Pyaap's T4: Featured Modified Car No6

[IC]

I bought my T4 new and merely weeks into ownership decided that the car could do with a little more “poke”. All my previous T4s had TME ECU upgrades, which I had been extremely happy with, so choosing a tuner was easy, but this time I decided it was going to go a little further than something ‘simple’ like an ECU remap. I got in touch with Don Norchi from Kalmar Union and Stuart Williams from SW Autos and have been slowly developing the car with their assistance eversince. The car is currently running around 310bhp and 450Nm and the next stage of planned modifications will hopefully take her closer to the 400bhp barrier! 

The Car
V40 T4 SE Sport Manual
Peacock Green / Blue with Black Leather and Dark Wood
Winter Pack (Headlamp Wash/Wipe & Floor Carpets)
Family Pack (Double Integrated Rear Child Seats and Remote Child-Lock Button)
Estate Pack (Roof Rails, Luggage Net and Self-Levelling Rear Suspension)
Factory Lowered Sports Chassis (incl 19mm Rear Anti-Roll Bar)
Electric Front Seats (Driver & Passenger)
Factory Reversing Sensor
Factory Xenon Headlamps (dipped) and Volvo Gold Bulb Upgrade (high-beam)
17” VIP (OZ Racing) Alloy Wheels (8Jx17; 225/35ZR17 Bridgestone SO2 Pole Position Tyres)
Electric Glass Sunroof
HU-1205 RTI Navigation System with latest 2005 Software Upgrade
Volvo Special Vehicles Program Side Marker Lights
Volvo 10-Disc Boot Mounted CD Changer
Volvo Nokia Handsfree Preparation (with integrated microphone and speaker in driver’s headrest)
Volvo Anti Theft Alarm Upgrade to include Level Sensor and Auto-Arming

Engine / Tuning
MTE Custom ECU Remap
3" Ferrita Downpipe with Kemira Race CAT
2.5" CAT-back through HKS ‘Hiper’ free-flow Muffler
Aquamist Water Injection System 1s
Volvo OEM Front Strut Bar
Custom MTE Larger Intercooler
Volvo TD04-19T Turbocharger
Custom S60R Exhaust Manifold
Walbro High-Pressure 280 L / h In-tank Fuel Pump
High Impedence / Saturated 550cc/min Fuel Injectors

Suspension / Handling / Brakes
Koni Yellow (Sport) Adjustable Front Shock Absorbers
HiSpec Motorsport 6-piston front brakes, 335x32mm with Ferodo DS2500 pads
EBC Redstuff Ceramic Rear Pads
Goodridge Stainless Steel Brake Hoses
17” VIP (OZ Racing) Alloys
225/35ZR17 Bridgestone SO2 Pole Position Tyres

Interior Upgrades & Misc.
Pentagon ‘Supaglass’ Security Film with Front Sun Strip
Volvo Individual Program Alloy Foot Pedals
Defi-Link BF Series Electronic Boost Gauge
Innovate XD-1 Pre-CAT Wide Band Air-Fuel Gauge with full Data Logging
OMEX Sequential Shift Light
Broquet in-tank Fuel Catalyst


Future Mods to Include..
Fully adjustable suspension
Garrett Turbocharger
Hi performance clutch / Limited slip differential

[Rooster]

Bet thats not shy

Like the brakes are they a custom job or do high spec do a kit for s40

[pyaap]

Hi,

The brakes are a development kit which was done in conjunction with SW Autos. They are still undergoing extensive testing so I'll post back with my impressions of how they perform (both or road and track) once I've finshed putting them through their paces.

One thing I will mention now is that I decided to go for Ferodo DS2500 pads after having read very good reviews here. However, I have found them to be extremely dusty (much more than even stock pads), they do squeal a fair bit and they're better, but not really leagues ahead, of the EBC Redstuff Ceramic pads I had previous tried, and which some forum members have branded as "rubbish". I still think, from my experience, that Mintex 1144s performed much better and all of these, collectively, are hit for a six by Pagid Blues.

[pangster]

fantastic power and good specs!!

just one question - you say you have a custom S60R manifold.. but the T4 is a 4 cylinder car and the S60R is a 5 cylinder car so how does that work??.. or is the fact it's custom mean you loped the last pipe off? lol!!

are there any pics of the car as a whole as well??.. keep up the good work!!

[Al115]

Of course Ashok has the definitive answer, but I'm pretty sure there was some conversion work done to make a 5-cyl manifold work on a 4-cyl car

[Nunchukhamster]

And more has been done to that car since this was written...

[pyaap]

Originally Posted by pangster

fantastic power and good specs!!

just one question - you say you have a custom S60R manifold.. but the T4 is a 4 cylinder car and the S60R is a 5 cylinder car so how does that work??.. or is the fact it's custom mean you loped the last pipe off? lol!!

are there any pics of the car as a whole as well??.. keep up the good work!!

Yes, one cylinder has been given "the chop" and a little grinding was required to get proper clearance of the block. Other than that, it bolts straight up and the flange can take a 19T, or a T25 Garrett flange with minimal modification. I've heard very bad things about the reliability of tubular manifolds and the only other company which offer a "log" manifold for an X40 (Volvo Motor Sports in the US) have a truly appalling reputation so I decided to stick with the cast S60R one and it works a treat!!

I will get some pics posted sometime soon; here's one taken at the last Marham track day:

[pangster]

Originally Posted by pyaap

Yes, one cylinder has been given "the chop" and a little grinding was required to get proper clearance of the block. Other than that, it bolts straight up and the flange can take a 19T, or a T25 Garrett flange with minimal modification. I've heard very bad things about the reliability of tubular manifolds and the only other company which offer a "log" manifold for an X40 (Volvo Motor Sports in the US) have a truly appalling reputation so I decided to stick with the cast S60R one and it works a treat!!

I will get some pics posted sometime soon; here's one taken at the last Marham track day:

lol! - that clarifies that then.. i was getting brain ache for a while trying to work out how you managed it! lol!...

Car looks mint BTW - would be nice to see some more pics to go with the stunning spec i.e. interior and engine!

[pyaap]

Originally Posted by pyaap

Hi,

The brakes are a development kit which was done in conjunction with SW Autos. They are still undergoing extensive testing so I'll post back with my impressions of how they perform (both or road and track) once I've finshed putting them through their paces.

One thing I will mention now is that I decided to go for Ferodo DS2500 pads after having read very good reviews here. However, I have found them to be extremely dusty (much more than even stock pads), they do squeal a fair bit and they're better, but not really leagues ahead, of the EBC Redstuff Ceramic pads I had previous tried, and which some forum members have branded as "rubbish". I still think, from my experience, that Mintex 1144s performed much better and all of these, collectively, are hit for a six by Pagid Blues.

Update on these: some people refer to this company as "Low-Spec" and sadly I can totally understand why. The callipers are aesthetically very appealing, but the quality of the discs they supply is diabolical. They have twice warped, once after "spirited" road driving and another time during a track day and Hi-Spec are very quick to fob you off as having "damaged" them by not bedding them in carefully. Only after Stuart from SW Autos got a gunsmith to check the run-out tolerance and report that it was unacceptable did they grudgingly replace them. I've also had the discs examined and have been advised that they appear not to be motorsport discs, but road discs and that could explain why they've taken so badly to racing pads. I do not believe them to be suitable for our application as Volvo cars are heavy so my advice would be to stick with AP Racing, Brembo or Porsche upgrade kits which have been tried and tested; I can certainly vouch for an AP Racing upgrade - 12 laps of Bruntingthorpe without a hint of fade.

It would seem my experience with Hi / Low Spec is not an isolated case:

http://homepages.nildram.co.uk/~rich...kes/brakes.htm

[spangoolies]

pyaap, have you considered installing the ph1 rear bumper skirts and colour matching them and the side skirts? would look great on your car(not that it doesnt look sweet already!)
-ash