Tag: wasa limited edition

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


Volvo S80 2.4T New Cream Vinyl Armrest

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!

URL: https://www.aliexpress.com/item/32843890907.html

Volvo S80 2.4T OEM Armrest

Volvo S80 2.4T New Cream Vinyl Armrest

Volvo S80 2.4T New Cream Vinyl Armrest


Volvo S80 2.4T Diffuser

Added 2 diffusers to the rear bumper of the S80. Looks very nice and makes the S80 less of a Old Man car haha ๐Ÿ™‚

URL: https://www.aliexpress.com/item/32853258621.html

Volvo S80 2.4T Diffuser

Volvo S80 2.4T Diffuser


Volvo S80 2.4T Replacing the Shift Gaiter

Replaced the tatty old shift gaiter with a new universal one. Lubed up the shifter mechanism, happy days ๐Ÿ™‚

Forgot to take an result picture ๐Ÿ™

Volvo S80 2.4T Replacing the Shift Gaiter


Volvo S80 2.4T OEM Rubber Floor Mats

Ditched the old floor mats and bought me some original Volvo rubber mats. They might not look as nice, but they are far sturdier and they are much easier to maintain.

Volvo S80 2.4T OEM Rubber Floor Mats


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: https://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 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 Prancing Moose Decal

Bought me some yellow Prancing Mooses / Moose decal as it’s a Volvo thing to do ๐Ÿ™‚

In the meantime, they have been replaced by black “carbon” units, which look better. This will be shown in a later post.

Volvo S80 2.4T Prancing Moose Decal

Volvo S80 2.4T Prancing Moose Decal

Volvo S80 2.4T Prancing Moose Decal

Volvo S80 2.4T Prancing Moose Decal



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 properlyโ€ฆShameful 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 Black Flyeyes Wrapping

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 ๐Ÿ™‚

Volvo S80 2.4T Black Flyeyes Wrapping

Volvo S80 2.4T Black Flyeyes Wrapping

Volvo S80 2.4T Black Flyeyes Wrapping

Volvo S80 2.4T Black Flyeyes Wrapping


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 ๐Ÿ™‚ 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




Volvo S80 2.4T Chrome Side Indicators

Small modification, getting rid of the fried egg look and replacing them with Chrome / Amber versions does the front of the S80 good. Cost a small amount and looks much cleaner.

Before…

Volvo S80 2.4T Fried egg stock amber bulb

After ๐Ÿ™‚

Volvo S80 2.4T Chrome indicator bulb