2004 Volvo S40 - Tuner Car - Sport Car Compact Magazine

The Plan
The latest Volvo S40 defies conventional Volvo thinking. The redesigned sports sedan, introduced in 2004, relies more on its 218-hp turbocharged five-cylinder powerplant and six-speed gearbox than on its airbag count to generate sales. It's a new direction for a car company not known for its performance heritage.

With the fundamental elements in place we wondered how much potential the S40 might have. International Product Development (IPD) USA has been tuning Volvos since 1963 and offers performance parts for the S40. We teamed with IPD's experts to enhance the S40's power and driveability. Next month, we tackle the chassis.

The Parts
The S40's ECU is integrated with nearly every electrical component of the car, so tuning it requires specialized software and intimate knowledge of its Bosch code. The days of simply soldering a chip into place are gone.

IPD sent the computer to Swedish firm TME, which, according to IPD, raised boost from 8 to 14 psi and remapped both fuel and ignition tables to compensate for the added cylinder pressure. The redline bumped from 6200 to 6600 rpm and TME increased the knock sensor's sensitivity at high rpm. The speed limiter was also removed.

The calibration goals promise more power, yet remain realistic. IPD engineers say the program retains full functionality and meets all emissions standards (probably because it's virtually impossible to detect).

Accessing the ECU is easy. The computer's housing is located adjacent to the air filter compartment in front of the radiator. Two electrical connectors and a series of Torx bolts hold it in place.

Heico Sport Exhaust
The Heico system differs little from the original save for stainless-steel construction, a pair of chrome tips and a protective matte coating.

The muffler must be severed from the exhaust piping in this general location. The exhaust system can alternatively be unbolted and routed through the rear suspension, but this takes significantly longer and only prolongs having to make the cut.

The muffler must be severed from the exhaust piping in this general location. The exhaust

The original muffler piping must be cut behind the rear crossmember since Heico uses a slip joint and clamp design instead of flanges and bolts. With the muffler free, disconnect the rubber bushings to remove it. A precise cut must be made on the remaining section of piping. Heico supplies measurements and diagrams, making the installation easy.

The Results
Back on the dyno with the retuned ECU and new exhaust, peak power increased by 7 hp. Torque increased by 9 lb-ft at about 3500 rpm. Both power and torque improved from 2500 rpm to redline. These changes were good for a slight e.t. drop of .2 seconds.

The power difference appears rather insignificant on the track but proves itself on the street in real-world application. The low-end torque increase won't shatter any records but it's a noticeable and worthy addition when it comes to the daily commute.

Cost
ECU reflash: $995
Exhaust: $999

The section of previously cut piping can now be reinstalled. Slide the pipe into the muffler tubing and bolt the other end to its original location.
The section of previously cut piping can now be reinstalled. Slide the pipe into the muffl

Heico supplies a template and measurement for making the cut. By performing the previous arbitrary cut near the muffler, we were able to remove this section of piping from the car to ensure accuracy.
Heico supplies a template and measurement for making the cut. By performing the previous a
Both the muffler tips and muffler tubing connect using slip joints and clamps. Orient the tips, muffler and tubing properly prior to tightening the clamps.
Both the muffler tips and muffler tubing connect using slip joints and clamps. Orient the