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Project - 2002 S60 T5 - Need Advice on this Build - Engine, Stage 1+

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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Robz
Posts: 1
Joined: 30 November 2017
Year and Model: 2002 s60 t5
Location: Toronto

Project - 2002 S60 T5 - Need Advice on this Build - Engine, Stage 1+

Post by Robz »

Hey guys im new to the forum, volvos, and this is my first ever project lmao. That being said ive done full engine/ trans/ drivetrain rebuilds etc. So im somewhat experienced. NEED HELP WITH THIS BUILD. this guy has a 2002 s60 t5 automatic with 135000kms for 3k and in my mind ive already bought it. I want to get as close to 300 whp as i can and daily drive the thing, i was wondering how hard i can push this engine without having to pull out the engine (limited tools and garage space and money :mrgreen: ) after i stage 0 it i was thinking of a full turbo back, fmic, and a solid tune... what else can i do without breaking the bank. What nightmares should i expect with this car. What parts do you guys suggest.Thnx :D

JRL
Posts: 9350
Joined: 22 November 2005
Year and Model: Several
Location: 19333
Been thanked: 16 times

Post by JRL »

Tune, downpipe. exhaust and an FMIC will get you close to that (280-290 ish) while retaining 100% reliability as long as you don't beat it to death and keep it at a good stage 0.
(Do that first, stage 0, Google it).

Also check the transmission BEFORE you plunk down your dollars. Drive it for AT LEAST 45 minutes, (it has to get HOT).
Be aware of any weird shift flares, any clunking on the downshifts, 3rd to 2nd and 2nd to 1st gears.

Since you're not familiar with Volvos. spend the dollars for a 1 hour check out from a VOLVO mechanic, best money you can spend!

Ask to see all service history the seller has and good luck, I hope it's a good one!
Also, be aware that it's right at the mileage for a full or partial suspension rebuild.
While it's nothing complicated it could run into some serious money for parts, especially if it needs control arms and/or motor mounts.
Have the Volvo tech check the breather pressure and has it had a timing belt done (for time, 10 years or 105K miles).
Mod note. Jim passed away in early 2022, his contributions to this forum are immortal, and he is missed. RIP

2000 V70R Black, 144,000 miles Wife's R.
2007 V70 2.5T White/Oak 111,000 MILES. Polestar tune, IPD bars, rear spoiler, dark grey Thors, DWS 06, HU850, sub.

BBettis
Posts: 1
Joined: 30 November 2017
Year and Model: 2004 Volvo S60 2.5T
Location: Kansas

Post by BBettis »

I have a 2004 S60 2.5T AWD that I am currently having a replacement motor installed in it. It's a low pressure turbo set up so I am assuming it has a higher compression ratio than the 2.4T or T5. I am also installing a T16 turbo upgrade, Rica i-Loader software upgrade, and a Stage 2 Power pack: high flow down-pipe and a Mototec cat-back exhaust system. I was wondering if this configuration is one that might produce around the 300hp mark? Thank you for your time.

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