laggys40

Holset powered s40

57 posts in this topic

Hey guys. I'm very familiar with the phase one and phase two s40s and currently in the process of building up a holset powered s40. The car is a 2003 USA edition volvo s40 with the automatic tranny that comes with the td04hl-12t. The car has a manual 5speed swap in the future but would like to get it running smooth before I spend the cash on the m56 swap. I got a few parts together so far, here's what I have; phase one motor swap(stronger sleeves and better engine all round for more horsepower )Holset hy35 turbo, tial 38mm external wastegate with screamer pipe, 3" high flow cat, stainless oil feed lines,egt gauge,wideband gauge. I followed mitchyboy01 testing on the holset with the stock map and was impressed. I originally was going for a td05-big 16g but after coming across a almost brand new hy35 for half the money I'm going for it! For those who don't know the hy35 has a 9cm turbine housing and expect spool to be in the mid/high 3,000rpm range. I'm a welder and metal fabricator by trade so most of this will be done all custom and hoping you guys can help out a fellow volvo nut,lol. Right now I'm on the exhaust manifold and external wastegate fabrication phase. Can anyone shine any light on where to start here? Here are my thoughts.... First I would still use the stock exhaust manifold and I would make an adaptor to bolt on the external wastegate.

Like this--->http://trendgears.com/ebay/MiragePower/TurboAccesssories/Mr2Adaptor.jpg

I'm going to run a low boost 7psi spring to get things dialed in with tuning. As far as engine management goes thats going to be the last thing I buy at the moment. Appears VEMS is a popular choice but would really like some first hand experience at this point in my build. I didn't go nearly as far with modding my old s40 I had last year. She had around 210whp with the stock 12t, and a few bolt ons. Never ran it at the track but gave wrx's and mustangs a run for their money,lol.

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Or a stock s60,s70,s60r,v70r manifold that comes with the t3 flange already. I'd just cut the 5th lobe off the runner so I could run it on my 4 pot s40....?

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Hi, great to see you are having a go with a custom turbo swap. VEMS will be a must as the HY35 will flow up to 500bhp of air so even at 7psi it will probably saturate the MAF @ 195G/S (250bhp). Bigger injectors, a fuel return and adjustable fpr can compensate to a point but you will run rich open loop at low rpm and lean up top.

I will be watching this with interest! Good luck.

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And yes you can use the Japan manifold from the post 2001 5 cylinder turbos. Doesn't have to be a T5 one iirc

Edited by mitchyboy01

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And yes you can use the Japan manifold from the post 2001 5 cylinder turbos. Doesn't have to be a T5 one iirc

Thanks man.I just got the "small yellow spring"(4.5psi) from my friend who had left over parts from a previous 240sx biuld today and going to put that in to start off. Also got a oil temp and oil pressure gauge. What kinda power did you put down with stock internals with your setup?

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Not much power tbh because mapping became a big issue. It was starting to run lean and I couldn't afford a standalone. There is no-one who can map the phase 1 ecu. My Holset was also much smaller, a billet HE221W. Only good for 360-390 max at big boost. I had 285bhp 320lbft but it had loads more to give.

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I have the phase two platform(2003) so hoping to squeeze out a a little more with the phase two maf and 420cc red top injectors. :) I can't wait to hear the holset spool up! 

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Small update. I did a test fitment with the turbo and its going to be waaay to tight to get the new turbo in. It fits no problem between the engine and firewall but where it sits after bolting it up space is just not enough for my satisfaction for my intake tube which is 4" diameter. I figured that anyways but oh well. So I have a solution..... My buddy with his project 240sx has a spare ram horn manifold that I'm going to use for my car. Has a two bolt flange for my 38mm external wastegate on the manifold as well. I'm going to cut all the runners off of my stock s40 exhaust manifold and weld on the ram horn runners onto the oem s40 flange. Its going to take some cutting and welding but she's going to work! The exhaust manifold is going to look sick! 

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Could anyone chime in on piggyback ecu's, specifically the AEM f/ic? I'm not big on piggybacks but this one has me very interested because it's not like a Apexi- neo or SAFC-2, its far more superior. While a standalone like a vems,AEM, or megasquirt would be essential but the aem f/ic looks like a good buy for me at the moment. I have the AEM wideband already and works in unison with the aem f/ic; has the ability to read maf,clamp the maf, retard timing(doesnt advance), fuel enrichment and injector pulse width adjustments, and a map sensor for further tuning capabilities. On paper it looks like a good solution. Any help would be greatly appreciated. 

 

http://www.aemelectronics.com/products/programmable-engine-management-systems/fuel-ignition-controller/fic-6

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Here's the new ram-horn manifold. I threw on the hy35 to get a visual. I'm going to fab up the oem flange to work with it. Oem runners are 3.6041" apart on center and the ram-horn is 3.8125" on center. With a little heat and some force I'll get the oem flange fabbed up on the ram-horn. The flow in this new manifold is going to be awesome!

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Interesting build.  Looking forward to seeing the progress.  Keep posting, things are a bit quiet here at the moment but I'm sure it will pick up!

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Thanks man. Made a little more progress today. Got the engine stand for a great deal at $47(us) and got a assortment of rotary files to gasket match.....everything. :)

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Where to dump the external? Through the hood or underneath? >:)

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Just got my phase one motor delivered today finally! Brought it to the car wash and degreased the motor with simple green and and a pressure washer carefully. Next plan of attack is doing the timing belt and replacing all the hoses this week.

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Got a full day in on the motor. Did some degreasing and polishing. Still have a few more hours of polishing, need a different wheel to get into all the tough to get spots.

 

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Started the exhaust manifold today. Waiting on the exhaust manifold gasket to come into the mail to mark out the holes and finish porting out the exhaust ports. Runners measure 1.5" wide x 1.25" tall.

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Got a little more time on the project. Got the timing belt side of the motor all cleaned up and decreased 100%. I played with a spare throttle body I had kicking around and bored it out to gasket match the intake manifold casting. My 4" --->3" reducer came in the mail finally. Going to use this on the intake pipe prior to the MAF sensor.

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Gregs T5R likes this

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Got some more time in on the motor. Got her all degreased and prepped for the belt. Installed all new OEM cam seals, water pump, tensioner pulley, and idler pulley. The intake cam seal wasn't leaking at all but the exhaust cam was leaking quite a lot. Getting the timing belt on hopefully Saturday babysitter permitting,lol. Next up is getting the car towed to the shop tomorrow morning!  :D

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Got any pics of what it looked like when you started?

Keep us updated be good to see how this goes when its done

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Here she is! The blue phase two s40 is the project car. Photo here was taken where I had bought the car and drove her 1 hour back home that day. My old 2000 s40 wasn't so lucky as seen in the bonfire pictures,lol. I've owned three s40's so far and the blue one being my 3rd. Phase two is the way to go, handling is much better with the upraded front suspension. My first s40 is the silver one shown in the picture,it blew the diff right out the transmission block. OPPS! 

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Sheesh any ideas what caused the fire or the diff to decide to leave the gearbox?

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