So i drive a s80 for 1year now very reliable, comfy, classic look, but somewhat sluggish at high rpms and the interior is a notch too plasticky, anyway since i come from a bimmer word making a sportier s80 is a necessity!
big project so trying to combine all the knowledge to achieve those goals with updates when progress is made, so any advice is welcomed
Goals:
-Performance:
- 400hp with aftermarket sleeves
- 300hp stock
- Sport Suspension set up
-Interior:
- Less plastic lol
- Mood Lights
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Interior Mods:
First thing that i didn’t like is the black cheap looking plastic sprayed around all the dashboard, find a semi Solution: VOLVO Wood Trim Kit 8640112 For 2005-2006 S80 OEM New VOLVO Genuine | eBay, easy to install and fill nice
Before:
After:
Ipd Radio Knob can be a nice feature making the button nicer to the feel:
Radio/Climate Control Knob Decor Kit – for Volvo – Aftermarket (ipdusa.com)
AfterMarket headunit can be a good option but i have no experience with those, what i can say is switching from a 801 radio to a hu850 is a defenetly recommendation if fine tuning ur audio system is ur thing
LED bulbs interior are also an option but the stock ones look warmer and more cozy.
What would be a nice touch is LED strips! still didn’t install those but im thinking about taping from the headlight switch or the fuse box from driver side.
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Performance:
–Handling
So where to start, yeah the boat feel when u go into corners haha, (Disclaimer: to start with im not saying this car suck or what not is just volvo made the car to be a comfy cruiser not a 5series. Im just having fun changing the car characteristics to suit my need and develope my personal skills on tunning and mechanics),
– IPD sway bar link: those are thicker and stiffer it help with body roll when cornering, will recommend, since i use them didn’t notice a huge difference but defently help, cheap upgrade for those who are gonna change their links anyway
Front & Rear HD End Link Kit – IPD 124647 – Volvo 31212692 31201603 (ipdusa.com)
– Poly Upper Engine mount bushing from powerflex, will recommend, what i wouldn’t recommend is the ipd ones, especially right now since they have a logistic issue with their kit because they experience a high failure rate and their supplier is revisioning the design of the bushing, waited 3month! didn’t received anything so i canceled and bought the powerflex ones with a lifetime warrenty, doesn’t transmit that much vibration and again help with body roll and engine movement
Volvo Engine Mount Bushing – Powerflex PFF88622 | FCP Euro (can buy them from fcp euro or anywhere else really, the company offer a lifetime warranty)
– Poly subframe bushing insert, hard to recommend, went with ipd subframe poly insert, didn’t notice much difference on the ride i guess it would be more noticeable if ur subframe bushing is torn apart completely?
IPD Poly Front Subframe Bushing Insert Kit – Volvo 3507923 (ipdusa.com)
– Poly insert for upper engine stabilizer, will NOT recommend, didn’t remove the play on the bar, i guess it reduce it a bit but there is a better option
Upper Engine Stabilizer Poly Bushing Kit – IPD 110933 – Volvo 8666204 (ipdusa.com)
– Strut mount bar conversion, this one will recommend, wouldn’t buy the insert if i was aware that a such kit exist, it definetly remove the play on the strut bar and did notice a slightly better handling capability since it help with the rigidity of the structure one of the best bang for the buck
Strut Bar Mount Conversion Kit Blue – Aftermarket – Volvo 8666204 (ipdusa.com)
– Poly Lower Torque mount, i recommend, improve the ride quality by limiting transmission movement, and delete a weak point since this bushing is known to failing especially after 100K mile, i went with ipd
Polyurethane Transmission Torque Mount – IPD 139369 – Volvo 30680750 (ipdusa.com)
*On to do list
– Coil Over of course, can go a lot of routes for those, but the easiest one to install and that come with a kit seems to be BC Racings, BR series with swift springs seems to be the more balanced approach between ride stiffness and comfort and pricing. S60AWD coils seems to fit on the S80 even if the website say it doesn’t for some reason.
BC Coilovers | 2001-2009 – VOLVO – S60/S70 AWD – RacingCoiloversCanada.com
– Sway Bar upgrade, again helping with body roll and cornering stability with poly bushing, ipd sell a kit with thicker bar’s and seems like a good product with good reviews.
Front & Rear Anti-Sway Bar Kit – 240 Models for Volvo – IPD 100987 (ipdusa.com)
– Brake upgrade, R calipers and pads, what can i say? the car need to stop lol
-feel free to add any recommendations-
-Engine
Right now the engine is stock, since i still didn’t finish the handling side but i start buying and rebuilding some parts,
– Turbo! again lot of option, stock turbo is a 14t seems the turbo can push safely to 11-12 psi of boost but more than that would need a upgrade, on my case i went with a 16T from a T5, able to push all the way to 21psi without a issue according to HiltonTunning team, R turbo is also an option but for a 300Hp goal (for now) 16t will do especially for the price (15$ on a junk yard lol), since im aiming for 18psi at first and 21psi at max, i bought a turbosmart Universal wastegate 140mm 10PSI, i might increase the spring to 14psi will see ^^, mamba (ebay) rebuilt kit is also on the way with a upgraded compressor wheel (9-11 billet wheel).
– Green Injectors are also a must have when pushing above 250hp, R injectors can be found on FCP euro.
– Coolant and Oil line, not going to increase power but teflon lines would give peace, i choose mamba and will see how it goes.
– Oil Cooler, Stock one is fine for stock setups, but increasing the hp need to coupled with adequate cooling capabilities, VIVA make a upgraded one that seems to work well, but on my case i went with MAHLE from rockauto, it seems to be a better cooler than the oem one, no plastic bracket restricting the air exchange, and are a bit lager in size to increase the contact surface with air for better cooling.
More Information for MAHLE / CLEVITE CLC41000P (rockauto.com)
– Intercooler, a must have upgrade to keep the air nice and cool before going to the engine, especially for the 2.5t u dont need additional knocks on the engine that can torn apart the sleeves, DO88 make a good unit
Aluminum Intercooler – S60 / V70 / XC70 / S80 Turbo (eurosporttuning.com)
– Dowpipe, needed to increase the exhaust flow also needed to achieve 21 psi of boost with a fill 3inch exhaust setup, Snabb seems to be the way to go, for the catback will make a custom 3inch while keeping the resonator and a magnaflow muffler.
3″ Performance Downpipe, P2 S60, V70, XC70, S80, XC90 AWD 5-Cylinder Turbo – Snabb Performance Parts
– Talking about airflow Silicon hooses are a good way to help the engine breath in air even better, and reduce turbo lag, on my case i still didn`t look for those yet even if DO88 seems again like a legit option but IPD and Snap are good as well
– BCV valve, since the goal is not to creat a drag monster a bcv should be more efficient, kunigawa seems to make good unit but turbosmart seems to have a smarter bcv with no spring inside? in any case Kunigawa bcv loaded with a 15-23psi spring would be fine will see, any recommendations is appreciated.
– Tunning, Hilton Tunning Stage 3, very good team and very communicative, bit pricy but u get what u pay for.
– Shimming the engine… the hardest task to accomplish… how u probably know those engines are prone to sleeves cracking, the issue according to hilton team and my testings is high cylinder temperatures caused by different factors, (driving habits, fuel octane, oil cooler, intercooler) and the oem tune itself, the ignition timing is too advanced from factory that caused knocking, that factory sensor are not able to detect, anyway there is 2 option, the easiest one and cheapest one is putting little metal insert between the liners to increase the rigidity of the walls, this solution doesn’t create the consensus but there is pros and cons, the second option is Custom sleeves, this is the most expensive and time consuming solution that will guaranty u that u will never run over a sleeve issue, Elevate sell a kit:
Elevate Volvo / Ford Turbo Five Cylinder Performance Engine Cylinder Sleeves (CLOSED DECK) Set of Five (elevatecars.com)
My opinion is that insert are sufficient to secure the cylinders when we talke about sub 500hp builts, since the crack come only from the section where there is a void between those same cylinders.
Little Side note:
-installed a transmission filter on the return line to keep any debris out, no leaks didn’t mess up the flow causing miss shifts, so will recommend doing it as well
Amazon.com: Magnefine 3/8″ Magnetic Inline Transmission/Power Steering Filter : Automotive
How u can see the build is still going there isn’t much to show at this state, but will update u on the advancement slowly but surely, and let u know if any part fail!
Thanks for reading Talking