2007 S60 T5 Build

07T5M66 · Post by **07T5M66** » 23 Nov 2025, 09:45

Hey all!

I was hoping to get some insight into some upgrades that I am doing to my 2007 S60 T5 (M66).

Right now, the car is pushing around 350hp, but I have some upgrades "Coming Soon". The new turbo should be done shortly thanks to Nick Knight. Before I went forward, I made sure "Stage 0" was complete and everything was in good order. I bought the car from a fellow Volvo enthusiast on here who took great care of it.

I'm looking for some insight/recommendations for anything I should do before I put in the "Coming Soon" list.

Current

3" IPD Turbo-back Exhaust

Do88 Front Mount Intercooler

Green Injectors

Custom Tune (Thanks Sanders!)

Coming Soon

RS4 MAF Sensor

DW300c Fuel Pump

NGK Iridium Spark Plugs

K24 Super Hybrid (75mm)

Custom Tune (Sanders)

Deciding on Injectors either

FID 1100cc/min

or

Alpha 750's (probably these)

Questions are, is there anything else you guys would recommend I do? I'm shooting for around 450-475. From what I have heard, the B5254T5 are very reliable and can handle up to 500hp.

Now, I want this car to be as reliable as possible with these new upgrades. I do know that the more power this engine outputs the more issues I may run into. Should I consider doing Pistons? Rods? Or any other upgrades to ensure she runs smooth?

Unfortuantely, I will be getting deployed soon so me putting it on the dyno will have to wait a year to see what the final numbers are with all the upgrades put into it.

Thanks!

dikidera · Post by **dikidera** » 23 Nov 2025, 10:56

Is this the thicker cylinder wall block?

07T5M66 · Post by **07T5M66** » 23 Nov 2025, 12:44

It is!

Post by **DavidE7** » 24 Nov 2025, 09:51

The problem with 500+ horsepower is getting it from the engine to the road. The next upgrade that will make your car faster is switching from front wheel drive to all wheel drive. You already have the wide wheels and tires - just need to get the back two into the game. Then the best upgrade is being able to stop the car repeatably without overheating the brake calipers and fluid. I can't see from the pictures if you have already upgraded to brembo calipers.

07T5M66 · Post by **07T5M66** » 24 Nov 2025, 14:43

DavidE7 wrote: ↑24 Nov 2025, 09:51 The problem with 500+ horsepower is getting it from the engine to the road. The next upgrade that will make your car faster is switching from front wheel drive to all wheel drive. You already have the wide wheels and tires - just need to get the back two into the game. Then the best upgrade is being able to stop the car repeatably without overheating the brake calipers and fluid. I can't see from the pictures if you have already upgraded to brembo calipers.

After the upgrades Im hoping to be around 430-475. I do plan on doing a big brake kit as well with some Brembos

Post by **matthew1** » 24 Nov 2025, 15:09

So the P2 R B5254T4 had the sleeve problem at high heat, high power, but the B5254T5 did not?

Yea the big brakes kit/Brembo thing is very important to do at that hp level.

07T5M66 · Post by **07T5M66** » 24 Nov 2025, 17:08

matthew1 wrote: ↑24 Nov 2025, 15:09 So the P2 R B5254T4 had the sleeve problem at high heat, high power, but the B5254T5 did not?

Yea the big brakes kit/Brembo thing is very important to do at that hp level.

From my understanding. The B5254T4 has an 83mm bore and the B5254T5 has a 81mm bore.

This means that the B5254T5 has a thicker cylinder sleeve thickness so the cylinder walls are less prone to failure.

If anyone knows anything else or if I'm wrong please feel free to correct me.

Post by **volvolugnut** » 24 Nov 2025, 17:51

Other comments suggest high boost at low speed can bend the rods.
volvolugnut

Post by **matthew1** » 24 Nov 2025, 18:11

volvolugnut wrote: ↑24 Nov 2025, 17:51 Other comments suggest high boost at low speed can bend the rods.
volvolugnut

This should be addressed in the tune, but 07T5M66 do check with the tuner. Generally the torque is backloaded onto the higher RPMs, which is violent, and IMHO, fun if the wheels don't break traction.

07T5M66 · Post by **07T5M66** » 24 Nov 2025, 20:11

matthew1 wrote: ↑24 Nov 2025, 18:11
volvolugnut wrote: ↑24 Nov 2025, 17:51 Other comments suggest high boost at low speed can bend the rods.
volvolugnut
This should be addressed in the tune, but 07T5M66 do check with the tuner. Generally the torque is backloaded onto the higher RPMs, which is violent, and IMHO, fun if the wheels don't break traction.

Tuner is very experienced. He's tune a lot of Volvos. Ill make sure to double check with him to see.

What it be worth it to upgrade the rods?