Product development

HEICO SPORTIV´s e.motion®performance products goes well beyond Volvo's own Polestar range. It is not a performance optimization, it offers noticeable increase in power and torque. HEICO SPORTIV e.motion® engine tuning works in parallel with the original engine control unit (ECU) and acts autonomously as a second "brain". This intelligent variant of chip tuning makes maximum use of the existing potential of Volvo engines through consistent and harmonious tuning. The additional control unit records all important engine data and specifically influences the relevant parameters. This significantly improves acceleration and elasticity, and optimizes responsiveness, top speed (until MY 2020) and consumption.

All standard engine protection functions are permanently monitored. If irregularities occur, the e.motion® engine tuning system shuts down at lightning speed and prevents overstressing of the engine and drivetrain. Your Volvo drives as usual with standard power. The same applies if the engine is too warm or still cold: e.motion® only switches on as soon as the engine's operating temperature is in the optimum range. HEICO SPORTIV provides a warranty of up to 60 months / 150,000 km from the date of initial registration, the scope and procedure are based on the Volvo manufacturer's warranty*.

* according to HEICO SPORTIV terms of guarantee

To ensure this excellent quality at manufacturer level, every engine tuning of all specific engine and transmission variants goes through a precisely defined product development process.

All relevant parameters are modified, matched and evaluated on the in-house performance test bench. The aim is to achieve the highly complex and perfect interplay of rail and boost pressure, injection period and injection timing without touching the structural load limits of the engine, transmission, powertrain or of the particulate filter.

Particularly noteworthy is the indexing of the combustion pressure in the cylinder, which guarantees the long-life cycle of the engine. This is followed by the time-consuming driving test. First to simulate long-term stress on the test track, then under everyday conditions in road traffic.

For consistent and sustainable implementation, all product development processes are certified by the Kraftfahrt-Bundesamt (KBA) in accordance with the quality assurance system DIN ISO 9001:2015. All diagnostic and update functions remain fully intact, as do the reliability and everyday usability typical of Volvo automobiles. In addition, the applicable emissions standards are fulfilled.

HEICO SPORTIV performance upgrades are tested by an independent, technical testing organization (e.g. TÜV) and are supplied with the necessary expert opinion on parts according to § 19 StVZO or General Operating Certificate (ABE) and Conformity Certification (CH) for trouble-free registration*. Another unique selling point of engine tuning from HEICO SPORTIV is the production plate. It identifies the software version used with a unique serial number and is mounted in the engine compartment.

* Country-specific

Acceleraton and speed
To validly the benefits of HEICO SPORTIV power upgrades, we use professional equipment from Racelogic to determine the acceleration values. Racelogic develops and produces electronic systems for measuring, recording, displaying, analyzing and simulating vehicle data.

Exhaust emissions
When developing HEICO products, we pay the utmost attention to carrying out measurements under real conditions in order to be able to provide our customers with truly reliable information on performance and environmental compatibility.

For this reason, we subject our vehicles to elaborate RDE tests, among other things, which comply with the strict specifications of TÜV NORD and thus also with HEICO's typical quality standards.

Yes, as long as you know how to use intelligent technologies.

HEICO SPORTIV thinks holistically. Admittedly, it's about more horsepower, more driving dynamics, more driving pleasure. But not at the expense of our environment. The goal is to exploit the existing potential and optimize the efficiency of your Volvo engine. Finding the perfect balance of more power and less fuel consumption. In short: it's all about efficiency.

The result of e.motion® engine tuning is most evident in driving practice. To reach the favored speed, you can literally step on the gas padel less - thanks to the higher torque. The engine operates less frequently in the full load range, and a reduced revolution speed level lowers fuel consumption. In addition to the intended increase in performance and driving safety, this is a pleasant and measurable effect.

Furthermore, all HEICO SPORTIV e.motion® performance upgrades fulfill the current emission standards that apply in Germany and Switzerland. A proof that your Volvo from HEICO SPORTIV is at least as clean as the comparable standard model. Performance and the environment. Not a contradiction.

Selected Sound® is a technology designed by HEICO SPORTIV that significantly enhances the sound experience of smaller four-cylinder engines. The principle: The HEICO SPORTIV e.motion® control unit transmits data relevant to driving dynamics, such as speed, engine speed, engine load and accelerator pedal position, directly from the CAN bus to a sound processor. This is connected to a conventional HEICO SPORTIV stainless steel rear muffler and an actuator, which produces the superior sound of a large-volume engine.

All HEICO SPORTIV exhaust systems are made entirely of high-quality stainless steel and feature perfect fit and OEM-quality manufacturing processes. They comply with the applicable noise and exhaust regulations and have EC approval without the need for an extra registration.

Selected Level is a technology developed by HEICO for lowering the adaptive air suspension by a further 30 mm. It is individually tuned to the Comfort, Eco, Dynamic and Hybrid driving modes.

Of course, all products have the necessary approval certificates and a guaranteed delivery promise of wear parts.

However, the actual know-how comes from the race track. The successful and harmonious tuning of a sports suspension requires a great deal of intuition and experience. For decades, HEICO SPORTIV has used the Nürburgring-Nordschleife and other reference tracks as test terrain to meticulously work out the perfect setup in simulations - of an American highway, for example, or a typical Swabian country road.

Behind every HEICO SPORTIV sports suspension is Martin Müller as a person. He is a racing driver in the HEICO SPORTIV motorsport team and has been responsible for suspension setups since the beginning. "From the race track to the road". A slogan that is lived and factual at HEICO SPORTIV.

The brake discs are also significantly different from the standard ones. They are also tempered and features larger dimensions and more transverse holes to dissipate heat faster and better. Each pre-cast hole is re-drilled and countersunk separately, which has a favorable effect in terms of flow.

The complex design of the brake disc increases the surface area by around 80%. This significantly reduces the temperature of the brake disc and thus also its wear. At the same time, this increases stability.

Compared to the standard brake, the high-performance sports brake system from HEICO SPORTIV impresses with significantly shorter braking distances. In figures, using the example of a Volvo V60 T6 Recharge, this means: deceleration values of over 10.35 m/s² and, at 34.8 meters from 100 km/h, a braking distance that is once again significantly shorter than that of the standard vehicle (37.9 m), and thus a major gain in safety.

All HEICO SPORTIV high-performance sports brake systems have a parts certificate in accordance with §19.3 (StVZO) and a conformity certification (CH) for problem-free modification approval and registration.

Bending circulation test
In this test, the resistance of the aluminum structure is tested. During the test, the rim is firmly locked in place and subjected to constantly changing forces.

Material test
The material quality of the aluminum composition is tested for purity and consistency.

Endurance roll-off test
The durability of the complete wheel (= with tire) is recorded during cornering and on the straightaway running. Thereby the strength of the rim flange, the wheel star, and the stress on bolt holes and central bore are tested. It is ensured that no cracks or damage occur and that no air escapes.

Rim flange test
The main criterion here is the stress on the rim flange during a simulated risk drive, in which various driving conditions are simulated. Critical areas are also the spokes and the area around the valve stem, which may not break, for example, on contact with a curb.

Impact test
In order to simulate an impact at 40 km/h on a curb, various weights are shot onto the rim. The drop height of the weights, which weigh up to 1,000 kg depending on the vehicle class, is 230 mm. At the same time, it is determined if and how much air escapes.

Torsion test (interaction/twisting)
This long-term test checks the tangential forces acting on the wheel during acceleration and braking. The main focus is on ensuring that no hairline cracks occur. The rim is mounted on a test bench without tires to simulate loads and determine the degree of torsion.

Corrosion test
The wheel is sprayed with a concentrated salt solution for 384 hours. Prior to this, grid lines are applied to the rim flange, wheel star and rim bed in order to be able to precisely trace corrosion in each area of the rim during the test. Some parts on the rim were deliberately damaged for this purpose (such as by a stone chip) in order to subsequently analyze whether the defective aluminum wheel is resistant and does not corrode.

Mounting test
Finally, all wheel-tire combinations are mounted on each vehicle type and checked with regard to current wheel guidelines, body-to-tire clearance and wheel cover. Only now can an application certificate be applied for.

The Kraftfahrt-Bundesamt (KBA) is authorized to carry out random field tests. This ensures that the wheels produced for the TÜV tests are of the same quality as those produced for the road. If there are discrepancies, the KBA can recall all wheels at the manufacturer's expense. This is comparable to a recall action by an automobile manufacturer.

After the design finding process is completed, the draft is refined and finally photo-realistically animated. A clay model (depending on application) is created on the real vehicle and modeled in detail until it meets the requirements and ideas of the precisely defined HEICO SPORTIV design language. At the next step the prototype will digitized via an elaborate scanning process and all data will perfected down to the last detail by using CAD (Computer Aided Design).

HEICO SPORTIV is doing the entire development process digital for several years now. This type of product development corresponds 1:1 to the procedure used by automobile manufacturers and guarantees maximum fitting accuracy and surface quality.

But it's not just the design that matters. To ensure easy assembly later on, we have to ensure that original fixing point such as clips and screws are adopted for the new HEICO SPORTIV tuning part.

Now the test mold can be milled and the prototype part laminated. The COP test part - mandatory for the conformity checks of Kraftfahrt-Bundesamt (KBA)  - is mounted on the test vehicle and checked for fit and function of the peripherals, such as air ducts, towing devices and sensors. Only now is the final production mold released for manufacture. After approx. 4 - 6 weeks, once the mold has been completed, the first final series part can be produced.

At the same time, bilingual assembly instructions, video instructions and the complete documentation for the application for ABE or parts approval are prepared.

Where relevant, crash tests are carried out in accordance with the latest pedestrian protection guidelines. This is mandatory for the homologation of add-on parts in the front area. Here, a legform impactor is shot against the add-on part in a ballistic curve to measure acceleration, bending and shear.

The material of the add-on parts is also decisive for the accuracy of fit and surface quality. HEICO SPORTIV exterior parts are made of PUR-R using the complex RIM process. PUR (polyurethane) is a hard, homogeneous material that can be manufactured in thin wall thicknesses. It is characterized by its extreme load-bearing capacity due to special impact strength and high tear resistance. So-called PUR-RIM parts are used wherever safety, durability, impact and shock resistance are required. PUR (polyurethane) stands for the plastics or synthetic resins from which the part is made, while R (reinforced) and RIM (reaction injection molding) describe the manufacturing process.

With this high-quality material and the complex manufacturing process, we can ensure material and fit qualities analogous to series production.