How to tune a 1.9 T4 in 2020?
 

Hello, how are you doing?
After some hunting, I am about to finally pull the trigger on my first Volvo.
I am looking at a 1998 S40 T4 with the 1.9 engine.

The car looks to be in good shape, especially for its age.
It has been taken care of and maintained and does not have a very high mileage.

If I do get the car, I will first have it serviced and see if there is anything that needs replacing.

Then, if everything checks out, I will be looking at getting some more extra horses from the engine.

I will not want to open the engine and do a crazy build.
So internals are to remain stock.
Besides down pipe, exhaust, remapping and maybe either a bigger turbo or a hybrid stock one, I would not be looking at doing much more.

I find some information about mods and tuning for these cars, but most of it is from around 2005 or 2006. And we all know that engine tuning has come a long way since then.

So I am looking if there are some upgrades and some guides that are more current and up to date on what to do the engine while remaking on stock internal to get a good and reliable power boost.

Also, how are the stock brakes and suspension?
And does the gearbox hold up to more power?
Are there any LSD units that are plug and play from other models? Or is an aftermarket one like a Quaife the only option?

Thank you for your help.
Best regards

Tuning hasn't changed :-) Just raise the boost a little . The Transaxle is from the 850 T5 , very over engineered .

From what I read online, the stock turbo is not enough for increase power close to the 300hp.

A popular solution seems to be to hybrid the stock turbo to a 16g compressor.
Is this the best way to go turbo wise? To avoid having to use a a different turbo manifold.

Also, an exhaust setup is also a must.
Are there any full exhaust with down pipe that are good?
Or do I need a custom one to be made?

So the basic here is hybrid turbo, downpipe, exhaust and have it custom mapped.

Do I need to swap injectors? If so, to which ones?
And with new injectors, is a new fuel pump necessary?

Anything else needed?

Thanks.

Yeh a hybrid turbo would be a good way to go to get an extra bit out of that turbo ... but unsure if you will hit your desired 300bhp band with a hybrid? sounds like you might need a bigger turbo. I dont really know much on these cars, they are the 200bhp?

As you mentioned a full exhaust system is a must, an I would probably go for a custom system. Get it made to how you would like it.

I cannot say anything on the injectrs / fuel pump as I dont know their limitations. Just modded my S40 T5 from around 290bhp to hoping 400+bhp but upgraded the injectors and fuel pump as well. I know the factory fuel pumps could be could for a lot more but how long it will last, will be another question.

Probably another thing to think about is your handling, hunting big gains without tackling the handling problems will make it worse to drive.

Few other things to think about:
- Limited slip diff
- Wider tires
- Coilovers (to help cornering and control the body of the car)
- Bigger brakes

You should probably do some research into your block \ pistons and rods? and its safe limits?

Try posting in the below area

https://www.volvoforums.org.uk/forumdisplay.php?f=17

These guys should know more about your car and engine, quite a few T4 owners there that have modded their cars.

if i still had my T4 it would now have a Microsquirt standalone on it

the siemens ecu removes all opportunity to map it as nobody really bothers with them

get a gt3076, some 750cc injectors and send it