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Discussion Starter #1 (Edited)
What specifically are the limiting factors of the B5254 T4?
Sure, turbo swaps are a relatively inexpensive way to make power, but there should not be any reason that the stock K24 can't hold 20# with 2-3psi+ spikes.

Plenty of people running smaller displacement motors than the 2.5 I5 are running similarly sized (midget) turbos making more power on stock internals.

K04 on the 1.8T platform with stock internals have been known to make ~340awhp reliably!
Just don't see why the tuners haven't taken advantage of the S60R platform to its full potential.

Albeit DDM's easier tuning capabilities because of the R's EMS controlling boost.
Why wouldn't tricking the ECU's boost voltage by capping it from seeing 'overboost' conditions (not real overboost, just unregulated by ECU high boost) work? (0-5V max)

Anybody with Volvo specific tuning knowledge chime in.
 

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for sure Lucky will tell you exactly what do you want....but he is a bit busy tuning cars around USA now.
 

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Sure, turbo swaps are a relatively inexpensive way to make power, but there should not be any reason that the stock K24 can't hold 20# with 2-3psi+ spikes.
You must be new here. :)

With just a tune (depending on the tune), 20lbs of sustained boost is pretty typical. That brings it up to about 330hp reliably. The problem is going higher than that, when you get cracked cylinder walls. There are plenty of threads discussing these issues. Low 20's seems the limit for reliability. Other bolt on mods like exhaust, downpipe, FMIC, etc. bring HP up in the range of 340-360

If you want more than 350-375hp, you need to start upgrading internals and sleeving to take higher boost levels. The ECM tune will take care of over-boost conditions.
 

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Discussion Starter #4
You must be new here. :)

With just a tune (depending on the tune), 20lbs of sustained boost is pretty typical. That brings it up to about 330hp reliably. The problem is going higher than that, when you get cracked cylinder walls. There are plenty of threads discussing these issues. Low 20's seems the limit for reliability. Other bolt on mods like exhaust, downpipe, FMIC, etc. bring HP up in the range of 340-360

If you want more than 350-375hp, you need to start upgrading internals and sleeving to take higher boost levels. The ECM tune will take care of over-boost conditions.
Who does the sleeving?
I've seen issues with sleeves separating from the cylinders and also ovaling instead of perfectly round cylinders.
Is there enough sidewalks to increase the diameter and sleeve the block reliably?

See HPF's issue with Marcus's build, $30k turbo build with built motor blowing up.
 
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