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!
The TD04HL-16T with the R-manifold
The TD04HL-13T vs TD04HL-16T
Modifications needed for fitting the coolant lines
Rubbing will occur here
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) 🙂
I actually wasn’t planning to upgrade the OEM Compressor Bypass Valve (CBV), but I am glad I decided to do so with this ProPerfekt piston type Diverter Valve (DV).
The rubber rings don’t leak (so much) boost, which means the power output is better (and faster) compared to the stock CBV. The stock CBV has a rubber outer ring (diaphragm) and a plastic ring on the inside (this is the flaw in the design).
The ProPerfekt DV is a known mod with the Renault Megane RS drivers, but I haven’t seen it before on another Volvo forum. The results are clear to me, the boost buildup is quicker, which means the car is faster. I would recommend this mod to anyone who has a TD04 turbo (who is still using the stock CBV). My S80 has the TD04HL-13T turbo, but will also fit the TD04HL-16T. Please note that the CBV I had fitted is quite new, so no ruptured diaphragm or something.
And this is how it compares to the stock 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.
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