My Volvo S40 T4 project

[Kerry_T-5R]

The Volvo S40 T4 engine is basically 4 out of 5 cylinders form a T5 engine. it is 1855 cc (80% of a 2319 cc T5 engine). The Volvo S40 was a joint project with Mitsubishi so shares the same chassis as the Lancer Evo 3 - so it handles well.

Here is some pictures of when I bought it in 2006 :

http://i238.photobucket.com/albums/ff190/t4kerry/oct06.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/oct06-2.jpg

The nex few posts I will copy and paste from another forum :

[Kerry_T-5R]

NOVEMBER 2006
While driving home, I had noticed a few worrying things about the car.
Firstly, there was an occasional miss-fire under load in third, fourth and fifth gear – which was most apparent at about 3,000 rpm all the way up to 5,000 rpm but only occurred when the accelerator was pressed more than half way down.
Secondly, there was a loud hum coming from all four corners of the car at all speeds.
I decided to have a large service done in November.
I bought:

NGK platinum tipped spark plugs
6 litres of Mobil 1 0w 40 (some for topping up)
genuine oil filter
genuine air filter
2 litres of Volvo anti-freeze
genuine thermostat
genuine fuel filter
I had the service carried out by my local mechanic in mid November and after extensive testing, the spark plug change had cured the occasional miss-fire. £40 of plugs is almost a cheap fix!
Still wasn't sure about the hum though - and after enquiring about wheel bearing prices I was hoping it wasn't them!

[Kerry_T-5R]

DECEMBER 2006
This month was to be another expensive one!
After looking very closely at the tyres, they looked as though they were beginning to de-laminate, most likely due to under inflation (the pressures were low when I got the car home originally)
Next came four new tyres to replace my Pirelli P6000’s. I went for Pirelli’s range topping P-Zero Nero’s (205, 50, 16’s). The tread goes all the way round on to the sidewall – creating almost endless grip! But they weren’t cheap at £115 per corner (including fitting).
http://www.pirellityre.com/web/catalog/car-suv-van/catalogo_desc.page?uri=/pirellityre/en_IT/browser/xml/catalog/car-suv-van/CAR_PZERON_SUM.xml
After pulling away from the tyre company, the car was silent! Luckily changing the tyres had cured the loud hum – which was getting louder up until I had the tyres replaced! Lots of people on here seem to have noticed a hum with their P6000’s due to the block pattern of tread.
I increased the tyre pressures to 38psi (front) and 35psi (rear) as the guide inside the door is incorrect for a T4!
In the S40 owners book that T4’s and 2.0t’s should have a higher tyre pressure.

[Kerry_T-5R]

JANUARY 2007
January was time to do something about the handling:
I went to my local Volvo dealership and ordered a front alloy strut brace. The quality of the Volvo alloy brace is outstanding – it can’t weigh more than a few hundred grams! The strut brace is very easy to fit and I did it myself.
The part number if anyone is interested is 9481207
The handling was improved dramatically. Body roll is heavily reduced and the car feels much more stable through long or sweeping bends.
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN2424.jpg
photo taken after i spent the day cleaning the engine bay!
Also shown in the bottom right of the photo is a forge dump valve which I bought from Kalmar-Union - I only put it on there for the noise!

[Kerry_T-5R]

MARCH 2007
My front discs were nearly fully worn down by March with a huge lip! So I purchased new front 280 mm discs (part no: 30818027), front pads (part no: 30769199) and rear pads (part no: 30769186). I didn’t bother with rear discs, as these were fairly recently replaced and had no lip on them!
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN2418.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN2420.jpg
As the car was going in for some work anyway………………..I also bought some SPAX 40 mm lowering springs after some useful advice on the forum.
http://www.volvoforums.org.uk/showthread.php?t=31708
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN2423.jpg
The main reason to lower the car was to remove the huge gap in the wheel arches between the body of the car and the wheels! An added bonus was improved handling without compromising comfort too much. The car now feels much less twitchy when changing direction quickly.
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN25222.jpg

[Kerry_T-5R]

APRIL 2007
Time for another service! The previous owner before me had the car serviced every 6k, I may as well keep this up so I dropped my car in to have an oil and oil filter change - went for Mobil 1 0w 40 again.

MAY 2007
Two of my P-Zero's were getting worn by May, so I bought two new tyres (same again) and sent two of my standard BBS (Crater) wheels off to be re-furbished.
I got the wheels re-furbished as the paint had started to bubble in places and looked nasty up close. I am quite a perfectionist, especially with wheels!
I was really pleased with the finish when they came back:
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN2884.jpg

[Kerry_T-5R]

JUNE - AUGUST 2007
June and July mainly involved saving for the work that was going to be carried out in August!
After going up to Headcorn in June with my Dad to get his T-5R re-mapped, I talked to Stuart of SW Autos and he ran through some options to think about for my T4.
I phoned him a couple of weeks later and booked my car in with him.
The work consisted of:
A BSR PPC (including SW's custom map).
An adapted T-5 manifold.
An adapted T-5 downpipe.
A 15G T-5 turbo.
A BSR optiflow filter.
The bhp is now 272 (271.7) with 302.5 ft lbs of torque (411 NM).
The car is now transformed! It pulls hard in every gear and has masses of torque!
http://i238.photobucket.com/albums/ff190/t4kerry/SWScan00034.jpg
Very pleased with the work carried out!

[Kerry_T-5R]

SEPTEMBER
By chance I found a rear strut bar for a Mitsubishi Evo 3 on ebay USA. The Mitsubishi Evo's / carisma's and Volvo S40's share the same platform because the S40 was a joint venture between Mitsubishi and Volvo.

I ordered a rear Strut bar from ebay USA as the company shipped to the UK.
To fit, you simply remove the boot lining by removing several grey clips and then un doing the nuts on top of the suspension strut and re-bolting the bots on top of the strut bar mounts. I used a stanley knife to neatly cut a hole for the bar.
The handling of the car seems to be more precise in sharp bends and exceptionally stable.
Here's some pics!
http://i238.photobucket.com/albums/ff190/t4kerry/0607104.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/0607106.jpg

[Kerry_T-5R]

OCTOBER
My car went in for some spray work last week, and I got it back today. I had the bonnet re-painted due to stone chips on the front (extremely flat front around the grille which catches stones). I used a touch up brush on them but I knew they were there! So I saved up to have the bonnet re-painted.
I also got a new lower section on my front valance (made by heico Germany), its very subtle which is excellent as I don't want to move the car away from standard too much.
pics:
http://i238.photobucket.com/albums/ff190/t4kerry/0607103.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/0607101.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/0607102.jpg

[Kerry_T-5R]

Just got my car back from its service today, changed the oil again to Mobil 1 0W 40 and a genuine Volvo filter and gasget.
I also purchased some goodridge braided brake hoses as my 8 year old ones on there had a slight spongy feel through the pedal. The difference was noticeable the first time I pressed the pedal - no spongeyness at all.
I also had the system bled and replaced the dot 4 fluid with high temperature dot 5 fluid.
Here's some pictures taken through the spokes of my wheels:
Rear hose:
http://i238.photobucket.com/albums/ff190/t4kerry/rearhose.jpg
Front hose:
http://i238.photobucket.com/albums/ff190/t4kerry/fronthose.jpg

[Kerry_T-5R]

October 2007 (2)
Just finished a couple of changes to my T4.
The first is some pressed aluminium Swedish Euro number plates with the Sweedish S in the corner.
Second is some reflective black headlight inserts to replace my original chrome ones. I noticed them on Pyaap's T4 up at the Crooked Billet meeting at the weekend and then ordered them from my local Volvo dealership. They took 2 days to arrive from Sweden - bit tricky to fit but worth it in the end!
To fit: (ONLY COMPATIBLE WITH DOUBLE BULBED HEADLIGHTS)
Tools: Flat head screwdriver for levering metal clips, cross head screw driver for removing indicator screws, 10 mm socket.
1. open bonnet and remove screw holding in the indicator (cross head), then gently slide out the indicator being careful not to break the plastic lugs.
2. undo the two nuts on the side of the light (hidden by the indicator) then remove the two behind the light. I used a flexible socket set as access was restricted.
3. flex the front bumper away from the headlight and then carefully twist and slide the headlight out - Be careful of your paint on bumper as clearance is minimul!!
4. remove the clips holding the glass cover either by hand or carefully with a screwdriver, then lever the glass and the rubber seal away from the plastic section.
5. carefully pull the old plastic liner away from its 3 clip in sections (mine was chromed) and replace with the new one (I went for shiney black).
6. replace the glass and locate the rubber seal and carefully replace all of the clips.
7. flex the front bumper away from the headlight and then carefully twist and slide the headlight back in.
8. tighten back up the four nuts removed.
9. replace indicator and tighten screw.
10. stand back and admire!
Here's a picture:
http://i238.photobucket.com/albums/ff190/t4kerry/lightsplates.jpg

[Kerry_T-5R]

I have just fitted my new indicators, I ordered some of the black bezel ones to match my black inserts.
Included with the indicators is the bulb holders and new bulbs!
Here's a picture:
http://i238.photobucket.com/albums/ff190/t4kerry/newindicators.jpg

[Kerry_T-5R]

Project update
I haven't posted on my project for a while, but I have still been spending!
As I mentioned earlier in the project, the Volvo S40 chassis is the same as an Evolution 3 Lancer so many of the parts are compatible - I already have the rear strut brace from an evo 3!
With this in mind I ordered a set of twin piston Evolution 3 calipers complete with second hand discs and pads - no guarantee that the discs or pads would be ok, but I only really wanted them to check if they fitted!
The brakes arrived on Friday and one of my friends who is a mechanic checked the seals and fitted them on Sunday. The calipers, Mitsubishi 276 mm discs and the Mitsubishi pads all fitted perfectly with no rubbing. My braided hoses were also a perfect fit.
Brakes before:
http://i238.photobucket.com/albums/ff190/t4kerry/oldbrake.jpg
New brakes:
http://i238.photobucket.com/albums/ff190/t4kerry/newbrake.jpg
Unfortunately my 281 mm Volvo discs did not fit, they were just too big to clear the carriers without scraping, and they have only done 800 miles! (If anyone on the forum fancies them, I will be selling the discs and pads which have only covered approximately 800 miles on here - please send a pm if interested)
The improvement in brake performance was immediately noticeable after fitment. Stopping distance is dramatically reduced without compromising brake pedal "feel". Also the ABS still operates perfectly (im not sure where the sensor readers are though!). In fact the brakes are so much better that when my friend test-drove the car and braked down from about 60 mph to a stand still (with me in the passenger seat), it gave me a bruise the shape of the passenger seat belt across my chest!
Now that I know the brakes are ok, I am waiting for calliper paint, Ferodo premier pads, and Blueprint ADL discs to arrive. Also a big thanks to Firebolt for all the advice!
Kerry

[Kerry_T-5R]

Quick update
My discs and pads arrived today to my mechanic, and were also fitted! The discs are ADL (made by Blueprint, for Japanese cars only) and the pads are Ferodo Premier as I mentioned earlier in one of my previous posts.
The discs are fantastic quality and come with a 2 year warranty - they look as good as OEM Volvo, I will post my progress with these. My Dad has used the Ferodo Premier pads for years and they always work excellently without fading, I will also post my progress with these when I have tested them to high temperatures etc.
The brakes now work perfectly, although I wont be braking hard for the next couple of hundred miles if I can help it, as im going to give the discs a fair amount of time to cure - to avoid warping!
http://i238.photobucket.com/albums/ff190/t4kerry/newdiscpad.jpg
My left front wheel has also been refurbished! I use spit & polish as they are fairly local to me, they have made an excellent job as they did with the previous two - you can also see my new shiny discs through the wheel! Only one wheel left to re-furbish!
http://i238.photobucket.com/albums/ff190/t4kerry/re-furb151107.jpg
Kerry

[Kerry_T-5R]

Quick update

http://i238.photobucket.com/albums/ff190/t4kerry/quaife.jpg
Received my M56 Quaife Limited Slip Differential which I ordered direct from Quaife on Monday.
Speedy delivery, but prices quoted on the internet don't quote VAT so it was even more expensive than I thought it would be!
I will post an update when it is fitted!
Kerry

[Kerry_T-5R]

Project update
I picked my car up from SW Auto's yesterday - and the diff was noticeable from the first bend I took.
The roads were greasey from all the salt on the road, and the grip now is incredible - it is difficult to make the wheels spin at all even on the winter roads!
Stuart took the gearbox apart, changed the diff for the quaife one and then replaced the gear box oil and gear changing couldn't be smoother!
Here are a couple of photos taken of the two diffs - the quaife is on the right.
http://i238.photobucket.com/albums/ff190/t4kerry/DSC0015712.jpg
Here is a picture of the internals of my M56 gear box.
http://i238.photobucket.com/albums/ff190/t4kerry/DSC0015912.jpg
The diff is one of the best things I have purchased so far for the car - I didn't think the diff would make such a difference as it has done!

[Kerry_T-5R]

Hi all,
I sold my T4 to one of my best friends who in turn sold his T4 to buy mine! I would have kept the car if he wasn't buying it, as I wanted it to go to the best possible home! I owned it for 1 year and 4 months and spent thousands on it, although I probably could have run the car almost expense free for the amount of time I had it.
The T4's are fantastic cars and it was excellent owning and modifying one.
I originally tried to run my new car and my T4 together, but it was too expensive on insurance as I am only 22!
Here are some photo's of my new car. It is an 854 T-5R limited edition and has been one of my dream cars since I was at school. It has only had two owners before me. The original owner had it for 4 years, the second owner had it for 7 and a half years and I have owned it since December 2007. No expense has been spared, and I have a folder full of receipts, a fully stamped service book and all the old MOT's.
I couldn't be more pleased with my purchase, although it has taken 2 months of work on the car to get it to this condition! One of the hardest things so far was getting the wheels re-furbed in the correct colour!
Cheers,
Kerry
http://i238.photobucket.com/albums/ff190/t4kerry/t-5r3.jpg
Parked behind my old T4!
http://i238.photobucket.com/albums/ff190/t4kerry/t5r2.jpg

T-5R thread : http://www.southernpetrolheads.co.uk/forum/showthread.php?t=25

[T4Mark]

Hi all,
I recently bought this T4 from Kerry and sold my previous two T4's to buy it. I will continue to update this project with my further maintenance / modifications.
The first modification I carried out was a whiteline anti roll bar with poly bushes. As the anti roll bar was removed I replaced the rear drop links and drop link bushes (genuine Volvo).
http://i260.photobucket.com/albums/ii15/T4Mark/whitelinearb.jpg
The whiteline has made a noticeable improvement, especially in faster corners as the back of the car is much more stable than before. Highly recommended.
I also had to have two engine mounts replaced as the torque had ripped the old ones to pieces!
Cheers,
Mark

[T4Mark]

I haven't posted any updates for a long time! Here is the reason (From APRIL 08) :
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Broken%20rod%20and%20spare%20parts/DSC00985.jpg
Remains of a Rod
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Broken%20rod%20and%20spare%20parts/DSC00986.jpg
Close up
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Broken%20rod%20and%20spare%20parts/DSC00988.jpg
Close up
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Broken%20rod%20and%20spare%20parts/DSC00989.jpg
Close up

And here are some shots of the block. It is hard to see in the picture, but the cylinder wall has been completely blown away.
http://i260.photobucket.com/albums/ii15/T4Mark/DSC01018.jpg
The damage occured at about 6500 rpm in 4th gear on a private road. There was an intermittant misfire for a few seconds followed by a bottom end rattle and then a loud explosion followed by smoke (oil fire under the bonnet). Looks like 303 ft lb's is beyond the limit of stock internals.
Between April 08 and Now I have been saving for parts to re-build the car bigger and better.
Mark

[T4Mark]

Bits purchased:
THS Performance Rods:
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Broken%20rod%20and%20spare%20parts/DSC00978.jpg
Forged Rods & ARP bolts
www.thsperformance.co.uk Web quote
"Volvo S40, T4 Conrods
THSROD-VT4139
The THS H-Beam rods are made from high quality forged steel offering extreme reliability and stability over the standard Volvo rods. They come with a doweled cap design and 3/8" ARP 2000 Rod bolts.
Fits the following Models
Volvo S40 T4
These rods will handle in excess of 600bhp
Specifications
Forged Steel Conrods
Length = 139.5mm
Journal = 53mm
Pin = 23mm
Weight - 550grms
3/8" ARP 2000 Bolts
Dowelled Cap for Precision Fit
Balanced to within +/- 1.5 gram
All big and small ends are finished with SUNNEN cross grinder.
Bronze wrist pin bushings are made to withstand higher impact force.
Forged steel, vacuumed to remove impurities.
All surfaces are 100% machined.
Shot peened to relieve stress.
Multi Stage Heat Treated
Supports 600+BHP"
And £1,500 worth of seals, gasgets, bearings, rings, bosch green injectors etc from Volvo.
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Broken%20rod%20and%20spare%20parts/DSC00971.jpg
Mark

[T4Mark]

Stage 2
1 month after engine failure, we (Me, Kerry_T-5R, Rob T4, & Barrysc on here and Kerrys brother) managed to find a T4 with the better & much rarer T4 block : B4194-T2 (as the car already had).
The car was up in Lincoln and a 2000 model T4 in an undesirable flat purple colour with full service history and motorway miles. We set of in Robs T4 and drove 4 hours (210 miles) no bother at all.
After test driving the car, it drove perfectly so we handed over £750 only, as managed to get an ebay bargain. The car then drove perfectly back without missing a beat.
The car was then stripped with all the good bits sold on ebay : we made £700 back and still have 4 x crater wheels with tyres to sell. The engine was then removed and the rest of the car scrapped. It took me and Barry 3 days to remove the engine and ancilleries and we saved all sensors and the gearbox as spares.
Stage 3
Last week imacca, Barrycs, Kerry_T-5R and I started work on the donor engine:
We first of all removed the cam cover:
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Day%201%20head%20strip%20down/DSC00935.jpg
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Day%201%20head%20strip%20down/DSC00934.jpg
Then undid the head bolts in the correct order and removed the head:
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Day%201%20head%20strip%20down/DSC00937.jpg
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Day%201%20head%20strip%20down/DSC00939.jpg
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Day%201%20head%20strip%20down/DSC00940.jpg
The next step was to use a valve spring compressor so that the cuplets, valves and springs could be removed and cleaned up. We took care to note which position each one came from:
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Day%201%20head%20strip%20down/DSC00946.jpg
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Day%201%20head%20strip%20down/DSC00945.jpg
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Day%201%20head%20strip%20down/DSC00947.jpg
http://i254.photobucket.com/albums/hh94/barrysc/Marks%20Engine%20Build/Day%201%20head%20strip%20down/DSC00949.jpg
Mark

[T4Mark]

Hi all,
Fair amout of progress this weekend. Firstly we removed the crankshaft pulley securing nut and the locating bolts - with the help of my Eastbourne Tyres work van air powered truck gun.
http://i260.photobucket.com/albums/ii15/T4Mark/fitvan.jpg
:thumbs_up:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC01034.jpg
Then removed the sump and intermediate section :
http://i260.photobucket.com/albums/ii15/T4Mark/DSC01028.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC01027.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC01044.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC01047.jpg
Then removed the crank shaft sprocket and oil pump.
http://i260.photobucket.com/albums/ii15/T4Mark/DSC01039.jpg
And with the rest of the daylight we started removing the head from the broken engine, the cover, inlet manifold and exhaust manifold are removed :
http://i260.photobucket.com/albums/ii15/T4Mark/DSC01035.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC01036.jpg
Cheers,
Mark

[AndysR]

I do like this car, when it's finished it will certainly be a proper sleeper! :cool:

[T4Mark]

Long time no update! Here are a few more pictures of the old engine and the damage:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00130.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00131.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00132.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00133.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00134.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00135.jpg
Many more updates to follow!
Cheers,
Mark

[T4Mark]

Next step was to get the head skimmed, ported and re-built and I had the block re-honed. It was done at QEP : http://www.q-e-p.co.uk/ They did a brilliant job, here is a pic of the inlet side:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00183.jpg
Next a few bits arrived :
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00222.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00224.jpg
Ferrita cat back exhaust
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00139.jpg
Gaz Gold fully adjustable coilovers. Ride height, damping, camber etc.
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00189.jpg
Old engine out!
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00191.jpg
Barrysc in the engine bay!
Cheers Mark

[Ang]

Impressive damage on the old engine. Good to see all the time and effort and be good to see it all finished. QEP = very good and very local for us (2 min or about 30 secs in the GTO ;))

[T4Mark]

We finished assembling the engine by the end of April. Here are a few pics:
View of the forged rods:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00165-1.jpg
Head gasget on :
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00170-1.jpg
Head on:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00171-1.jpg
Cams in:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00178.jpg
Water pump on:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00175.jpg
More updates to follow today or tomorrow!
cheers,
Mark

[T4Mark]

Here are the pictures from May:
The engine is now timed
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00271.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00273.jpg
The next pics are from May up to today
Front coilovers are fitted, unfortunately no pics! But I do have a comparison pic of the old shocks and springs compared to the coilovers:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00460.jpg
Clutch and flywheel fitted
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00467.jpg
Standard turbo on (im using the standard turbo for running in etc)
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00468.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00469.jpg
Gearbox on (with Quaife diff inside :) ) :
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00472.jpg
Ready to go in:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00474.jpg
In the car:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00475.jpg
Ancillaries, radiator, intercooler, oil cooler etc
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00476.jpg
Same as above with bonnet back on:
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00478.jpg
As it is this evening (after turning around - knackered after that!) - getting close to finishing now!
http://i260.photobucket.com/albums/ii15/T4Mark/DSC00480.jpg
More updates to follow soon....
Cheers,
Mark

[T4Mark]

There has been a few updates over the last year....
Shot of new Ferrita exhaust on the car:
http://i260.photobucket.com/albums/ii15/T4Mark/iphonecamera229.jpg
Had a play around with the ride height :)
http://i260.photobucket.com/albums/ii15/T4Mark/iphonecamera228.jpg
Next the car went up to RT Mechanics & MA Developments for some more serious upgrades :

Custom Wiring loom by Rod Tarry
Standalone Vipec ECU with launch control & anti lag
Siemens 660cc injectors
Walbro 255 lph fuel pump
Secondary ignition amp
secondary coolant temp sensor
Custom remap by Mark Shead of MA Developments
Carbotech XP10 Mitsubishi Evo pads

Pic of the VIPEC ECU :
http://i260.photobucket.com/albums/ii15/T4Mark/V44kit.jpg
Next was time to enjoy the car for a few miles, a couple of poor quality camera pics on the way to goodwood breakfast club :
http://i260.photobucket.com/albums/ii15/T4Mark/iphonecamera520.jpg
http://i260.photobucket.com/albums/ii15/T4Mark/iphonecamera519.jpg
More updates to follow..

[T4Mark]

After enjoying the car for a few miles, it was time for an oil and filter change along with new 850R flywheel & Clutch as the original clutch was slipping and the map on the car was set to 0.7 bar.
Here are a few pics..
Old standard dual mass flywheel :
http://i260.photobucket.com/albums/ii15/T4Mark/DSCF0105.jpg
New 850R Flywheel :
http://i260.photobucket.com/albums/ii15/T4Mark/DSCF0106.jpg
Flywheel fitted :
http://i260.photobucket.com/albums/ii15/T4Mark/DSCF0107.jpg
Old hydraulic clutch release bearing :
http://i260.photobucket.com/albums/ii15/T4Mark/DSCF0110.jpg
New release bearing fitted :
http://i260.photobucket.com/albums/ii15/T4Mark/DSCF0109.jpg
Old Clutch :
http://i260.photobucket.com/albums/ii15/T4Mark/DSCF0103.jpg
New 850R clutch fitted :
http://i260.photobucket.com/albums/ii15/T4Mark/DSCF0111.jpg
Took me and my uncle 6 hours to do, also replaced the drop links as they were making slight noises.
The 850R clutch and solid flywheel make a good difference. Much firmer bite and more feel and in the future should stand more power.
Car went back to MA developments and now has 1.1 - 1.2 bar boost, pulling 1.4 bar in fifth gear, very happy with the car - will post current spec soon.

[T4Mark]

Took some pics after cleaning my car yesterday at beachy head, the green T-5R in some of the pictures belongs to Kerry_T-5R (see his project here : http://www.southernpetrolheads.co.uk/forum/showthread.php?t=25) Here are the pics of mine :
http://i238.photobucket.com/albums/ff190/t4kerry/f1609737.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/355861a7.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/8bfde64a.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0689.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0688.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0687.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0683.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0682.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0681.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0680.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0677.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0675.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/DSCN0674.jpg
See the full set of photos of both cars here : http://www.southernpetrolheads.co.uk/forum/showthread.php?p=4722#post4722
Mark

[macca]

Looking good Melv ;)

[Kerry_T-5R]

NURBURGRING TRIP - 10th - 18th JUNE 2011
Went to the ring for a week with a few friends (including T4Mark with his S40 T4). 5th time we have been now so know the route off by heart and can get down there hassle free. Well and truly turned into an annual trip now!
At Folekestone, way too early in the morning! :
http://i238.photobucket.com/albums/ff190/t4kerry/6e5be7cd.jpg
Shot on the way down taken from inside Marks T4 :
http://i238.photobucket.com/albums/ff190/t4kerry/7bfe67e7.jpg
Trip to the supermarket to get the essentials :
http://i238.photobucket.com/albums/ff190/t4kerry/be099b99.jpg
Marks t4 fully loaded, was low enough on coilovers without a boot full of beer! :
http://i238.photobucket.com/albums/ff190/t4kerry/493dac5b.jpg
Few random parked up shots :
http://i238.photobucket.com/albums/ff190/t4kerry/f4ec3556.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/297b83bc.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/d6273df0.jpg
Went to the nurburgring museum on a rainy day :
http://i238.photobucket.com/albums/ff190/t4kerry/023bf4dd.jpg
Most importantly.... Marks T4 on the circuit :
http://i238.photobucket.com/albums/ff190/t4kerry/8a931a7c.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/c3244a95.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/cd6496e8.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/e155df79.jpg
http://i238.photobucket.com/albums/ff190/t4kerry/b3ae8f33.jpg
And the reason why mine wasnt :( .... :
http://i238.photobucket.com/albums/ff190/t4kerry/195e8748.jpg
Split the big rear engine mount and couldnt risk taking it around. Gives me a good excuse to go back though if nothing else!

[Stavros]

Gutting news about the rear engine mount mate, must of been gutting, however im sure the road trip was worth it in its self. Few friends have just got back from a long weekend over there and said its a life experience, certainly on my bucket list.

Cars are looking good guys! Seen/heard kerrys car a few times on the way home from work recently, looks super clean!