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
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.
Also repainted the front trim with bumperspray (which didn’t hold by the way).
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 🙂
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.
It’s highly recommended to get some new nuts for securing the downpipe.
Old vs new, look into the differences in the diameter of the neck.
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!
The are very heavy, but that is also due to the runflat winter tyres. The combo weighed in a hefty 24.3 kg.
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
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!
The old OEM armrest with the phone which I replaced for a new one (without the phone).
It was replaced with a new cream colored vinyl armrest from Aliexpress. Looks like new!
Added 2 diffusers to the rear bumper of the S80. Looks very nice and makes the S80 less of a Old Man car haha 🙂
Finally did a replacement which was on my list for a long time. I replaced the old fuel pump with a new unit from Meat&Doria.
I needed to wait for the Fuel Ring Locking Ring Tool before I was able to continue as the rings (2!) sit very tight.
Car feels like new again!
Bought me some yellow Prancing Mooses / Moose decal as it’s a Volvo thing to do 🙂
In the meantime, they have been replaced by black “carbon” units, which look better. This will be shown in a later post.
I already wrapped part of the grille, but decided to also wrap the larger diagonal parts. Looks much more modern, which was the aim of this mini project.
In the meantime, I plastidipped the grill matte black, but that will be shown in later posts 🙂
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.
I had some Flyeyes wrap hanging around and decided to test it on the running light and the indicator side lights.
I forgot that I had some black wrap lying around and started off with anthracite wrap, which I re-did in the end. Very happy with the results, and it customizes the car a little bit more, which is exactly what I want 🙂
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!).
A very old fuel filter.
When I had the OEM exhaust, I wanted to have the center silencer removed, as the OEM exhaust is very good in keeping the car silent. But this car needs to make a little noise, so I decided to modify the stock middle pipe.
Gives a little bit more sound, without being to loud.
Also weighed it, and it weighs a mere 6.7KG .
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!
Old vs New. The mount should not be able to move like that 🙂
And this is how it looks under the engine. Easy job, 2x 14mm & 2x 18mm nuts.
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.
But this looks better to be honest…
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.
As a lot of older Volvo’s, my S80 showed the cumbersome “Alarmservice needed” message. I decided to search for a fix instead of buying a new one, which costs about €280 – €300, which is a lot of money.
The process is very simple, slicing open the siren, disconnecting the battery pack and plugging in the new battery pack. The hard part is to remove the security bolt, I used a angle grinder and then tapping it out. I used a normal bolt when I mounted the siren again.
I bought it here: https://www.ebay.com/itm/152151139597
S60, S70, V70, S80 & XC Series
Type: Varta button cells
Rating: 7.2V, 320mAh
P/N: GP320BVH6A6, N2H280
Finish: Green wrapped
Connector: Mini-Volvo connector
Compatible with 8637399, 8622268, 9452709 & 9162941 siren modules
Cable length: 60mm
Replaced some old deteriorated intercooler hoses with new fresh Do88.se blue silicone hoses, which do not collapse anymore. I solved a hiccup when flooring the car from low rpm (due to sturdiness of the new hoses).
My front gearbox mount was shot. Found a polybush replacement part which is a easy swap. Remove 4x 18mm bolts, swap the part and tighten the 4x 18mm bolts. Noticed a big improvement in pickup and shift handling. The engine/gearbox is able to move much less, which helps in driveability.
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.
I wanted to try an open filter, to hear the induction sound and the blowoff sound. I went with a big velocity stack type filter. Although it sounded nice, I already reverted it and went back to the original airbox.
And it looks like this again
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!
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
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!
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- Volvo S80 2.4T BSR Optiflow Kit
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