Tag: mod

Mercedes CLS55 AMG W219, How To Replace The TCU

When I searched for a step-by-step video for replacing the Transmission Control Unit (TCU), I could not find one for the CLS. Therefore I created one myself, to help out others who want/need to swap out this unit.

My tuned unit was stamped with:

Siemens A0355457532
KEIN Seriensteuergerat
Speedshift+ Race
Ubersetzung i=2.65

Visit my YouTube channel here: https://www.youtube.com/ndphotonl




Mercedes CLS55 AMG W219, Upgrade To LED License Plate Lights

Converted the license plate lights to LED units (thanks to Aliexpress). Instantly gives the car a more modern look. I applied some dark window tint film, to tone down the intensity. Too much LED light gives off a “chav” image, which is something I want to prevent at all times.

License Plate LED Lights not tinted yet in this picture

See all CLS55 AMG pictures here in my Google Photos album: https://photos.app.goo.gl/6SP5PFAUXCqanoSX9




Mercedes CLS55 AMG W219, Air Intake Flaps Modification

Made a small modification to the intake flaps, by removing a small portion of them. This should, in theory, make sure that air is able to enter the intake pipes directly (instead of indirectly).

Intake flap removed
Intake flap still intact

All CLS55 AMG pictures here in my Google Photos album: https://photos.app.goo.gl/6SP5PFAUXCqanoSX9




Mini Cooper S R53 JCW – Airbox Intake Modification

I wanted to replace the stock air pipe, as it contains a resonator which keeps it silent. It’s also not optimised, leaving room for improvement.

Used 2 aluminium joiners/couplers and flexible piping. Very happy with this cost effective result! Also, I love the supercharger whine 🙂

I also ordered a K&N RU-3190 filter, I didn’t know the previous owner fitted a Pipercross PX1875. In the end I sold the K&N as the fitment wasn’t good.

Mini Cooper S R53 JCW Airbox Intake Modification

Mini Cooper S R53 JCW Airbox Intake Modification

Mini Cooper S R53 JCW Pipercross PX1875 vs K&N RU-3190

Mini Cooper S R53 JCW Pipercross PX1875 vs K&N RU-3190


Mini Cooper S R53 JCW – Vacuum Gain System VGS Modification

As usual, the Mini Cooper S with the Eaton M45 supercharger also has a bypass valve, which helps with fuel economy and lighten the load on the supercharger during idling (for instance). On NAM (North American Motoring forum) I noticed a popular mod, which is also known as the VGS or Vacuum Gain System modification.

Basically, the VGS mod changes the way the Bypass valve is operated. From indirect vacuum to direct vacuum, allowing faster response of the butterfly valve, but also keeping it shut better so no boost is lost.

I liked it in the beginning, but it makes for a rough driving experience. So in the end I reverted and never went back. Thats why we experiment 🙂

Source: https://www.northamericanmotoring.com/forums/how-to/38268-drivetrain-operation-vacuum-gain-system-vgs.html

Changing the vacuum line routing.

Mini Cooper S R53 JCW Bypass Valve VGS Mod

Mini Cooper S R53 JCW Bypass Valve VGS Mod

Brand new Bapmic Compressor Bypass Valve (CBV).

Mini Cooper S R53 JCW Compressor Bypass Valve

Modifying the bypass valve.

Mini Cooper S R53 JCW Compressor Bypass Valve


Volvo S80 2.4T 3rd Brake Light Mod

Bought a long LED strip and mounted it next to the 3rd brake light cluster.

Should be a lot safer and looks good 🙂

Volvo S80 2.4T 3rd Brake Light Mod


Mini Cooper S R53 JCW Heatwrapped Stainless Exhaust

I heatwrapped the new stainless steel Gravity Performance catback exhaust. Unfortunately I ran out of titanium heatwrap, so I ordered some more (black) and finished the job.

It will help with scavenging and is a supporting mod for extracting more horsepower and torque from the Mini.

Mini Cooper S R53 JCW Heatwrapped Stainless Exhaust

Mini Cooper S R53 JCW Heatwrapped Stainless Exhaust


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 Polyurethane Lower Gearbox Mount

My original gearbox mount was shot and I decided to replace the mount with a brand new reinforced polyurethane mount, which tightens up the shifting and allows for less engine movement, which is better for the exhaust.

One disadvantage, the cabin has added drone due to extra vibration. But the advantages outweigh the one disadvantage, so for me it’s a keeper!

Volvo S80 2.4T DO88.se Intercooler hoses

Closeup view

Volvo S80 2.4T PU Gearbox mount

Old vs New. The mount should not be able to move like that 🙂

Volvo S80 2.4T New vs Old Gearbox mount
Volvo S80 2.4T New vs Old Gearbox mount

And this is how it looks under the engine. Easy job, 2x 14mm & 2x 18mm nuts.

Volvo S80 2.4T PU Gearbox mount



Volvo S80 2.4T Hella Style Horns

Wanted to see if the Hella style horns would fit the S80. First I painted them white (they were green). Mounting them was easy, but the front looks messy with the horns mounted, so I decided to remove them again.

Volvo S80 2.4T Hella Horns mod (white)

Volvo S80 2.4T Hella Horns mod (white)

But this looks better to be honest…

Volvo S80 2.4T Front view