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Discussion Starter · #1 ·
I have been planning out a custom intake for my car, and today I finally got around to examining the lower intake--which I have long suspected to limiting horsepower.<p>Here she is:<br><IMG SRC="http://i70.photobucket.com/albums/i117/paysts/Intake001.jpg" BORDER="0"><p>As you can see, the portion of the lower intake is not round, but oval shaped and not greater than 2" in diameter. I would estimate it to be about 1.75". The intake on the turbo side, however, is 2 1/2 inches in diameter. Why Volvo would do this is beyond me.<p>As you can see, this tiny flashlight doesn't have much room in the intake.<br><IMG SRC="http://i70.photobucket.com/albums/i117/paysts/Intake003.jpg" BORDER="0"><p><IMG SRC="http://i70.photobucket.com/albums/i117/paysts/Intake004.jpg" BORDER="0"><p>For this reason, before I bother with a tune or a FMIC or a downpipe, I am going to resolve this issue. I have took it upon myself to order some piping to ail this problem. I'll keep everyone updated.<p>By the way, can anyone with VADIS tell me what the sensor is that is on the intake tube? It looks like a temperature sensor, but I'd like to be sure about this.
 

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There are 2 sensors on the intake. MAP and IAT.<p>I don't really think there is much of a bottleneck with the piping. I really think it's a non issue with the kind of boost/power that the T5 engine is producing with a stock turbo, it simply doesn't push enough air for the intake to be a serious concern.
 

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cmurphy2266 is talking about the pipe between the intercooler and the throttle body and not the pipe between the air filter box and the turbo as in the pictues.<p>There are no sensors connected to the intake pipe (the plastic pipe) only the PCV system connection heater (the big one seen in the first picture) and two 'vacum' lines (one from the TCV and one from the intake manifold).<p>I redid the intake pipe on my mildly modified manual S60T5 2001 last week for the same reason as stated by Paysts. The smallest surface area of the pipe (first picture) is actually a bit smaller than the surface area of the intake on my 19T turbo, and in that way working as a restrictor.<p>I did my custom pipe of 3" aluminium pipe and silicone connectors as I wanted the pipe to be at least as wide as the air mass sensor housing (I can put up some pictures later). <p><br><i>Modified by Wille at 2:41 AM 8-17-2009</i><BR><BR>
<i>Modified by Wille at 2:42 AM 8-17-2009</i>
 

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this is post turbo - its pressurized air - smaller is better to get boost to proper levels in this scenario. you up the size of that piping, i suspect you will need a bigger turbo to maintain proper boost levels.
 

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Re: (Bender)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>Bender</b> »</i></TD></TR><TR><TD CLASS="quote">this is post turbo - its pressurized air - smaller is better to get boost to proper levels in this scenario. you up the size of that piping, i suspect you will need a bigger turbo to maintain proper boost levels.</TD></TR></TABLE><p>No it's pre turbo. The pipe is located between the air box and the turbo.<p>You will want this pipe to be bigger in diameter than the intake on your turbo (on my 19T bigger than the ~56mm cone) but not much bigger than the air mass sensor housing (~76mm). Besides the diameter you will want the intake pipe to be as non restrictive as possible, meaning as straigth as possible and no connections/other stuff going deep into the pipe. Then you could of course optimize the flow in the pipe by shaping it the 'right' way, but that's a whole diffrent story. <p>If you up the size of the piping a little bit on the pressurized side post turbo you won't need a bigger turbo to sustain the same level of boost as before. The only difference is that it will take a few more milliseconds for your turbo to reach the same level of boost as it did with the smaller pipe.
 

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makes sense!<p>I see you have a custom 3" turbo intake pipe - it seems you have already done this, so enlighten us!
 

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Re: (Bender)

In the past there were parts available but expensive. Best would be to fabricate something yourself.<p>Example,<p> <IMG SRC="http://home.kpn.nl/dijkstra/images/s60/intakeL.jpg" BORDER="0"> <p>The "sensor" is the PCV solenoid for the crank ventilation. With the normal tuning changing the pipe doesn't make that much of a difference but with a larger turbo like the 19T and some more mods there is some difference. <p>
 

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Re: (Wille)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>Wille</b> »</i></TD></TR><TR><TD CLASS="quote">cmurphy2266 is talking about the pipe between the intercooler and the throttle body and not the pipe between the air filter box and the turbo as in the pictues.<p>There are no sensors connected to the intake pipe (the plastic pipe) only the PCV system connection heater (the big one seen in the first picture) and two 'vacum' lines (one from the TCV and one from the intake manifold).<p>I redid the intake pipe on my mildly modified manual S60T5 2001 last week for the same reason as stated by Paysts. The smallest surface area of the pipe (first picture) is actually a bit smaller than the surface area of the intake on my 19T turbo, and in that way working as a restrictor.<p>I did my custom pipe of 3" aluminium pipe and silicone connectors as I wanted the pipe to be at least as wide as the air mass sensor housing (I can put up some pictures later).</TD></TR></TABLE><p>I wasn't sure what he was talking about, he made it a big confusing. I was thinking it was the cold side of the FMIC. <p>hard to see from those pictures...
 

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I was confused also. I agree the tube from the airbox to the turbo should be free flowing and open I'll have to check this tube out...
 

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Re: (cmurphy2266)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>cmurphy2266</b> »</i></TD></TR><TR><TD CLASS="quote"><p>I wasn't sure what he was talking about, he made it a big confusing. I was thinking it was the cold side of the FMIC. <p>hard to see from those pictures... </TD></TR></TABLE><p>I see.. they do look quite similar.<p>Earlier today I promised some pictures of my custom 3" intake pipe and here they are. <p>The pipe ready to be mounted (hose clamps missing from picture):<br><IMG SRC="http://i702.photobucket.com/albums/ww28/wilbrun/20090813086.jpg" BORDER="0"><p>Pipe installed upper section:<br><IMG SRC="http://i702.photobucket.com/albums/ww28/wilbrun/20090817098.jpg" BORDER="0"> <p>Lower section:<br><IMG SRC="http://i702.photobucket.com/albums/ww28/wilbrun/20090817101.jpg" BORDER="0"><p>Wide view:<br><IMG SRC="http://i702.photobucket.com/albums/ww28/wilbrun/20090817103.jpg" BORDER="0"><p>I also measured the diameters of the standard pipe where it's at smallest (the spot can be seen in Paysts first picture) and the diameters are 42mm in one direction and 47mm in the other, which both are way less than ~56mm inlet cone on my turbo (ported 19T). On the 19T the compressor inlet hole is 47mm so the pipe area is even smaller than the turbo inlet hole area! In my case the standard pipe is a clear restrictor. <p>Inlet cone and inlet hole of my old 16T can be seen here:<br><IMG SRC="http://i702.photobucket.com/albums/ww28/wilbrun/DSC00306.jpg" BORDER="0">
 

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Re: (Wille)

Might as well switch the MAF housing to S60R MAF housing, around 5mm larger. <p><IMG SRC="http://i116.photobucket.com/albums/o12/ifnt420/DSC03259Large.jpg" BORDER="0">
 

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Re: (Paysts)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>Paysts</b> »</i></TD></TR><TR><TD CLASS="quote">Nice. Does the car make anymore noise because of the intake? </TD></TR></TABLE><p>No, not at all because the suction and bypass noise from the turbo gets muted in the air box in the same way as on a standard car. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/smile.gif" BORDER="0"> <p>If you want noise then make a 4" intake tube and use a cone filter. <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/biggrin.gif" BORDER="0">
 

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Re: (ifnt420)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>ifnt420</b> »</i></TD></TR><TR><TD CLASS="quote">Might as well switch the MAF housing to S60R MAF housing, around 5mm larger. </TD></TR></TABLE><p>Yes why not. It would though need a calibration in the software which is not a problem if you already have a custom made for you. The T5 original MAF will however not be a bottleneck until you are making serious modifications to the engine and sucking a lot more CFM through it.
 

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Re: (Wille)

here's an intake I did for a WRX with a GT35/40<p><A HREF="http://autospeed.com/cms/A_1519/printArticle.html" TARGET="_blank">http://autospeed.com/cms/A_1519/printArticle.html</A><p>worked a treat but yeah, noisy, sounded like a giant vacuum cleaner at full noise on the dyno!!<p>Also while you're there check out the brake mod, did this myself using R32 GTR 4 pot calipers and some custom brackets and hats to mount the corvette rotors.<p>Nice Job on the intake piping to the turbo....I like! <p>Make a kit and i'll buy it.<p>Karl
 

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Re: (LPG Karl)

<IMG SRC="http://autospeed.com/cms/gallery/article.html?a=1519&i=4" BORDER="0"> <p>just attempting to get this working....
 

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Discussion Starter · #17 ·
Re: (LPG Karl)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>LPG Karl</b> »</i></TD></TR><TR><TD CLASS="quote"> <IMG SRC="http://autospeed.com/cms/gallery/article.html?a=1519&i=4" BORDER="0"> <p>just attempting to get this working....</TD></TR></TABLE><p><IMG SRC="http://us1.webpublications.com.au/static/images/articles/i15/1519_4mg.jpg" BORDER="0"><p>There you go. <p>Today I measured the inner diameter of the intake-to-turbo par with digital calipers, and it measured 2.375" or 60.27 mm (~60 mm). But it looks like the last of my parts are going to come in today, and I'll be posting some pictures up. This thing is definitely going up on a dyno soon.<p>Can anyone confirm that 2002 and newer Volvos use a different MAF sensor in terms of size than the 2001's?
 

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Discussion Starter · #18 ·
Hey guys, I finally finished the intake on my car this last Thursday. I have had the car out of commision for the last three weeks since I first made the original post. And the results are that the car F*CKING FLIES! It's amazing, the turbo actually starts spooling even harder and faster at 4000 RPM than the 2000 to 4000 RPM pull, and the noise from the intake is true turbo. You know when you are on the highway and you can hear the turbo on the big rig next to you spooling up? Well, it sounds like that, except this car will leave you in the dust. And it's been to early too say, but I've getting 1 MPG better on the highway consistently, which I observed while on my way to work and back to my home.<p>Well, I'll throw up some pictures as soon as I can. As far as I know, I'm one of the few people with an S60 and a performance lower intake (post MAF) in America. <p>*EDIT* New pictures<p><IMG SRC="http://i70.photobucket.com/albums/i117/paysts/0905091606a_209006.jpg" BORDER="0"><p><IMG SRC="http://i70.photobucket.com/albums/i117/paysts/0905091606b_218548.jpg" BORDER="0"><p><IMG SRC="http://i70.photobucket.com/albums/i117/paysts/0905091607a_192928.jpg" BORDER="0"><p>I know, I know--the engine bay is dirty, and the vacuum lines have yet to be set properly. <BR><BR>
<i>Modified by Paysts at 5:12 PM 9-5-2009</i>
 

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Re: (Paysts)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>Paysts</b> »</i></TD></TR><TR><TD CLASS="quote">Hey guys, I finally finished the intake on my car this last Thursday. I have had the car out of commision for the last three weeks since I first made the original post. And the results are that the car F*CKING FLIES! It's amazing, the turbo actually starts spooling even harder and faster at 4000 RPM than the 2000 to 4000 RPM pull, and the noise from the intake is true turbo. You know when you are on the highway and you can hear the turbo on the big rig next to you spooling up? Well, it sounds like that, except this car will leave you in the dust. And it's been to early too say, but I've getting 1 MPG better on the highway consistently, which I observed while on my way to work and back to my home.<p>Well, I'll throw up some pictures as soon as I can. As far as I know, I'm one of the few people with an S60 and a performance lower intake (post MAF) in America. </TD></TR></TABLE><p>Freaking werd, man!!! Wonder if it would work as well on a 2.5T? If so you may have a lot of friends...sounds like it may be a cheapish mod. <p>Could you give a ballpark on how much materials ($) cost and time it took too?<p>Nice job on innovating a new intake mod that no one seemed to consider yet <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0">
 

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Discussion Starter · #20 ·
Re: (stealthS60AWD)

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD><i>Quote, originally posted by <b>stealthS60AWD</b> »</i></TD></TR><TR><TD CLASS="quote"><p>Freaking werd, man!!! Wonder if it would work as well on a 2.5T? If so you may have a lot of friends...sounds like it may be a cheapish mod. <p>Could you give a ballpark on how much materials ($) cost and time it took too?<p>Nice job on innovating a new intake mod that no one seemed to consider yet <IMG NAME="icon" SRC="http://********************/smile/emthup.gif" BORDER="0"> </TD></TR></TABLE><p>A. I can't say if Volvo has redesigned the air intake tract past the MAF sensor from 2005+, but if it is the same, it should work.<p>B. The cost of the materials was approximately $125, including shipping. I had to order these parts from several different vendors, thus the higher costs. For example, I had to place a lone order for a 2.5" to 2.25" coupler. Then, factor in all of the wrong parts that I ordered, or parts that didn't fit, and there is an additional $150 dollars. In truth, I don't feel too bad about this situation due to the absence of a how-to guide. Finally, although this would not count if you had all of the available tools, I had to update my tools, buying several more tools and parts for cutting and drilling. For instance, I had to buy a larger pipe cutter.<p>In terms of time, I spend approximately 1.5 hours taking off the lower intake pipe, taking my time and being careful. It took approximately 3 hours to measure and cut the final pieces of the pipe. But it was well worth it as my air box lid closes nice and tight. I also had to take into consideration that the engine rocks back and forth due to shifts and engine load. To attatch the PCV solenoid to the pipe, well, that took away untold hours of sleep as I tried to figure out how to attatch it so that it was air tight to the pipe. Lastly, when I had everything settled, it took me another 7 hours to install the pipe, although I did spend about 2 hours at the hardware store, going back and forth for barbs, a tap, a drill bit, and what not. I also had to find a new line for the flame trap, since it is slightly smaller than .5". So--if you're still reading this <IMG NAME="icon" SRC="http://www.vwvortex.com/vwbb/biggrin.gif" BORDER="0"> -- the installation took approximately 2 hours. I also would not advise you to performan any work on this car whatsoever if the car has been running for less than 6 hours from the time you decide to work on the car.<br> <br>C. Thanks! I'm going to be doing another intake for my friend who owns an 01 S60, which I hope it will all be done in 2 weeks time. I am still testing my pipe out, beta if you will. Next time around, the intake is going to get a coat of primer ceramic coating, then aluminum paint. <BR><BR>
<i>Modified by Paysts at 5:41 PM 9-5-2009</i>
 
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