S40 T5 sleeper project

_Tom · Jan 13, 2015

Chrisgti6 said:
Heat rises though, so it stays pretty cool, that's the standard pipework route. Also it's pre intercooler so doesn't really matter. I've checked and my intake temps are nice and low (last time i checked it was 6 degrees ambient and 9 degrees intake, so working well!)

Yeah I have no doubt that Volvo have gone for the best/easiest route but also being safe. I'm guessing with that big 'ol lump there isn't much room to play.

Chrisgti6 · Jan 13, 2015

TomSx said:
Yeah I have no doubt that Volvo have gone for the best/easiest route but also being safe. I'm guessing with that big 'ol lump there isn't much room to play.

Its the same in the Focus ST & RS too, it follows the exact same route so it's pretty tried and tested.

philmots · Jan 14, 2015

Chrisgti6 said:
Not as much as you'd think

Downpipe & decat £400
Intercooler £250
Remap £400
K&N air filter £40
Brakes £350
Pipework £400
I've done all the work (apart form the mapping) so no labour costs so has cost £1,840

That means the car stands me at £5,840 which for 300hp and 350lb-ft of torque, and the level of comfort it gives, plus all the toys I really can't grumble at. Also - it costs no more to run or maintain than your average ford focus (well, apart from fuel costs) parts etc are all dirt cheap. There's not much for 6k that offers the same as I get from this car (that i'm aware of)

That's not too bad really..

Only way you could go faster for cheaper with comfort is buying a £3k 9-3 2.8T and banging a map in it and go straight to 300hp and 400lbft, or maybe a Vectra VXR with same engine but they're a bit chavy.

thedjse · Jan 14, 2015

Nice work matey, love the sleeper look

Chrisgti6 · Jan 14, 2015

philmots said:
That's not too bad really..

Only way you could go faster for cheaper with comfort is buying a £3k 9-3 2.8T and banging a map in it and go straight to 300hp and 400lbft, or maybe a Vectra VXR with same engine but they're a bit chavy.

I did look at the Saab's before I bought this (no chance I was going to look at the Vectra!) but once I looked at parts prices, tax, etc etc I just couldn't buy one. I'm not a big fan of how they look either, I much prefer the S40 in the looks department personally.

philmots · Jan 14, 2015

Yeah, i prefer the Volvo tbh, specially in V50 guise!

Chrisgti6 · Jan 14, 2015

philmots said:
Yeah, i prefer the Volvo tbh, specially in V50 guise!

I've just managed to talk my dad into a v50. He's bought a lovely dark blue D5

Chrisgti6 · Jan 15, 2015

OK - quick update. I wasn't happy with how one of the intercooler pipes was sitting. As i'm not running the std intercooler (or one specificly for my car) one pipe was slightly too short meaning it was on at a funny angle.

I ordered 1m of 63mm silicone and had a spare 90 degree bend so had a go at re-routing it. It shouldn't be a problem now!

Much happier with how it is now, so shouldn't experience any issues.

Chrisgti6 · Jun 17, 2015

It's a long time since i've updated this thread - nothing much has changed this year, been busy with the little one she's just coming up for 8 months old now and loves to drive my car:-

The car has been perfect for the last 6 months, giving 24mpg average and lots of smiles. No more issues with boost pipes, and aside for a small issue with the passenger side window motor (that took 30 mins to fix) I've had no issues.

I've had the opportunity to have a play with a few motors recently, the few that pop into my mind are an M135i, Mazda 3 MPS (a colleagues) and a 1999 911 Carrera - all of which felt the wrath of the Lolvo - much to the dissapointment of the owners.

I love this car. It's rare for me to still love a car 12+ months after buying it, but everytime I drive this car is like an event. It's got so much character. This wife has started to relaise that's it's not 100% as I bought it. For a start the exhaust now has a habit of cracking at low speeds, usually as you pull off from a set of lights and change first to second. Just as the revs drop to about 1500rpm - pop. I've used it to sow the seed that the exhaust will need to be changed in the near future.

I think it will stay as it is now for maybe another 12 months, then i'll be looking into a K16 turbo and aiming for 400+ bhp.

_Tom · Jun 17, 2015

Remind me, what power is it running now?

Chrisgti6 · Jun 17, 2015

TomSx said:
Remind me, what power is it running now?

I've not had it on the rollers again since it ran 282, but with the new pipework and relocated ecu I suspect 290-300. I could definitely feel a difference anyway!

BoatNonce · Jun 17, 2015

Chrisgti6 said:
I think it will stay as it is now for maybe another 12 months, then i'll be looking into a K16 turbo and aiming for 400+ bhp.

Subbed. Because it's my plan too, albeit with a C30.

What are you budgeting?

Chrisgti6 · Jun 17, 2015

McGherkin said:
Subbed. Because it's my plan too, albeit with a C30.

What are you budgeting?

£1500 should do it, if I can pick up a turbo cheaply. If I have to buy new then £2k. Should be good for 400 - 440bhp and 400blft+

Quick vid of the exhaust note

BoatNonce · Jun 17, 2015

Vid doesn't work.

I'm budgeting a bit more than that, lol. More like 8k. But then that's from totally standard.

Chrisgti6 · Jun 17, 2015

Video fixed!

Nah, nothing like that sort of cost. It's taken about £1500 to get where I am. All I need is turbo and injectors then a map. Everything else is good to go.

BoatNonce · Jun 17, 2015

You don't need to upgrade the inlet manifolds then?

Also have you fitted the uprated Torque mount?

Chrisgti6 · Jun 17, 2015

McGherkin said:
You don't need to upgrade the inlet manifolds then?

Also have you fitted the uprated Torque mount?

Ideally yes, I'll change the inlet to a metal one, but they aren't all that expensive.

I've got the powerflex insert for the torque mount, a common upgrade is the efocus mount from the USA

BoatNonce · Jun 17, 2015

Tidy. I'll be running standard power for a while until the insurance is happy so chances are you'll go down the K16 route before me, so I'll be keeping my eyes on this thread

charltjr · Jun 17, 2015

What about getting the liners shimmed, is that part of the budget?

Nice car

Chrisgti6 · Jun 17, 2015

charltjr said:
What about getting the liners shimmed, is that part of the budget?

Nice car :smile:

Shouldn't need it done really, it seems to be that only badly mapped cars are cracking liners. That said, I'm still contemplating doing it when I come to do the belts, the kit is only a couple of hundred quid for the belts and the shins etc.

charltjr · Jun 17, 2015

Fair play, I think it would always bug me if I was taking one to that sort of power level but I'm not very up to date on the latest thinking in tuning the 2.5T engine.

I love a Volvo sleeper, I've had a few tuned T5 ones over the years and they are great fun in an "I really shouldn't be able to do this in a car like this" way for not much money.

BigDaveRotary · Jun 18, 2015

The current feeling on shimming the head is (on FocusSTOC)...... if you need belts anyway it just makes sense. If not, then just roll the dice to see if you are one of the few that will go.

Cracked liners seems to affect standard as well as mapped. Basically a lottery!

Chrisgti6 · Jun 18, 2015

BigDaveAMG said:
The current feeling on shimming the head is (on FocusSTOC)...... if you need belts anyway it just makes sense. If not, then just roll the dice to see if you are one of the few that will go.

Cracked liners seems to affect standard as well as mapped. Basically a lottery!

That's my thinking, i'll be doing the belts at some point anyway, so it's not much more of a job to whip the head off and drop the shims in. The kit's abpout £350 I think, and that's with OEM belts, gaskets etc so not bad really. Unless I can just get the shims from somewhere? Not really looked into it too much yet.

BigDaveRotary · Jun 18, 2015

I haven't seen anywhere that just sells the shims. They seem just to be cut from some sheet metal anyway!
My belts are due by next year, so I will take mine to Tim Williams near Leicester to go. He charges £550 all in at the moment. Which is the best price around I think.

charltjr · Jun 18, 2015

Tim is the man for that stuff, no doubt about that.

Chrisgti6 · Jun 19, 2015

Here's a very quick video of what the exhaust is doing. Only when it feels like it, and it's only as it drops back down from 2000 revs, it pops at about 1500 revs.

There's one thing though, at least i'vew not had to choose a 'pop's and bang's' map for this to happen, it's just a by-product of the tuning i've done!

This is in works carpark, with my phone out the car window:

Chrisgti6 · Jul 15, 2015

1 very small update - i've pranged it! lol

Backed into a metal gate, in my defence i've never known this gate to be closed and it's at a funny height. I couldn't see it in my rear view and the parking sensors didn't pick it up!

No big deal, just needs a boot lid - i'm keeping my eye out on eBay for one in the right colour.

Also, i've had to switch the brakes back to the original 300mm setup. Something very odd is going on with the ST calipers, they are killing brake discs within 2- 3 weeks of being fitted. I can only assume that one of the calipers is perhaps bent or something.

BoatNonce · Jul 15, 2015

:frowning: What the hell did you do that for? Bumper looks a little dented too.

Was hoping for boostings updates.

Chrisgti6 · Jul 15, 2015

It's just a reflection, the bumper has escaped unharmed thankfully!

philmots · Jul 17, 2015

Still like this car, I've just found this video of a mate driving my old S60 2.4 T5..

th_124A5460-127A-4395-8B2F-2A47BA49FC67_zpsr7npqddd.jpg

How does yours compare? I always thought it went well for just a remap..

Chrisgti6 · Jul 25, 2015

Another video of th random exhaust popping!

philmots said:
Still like this car, I've just found this video of a mate driving my old S60 2.4 T5..

How does yours compare? I always thought it went well for just a remap..

No idea to be honest, it's not really easy to time from videos.

It goes well though!

BoatNonce · Aug 3, 2015

Did you get the EML on when you decatted it?

Chrisgti6 · Aug 3, 2015

McGherkin said:
Did you get the EML on when you decatted it?

Yes, but only after a couple of days. My remap took care of that though.

BoatNonce · Aug 3, 2015

That's fair enough then.

Looks like a trip to Shark is in order!

Jekyll · Aug 23, 2015

I like this car/thread, makes me want a Volvo. Loving the look of them lately, especially v50's.

Chrisgti6 · Aug 23, 2015

Dr Jekyll said:
I like this car/thread, makes me want a Volvo. Loving the look of them lately, especially v50's.

Thanks!

My dad has a V50 D5, I only bought it because of my S40.

They're so cheap for what they provide, very little else in this price range gives the same amount of comfort, performance and reliability!

So, im planning on upgrading the suspension in the near future, but I don't want to lower it - any suggestions anyone? Was thinking of maybe some Bilstein B6's or Koni FSD. What other option do I have?

Also - brakes. The ST brakes weren't really an upgrade. Other than the slight increase in disc size, they were no different. Same piston size etc. if being used for track work I could see them being beneficial as the calipers was much bigger - making them better at dealing with heat, but for general road work they are a pointless upgrade.

I've found a guy selling a conversion letting me run 336mm Focus RS discs and 4 pot brembo's from a 7 series (E38) BMW. It's a cheap upgrade, coming in at under £500 for everything, but I don't know much about the calipers, are they any good?

Any help would be greatly appreciated!

Jekyll · Aug 23, 2015

Why not get the wilwood kit you posted for the same kind of money?

Chrisgti6 · Aug 23, 2015

Dr Jekyll said:
Why not get the wilwood kit you posted for the same kind of money?

I've since done my homework properly, by the time I add postage, import taxes etc it works out about £800 so is a no go unfortunately

BoatNonce · Aug 23, 2015

Try the Elevate 6 pot kit, silly expensive!

https://www.elevatecars.com/vehicle...vo-s40-performance-complete-brake-system.html

Mr R. · Aug 23, 2015

Hi-spec?

Although i thinks its going to be another expensive option

S40 T5 sleeper project

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