Volvos do a very good job of running fairly well with very worn components, and in some cases do well even with fairly damaged components. One of the most important things to do before tuning your vehicle is to make sure it is in perfect running order. This initial preparation stage is referred to as ‘Stage 0’.
One of the most important checks are vacuum lines, even a small nick or tear can cause a major problem when it comes to idle quality and wide open throttle air to fuel ratios. It is best to replace all original rubber lines with high quality silicone lines that will not degrade.
Remember that tuning increases the output of your engine, so it is crucial that it is functioning 100% properly before carrying out any modifications. Before modifying your car, make sure all ignition components are new, and quality parts have been used. This includes the distributor cap and rotor, spark plugs wires, spark plugs and in some cases, the ignition coil. Please see the article ‘Spark Plug Selection and Spark Blowout‘ for more information.
The fuel system is also extremely important. Check to make sure your fuel filter is new and your fuel pump is in good condition. It is good insurance to preemptively replace the fuel pump, since the original’s pump capacity decreases with age. Even when new, the stock fuel pump struggles to supply enough fuel for any turbo larger than the stock 15g or 16t.
The Whiteblock engine from Volvo is a very stout engine and can handle up to 400WHP with no internal modification. Although the engine will handle this amount of power, it is treading on thin ice, as knock, boost overshoot or lean running will bend a rod. If you plan to have more than 350WHP it is recommend to install forged connecting rods.
At VAST we do not provide tune ‘stages’. Rather, we tune every car to the maximum amount of power that it can safely produce with the given modifications.
Stage 0
This is a entirely stock setup with a 15g/16t and a full ‘stage 0’ performed.
Expected Power – 210WHP/240TQ
Stage 1
The first recommended modification, after a tune, is a full turbo-back exhaust kit. A free flowing exhaust can help net up to 30WHP. Also, one step up in injector size is recommended, to either white or blue injectors. The factory fuel pump is rated to flow enough fuel for this level of power, but given fuel volume drop off due to age we recommend replacing the fuel pump with a DW200 and also upgrading the fuel pump wiring.
Expected Power – 235WHP/280TQ
Stage 1.5
After an exhaust the next recommended modification is an upgraded intercooler and or water methanol injection.
Expected Power – 245WHP/330TQ
Stage 2
18t/19t turbo including an exhaust and intercooler or water methanol injection or E85. Green injectors are the minimum injector size for either of these turbos, but 650cc injectors are required for E85. The factory MAF housing can only register 826kg/hr of air flow, which is about 13psi from a 18t/19t. There upgrading to a 960 MAF housing is needed to accurate tune the car. A wideband gauge is highly recommend at this stage.
Expected Power – 290WHP/360TQ
Stage 2.5
20t/22t/K24 turbo, an incremental increase over the 18t/19t turbo, but with more top end pull.
Expected Power – 310WHP/370TQ
Stage 3
20G, forged connecting rods, 650CC or larger injectors. 3.25″ MAF housing. PCV system upgrade.
Expected Power – 410WHP/410TQ
Stage 4+
Large frame turbo.