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S40 T5 sleeper project

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

FE6B3426-1AAF-4287-B51A-235B00069800_zpsthcrxqa5.jpg

B86B6A27-C15A-4094-8268-1899FD0E6761_zpsf2qry2vd.jpg


Much happier with how it is now, so shouldn't experience any issues.
 
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:-
71A2D338-81BC-471A-8E1B-7AD5CFC435A4_zpsdusi9znp.jpg


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

What are you budgeting?
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£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

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

Also have you fitted the uprated Torque mount?
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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
 
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 said:
What about getting the liners shimmed, is that part of the budget?

Nice car :smile:
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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.
 
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.
 
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!
 
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!
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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.
 
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.
 
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:

 
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.

DF68D69C-8419-44EC-BEB0-123D88A39EFC_zps94updpzl.jpg


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.
 
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..
 
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..

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


How does yours compare? I always thought it went well for just a remap..
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No idea to be honest, it's not really easy to time from videos.

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