Volvo S40 2.0d tuning project

Moosebus50

New member
Points
13
From
London
Car
Volvo v50 2.0d
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

Torque Junkie
Points
292
From
Pontefract
Car
S40 2.0D SE sport
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
 
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Moosebus50

New member
Points
13
From
London
Car
Volvo v50 2.0d
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

Torque Junkie
Points
292
From
Pontefract
Car
S40 2.0D SE sport
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

Torque King
Points
652
From
Brisbane
Car
JB Starion
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Greg1990

Torque Junkie
Points
292
From
Pontefract
Car
S40 2.0D SE sport
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..
 

Greg1990

Torque Junkie
Points
292
From
Pontefract
Car
S40 2.0D SE sport
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

Torque King
Points
652
From
Brisbane
Car
JB Starion
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 |B
 

Greg1990

Torque Junkie
Points
292
From
Pontefract
Car
S40 2.0D SE sport
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

Torque King
Points
652
From
Brisbane
Car
JB Starion
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

Torque Junkie
Points
292
From
Pontefract
Car
S40 2.0D SE sport
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

New member
Points
13
From
London
Car
Volvo v50 2.0d
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

Torque Junkie
Points
292
From
Pontefract
Car
S40 2.0D SE sport
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

Administrator
Staff member
Moderator
Points
887
From
Deal, Kent UK
Car
A3 1.4 TFSI 150 COD
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

New member
Points
11
From
CumbriaUK
Car
Mk2 volvo s40 2.0d
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

Torque Junkie
Points
292
From
Pontefract
Car
S40 2.0D SE sport
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...
 

Greg1990

Torque Junkie
Points
292
From
Pontefract
Car
S40 2.0D SE sport
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..:)..
 
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obi_waynne

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Points
887
From
Deal, Kent UK
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A3 1.4 TFSI 150 COD
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