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VulvaS40T4

My Volvo S40 T4 700hp with Holset

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Nice pics!

That certainly looks better - it definitely looked restricted by the narrower previous slots.

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Final edition intake manifold measured on flow bench today 186.5hp 11mm lift. :) Earlier had 177.5hp. This means that on 2.8bar boost it should produce now 708hp vs earlier 674hp in theory (34hv more). In spring we have real life dyno facts. :)

Im happy now. ;)

Edited by VulvaS40T4
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Done for low maintenance? I personally prefer the polished look ;)

 

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Very interesting, copper gasket! Scary expensive but so is your build!

Is it exactly the same as your factory gasket?  More holes less holes?

Does having Darton sleeves change coolant circulation?  In the photo (cyl.#1) you can see the Darton sleeve.

 

 

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Yes same as stock as design dartons wont change anything. My friends with 950hp(sute/dartons) and 1002hp(vekku/stock block) on same 4cyl engine has used same custom headgasket without any problems. :)

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Updates:

-D5 sputter rod bearings

-1.2mm piston oil cooling jets (stock 1.9mm) to reduce crankcase pressure problems on standing mile

-modified intake manifold

-darton 81.5mm mid sleeves

-e85 fuel cooler 

-extra crankcase catch can under stock place catch can

-electronic boost control from 1.7bar 500hp to 2.8bar 700hp

This summer goal 700hp / 650nm with good daily realibility. :) 

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NICE WORK!

Curious how going to a smaller oil squirter impacts the CC pressure?

Your 2 -stage breather box is straight VTA under the motor, or did you add a connection back to the intake tract? Did you add a MAP sensor to monitor CC pressure at the box?

Any more pics of the exhaust manifold design? Looks pretty cool - it has a mini- collector that feeds the WG? 

What size exhaust do you run to the back, is it larger than 3" for these goals? Do you use straight through mufflers since is it DD? or does it need to be quieter for you noise ordinance laws? Do you have to run a Cat?

Are you using a transmission type oil cooler for the fuel cooling? Where do you locate it?

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Thanks. 3.5" Stainless steel exhaust with 3 straight through mufflers from turbo to back bumper and it has good sound and very silent for its size because this is DD car. Wastegate goes to downpipe and no CAT because with e85 fuel i can get good emissions even without CAT.

Manifold is divider to turbo and also to one wastegate and 38mm/33mm runners.

3" old exhaust was limiting power after 550hp and 3.5" is good after that. When running wastegate to outside air you can get littlebit more from 3" exhaust.

Oil squirters cause oil fog inside crankcase on high rpms and because our crankcase is so tiny it will splash to crankshaft and that is one reason we get lots off crankcase fumes out off block on long WOT runs. With e85 fuel temps inside engine are lot colder than with gasoline so i could run even without oil squirters with no risks.

Fuel cooler will be installed in front off radiator and it is big oil cooler connected to return line from injectors and from there to my fuel surge tank. Fuel temp is also issue with e85 fuel because it has low vaporation point like 50celsius.

Breather fumes go directly under motor from second breather box and it has also return line to oil pan over the oil level. I had CC pressure sensor earlier but because these pressures are so small like 0.1bar maximum you dont see much from that sensor and thats why i dont anymore have that sensor. I have oil pressure sensor in my logs now on same channel. :) Also my breather systems breather box number one has now bypass to directly under car also from bottom off that breather so in winter i can bypass that second breather box because lots off condensation is also issue on cold temps when running e85 fuel. 

 

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20130803_125255-1_zpsf116ecb3.jpg

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Now that's a fun DD!!  :blink:

 

Is that 3.5" all the way back?

Edited by gdog

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For your crankcase ventilation system you have no additional valve cover vents, correct? You're only running the stock block vent, the old turbo drain return as a new vent and the stock valve cover vent, right?

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