Added Window Spoilers to the Volvo S80, I like the look but also they lower the wind noise when driving with open windows.
Also if it rains, you are still able to drive around with open windows, without any water ingress. And in the hot summers, you can safely let your windows down a little to stop the heat from building up in the car.
When I wanted to mount the TD04HL-16T turbo, I also wanted to couple it with the Japanifold, that should give good performance, but also the distinctive rumble of the 5 cilinder engine. I scored one via internet for a good price. The quality is immaculate, as they can handle a lot of abuse before they even start cracking.
But in the end I sold it, because my 2.4T already had the Japanifold fitted, so happy days 🙂 !
They are made in Japan, hence the name “Japanifold”. Partnr: 9207688
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 🙂
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.
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.
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 🙂
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!
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 🙂
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…
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 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!
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!
I was missing the option to play my own music using a iPod Classic interface, so decided to convert my HU-801 Volvo headunit to my trusty Pioneer 1DIN / Single DIN using a fascia plate and some converter cables.
I like the original look better, but the functionality of the Pioneer outweighs the look a couple of times, which makes it a no-brainer for me.
Upgraded the rear with a trunk spoiler (stick-on type) and it looks quite OEM, which I am very pleased with. Doubt it will give me any extra noticeable downforce, but it looks the parts 🙂
To modernize the car and make it more future proof, I decided the replace as much halogen bulbs with LEDs. I didn’t want the 6500k Blueish tint, but instead opted for a warmer white color, which are a little bit more white than their halogen counterparts. Very happy with the end result!
Upgrading the rear light dome cluster
Halogen vs LED
Warm white Festoon LEDs
Unhooking the tab
End result for the rear light cluster
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 🙂 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…
Tearing it down
Comparing old to new
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.
- DeWalt DCF899 impact wrench VS stubborn Volvo S80 Crank Pulley Nut VS Parkside PASSK 20-Li A1
- Mini Cooper S R53 JCW – New Downstream O2 Sensor
- Mini Cooper S R53 JCW – Injector Service
- Mini Cooper S R53 JCW – Servicing the Eaton M45 supercharger
- Mini Cooper S R53 JCW – Sitting in the driveway
- Mini Cooper S R53 JCW – Airbox Intake Modification
- Mini Cooper S R53 JCW – Vacuum Gain System VGS Modification