Monthly archives: June, 2020

Volvo S80 2.4T Privacy Shades

Fitted some Volvo OEM Privacy Shades, which are better than the standard solution. I removed them from the door cards completely.

Volvo S80 2.4T Privacy Shades

Volvo S80 2.4T Privacy Shades


Volvo S80 2.4T Wrapping the fog lights

Added some tint film to the fog lights, to improve the looks of the front. Mission success!

Volvo S80 2.4T Wrapping The Fog Lights

Volvo S80 2.4T Wrapping The Fog Lights


Volvo S80 2.4T Rezaw-Plast Plastic Skidplate

When I bought the car, it was missing a skidplate. A skidplate has a number of purposes, like protection, keeping dirt out, but also improving underbody aerodynamics and improving cooling and fuel economy of the car. A car is cooled by pulling air through your radiator (by the flow of lower pressure air under your car), instead of purely relying on high pressure on the front of the car.

I bought this Rezaw-Plast one via Motointegrator.de and it had a very good price (33 euro is a steal!). Fitment is very good, aligns well with the stock mounting holes.

Partnr: RP151901 / 151901 / 8634813 / 30741855 / 8624664 / 30741968

Volvo S80 2.4T Rezaw Plast Engine Undertray Fitted

Volvo S80 2.4T Rezaw Plast Engine Undertray Fitted

Volvo S80 2.4T Rezaw Plast Engine Undertray Fitted


Volvo S80 2.4T Plastidipped Grill

I wanted a cleaner look for the front grill and decided to use plastidip instead of the carbon wrap. It came out great and suits the black S80 very well.

I used Motip Removable Coating instead of classic Plastidip and it holds very well till this day.

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Volvo S80 2.4T Plastidipped Grille

Also repainted the front trim with bumperspray (which didn’t hold by the way).

Volvo S80 2.4T Repainted Trim


Volvo S80 2.4T Custom Exhaust

When fitting the 3″ BSR downpipe, I needed a new exhaust. As a temporary solution, I bought a standard exhaust kit (resonator and backbox) and modified the midpipe (cut the resonator out). It sounds quite nice for a default exhaust, but cannot beat a stainless exhaust 🙂

Volvo S80 2.4T Old vs New Backbox

Volvo S80 2.4T Old vs New Backbox

Volvo S80 2.4T Old vs New Modified Exhaust

Volvo S80 2.4T New Catback

Volvo S80 2.4T New Catback

Volvo S80 2.4T BSR 3" Downpipe + New Catback

Volvo S80 2.4T Modified Center Silencer

Volvo S80 2.4T Modified Center Silencer

Volvo S80 2.4T Modified Center Silencer

Volvo S80 2.4T Modified Center Silencer


Volvo S80 2.4T BSR Tuning 3″ Downpipe

To upgrade the performance on any turbo powered car, you need “breating” upgrades. The car needs to inhale better (intake modifications), but also exhale better (exhaust modifications).

The most important component in the exhale process is the downpipe, the first pipe after the turbo. Upgrading this to a larger diameter, will allow for quicker turbo spool, which helps in scavenging but also in building boost.

As a pleasant side effect, the exhaust note will also be more throaty! The S80 has very limited options on paper, but I was able to buy and fit this with help from J&D Auto Onderdelen, who helped me tremendously in the pre-sales process (making sure that everything would fit). I can highly recommend them!

It’s a quite expensive upgrade, but well worth it.

BSR 3" Downpipe with Sports Catalyst

BSR 3" Downpipe with Sports Catalyst

BSR 3" Downpipe with Sports Catalyst

BSR 3" Downpipe with Sports Catalyst

Volvo S80 2.4T 3" BSR Downpipe (Inside view)

It’s highly recommended to get some new nuts for securing the downpipe.

Volvo S80 2.4T Genuine Parts (Locking Nuts)

Old vs new, look into the differences in the diameter of the neck.

Volvo S80 2.4T 3" BSR Downpipe

Volvo S80 2.4T BSR 3" Downpipe + New Catback

Volvo S80 2.4T BSR 3" Downpipe + New Catback


Volvo S80 2.4T BBS ASA TEC GT3 Wheels (Candy Red)

In the mean time, they have been sold already, but I stumbled upon a pristine set of winter wheels. Not far over the border, I found a 19″ BBS ASA TEC GT3 set in candy red, which on paper should look awesome (black car, candy red wheels).

Unfortunately I wasn’t happy with the looks, but they served me well for 1 winter and I got a lot of feedback on it, which was funny!

19" BBS ASA GT3 Wheels

19" BBS ASA GT3 Wheels

Volvo S80 2.4T 19" BBS ASA GT3 Wheels

Volvo S80 2.4T 19" BBS ASA GT3 Wheels

The are very heavy, but that is also due to the runflat winter tyres. The combo weighed in a hefty 24.3 kg.

19" BBS ASA GT3 Wheels


Volvo S80 2.4T Project 16T Turbo

I had pretty big plans for the S80, shooting for a 270bhp instead of the 200bhp that the 2.4T has normally. You need an upgrade turbo for this, which I sourced from a T5 model, which has 250bhp bone stock. The swap would involve the TD04HL-13T to TD04HL-16T or 13T to 16T for short.

Fitment is pretty straightforward, but the coolant lines run differently, and this was quite a hassle as information on the internet seems very scarce. I found some, but needed some creativity as the build progressed.

I was also planning to mount the later “R” series manifold, but decided to sell it, as the Japanifold would give much better sound and equal performance.

In the end, I sold the 16T and mounted the 13T, saving the money up for something else. I needed to adjust the car a little bit, and according to the max MAF values, it makes about 240-245bhp, which is awesome.

It’s a totally different car from when I first bought it, that’s for sure!

Volvo S80 2.4t TD04HL-16T Turbo

Volvo S80 2.4t TD04HL-16T Turbo

The TD04HL-16T with the R-manifold

Volvo S80 2.4T TD04HL-16T + Upgrade Exhaust Manifold

The TD04HL-13T vs TD04HL-16T

Volvo S80 2.4T TD04HL-16T vs 13T turbo

Volvo S80 2.4T TD04HL-16T vs 13T turbo

Volvo S80 2.4T TD04HL-16T vs 13T turbo

Modifications needed for fitting the coolant lines

Volvo S80 2.4T Coolant Line Modification

Volvo S80 2.4T Coolant Line Modification

Rubbing will occur here

Volvo S80 2.4T Coolant Line Modification


Volvo S80 2.4T New Engine Mounts

When you have an older car, always think about replacing the engine mounts. They are almost always made of rubber, which becomes brittle over time due to aging/drying out.

I replaced all the engine mounts, which tightens up handling and improves performance and reduces strain on components like the exhaust, as the engine swivels way less. Highly recommended!

Volvo S80 2.4T Engine Mounts

Volvo S80 2.4T Engine Mounts

Volvo S80 2.4T Engine Mounts

Volvo S80 2.4T Engine Mounts