Volvo S40 T5 K16 hybrid Upgrade
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    1. #1
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      Volvo S40 T5 K16 hybrid Upgrade

      Hi Guys, been a member here for a while but not active as am a member of the volvo uk forums as well but seems like the forums here are way better and more active so I thought I would post up my project here and also get some advice really as there are a few challanges.

      Anyway looking to upgrade the turbo, have a K16 hybrid waiting to go on with all the supporting mods. Am forging the engine and getting the block mod done. Pictures below of the car and the parts.

      Summer Setup Wheels | 18's Rep Focus RS MK3 with PS4 tires
      Another clean by Dom Hartland, on Flickr

      Winter Setup | 17's MSW 85s (I think) with pirelli sottozero
      Winter clean down by Dom Hartland, on Flickr

      Current mod list
      - Powerflow 2.5" catback exhaust syste
      - Generic remap
      - Bilstein B14's coilovers
      - 3" Intake pipe
      - k&n filter in OEM airbox
      - Bell FMIC

      On the list to install to support the K16 upgrade
      - K1 rods
      Next few bits have arrived by Dom Hartland, on Flickr

      - weisco pistons
      Next few bits have arrived by Dom Hartland, on Flickr

      - Mahle race bearings
      Race bearings by Dom Hartland, on Flickr

      - RS ECU holder
      Here come the mods by Dom Hartland, on Flickr

      - Group A Induction
      Here come the mods by Dom Hartland, on Flickr

      - Focus St225 short shift (Not sure if this will fit but we shall see)
      Here come the mods by Dom Hartland, on Flickr

      - RS Oil cooler
      Here come the mods by Dom Hartland, on Flickr

      - Volvo S60R Clutch kit
      Here come the mods by Dom Hartland, on Flickr

      - Port polished lower manifold
      Here come the mods by Dom Hartland, on Flickr

      - Port polished head (No pictures of this though)

      - RS K16 Hybrid turbo
      Here come the mods by Dom Hartland, on Flickr

      - 550cc fuel injectors with rail
      Here come the mods by Dom Hartland, on Flickr

      - Uprated fuel pump
      Here come the mods by Dom Hartland, on Flickr

      - Vibratech torque mount
      Here come the mods by Dom Hartland, on Flickr

      - AS Plenum
      Here come the mods by Dom Hartland, on Flickr

      - Full Exhaust system 3" downpipe to 3" pipe to the end, I think the system is a Nortec system (No pictures)

      One thing that I am still deciding and have been told is if I should stay using the original OEM MAF? I am on the edge of getting the Focus RS MK2 cross over intake pipe which has the RS MAF build in, so probably looking to get that.

      The other thing im still not sure about is if the 550cc injectors are enough? or if I can push to maybe 650cc or 750cc? I dont really have any power goald but later in the year I will be looking at a Gripper Diff as I use this car for track days.

      Anyway thats a start for whats coming so anyone else doing the K16 can have a look as I have really struggled with finding content fo this build and to get it done while keeping the car safe.

      Car will be build and mapped im hoping in the next couple of months so will have some video's print outs and any ups and downs doing this upgrade. One thing to note at the moment is its defenitly easier to do this on an ST225 as im struggling for anyone to be able to MAP the car at the moment here in England.

      Anywa thats all for now folks. Open to any further advise on things to look out for etc etc as well if I have missed out anything on the list.
      -------------------------------------------------
      2009 Volvo S40 - With a few mods

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    3. #2
      Member LizardOfBodom's Avatar
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      Oh wow!.... (salivating)...

      btw how come your fuel pump looks like 1/3 of mine, is that just n actual motor to retrofit in whole sender unit or what? I still have my old one, never attempted to disembow it but is that actually a replaceble part?
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    4. #3
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      haha yeh a lot of parts to go on ..... yes mate I think its just the actual motor. It came off another V50 T5 so im guessing its just a better pump really.
      -------------------------------------------------
      2009 Volvo S40 - With a few mods

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    6. #4
      Member LizardOfBodom's Avatar
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      Quote Originally Posted by domwild43 View Post
      haha yeh a lot of parts to go on ..... yes mate I think its just the actual motor. It came off another V50 T5 so im guessing its just a better pump really.
      Interesting, I want to hear how it goes for you with retrofitting this part into existing pump assembly (see my old one off the car - hence my surprise seeing your tiny filter-like one :})

      tmp2.JPG

      Will be following this thread anyway, that thing will be a beast after you finish! :}
      Titanium Grey 2005 V50, T5AWD, M66, Stage 1 Hilton tune<-Click me
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    7. #5
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      haha thanks mate yeh scares me with the current power it has a bit so am a bit nervous with what its going to do after.

      Yeh to be honest I have no idea how that pumps going to be done, I got it from another V50 T5 that was doing over 400bhp so I thought I would snap that up and it came as it was. The guy that removed it from the other car is hopefully the guy who is going to install it in mine so I will check with him and let you know.
      -------------------------------------------------
      2009 Volvo S40 - With a few mods

    8. #6
      Junior Member hq_'s Avatar
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      Quote Originally Posted by domwild43 View Post
      Yeh to be honest I have no idea how that pumps going to be done
      As long as it's dimensionally compatible, it's a straightforward installation to the cradle. Walbro 255 (or equivalent) can support 400bhp+ quite easily, even though I'd refrain from installing a second hand pump. Their service life is limited and even though the ME9 does a good job protecting the engine, a failing pump can cause a lean situation and melt the pistons.
      All in all this looks like an interesting build. What kind of intercooler are you planning to use? The K16 is quite a bit less efficient than the EFR I've chosen for my project and charge air heat management definitely needs to be addressed.

    9. #7
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      Ive got a Bell Intercooler on at the moment and going to stick with it I think and see how that goes, should be big enough. Its the biggest intercooler you can fit in without having to start cutting any bumper off.

      Thanks yeh cant wait to get it on and mapped to see how it all goes, Hopefully not long till its done.
      -------------------------------------------------
      2009 Volvo S40 - With a few mods

    10. #8
      Member jondevieonS40's Avatar
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      Nice to see someone with some serious power goals, for advice on K16 builds there is a few on here but i would make a point to subscribe to the C30crew forum as they have a few more builds and active tuners on the site although this forum is pretty tight as well and perfect for troubleshooting and maintenance issues.

      I would love to see the progress of your build hopefully everything goes smooth. Is this something your doing at home or having a shop have at it?
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    11. #9
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      Thanks for that yeh never been on the C30 forum. But yeh this is all being done in a garage for all the engine work and mapping. Really struggle to find any mappers that would map this car.
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      2009 Volvo S40 - With a few mods

    12. #10
      Member lookforjoe's Avatar
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      Nice!

      Hilton can tune that.

      The Deatchwerks pumps I've used have reversed polarity, so check that - you may have to transfer over the pigtail. I also found they didn't last that long




      I specified a larger IC (28x3.5" core, 2.75" I/O) from BELL than their production version for my K16 build. Absolute largest core without cutting (the bumper, honeycomb in lower splash plate has to be trimmed). I'd say the standard BELL is better than many others, but not the best for K16 setups






      Just curious, but since you're in England, why not just get the LUK Ford RS clutch & flywheel setup?
      Last edited by lookforjoe; 03-05-2019 at 08:04 PM.

    13. #11
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      wow that looks great, yeh ok will defenitly look out on that fuel pump then thanks!

      Yeh I had remove the lower grille on my bumper to fit in the IC .... certainly is a tight fit but couldnt get it any bigger.

      CDTD12_2154p by Dom Hartland, on Flickr


      Are you running the K16 setup now as well? how are you finding it?
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      2009 Volvo S40 - With a few mods

    14. #12
      Member lookforjoe's Avatar
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      Quote Originally Posted by domwild43 View Post
      wow that looks great, yeh ok will defenitly look out on that fuel pump then thanks!

      Yeh I had remove the lower grille on my bumper to fit in the IC .... certainly is a tight fit but couldnt get it any bigger.

      CDTD12_2154p by Dom Hartland, on Flickr


      Are you running the K16 setup now as well? how are you finding it?
      I guess there's less room behind the early bumpers - the standard Bell IC is much smaller than mine.

      I've had the K16 in there for 2 years now, running the Hilton Stage III (or whatever he calls it). The problem with FWD, is that it's hard to have traction in the lower 3 gears & not get wheel hop off the line. That's why I'm converting my C30 to AWD. BTW, It's much worse if you don't have a posi, so you should deal with that ASAP. I've used Quaife & Wavtrac, prefer Quaife. Haven't used Gripper, but if that's one you can 'customize" I'd avoid it, unless you like R&R'ing the transaxle on a regular basis.

    15. #13
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      oh wow thats good so, who does the hilton stage 3's? maybe I should consider it?

      But yes will be looking to get a gripper later on in the summer as I use the car for track days.
      -------------------------------------------------
      2009 Volvo S40 - With a few mods

    16. #14
      Junior Member LittleRedRidingHood's Avatar
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      Quote Originally Posted by domwild43 View Post
      oh wow thats good so, who does the hilton stage 3's? maybe I should consider it?

      But yes will be looking to get a gripper later on in the summer as I use the car for track days.
      It's provided by Hilton Tuning (https://hiltontuning.com/), operated by Robert Hilton.
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    17. #15
      Member LizardOfBodom's Avatar
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      Dom, thats the same tuner that did my car, its done remotely and using Dice interface.
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    18. #16
      Let me know how that short shifter kit goes. I found some for hte Focus RS/ST's but the manufacturer's page doesn't mention what transmission they go on... (m56 vs m66)
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    19. #17
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      Ah right ok thanks guys, yes dropped him a message as he might be able to speed things up for me as well a bit. I saw on his site he recommends 650cc fuel injectors and I was advised 550cc and after doing a lot of reading I think I need to swap the 550cc injectors to either 650cc or 750cc even.

      avenger, will defenitly let you know on that short shifter kit, I had no idea myself but was very cheap so thought id give it a try.
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      2009 Volvo S40 - With a few mods

    20. #18
      Member lookforjoe's Avatar
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      Quote Originally Posted by avenger09123 View Post
      Let me know how that short shifter kit goes. I found some for hte Focus RS/ST's but the manufacturer's page doesn't mention what transmission they go on... (m56 vs m66)
      Not gonna be for M56 - that is a completely different generation (older) transmission that pre-dates Ford ownership of Volvo. Ford would only have used the M66 in their Volvo-powered manual trans Focus models.

    21. #19
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      Just thought I would update the threat here on the build, car has been sent of for parts to be bolted on now. Its being done in several stages. First steps here are to forge the engine and bolt on all the parts to get the car running with a temporary map for the new K16 turbo. Its an old map from Shark for the K16 and will then later on get the map done properly and have someone already lined up to do this.

      Few images of the car being collected and taken to the garage, cross fingers it all goes well:
      Towed away by Dom Hartland, on Flickr

      Towed away by Dom Hartland, on Flickr


      There is also a larger port polished head on the way to aid the engine build, pictures below:

      Port polished head by Dom Hartland, on Flickr

      Port polished head by Dom Hartland, on Flickr

      Will be interesting to see what the car is like after, also recently found out that the turbo is a K16 hybrid stage 3 .... initially thought it was just a hybrid stage 1.
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      2009 Volvo S40 - With a few mods

    22. #20
      Member LizardOfBodom's Avatar
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      Quote Originally Posted by domwild43 View Post
      Will be interesting to see what the car is like after, also recently found out that the turbo is a K16 hybrid stage 3 .... initially thought it was just a hybrid stage 1.
      whats the difference , plz? :>
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    23. #21
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      Quote Originally Posted by LizardOfBodom View Post
      whats the difference , plz? :>
      The difference should be similar to the below turbo chargers by Pumaspeed

      Here is a K16 hybrid stage 1:
      http://pumaspeed.com/product-Focus-R...harger_882.jsp

      Here is a K16 hybrid stage 3:
      http://pumaspeed.com/product-Focus-R...rger_16268.jsp
      -------------------------------------------------
      2009 Volvo S40 - With a few mods

    24. #22
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      Completly forgot to update here, have been keeping all build notes on www.volvoforums.org.uk as tuning this car seems to be a massive headache.... anyway I will update this thread.

      Forge build was completed with the k16 hybrid turbo and everything else bolted on. Temporarily drove the car for a week on the standard map which was insane (car accelerated faster than I could change gears) tried loading shark map for a k16 which was running on another S40 T5 but pre facelift and that went catestrophically wrong resulting in a new ECU and reloading the initial map back on the new ECU.

      Anyway car was running on standard map and send of to a local volvo specialist mapper who has had the car an been working on it where we have come across some issues that might help others when doing a similar thing on the facelift:

      - When getting an uprated fuel pump the preface lift and the facelift actually have different fuel pump and sizes are different so the prefacelift fuel pumps are smaller than the facelift ones which required some fabrication work to get that to fit. also pre facelift has 2 holes at the bottom in the harness where as the facelift has 3 .... think this was there to help with some fluxuation of the fuel pressure ... I dont really know. But got prefacelift daushworks fuel pump installed which has then led to a whole load of starting issues all pointing back towards the ECU. when priming fuel was coming through but on crank ... stone dry. after about a week the car then decides to randomly start up? so even though im releived that it is now running, im hoping this doesnt happen again.

      Car has also had a brand new fabricated exhaust to get rid of the straight through pipe which was massivly loud.

      Still a few more days left on the mapping but cross fingers all done.

      Whats next after the mapping? will defenitly be getting an LSD on the car once it has been mapped.
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      2009 Volvo S40 - With a few mods

    25. #23
      Member jondevieonS40's Avatar
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      Thats dope and thank you for sharing, cant wait to see some pics or videos of the process.
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    26. #24
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      Still problems with the last bits of calibration mapping, reads can vary by 200kg/hr from one day to the next. Its like there is a boost leak. Done a smoke test which didnt find anything.

      Having a look at either a check valve, based on another S40 K16 build, or it could be a failing recirc valve?

      These are all with the new bigger MAF.
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      2009 Volvo S40 - With a few mods

    27. #25
      Global Moderator tmtalpey's Avatar
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      Failed recirc valve will cause low boost but will not cause a leak/lost air. The vent fitting by the turbo won't either, unless its connection has come loose.

      If you can't find a leak, is it possible the MAF is sensing at the upper level of its range, with the new turbo and tune?
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    28. #26
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      Thanks man, so you recon it might be possible that its above the range that the maf can handle?
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      2009 Volvo S40 - With a few mods

    29. #27
      Global Moderator tmtalpey's Avatar
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      It's just an idea since you said you installed a "bigger MAF". Have you tried replacing with the original to see if things change?
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    30. #28
      Member EngTech's Avatar
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      Interesting , but would Like to have seen Inside of the Head & Turbo Housing , Not even showing any Porting at all . . at Best there may be some larger valves with Matching Cuts done to
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    31. #29
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      Speaking of Broken Belts - I have a Complete Belt , Cam Tension , Idler Pulley ( Genuine Volvo Parts ) in the Volvo Box Kit - placing It today ..Very Reasonable Thank You -
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      Or Like this : Ported Match Manifolds_zpsfzylxgo0.jpg
      Last edited by EngTech; 11-19-2019 at 10:27 AM.
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      Hey EngTech, Sorry yeh as it turns out the larger head had a crack in it as I purchased it and the guy was meant to refurb it but was wasting my time so I had my current head redone instead.

      The turbo (K16 Stage 3 Hybrid) itself I cant take any photo's of it as its on the car now, but this was second hand as well. It has done about 2000 miles since being built to stage 3 spec by another member within the UK volvo forum and came complete with Actuator, Rec Valve, Oil feed & Return lines, .... so naturally I had to snap it up.
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      2009 Volvo S40 - With a few mods

    33. #31
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      tmtalpey, the original never ran right at all ... it couldnt handle that turbo. From what I remember driving it on the standard MAF for a week the car was really failing to boost and kept on cutting out, but when it did that turbo was crazy but would cut out at 1.5k revs so going back to the standard MAF I think would just cause those issues again. The larger MAF is running well its just the last little configs that need to get done, but the mapper said on some days it seems to be fine but on others its not and feels like a leak?

      I have recent purchased a Focus st225 vac pipe kit, recommended by another guy running an S40 T5 here in the UK which he said fitting this vac pipe seemed to of solve a lot of his mapping problems. So cross fingers that helps, link below:

      https://customod.co.uk/products/focu...5-vac-pipe-kit
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      2009 Volvo S40 - With a few mods

    34. #32
      Member EngTech's Avatar
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      Map & Maf sensors from a RS seems would Help , and also couldn't just run stock Boost to get it broken in for 1500 miles and Leave
      the Higher Boost and Special Mapping to be down after some Seating in Miles and Rings have beaded In ?
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    35. #33
      Quote Originally Posted by domwild43 View Post
      tmtalpey, the original never ran right at all ... it couldnt handle that turbo. From what I remember driving it on the standard MAF for a week the car was really failing to boost and kept on cutting out, but when it did that turbo was crazy but would cut out at 1.5k revs so going back to the standard MAF I think would just cause those issues again. The larger MAF is running well its just the last little configs that need to get done, but the mapper said on some days it seems to be fine but on others its not and feels like a leak?

      I have recent purchased a Focus st225 vac pipe kit, recommended by another guy running an S40 T5 here in the UK which he said fitting this vac pipe seemed to of solve a lot of his mapping problems. So cross fingers that helps, link below:

      https://customod.co.uk/products/focu...5-vac-pipe-kit
      Just put in an inquiry with them - I want to get rid of the horrible stock unit in there now and help clean up the enginebay a bit too.
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    36. #34
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      Quote Originally Posted by EngTech View Post
      Map & Maf sensors from a RS seems would Help , and also couldn't just run stock Boost to get it broken in for 1500 miles and Leave
      the Higher Boost and Special Mapping to be down after some Seating in Miles and Rings have beaded In ?
      already did the breaking in of the forged engine running the standard map for a bit inbetween the engine being done and now the mapping so car should of been good to go. beading minus the performance fuel pump.

      Yes well cross fingers the mapper sorts it soon as he says some days its running fine, and others its as if there is a boost leak which is weird. But no sign of a leak after smoke test.
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    37. #35
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      85
      Quote Originally Posted by avenger09123 View Post
      Just put in an inquiry with them - I want to get rid of the horrible stock unit in there now and help clean up the enginebay a bit too.
      Yeh man, looks much nicer. Regardless if it helps of not its always a nice addition to the engine bay!

      Although later on I think it would be nice to relocate the battery to the boot here to free up more space. Few other S40 T5's here in the UK have done this and looks much better.
      -------------------------------------------------
      2009 Volvo S40 - With a few mods

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