Performance upgrades

[PaulWilky28]

I have a 2003 S60 2.0T petrol engine, manual transmission, car is currently not modified from manufacturing standard. I’d like to begin modifying the engine to produce better power output and higher performance. Before I do that, I want to be sure the mechanical working of my car are up to scratch. Can anyone advise on reinforcing the gearbox and upgrading the clutch?

[eternal optimist]

Do you know if the box and clutch are different to (say) the 2.5T or the R?

[PaulWilky28]

I don’t know about the clutch, but my gearbox is a 5 speed instead of a 6

[Ripmax]

This might give you some more info on the M56 box.

http://www.vpcuk.org/forums/showthre...olvo-Gearboxes

Before tuning a Volvo (or any car for that matter). You should do something called Stage 0. This is essentially restoring the car back to it's factory standard mechanically. So, new engine oil, new g/box oil, new rear diff/haldex oil (if it's an AWD model), new spark plugs, coolant etc etc. Obviously before any tuning go get your engine compression tested, this is a good indicator of general engine health. No point dialing up your boost to find out you have busted rings.

The 2.0T engines have quite a high compression ratio, meaning there's not a whole lot of margin for power so don't expect huge gains without doing some damage!

It seems the M56 boxes are prone to damage on gear 3. Standard clutch will probably be fine for a little while, but as you have the gearbox out you may as well change it out for a Stage 1 clutch or tougher.