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Airbox thermostat failure...

Help, Advice and DIY Tutorials on Volvo's P80 platform cars -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

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This topic is in the MVS Volvo Repair Database » Airbox Thermostat Cleaning = Better Performance, MPG on Non-turbo's
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matthew1
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Re: Airbox thermostat failure...

Post by matthew1 »

polskamafia mjl wrote:The first gen s40's were from 95 to 2004. I have a friend w/ a 2.4 NA s40 and she is in the United States.
According to this http://en.wikipedia.org/wiki/Volvo_S40 her S40 would have to be a 2004.5 or newer.
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Post by tjts1 »

polskamafia mjl wrote:The first gen s40's were from 95 to 2004.
Not in the US. First year was 2000.
polskamafia mjl wrote:I have a friend w/ a 2.4 NA s40 and she is in the United States.
The 2.4 was the second gen S40 which doesn't have the thermostatic intake regardless of turbo or non turbo. Its a non issue. All first gen cars in the US (2000-2004) had a 1.9 liter low pressure turbo.
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Post by polskamafia mjl »

matthew1 wrote:
polskamafia mjl wrote:The first gen s40's were from 95 to 2004. I have a friend w/ a 2.4 NA s40 and she is in the United States.
According to this http://en.wikipedia.org/wiki/Volvo_S40 her S40 would have to be a 2004.5 or newer.
Matt, wikipedia isn't entirely correct as another friend of mine has an 01 s40 2.3 turbo which isn't even listed by wikipedia as an option. :D
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Post by tjts1 »

polskamafia mjl wrote: Matt, wikipedia isn't entirely correct as another friend of mine has an 01 s40 2.3 turbo which isn't even listed by wikipedia as an option. :D
In this situation Wikipedia is right. If its a 2001 he probably has a S60. All first gen S40s had the 1.9 liter LPT 4 cylinder in the US.
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Post by polskamafia mjl »

No, it's an s40.
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Post by ADent »

I just did this on my 96 854. The housing for the flapper is different, snapped together and not screwed. The hot air opening is round and seals with a round thing on a long stem.

Anyways I gutted it and epoxied the round side closed - looks like a lot more area to flow now.
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Post by ADent »

The 2001 S40 was not available with anything other than the 1.9L turbo in the US market. See http://www.volvoclub.org.uk/press/volvo ... 0_v40.html . The only engine listed is the B4204T3, which is the 1.9L turbo.

Looking at a Canadian site, same for them as of 2000.

I don't see a 2.3T - unless it was a swapped motor or some one off Volvo thing? A grey market import? (Even though the top of of the line T4 was still a 2.0L)
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Post by tjts1 »

There was never a 5 cylinder first gen S40 so your friend is just plain wrong. The largest engine ever fitted to the first gen S40 was the 2.0 turbo and that was in Europe. End of story.
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Post by jblackburn »

Confirmed...as you can see here by the engine designations (B4, D4), the only engines ever put in the S40 in ANY country were all 4-cylinder models < 2L. The 5-cyl did not appear until the 2004 1/2 model, where it was 2.4 or 2.5 L.
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Post by Faheyk1981 »

So driving a 99 v70, (1984cc N/A automatic with 147k miles) thats meant to go 0-60 from the factory in 12.1 secs. I was curious since i purchased the car 2yrs ago why it feels very slow on take off and felt under powered while overtaking. And from doing my own 0-60 tests i was only getting 0-60 in 15.5 seconds.

Other than this the car runs smooth and is 100%, no cels, regularly serviced, seafoamed etc and minded very well. And with UK MPG averaging 25mpg, thats driving highway 40% and town 60%, i felt thats not too bad. BUT i still always felt the car should be giving me more power.

So i found this post which suggests testing the Airbox thermostat. Because if it's broken and stuck all the time in the HOT air position, then your car will be sucking in just HOT air and feel like it's pulling a truck behind you. After inspecting the airbox thermostat i found it was indeed always in the HOT air position regardless of running temperature. To be certain I took it out of the car and stuck it in the freezer and then in front of a heater for a while but no movement what so ever going from hot to cold. So i knew it was broken.

Instead of replacing the thermostat, i decided to force open the flap in the COLD air position as others have done in this posting. I done this by using just 1 screw as shown below. I know i could of opened the air box thermostat housing and cut it out like other N/A drivers have done, in order to let more air flow through but i wanted to have the option to go back to the original factory format. Just in case something went wrong in the future. I also didn't bother inserting tin foil in the hot air part of the housing like some of you have done but the hot air pipe is still attached. Now the flap feels secure open in the cold air position.

So whats the verdict???

Well i re-done my 0-60 test and i'm now getting 0-60 in 14 seconds. Instead of the 15.5 seconds i was getting before i done this mod. Its still not the 12.1 seconds that the car should be getting since it was new but it is 14yrs old now and with nearly 150k miles. I'll see over time if i'll get any improvement in MPG. I certainly feel the car is now more zippy on start off and better on overtaking. It's still no rocket ship but it is a good improvement and it was worth doing.

And all thanks to this site!
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