Tag: maintenance

Volvo S80 2.4T Replacing the Car Battery

Replaced the old battery with a fresh new battery. Decided to mount a larger type, as the S80 has room for it.

See the big difference in size, which should account for a little bit more performance and safety as it has a lot more power.

Link to product: https://www.ebay.com/itm/252638760566

Chose a Powerline with the following specifications:

Spanning12 Volts
Capaciteit (C20)82 Ah
Capaciteit (C100)90 Ah
Koude start Amps (EN)680 A
Koude start Amps (SAE)730 A
Lengte353 mm
Breedte175 mm
Hoogte190 mm

Volvo S80 2.4T Replacing the Car Battery

Volvo S80 2.4T Replacing the Car Battery

Volvo S80 2.4T Replacing the Car Battery

Volvo S80 2.4T Replacing the Car Battery


Volvo S80 2.4T PCV DIY Repair / Service

Repaired / cleaned the PCV circuit as I saw a lot of oil in the pressure circuit (also see my previous post: http://www.ducked.nl/blog-entries/volvo-s80-2-4t-dirty-clean-turbo-coldside/ ).

Did a little research and the PCV system is almost always the culprit for such issues.

Decided to buy a complete system although ended up cleaning the existing system and only replacing the oil seperator. The tubing was quite some work, I will save that for another time.

Volvo S80 2.4T PCV Repair

Volvo S80 2.4T PCV Repair

Volvo S80 2.4T Clean Valves :)

Volvo S80 2.4T PCV Repair

Volvo S80 2.4T PCV Repair


Volvo S80 2.4T Dirty / Clean Turbo Coldside

Replaced the air filter and the turbo intake pipe. Please note that a dirty intake might also point out a badly functioning PCV system!

The intake pipe was upgraded to a blue Do88.se / Do88 silicone intake pipe, which is a fair bit larger, but also deletes some bottlenecks from the original part (like the narrowing bend on the bottom and the “harmonica”).

Gives a little bit more power from the butt dyno and noticed more intake growl (which is a good thing) 🙂

Volvo S80 2.4T Dirty Turbo Coldside

Volvo S80 2.4T Cleaned Turbo Coldside


Volvo S80 2.4T DO88.se Turbo Intake pipe

Replaced the air filter and the turbo intake pipe.

The intake pipe was upgraded to a blue Do88.se / Do88 silicone intake pipe, which is a fair bit larger, but also deletes some bottlenecks from the original part (like the narrowing bend on the bottom and the “harmonica”).

Gives a little bit more power from the butt dyno and noticed more intake growl (which is a good thing) 🙂

Volvo S80 2.4T Do88 Turbo Intake pipe

Volvo S80 2.4T OEM vs Do88 Turbo Intake Pipe

Volvo S80 2.4T OEM vs Do88 Turbo Intake Pipe

Volvo S80 2.4T OEM vs Do88 Turbo Intake Pipe

Volvo S80 2.4T Modified PTC Sensor


Volvo S80 2.4T Dirty vs New Airfilter

Replaced the air filter. This is what a dirty airfilter looks like.

Change it on time, so your car keeps performing at peak efficiency!

Volvo S80 2.4T Dirty vs New Airfilter


Volvo S80 2.4T Painting the Brake Calipers Daytona Yellow

Decided to paint the calipers for extra flair and to be honest it looks way better than that rusty brown color.

Bought some MHW Daytona Yellow paint and combined it with the yellow Prancing moose shield.

Volvo S80 2.4T Painting the Brake Calipers Daytona Yellow

Volvo S80 2.4T Painting the Brake Calipers Daytona Yellow

Volvo S80 2.4T Painting the Brake Calipers Daytona Yellow

Volvo S80 2.4T New Volvo Hubcap Stickers


Volvo S80 2.4T Changing the Interior Combo filter

Needed to change the interior / combofilter and was suprised by this malformed unit.

Looks like someone didnt do their job properly…Shameful really.

Easy DIY job, which shouldn’t take more than half an hour.

Volvo S80 2.4T Changing the Combo filter


Volvo S80 2.4T Soundproofing

When I last performed maintenance to the window sliders, I noticed the doors had not been soundproofed yet. Bought me a big mat on Aliexpress and went to work today.

Door card removal is very easy on the Volvo, so I was done in a very small time frame, which is always nice. The impact of such a simple thing like soundproofing is always noticeable, as the resonance from the tinny doors are removed, which allows for better sounding music + less cabin sound/drone.

Highly recommended & easy to do yourself!

Volvo S80 2.4T Soundproofing

Volvo S80 2.4T Soundproofing


Volvo S80 2.4T Denso Injector Service

Decided to clean and service the stock Denso injectors. Rubber rings get hard and brittle over time and tend to leak. Also the filter baskets might be contaminated over time, especially if the fuel filter is not part of your regular service intervals (which mine S80 lacked…).

I bought this kit of Aliexpress and the quality looks very nice. It contains all the items needed, including a special tool for removing/mounting the filter baskets.

The pictures will speak for themselves (it was needed!).

Volvo S80 2.4T Denso Injector Service
Volvo S80 2.4T Denso Injector Service
Volvo S80 2.4T Denso Injector Service
Volvo S80 2.4T Denso Injector Service

A very old fuel filter.

Volvo S80 2.4T Old Fuel filter





Volvo S80 2.4T Changing Spark Plugs (NGK K20TT 4604)

Fitted some fresh new plugs and decided to try NGK copper plug instead of Volvo OEM Iridium plugs. They work great and cost next to nothing. Decided to try NGK K20TT 4606. Double checked the gap to be sure, they are correctly preset for the Volvo S80 2.4 / 2.5T.

Still have to get used to swapping out 5 spark plugs instead of the “usual” 4.

Volvo S80 2.4T Changing Spark plugs

Volvo S80 2.4T Changing Spark plugs

Volvo S80 2.4T Changing Spark plugs




Volvo S80 2.4T Fitting a new Compressor Bypass Valve (CBV)

I noticed some strange behaviour when lifting the throttle and decided to service the CBV aka Compressor Bypass Valve. I was right, car drives a lot better after replacing it with a fresh CBV / DV (Diverter Valve).

I went with an aftermarket TRITDT K5T09671.

Volvo S80 2.4T New TRITDT Compressor Bypass Valve (CBV) repair kit

Volvo S80 2.4T New TRITDT Compressor Bypass Valve (CBV) vs Old

Volvo S80 2.4T New TRITDT Compressor Bypass Valve (CBV) vs Old

Volvo S80 2.4T Fitting a new Compressor Bypass Valve (CBV)




Volvo S80 2.4T Replacing Window Sliders

Easy mod with big results. If you have a Volvo with a choppy window, 9 out of 10, it will be the window sliders. They are quite easy to replace though. Tip: buy them on Aliexpress for cheap!

Volvo S80 2.4T Repairing Window Mechanism

Volvo S80 2.4T Repairing Window Mechanism

Volvo S80 2.4T Repairing Window Mechanism




Volvo S80 2.4T Replacing the Bosch O2 Lambda Sensor

Many people tend to forget that O2 aka Lambda sensors have a replacement interval (in my case 250.000km). Failing to do so will have direct impact on your power and mileage. I checked using Torque (Android app) and checking the Long Term Fuel Trims (LTFT). I noticed that they dropped after installing the new Bosch O2 sensor.

Partnr: 0 258 007 137 / 0258007137
LSU42, LS7137
EAN: 3165143196243

Volvo S80 2.4T Bosch O2 Precat Lambda Sensor

Volvo S80 2.4T Bosch O2 Precat Lambda Sensor

Volvo S80 2.4T Bosch O2 Precat Lambda Sensor




Volvo S80 2.4T LED License Plate Lights

Upgraded / updated the License plate lights to LED versions, which look much better than the stock items. Highly recommended mod!

Volvo S80 2.4T LED License Plate Lights

Volvo S80 2.4T LED License Plate Lights




Volvo S80 2.4T Repainting All The Trim

When I bought the S80, it was evident that the plastic trim had seen better days. So I decided to spend some time and repaint it black. As expected, it transformed the car tremendously. I highly recommend this!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!

Volvo S80 2.4T Repainting All The Trim!




Volvo S80 2.4T Replacing vacuum lines with Silicone Hoses

A highly recommended repair / modification for all older Volvo owners. Replacing the old rubber vacuum lines with strong durable silicone hoses. I bought 3 color hoses (red / black/ blue) as the original hoses also have color stamps on them. Old rubber hoses deteriorate from heat and moisture and will fail over time. Replacing them with silicone hoses ensures a proper running car!

Volvo S80 2.4T Replacing Vacuum Lines




Volvo S80 2.4T Upgrading Interior Lights with LEDs

To modernize the car and make it more future proof, I decided the replace as much halogen bulbs with LEDs. I didn’t want the 6500k Blueish tint, but instead opted for a warmer white color, which are a little bit more white than their halogen counterparts. Very happy with the end result!

Old

Volvo S80 2.4T Rear Vanity Lights LED

And New

Volvo S80 2.4T Rear Vanity Lights Halogen

Upgrading the rear light dome cluster

Volvo S80 2.4T Rear Light Cluster

Halogen vs LED

Volvo S80 2.4T Rear Light Cluster Halogen vs LED

Volvo S80 2.4T Rear Light Cluster Halogen vs LED

Warm white Festoon LEDs

Volvo S80 2.4T Rear Light Cluster

Unhooking the tab

Volvo S80 2.4T Rear Light Cluster

End result for the rear light cluster

Volvo S80 2.4T Rear light cluster after LED replacements

Front cluster

Volvo S80 2.4T Front Light Cluster

Volvo S80 2.4T Front Light Cluster




Volvo S80 2.4T Replacing the Upper Engine Mount with SuperPro Polybush

I noticed that when lifting off (like shifting), there was a lot of movement / play in the engine / gearbox. So when I inspected the upper engine mount, I found the root cause rather quickly. The rubber deteriorated and there wasn’t much left of the original rubber bushing.

Having read the other options, like fitting a polybush, I went with the SuperPro version which looked like a good bit of kit. Mounting the new polyurethane kit was quite a breeze. Fortunately, the original bushing has a plastic ring 🙂 The SuperPro kit consists of 2 pieces, which makes the mount very easy to replace.

Result: a much better shifting car, putting the power down goes a lot better now. I will also replace the bottom gearbox mount with a polyurethane version soon.

Very easy job to do at home. This also applies to the S60 and V70, as these are quite identical.

Broken upper engine mount…

Volvo S80 2.4T worn engine mount

Tearing it down

Volvo S80 2.4T Removing the Upper Engine Mount OEM bushing

Volvo S80 2.4T Upper Engine Mount shot OEM bush

Comparing old to new

Volvo S80 2.4T Polyurethane Upper Engine Mount vs OEM top view

Volvo S80 2.4T Polyurethane Upper Engine Mount vs OEM side view

Et voila!

Volvo S80 2.4T Polyurethane Upper Engine Mount completed




Vw Golf MK3 GTI, Repaint All The Trim

As the car is quite old, the plastic trim of the car has been exposed to the influence of the sun for countless of times, which greys out the once black plastic trim. I decided to repaint it all, as the grey trim is just plain ugly. The most work was to mask of the rest of the car, the rest was easy 🙂

Work in progress
VW Golf MK3 GTI / Painting the trim matte black again

Ugly greyed out trim…

VW Golf MK3 / Old Grey Trim

VW Golf MK3 / Old Grey Trim




VW Golf MK3 GTI, New Fuel Pump

As the car is about 21 years old, it was about time the fuel pump was renewed. A fuel pump gets old and will be unable to deliver the desired fuel pressure when needed. This will have a big impact on the performance as you might imagine. It took me quite some time as the retaining ring was stuck, like real stuck…

I was finally able to prise it of, but needed to perform some cleaning before putting in the new pump. But it was worth it!

Partnr: 1H0919051AK

Dirty pump
VW Golf MK3 GTI / Replacing the Fuel Pump 1H0919051AK

Fresh new pump!

VW Golf MK3 GTI / Replacing the Fuel Pump 1H0919051AK




VW Golf MK3 GTI, Maintenance time

Performed some big maintenance work on the Golf GTI as this was highly needed. Always feels good when it has been done, in a nutshell:

  • Oil change (5W40)
  • Brake fluid change (DOT 4)
  • Fuel filter change
  • Oil filter change
  • New PCV / Oil Seperator valve
  • New Ignition coil
  • New Coolant Temperature sensor
  • New Air filter element
  • New interior filter (active carbon filter)
  • New Bosch Aerotwin Wiper blades
  • New Brake pads front + back

Maintenance time




Swapping out the VW Golf MK3 GTI Crankshaft Position Sensor

My car was cutting out when the engine was hot. RPM gauge dropped to zero instantly & engine cuts out immediateley. Scanning the car with vagcom / VCDS showed an error with the G28 sensor aka Crankshaft Position sensor. Other names are Engine Speed sensor and in Dutch BDP sensor or krukaspositie sensor.

I followed this video guide, which helped me tremendously, so thank you Thomas EXOVCDS. Took me about an hour on axle stands, so not that bad.




VW Lupo 1.4 old sparkplugs replaced

Driving 140km a couple times per week stresses the car more than you would think. Keeping it in tip top shape is important, even more so with an older car like our VW Lupo which was born in 1999 (1.4 16v, engine code AHW). Less than a year when the last service was done, I checked the spark plugs (as it was starting a bit rough). Look at the picture to understand why…

Please note that I needed to wait before the NGK Iridium sparkplugs (type: BKR6EIX-11 3764) were delivered, So I bent the old one, so that the gap was made smaller.

 VW Lupo New NGK Iridum vs Old




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groeten Andy