Seen a reply to this for Jacq's T4 on the first page in 2005 but no idea if I ever added a second once the car was "finished" (its never finished lol) so here goes and apologies if its a repost.

CURRENT SPEC OF CAR

ENGINE

2.0 16v Turbo S40 T4
Rebuilt bottom end with replaced liners
Forged Pistons
Forged Con Rods
ARP Conrod Bolts
Kent Cams repfrofiled OE Camshafts
GT3076R Turbo at 1.7 BAR boost
Meercat Custom Tubular Exhaust manifold and full exhaust system inc external wastegate piping
Tial External Wastegate
MBC Boost Controller
Pipercross Cone filter and BSR Cold Air enclosure
Custom modified Fuel system to incorporate return line and adjustable fuel pressure regulator
RC 750cc Fuel Injectors
MTE Custom on the road mapping
Custom Modified Crank Case Ventilation System incorporating external catch tank
Forge Motorsport Front Mounted Intercooler (dimensioned by Ross9)
Free-Flow Custom hard intercooler piping
Aquamist Water Injection (fitted but not yet functioning)

BRAKES

EBC Dimpled and Grooved Discs
Ferrodo Premier Pads
Dot 5.1 Fluid

TRANSMISSION

SPEC uprated paddle clutch
Quaiffe ATB Differential

SUSPENSION

KONI suspension kit with adjustable dampers and lowered springs
Rear Strut brace

STYLING

Aftermarket grill
Removed front splitter (via unfortunate feline incident)

INTERIOR

Boost guage

Does anyone with an s40 t4 run a billet fuel rail.?

No S40 T5's here so I thought i'd drop mine in.

2009 S40 T5 R Design

Current Mods
- K&N AirF
- Jetex exhaust system
- Superchips Remap
- Gates Performance Kevlar Timingbelt
- E-Focus Low Vib Torque mount

On the list this year
- D088 Performance Intercooler with pipework
- Turbo Intake Pipe (Not sure which one yet)
- Not 100% sure on Turbo yet but have been looking at Hybrid Turbo charger K16 / K04

Only performance gains this year ... next year will be ride and handling :thumbs_up:

Volvo 855
Two T5 engines, one 2.4 and one 2.3
two gt35 turbos
two eaton m45 turbos
Coilover suspension all round
380mm carbon ceramic disks with 6pot front and 4pot rear calipers
electric handbrake calipers
V70R front panels
wide arch kit
active aero front and rear.

2004 V50 T5

Stopping:

Black Diamond 320mm 6 groove disks
Tarox Pads

Handling:

IPD rear anti-roll bar (highly recommend)
Bilstein B4 shocks
Eibach Pro Springs
Meile Heavy Duty front anti-roll bar drop links
Goodyear Eagle F1 Tyres (215/45 R17)

Performance:

DO 88 intercooler (big difference)
Custom 2.5" stainless cat back exhaust
Auto Specialists Intake Manifold
IPD Turbo Control Valve
Shark Stage 1 Map (massive difference)

Transmission:

E-Focus Lower Torque Mount
Focus RS Clutch and Dual Mass Flywheel

Styling:

Custom mesh front grill with Volvo slash
Sport front and rear lower bumper trims
Custom 'R Design' mirror caps
Facelift rear badge lettering
LED number plate lights
Prancing Moose Badges (20bhp!)
Facelift interior console drinks holder
Silver brake calipers


Gets addictive doesn't it?

Nice list .... just looking at the D088 intercooler, what big difference did you get from this? are you looking towards that block shimming that everyones going on about if you want anymore out of it?

S60R TWR Modifications
 

Thought I'd update my car mods since my last post back in 2005! and also give something for IC to get excited about :o)

Well the S70R went and was replaced with a brand new 2006 V70R, that went in 2010.
leaving an itch and a feeling of unfinished business, a 2007 S60R in Sonic blue was acquired in 2014. The following has been installed or retrofitted.

Active Bi-Xenon with washer jets
Volvo sport body kit
Volvo Challenge series rear wing
Volvo Pegasus 18x8” with
Michelin Pilot sport cup 2 235/40R18
Or Bola B8R 18x8.5” with
Dunlop racing slick 245/640R18
AP Racing CP5555 6 piston brake Calipers, with 2 piece 362mm floating J-Hook discs front. Std Brembo 4 piston brake caliper with 330mm 2 piece J-Hook discs rear.
4C software uninstall with KW V2 Coilover suspension, iPD Track spec anti-roll bars front and rear. Powerflex Black bushes.
2521cc engine block, shimmed. MPRE O/S Solid engine mount. ipD gearbox tie bar.
2000 R exhaust manifold with Garret GTX3071R Gen 2 Turbo. TiAL Wastegate actuator.
Custom 3” downpipe with divorced wastegate flange, 100 CEL FIA race cat, modified TME Sport Exhaust system.
Audi V8 MAF with custom 3.5” air intake.
750cc Bosch motorsport EV14 fuel injectors
NGK Racing spark plugs
AEM 500cc Methanol Injection
iPD air charge hoses, Forge recirc valve.
Tim Williams Intercooler, D088 Radiator,
Laminova engine oil cooler, 2.9 T6 Oil Pump.
All oils now Ester based for pressure & heat. Millers, Motul & Redline.
Solid engine mount, Solid subframe bushes.
Quaife Front Diff, AP Racing Clutch, Kalmar union solid flywheel. Snabb short shift.
Custom Haldex Software for more rear drive.
Defi aux gauges. Boost, EGT, Engine Oil Temp & Pressure.
Currently 445hp 468lbs-ft

Wow, that's an impressive list and figures, 445!!

I may be back here updating like that in a few years, if the Mrs and bank manager dont get wind of my ideas lol.
After about 2 months of ownership of my 2004 S60 2.0t s heres a list of what I've done, (not all mods but make it feel like a race car compared to when I bought her)

Repair power steering leak
Replace top strut mounts
Replace front wheel bearings
Pirrelli tyres
Dechromed and debadged Matt black front grille
Matt black Thor wheels
Custom matt black Headlamp eyebrows
Yellow Calipers
Black sunstrip
Tinted tail lamps
Straight thru exhaust
Ramair induction
Boost gauge
Heko wind deflectors.

I feel theres more, but there is definitely updates to come anyway, needs to be lower!

Hybrid turbo - not sure what he did to it (bearings and bigger billet wheel I think)

Flux fabrications exhaust with 3 inch down-pipe

Bigger injectors

Custom air intake (again - unsure what he did - has a big piece of metal in engine bay that wasn't there before) - I did have a big plastic tube over the engine that is now made of metal

I have a big cone filter thing and an upgraded MAF

I have a large intercooler at the front of my car and unsure what it does but it is shiney and has lots of shiney black tubing

A Gripper plate limited slip differential - it makes noises occasionally when I go around corners

An S60R clutch has been fitted

The engine has been tuned - a lot, given the invoices I paid

A Stage 0 before any work was carried out which involved, essentially, rebuilding the whole car - some idiot had smashed out the LEDs on the DIM to hide the error messages, the CEM was knackered as another idiot had not reconnected a water washer tube, timing belt and water pump was done, most of the suspension replaced, ABS module...list is endless.

Uprated fuel pump

Just put on some 18 inch Eudora alloys with Michelin PS4s

2004 s60r

Month old forged pistons and rods
Block shimed
Snabb front brace
Snabb oversized ic and pipe work
Full 3 inch custom exhaust, race cat no silencer
Turbo diverter valve
Heavy duty boost control solenoid
Gustave stage 2 map.

In planning

Hi flow fuel pump
Bigger injectors
The biggest turbo I can cram in realistically
Said turbo modified by turbo dynamics
Water meth injection
Custom remap

In my dreams but will be needed

Sleeved block