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Discussion Starter · #1 ·
Project S60RR - MTE designed & tuned (hi-bandwidth)

Ok, since some of us seem to be in the doldrums.... let me share with the swedespeedsters what I've been busy with..


Started down the slippery slope of modification back in November 05, and now it is time to introduce my S60RR that was designed and tuned by MTE (Marco).

This car is considered as more of a 2nd prototype with the first protype (named Phoenix) done on a V70R. Similar in nature to the 450hp kit from MTE, these protypes were the result of looking for ways to bring the costs down..

The required fabrication was done by a local mod shop and I had the car back 11 days later. I've been testing the car since then for daily drivability and track "hardiness". Here are some pics during the transformation process.

Stock ICs removed and an ARC M079 FMIC was added with custom pipings. An IC waterspray with 2 nozzles for the FMIC and 2 nozzles for the radiator/air-con condenser can also be seen in the pic below.


The space created by moving the air-con condenser backwards allowed the 3" thick FMIC to be fitted behind the front bumper bar.


The new GT3076R WG turbo beside the stock.



The new turbo in place with the necessary mods to the oil/water lines. SVR DP had to be modified to fit and subsequently thermal wrapped.


With the FMIC in place, there was space to squeeze a 3" air duct just in front of the a/c condenser/radiator.


The Aquamist 2D system was added for water injection to keep any detonation in check. A GFB Stealth Universal BOV was used for internal recirculation between the cold side of the FMIC and turbo intake. The 3" air duct hose can also be seen.



The "Keyhole" plastic was cut off and an aluminium billet added to secure the air hose.



The intake pipe had to be modded for the new style of re-circulation.


I wanted the stock look of the engine to be retained and hence the stock turbo out pipe was modded to fit the new turbo.



The finished look of the engine bay.


The oil temp and boost gauge that some of you have seen before.


And the final outcome.


The engine internals are stock so Marco had the engine tuned to hold boost at 1.45bar or 21psi.

So what other stuff will I be looking at?
1. Oil cooler....cos I've seen oil temps as high as 135degC after 3 laps on an F1 track....
Did the temps go any higher than that? I could not tell during that test track session as the oil sensor wiring which was located a little too close to the turbo melted...


2. Intalling my SPEC stage 3+ clutch....I've had it for 3 months now but the stock clutch refuses to die...


Did everything go smoothly as planned?
Nope...this happened too during my test session on the track....
Burnt "Thrust" silicone hose...(due to turbo heat not shielded sufficiently from the hose). That caused the turbo out piping to "leak" and my track session was over as I could only limp home with about 1bar of boost...
.


I also realised my setup consumes a lot of water. Within 3 laps (5.5km course), I used up the entire 4.5lit of water (washer fluid reservoir). Looks like more tuning for the Labtronics intelligent IC water spray system as it seemed to be triggering a little too soon.

That's all for now..
Cheers!

Modified by blot at 11:10 PM 5-12-2007
 

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Re: Project S60RR - MTE designed & tuned (blot)

Wow!!! You kept yourself quite busy. I love the picture of the engine, you can't tell you have all those mods under the hood. Perfect for service time (not that it matters over there as it does here in the US).
How does your aquamist system activate? Through temperature or boost?

NICE WORK!!! http://********************/smile/emthup.gif http://********************/smile/emthup.gif
 

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Discussion Starter · #3 ·
Re: Project S60RR - MTE designed & tuned (mike_c70)

The aquamist 2D system that I'm using has an additional priming pump (Volvo OEM hi-pressure washer pump) and a 30cc anti-surge accumulator. That enables the pump to run at max pressure to provide water injection via 2 x 0.5mm nozzles that are spaced 6" apart prior to the IAT/Boost pressure sensor which has also been re-located nearer to the throttle body.

Currently I think I'm running a water to fuel ratio of 10 to 13%..

oops didn't ans the question fully:
The activation of the 2D system is based on boost pressure and injector duty cycle (i.e. engine load). A combi of above 0.7bar boost and high injector duty cycle (determined by the built in 3d water map in the system) will trigger the water injection. The amount of water injected is based thereafter on the injector duty cycle. A high speed solenoid valve (part of the system) controls the rate of water injection. The size of the water nozzles used also determines the water to fuel ratio.

Modified by blot at 7:38 PM 1-8-2006
 

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Re: Project S60RR - MTE designed & tuned (blot)

Jolly good show http://********************/smile/emcocktl.gif
 

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Re: Project S60RR - MTE designed & tuned (blot)

Wow, nice work!!! Glad to see someone pushing the envelope again...
-Aaron
 

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Re: Project S60RR - MTE designed & tuned (blot)

Schweet !!! Nice work http://********************/smile/emthup.gif http://********************/smile/emthup.gif
 

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Re: Project S60RR - MTE designed & tuned (blot)

Good work Benny!!

I hope the bugs will work out soon so you can enjoy the power!

http://********************/smile/emthup.gif
 

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Re: Project S60RR - MTE designed & tuned (blot)

Good afternoon,

Where is the water tank?

Looks good, and very stealth http://********************/smile/emthup.gif
 

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Re: Project S60RR - MTE designed & tuned (blot)

Wow. Awesome. http://********************/smile/emthup.gif

Questions:
What exhaust are you running after the SvR DP?
Will you release hours of labor & prices for the mods you are doing?
Where are you located?

Once again, http://********************/smile/emthup.gif Can't wait to hear some 1/4 mile or 0-60 times.
 

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Re: Project S60RR - MTE designed & tuned ("R" Kelly)

Quote, originally posted by "R" Kelly »
Can't wait to hear some 1/4 mile or 0-60 times.

There is more in life than that Kelly..
 

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Discussion Starter · #13 ·
Thanks guys.

The "inspiration" really came from Johann, SinR (who did it first over here), MTE, Marco and the various other mods posted in this forum.

Here's a 4-wheel dyno chart showing the original WHP and Torque in 3rd gear (Test 8) vs the latest runs in 3rd gear (Test 24) and 4th gear (Test 26).



Based on the dyno, I'm showing a gain of 48.5WHP and 48Nm of Torque from bone stock.

The turbo is much larger and laggier, so I've lost a little from idle to 3200rpm.

IAT has improved tremendously as my previous dyno runs have recorded IATs of up to 105degC or 221degF. The FMIC and more efficient turbo has reduced that to 66degC or 151degF. On the track, WOT showed peak IATs of about 56degC or 133degF. Goes to show how important the fan is on a dyno as there was a 10degC or 18degF difference in IAT.

If a "simple" backwards calculation of crank HP and Torque is made using Volvo's claimed 300BHP and 400Nm of Torque, then I guess I'm looking at the following:
371BHP and 463Nm of Torque at the crank.
But as we all know, real figures are probably lower... not giving any excuses, but perhaps it is the ambient temps here or just that the dyno that I go to seems to consistently give lower numbers as compared to what you guys have over there.

The bugs have been worked out since yesterday and I'm now just waiting for a 21st Jan Track session for more testing/enjoyment.

The dyno charts and OBD2 data that I've collected seem to indicate that the current main restriction is flow....either air-intake or exhaust.

Here's a chart showing why I think so. It shows the portion down the back and front straights of the track where I'm accelerating from 2nd to 4th. The IAT does not seem to that much of a factor now given that the turbo is capable of up to 2.2bar easily while still being efficient. The FMIC/WI/IC spray combi seems to be coping well too.


Detonation does not seem to be an issue as I'm seeing a rise in Ignition timing advance from 10deg all the way up to 25.5deg.

But if you look at the MAF data, you can see it topping out at about 265g/s... or 954kg/h. On the dyno, I had up to 273g/s or 980kg/h. BTW, our OEM MAF can only read up to 1020kg/h. Given that fact, i think the possible limiting areas are:
1. either my MAF is dying from too much oil from the filter, (new MAF and back to stock filter?)
2. air flow is just plain insufficient, (think ATspeed S60R)
3. the exhaust is not free flowing enough, (4" exhaust?)
4. or the ecu just can calculate above that figure. (piggy back ecu?)

Just some thoughts...
 

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Discussion Starter · #14 ·
Re: Project S60RR - MTE designed & tuned (Helmut Ranff)

..no water tank yet...still considering. The current setup uses the washer fluid reservoir (4.5lit).
 

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Discussion Starter · #15 ·
Re: Project S60RR - MTE designed & tuned ("R" Kelly)

Quote, originally posted by "R" Kelly »

... What exhaust are you running after the SvR DP?...

The head of the SVR DP had to be chopped and modded as at that point in time there was no flange on the market that could fit the DP to the turbo....there's one available now.


Quote, originally posted by "R" Kelly »

... Will you release hours of labor & prices for the mods you are doing?
Where are you located?...

I think I'll wait for MTE http://www.mte.se/default.asp?aGr=chLang (or IPD) or MTE works http://www.mteworks.com/ to work that out...

Quote, originally posted by "R" Kelly »

... Can't wait to hear some 1/4 mile or 0-60 times...

Sure...when I get the chance with my Gtech..
 

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Discussion Starter · #16 ·
hmm, my boost is sustained all the way to 7500 rpm too, but a much noticeable drop in torque past 5500rpm. Yours seem to continue climbing.

Yes, on hindsight, I think that for the R, a GT3071 is more than sufficient with stock internals as both compressor charts are quite similar with the GT3076 allowing more boost with the same efficiency....(areas in which a stock engine cannot take).

BTW, I noticed that your IATs are lower than the Ambient temps. How did that happen?
 

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Re: (blot)

Quote, originally posted by blot »

BTW, I noticed that your IATs are lower than the Ambient temps. How did that happen?

Not measured through the system.

IAT stayed below 60, often 55 or so max. Stock always measured 45 degree max. We do not have this steaming weather here..
 

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Re: Project S60RR - MTE designed & tuned (Johann)

Quote, originally posted by Johann »
There is more in life than that Kelly..

Well, I don't think the FMIC, MTE tuning, bigger turbo and aquamist system are going to help him pull more Gs, corner better or improve steering feel, so pretty confident improvement in acceleration are what he was hoping for


When he shows his suspension mods, I'll ask about reduced tail hop, higher g limits, etc.
 

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Re: (Johann)

Johann-

GT2871R is too small to make this amount of hp? http://********************/smile/emthup.gif http://********************/smile/emthdown.gif
 

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Re: Project S60RR - MTE designed & tuned (blot)

Quote, originally posted by blot »
The head of the SVR DP had to be chopped and modded as at that point in time there was no flange on the market that could fit the DP to the turbo....there's one available now.

I'll ask on behalf of someone else that may want to change turbos, who has this flange?

And what cat-back exhaust are you running? Custom, Svenske, Ferrita, Evolve, TME, Jetex/BSR or stock?

And are you in Europe or Asia...
 
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