I recently bought my 2004 Volvo S40i with a little wrong with it. Fixed ignition coil packs, wheel bearings, and suspension struts and had an idea. How possible is it to swap a 2.4i exhaust manifold with a T5 exhaust manifold? Just for the turbo option, and then mounting a smallish turbo. Is it hard to have it tuned? Will it even work? Has someone done this? The compression rate is smaller on the 2.4i than the T5 so I thought it would make it pretty unique. Any information about my crazy idea would be very helpful, thank you!

 

You would be better off selling the car and buying a T5.

 

not practical with a modern engine. To convert from an NA to turbo you'd not only need the manifold, turbo, downpipe but you'd need a full wiring harness and a list of sensors, tubing etc. If you were to simply drop on a turbo with no controls other than a waste gate, you'd be driving with a perpetual check engine light and risking engine damage. Your 2.4i has a 10.3:1 compression where the T's have 9:1 so you'd be pinking at anything more than a few lbs of boost. Best to invest in the wheels/suspension (sorry to say upgrading the sound system on the Gen2 S40s is difficult too) or trade for a T5 as EST6 suggested.

 

There is no way for an individual to do this because of the complications mentioned by other posters.

This is not a small block Chevy from 1973.

 

ah!! those were the days when you went to a "speed shop" in search of D port heads :-)

Best story: Had a roommate who owned a 67 'Vette with an LS7 blue print 454 that we installed. One day at a gas station, hood up checking the oil, a rube looked at the engine and asked "what'cha got in it?" My buddy replied without looking up "if you don't know a big block when you see one, you don't know cars..." :-)