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Volvo turbo rebuild
Complete in-house rebuild service for every turbocharged Volvo. 850 T5 and T5R, S70 and V70 T5, C70, S60 and V70 2.5T, S80 T6 twin turbo, S60R and V70R, XC90 T6 and 2.5T. Mitsubishi TD04HL and TD03 twin, BorgWarner K24. In-house VSR balancing since 2008.
- 850 / C70
- TD04HL-16T / 18T MHI
- S60 / V70 2.5T
- TD04HL-13T MHI
- S80 T6
- TD03 MHI Twin Turbo
- S60R / V70R
- K24 BorgWarner
- XC90
- TD03 Twin / TD04HL-13T
- In shop since
- 2008, 17+ years
Every turbocharged Volvo we rebuild
Volvo has used Mitsubishi Heavy Industries TD-series turbos as the backbone of their performance lineup since the 850 era. The S80 T6 twin turbo uses a pair of smaller MHI TD03 units. The S60R and V70R moved to a BorgWarner K24. All are fully supported at Boost Lab.
850 T5 / T5R / 850R 1993-1997: MHI TD04HL-16T / 15G
The 850 T5 and 850R put Volvo performance on the map. The turbo is a Mitsubishi TD04HL-16T on the B5234T3 and B5234T5 2.3L five-cylinder. Straight flange housing. Journal bearing water-cooled. Age and oil coking are the primary failure modes on these 25-30 year old cars.
Applications: 1993-1997 Volvo 850 T5 / T5R / 850R
- 49189-01350
- 8601238
C70 / S70 / V70 T5 1997-2004: MHI TD04HL-16T / 18T
The P80 platform carries the TD04HL with straight and angled housing configurations. 1997 uses the straight flange housing from the 850; 1998 onward uses the angled housing. Confirm the housing type before ordering parts.
Applications: 1997-2004 Volvo C70 T5 / S70 T5 / V70 T5
- 49189-01370
- 8602395
S60 / V70 / XC70 / XC90 2.5T LPT 1999-2009: MHI TD04HL-13T
The most common Volvo turbo rebuild unit we see. The TD04HL-13T covers an enormous span of Volvo 2.5T LPT applications. Angled housing. The 13T designation indicates a smaller compressor trim designed for broad torque delivery rather than peak power.
Applications: 1999-2009 Volvo S60 / V70 / XC70 / S80 / XC90 2.5T LPT
- 9454562
- 8601692
S80 T6 / XC90 T6 twin turbo 1999-2006: MHI TD03 twin
A twin-turbocharged 2.9L straight-six (B6294T) making 268 HP. Uses two small MHI TD03 units in a sequential arrangement. Both turbos must be rebuilt together. Running mismatched units in a sequential system creates boost anomalies.
Applications: 1999-2006 Volvo S80 T6 / 2003-2006 XC90 T6
- 49131-05161
- 30650210
S60R / V70R 2004-2007: BorgWarner K24
All-wheel drive, 300 HP from the B5254T4 2.5L five-cylinder. The BorgWarner K24 is the same frame used on the Porsche 964 Turbo and 944 Turbo S, a robust journal bearing unit. The Volvo K24 includes a diverter valve and revised wastegate actuator.
Applications: 2004-2007 Volvo S60R / V70R / 2005-2009 S60 T5 / V70 T5
- 8692170
- 5324-988-7201
Find your part number
Search by MHI part number, BorgWarner number, Volvo OEM number, or model. Volvo uses an 8-digit OEM format (8601692, 9454562, etc.) alongside the MHI 49189-XXXXX series.
| Part Number | Turbo Model | Engine | Application | Notes |
|---|---|---|---|---|
| 850 T5 / T5R / 850R | ||||
| 49189-01350 | MHI TD04HL-16T | B5234T3 / B5234T5 2.3L | 1993-1997 Volvo 850 T5 / 850R | Straight flange housing |
| 49189-01355 | MHI TD04HL-16T | B5234T3 / B5234T5 2.3L | 1993-1997 Volvo 850 T5R / 850R | Straight flange housing |
| 8601238 | MHI TD04HL-16T | B5234T3 / B5234T5 2.3L | 1993-1997 Volvo 850 T5 / T5R | Volvo OEM |
| 1275663 | MHI TD04HL-16T | B5234T3 2.3L | 1993-1997 Volvo 850 T5 | Volvo OEM alternate |
| 49189-01310 | MHI TD04HL-15G | B5234T 2.3L | 1993-1995 Volvo 850 T5 early | Straight flange early spec |
| 49189-01320 | MHI TD04HL-15G | B5234T 2.3L | 1993-1995 Volvo 850 T5 early | Straight flange early spec |
| C70 / S70 / V70 T5 | ||||
| 49189-01370 | MHI TD04HL-18T | B5234T5 / N2P23HTR 2.3L | 1998-2002 C70 T5 / S70 T5 / V70 T5 | Angled housing 1998+ |
| 49189-01375 | MHI TD04HL-18T | B5234T5 / N2P23HTR 2.3L | 1998-2002 C70 T5 / S70 T5 / V70 T5 | Angled housing 1998+ |
| 850 T5 / T5R / 850R | ||||
| 8602395 | MHI TD04HL | B5234T3 / B5234T5 2.3L | Volvo 850 / S70 / V70 / C70 T5 | Volvo OEM |
| C70 / S70 / V70 T5 | ||||
| 49189-05200 | MHI TD04HL-13T | B5254T2 / B5234T3 2.3/2.5L | 1999-2009 S60/V70/XC70/S80/XC90 2.5T | LPT angled housing |
| 49189-05201 | MHI TD04HL-13T | B5254T2 / B5234T3 2.3/2.5L | 1999-2009 S60/V70/XC70/S80/XC90 2.5T | LPT angled housing |
| S60 / V70 / XC70 / XC90 2.5T LPT | ||||
| 49189-05202 | MHI TD04HL-13T | B5254T2 2.5L | 2001-2004 S60/V70 2.5T early serial | LPT serial 2375007 or lower |
| C70 / S70 / V70 T5 | ||||
| 49189-05210 | MHI TD04HL-13T | B5254T2 / B5234T3 2.5L | 1999-2009 S60/V70/XC70/XC90 2.5T | LPT updated revision |
| 49189-05211 | MHI TD04HL-13T | B5254T2 2.5L | 1999-2009 S60/V70/XC70/XC90 2.5T | LPT updated revision |
| 9454562 | MHI TD04HL-13T | B5254T2 / B5234T3 2.5L | Volvo S60/S70/V70/XC70/S80/XC90 2.5T | Volvo OEM, most common |
| 8601692 | MHI TD04HL-13T | B5254T2 2.5L | Volvo S60/V70/XC70/XC90 2.5T | Volvo OEM |
| 8601456 | MHI TD04HL-13T | B5254T2 2.5L | Volvo S60/V70/XC70 2.5T | Volvo OEM |
| 8601691 | MHI TD04HL-13T | B5254T2 2.5L | Volvo S60/V70/XC70 2.5T | Volvo OEM alternate |
| 9471656 | MHI TD04HL-13T | B5254T2 2.5L | Volvo S60/V70/XC70/XC90 2.5T | Volvo OEM alternate |
| S60 / V70 / XC70 / XC90 2.5T LPT | ||||
| 8658098 | MHI TD04HL-13T | B5254T2 2.5L | Volvo XC90/S80 2.5T | Volvo OEM |
| S80 T6 / XC90 T6 Twin Turbo | ||||
| 49131-05161 | MHI TD03 | B6294T 2.9L straight-six | 1999-2006 Volvo S80 T6 / 2003-2006 XC90 T6 (each turbo) | Twin Turbo, rebuild in matched pairs |
| 49131-05150 | MHI TD03 | B6294T 2.9L straight-six | 1999-2006 Volvo S80 T6 / XC90 T6 | Twin Turbo, earlier revision |
| 30650210 | MHI TD03 | B6294T 2.9L | Volvo S80 T6 / XC90 T6 | Volvo OEM |
| 8602933 | MHI TD03 | B6294T 2.9L | Volvo S80 T6 / XC90 T6 | Volvo OEM |
| 8658624 | MHI TD03 | B6294T 2.9L | Volvo S80 T6 / XC90 T6 | Volvo OEM |
| 8602862 | MHI TD03 | B6294T 2.9L | Volvo S80 T6 | Volvo OEM |
| S60R / V70R / S60 T5 (K24) | ||||
| 8692170 | BorgWarner K24 | B5254T4 2.5L | 2004-2007 Volvo S60R / V70R / S60 T5 / V70 T5 | Volvo OEM, with diverter valve |
| 5324-988-7201 | BorgWarner K24 | B5254T4 2.5L | Volvo S60R / V70R | BorgWarner part number |
| 53249887201 | BorgWarner K24 | B5254T4 2.5L | Volvo S60R / V70R | BorgWarner alternate format |
No results? Contact us at sales@theboostlab.com with your model year, trim, and engine code.
Why Volvo turbos fail
The MHI TD04HL is a robust unit that fails almost exclusively for oil-related reasons. The TD03 twin turbo in the S80 T6 has specific thermal challenges. The BorgWarner K24 on the S60R is the toughest unit in the lineup.
Oil coking from hot shutdown
The most common Volvo turbo failure across every platform. The TD04HL is water-cooled, which helps manage heat after shutdown, but the water cooling only works when coolant is flowing. On cars that park immediately after hard driving, heat soak still occurs when the coolant pump stops. Over years of hard shutdowns the bearing housing accumulates carbon deposits that restrict oil passages.
Cracked turbo coolant lines
The Volvo TD04HL uses plastic coolant supply and return line connectors that deteriorate with age. Brittle plastic fittings crack at the turbo connection points. A cracked coolant line removes the post-shutdown cooling protection entirely. We inspect coolant line condition on every Volvo TD04HL rebuild and flag any deterioration.
Extended oil intervals on the five-cylinder
Volvo B5254T and B5234T five-cylinder engines are known for oil consumption, particularly at higher mileage. Low oil level reduces oil pressure at the turbo bearing housing. Short synthetic oil change intervals are the single most important preventive maintenance item on any turbocharged Volvo five-cylinder.
S80 T6 twin turbo matched wear
The S80 T6 sequential twin TD03 system operates both turbos under the same thermal and load conditions. When one unit fails, the other has almost always accumulated equivalent wear. Both TD03 units must come out together and return rebuilt to the same specification.
TD04HL angled vs straight housing confusion
The 850 and early C70/S70/V70 use a straight compressor housing outlet. 1998-onward models use an angled housing outlet. These are not interchangeable at the charge pipe. This is the most common parts ordering mistake on Volvo TD04HL rebuilds. We confirm housing type before any rebuild proceeds.
S60R / V70R K24 age-related wear
The BorgWarner K24 on the S60R and V70R is a robust unit but these cars are now 15-20 years old. Turbos on high-mileage R-chassis cars are typically running with worn bearings and shaft seals weeping oil into the intake. The K24 is a proven rebuild-friendly design and the process is well established.
Frequently asked questions
How do I know if my 850 has a straight or angled housing?
Look at the compressor housing outlet: if it points straight out parallel to the housing face it is the straight flange housing used on 1993-1997 850s and early C70/S70. If it angles downward it is the angled housing used from 1998 onward. You can also check the MHI part number on the tag: 49189-013XX series is the straight housing family and 49189-052XX series is the angled housing family. Send us a photo if you are unsure.
My S80 T6 has only one turbo making noise. Can I rebuild just that one?
No. The S80 T6 sequential twin TD03 system operates both turbos under identical conditions. If one has failed, the other has experienced the same environment and is close behind. Both must come out together and return rebuilt to matching spec.
Is the S60R K24 the same as the Porsche K24?
The S60R/V70R K24 uses the same BorgWarner K24 frame as the Porsche 964 Turbo and 944 Turbo S. The housing configurations, wastegate actuators, and wheel trims differ, but the center section architecture is identical. The rebuild process is well established and parts are available.
The 2.5T LPT part numbers cover a huge range of cars. Which one do I need?
The TD04HL-13T covers S60, V70, XC70, S80, and XC90 from 1999 through 2009. There are minor revisions within the 49189-052XX family but they are largely interchangeable. Match your existing Volvo OEM part number (8601692, 9454562, etc.) to confirm. If your car has engine code B5254T2 you have the LPT 2.5T and the TD04HL-13T is your turbo.
How do I ship my Volvo turbo?
Submit the rebuild form at repair.theboostlab.com first. Drain residual oil, plug all ports including coolant supply and return, and double-box with foam padding. Ship via UPS or FedEx to 37833 Pineapple Ave, Unit A, Dade City, FL 33523. For S80 T6 and XC90 T6 twin sets, ship both units together. We will send a receiving confirmation.
Ready to rebuild?
Start your rebuild request in our repair system. 850 through S60R, all supported. Every job documented from intake through return shipment with in-house VSR balancing.
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