C_&vet=1&usg=AI4_-kSdO5ZpUNuDhq_EslAeKRyBwflNiw&sa=X&ved=2ahUKEwjbte_DxK7mAhXj6nMBHdbpA68Q9QEwAXoECAcQHg#imgrc=ubVLn6IbNmlnWM:

 

[Greg1990]

That was my point..few can bend diameters 3.0” and above efficiently without crimping the tube,that’s why large bore exhausts are Usually lobster back welded which in turn leads to high cost..

 

[TCJBOLDIE]

In my experience lobster back bends are eye candy and are mainly seen on show cars to add bling and gain brownie points. Just thinking out loud

PS don't get me wrong as I love examples of excellent workmanship

 

[Greg1990]

Whenever he’s making exhausts with a 3.0” bore and above he lobster welds the bends but he has jus bought a bending machine with a 3.0” die but he’s unsure how well it will create the bends without crushing the pipe?..

 

[TCJBOLDIE]

If he has only bought the basic bender that all exhaust shops have then he has no chance BUT if he has bought a MANDREL bending machine like the one in the video then he will be able to bend various diameters without reducing the internal diameter like a press bender does.

 

[Greg1990]

That’s the one I think he’s just bought but he is still a bit dubious of it making good clean bends on tubes larger than 3.0”?...to be fair though,he specialises in making bespoke stainless exhausts so I reckon he knows what he’s on about..I’m not going to tell him any different..lol..

 

[Moosebus50]

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

Hi mate would you be able to post a picture of where you have routed the pipes from the engine to the catch can, thankyou

 

[Greg1990]

I’ve also asked him moose but I’m not sure if he can upload pics yet being a newby?..

 

[Mk2volvos40derv]

Hi mate would you be able to post a picture of where you have routed the pipes from the engine to the catch can, thankyou

Unfortunately no I cannot upload photos onto here due to the strange rules! my engine bay is looking pretty one off atm it's a shame I can't upload

 

[Greg1990]

You have to make so many posts,10 I think before you can upload pics?...me and my tuner are getting our heads together tomorrow with a view of installing a catch can setup..any advice?..

 

[obi_waynne]

Unfortunately no I cannot upload photos onto here due to the strange rules! my engine bay is looking pretty one off atm it's a shame I can't upload

Sorry about that, we had so much trouble with spammers and problem image uploads and it all went away when we put this rule in place. You are nearly there! We just wanted to stop the minority from spoiling things for the majority.

Hot polls is a great place to bump up your post count quickly.

 

[Mk2volvos40derv]

You have to make so many posts,10 I think before you can upload pics?...me and my tuner are getting our heads together tomorrow with a view of installing a catch can setup..any advice?..

Just Go for the biggest can you can fit in, i went for a twin breather setup to get more out, and 1st i had a open can and it made my bay oily so i changed to a baffled can and minimum oil escapes now so that's recomended,
looking at the photo of your engine bay i doubt you'll fit a can my size in without making changes, best advice is Just get it as free flowing as possible

 

[Greg1990]

My friends drift car has a catch can fitted and that’s a 500ml one which he says will be more than adequate for mine..been looking in the engine bay today and we’ve found a nice spot to the left of the batterie where it will sit nicely..just ordered all the bits so should be here in a few days...

 

[TCJBOLDIE]

You will need a proper oil air separator if you are hooking it up to the inlet manifold/tract.

 

[Greg1990]

Blanking the inlet manifold off and running the breather from the sump/head to the catch can and catch can filter...

 

[thexav]

Thanks for taking the time to share these tips, been reading this thread with interest.

 

[Greg1990]

This is a great forum and I’ve received many many invaluable tips myself which led me to firstly making a £10 donation then becoming a full member for 12 months...can’t believe this thread has had over 2000 views..I’ve modified my car far beyond what Volvo would ever had imagined and she’s still going strong....

 

[obi_waynne]

Your donation helped cover the cost of the forum software upgrade, so thank's to your support in word and deed we have been able to improve the site and keep it going from strength to strength.

 

[Greg1990]

No worries Waynne..liking the look of new layout

 

[Greg1990]

just installed the new oil catch can...