Volvo Turbocharger Rebuild Service

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.

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TD04HLMHI 850 S70 S60 V70
TD03S80 T6 Twin Turbo
K24S60R V70R BorgWarner
850 / C70
TD04HL -16T -18T MHI
S70 / V70 T5
TD04HL -16T -18T MHI
S60 / V70 2.5T
TD04HL -13T MHI
S80 T6 Twin
TD03 MHI Twin Turbo
S60R / V70R
K24 BorgWarner
In Shop Since
2008 17+ years
Platform Coverage

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.

1993 – 1997
Volvo 850 T5 / T5R / 850R
MHI TD04HL-16T / 15G
The 850 T5 and 850R are the cars that put Volvo performance on the map -- the 850 racing in BTCC was the moment the world took notice. The turbo behind the street 850 T5 is a Mitsubishi TD04HL-16T on the B5234T3 and B5234T5 2.3L five-cylinder. The higher-spec 850R and T5R use the TD04HL-16T on the B5234T5 engine rated at 240 HP. Straight flange housing. Journal bearing water-cooled. Age and oil coking are the primary failure modes on these cars, most of which are 25-30 years old. The 850 community is loyal and active -- finding a proper rebuild shop that knows these turbos is harder than it should be.
49189-01350 49189-01355 8601238 1275663 49189-01310 49189-01320
1997 – 2004
C70 T5 / S70 T5 / V70 T5
MHI TD04HL-16T / 18T
The P80 platform C70, S70, and V70 T5 carry the TD04HL into the late 1990s and early 2000s. Engine codes B5234T3 (174 KW) and B5234T5 (240 HP) with straight and angled housing configurations depending on model year and market. The 1998 model year is a split -- 1997 uses the straight flange housing carried from the 850, 1998 onward uses the angled housing. Confirm the housing type before ordering parts. Both configurations are fully supported.
49189-01350 49189-01355 49189-01370 49189-01375 8601238 8602395
1999 – 2009
S60 / V70 / XC70 / S80 / XC90 2.5T LPT
MHI TD04HL-13T
The low-pressure turbo (LPT) 2.5T variant across the P2 platform uses the TD04HL-13T -- a smaller trim than the T5 and T5R units but the same MHI TD04HL family. Engine code B5254T2 is the most common LPT application. Volvo OEM part numbers 9454562 and 8601692 cover a wide range of models from 1999 onward. This is the most common Volvo turbo rebuild unit we see. Angled housing. The 13T designation indicates a smaller compressor trim than the 16T and 18T high-performance variants -- it is designed for broad torque delivery rather than peak power.
49189-05200 49189-05201 49189-05202 49189-05210 49189-05211 9454562 8601692 8602395 8601456
1999 – 2006
S80 T6 Twin Turbo
MHI TD03 Twin Turbo
The S80 T6 is the standout of the P2 generation -- a twin-turbocharged 2.9L straight-six (B6294T) making 268 HP from the factory. It uses two small MHI TD03 units in a sequential arrangement rather than the parallel twin layout. This was an unusual and sophisticated setup for a production luxury sedan. Both turbos must be rebuilt together -- running mismatched units in a sequential system creates boost anomalies and accelerates wear on both. Part numbers 49131-05161 and 49131-05150 cover the T6 TD03 applications. Volvo OEM 30650210 / 8602933.
49131-05161 49131-05150 30650210 8602933 8658624 8602862
2004 – 2007
S60R / V70R
BorgWarner K24
The S60R and V70R are the performance outliers of the P2 platform -- all-wheel drive, 300 HP from the B5254T4 2.5L five-cylinder, and a BorgWarner K24 turbo replacing the MHI units used on the rest of the lineup. The K24 is the same BorgWarner unit used on the Porsche 964 Turbo and 944 Turbo S -- a robust journal bearing unit with a long service history. The S60R and V70R K24 also includes a diverter valve and revised wastegate actuator calibrated for the Volvo application. Volvo OEM part number 8692170.
8692170 5324-988-7201 5324-970-7201 53249887201
2005 – 2009
S60 T5 / V70 T5
BorgWarner K24
The late P2 S60 T5 and V70 T5 (2005-2007) and the P3 S60 T5 (through 2009) use the BorgWarner K24 -- the same unit as the S60R/V70R but in a different state of tune. The K24 in T5 trim is a direct bolt-on and the same rebuild process applies. The P3 generation S60 and V70 (post-2007 facelift) continued the K24. Contact us with your model year and trim to confirm which K24 variant your vehicle has -- the T5 and R specifications are different and not interchangeable.
8692170 5324-988-7201
2003 – 2014
XC90 T6 Twin Turbo / 2.5T
MHI TD03 Twin / TD04HL-13T
The XC90 spans two turbo configurations. The T6 variant uses the same twin MHI TD03 setup as the S80 T6 on the B6294T 2.9L six -- both turbos should be rebuilt together. The 2.5T XC90 uses the same TD04HL-13T as the S60 and V70 2.5T on the B5254T2 engine. The high thermal mass of the XC90 platform and its use as a heavy daily driver make hot-shutdown oil coking one of the most common failure causes. Coolant line inspection is included on every XC90 rebuild.
49131-05161 49189-05201 49189-05211 9454562
Part Number Reference

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. Both are cross-referenced here.

Showing -- results
Part Number Turbo Model Engine Application Notes
49189-01350MHI TD04HL-16TB5234T3 / B5234T5 2.3L1993-1997 Volvo 850 T5 / 850RStraight flange housing
49189-01355MHI TD04HL-16TB5234T3 / B5234T5 2.3L1993-1997 Volvo 850 T5R / 850RStraight flange housing
8601238MHI TD04HL-16TB5234T3 / B5234T5 2.3L1993-1997 Volvo 850 T5 / T5RVolvo OEM
1275663MHI TD04HL-16TB5234T3 2.3L1993-1997 Volvo 850 T5Volvo OEM alternate
49189-01310MHI TD04HL-15GB5234T 2.3L1993-1995 Volvo 850 T5 earlyStraight flange early spec
49189-01320MHI TD04HL-15GB5234T 2.3L1993-1995 Volvo 850 T5 earlyStraight flange early spec
49189-01370MHI TD04HL-18TB5234T5 / N2P23HTR 2.3L1998-2002 C70 T5 / S70 T5 / V70 T5Angled housing 1998+
49189-01375MHI TD04HL-18TB5234T5 / N2P23HTR 2.3L1998-2002 C70 T5 / S70 T5 / V70 T5Angled housing 1998+
8602395MHI TD04HLB5234T3 / B5234T5 2.3LVolvo 850 / S70 / V70 / C70 T5Volvo OEM
49189-05200MHI TD04HL-13TB5254T2 / B5234T3 2.3/2.5L1999-2009 S60/V70/XC70/S80/XC90 2.5TLPT angled housing
49189-05201MHI TD04HL-13TB5254T2 / B5234T3 2.3/2.5L1999-2009 S60/V70/XC70/S80/XC90 2.5TLPT angled housing
49189-05202MHI TD04HL-13TB5254T2 2.5L2001-2004 S60/V70 2.5T early serialLPT serial 2375007 or lower
49189-05210MHI TD04HL-13TB5254T2 / B5234T3 2.5L1999-2009 S60/V70/XC70/XC90 2.5TLPT updated revision
49189-05211MHI TD04HL-13TB5254T2 2.5L1999-2009 S60/V70/XC70/XC90 2.5TLPT updated revision
9454562MHI TD04HL-13TB5254T2 / B5234T3 2.5LVolvo S60/S70/V70/XC70/S80/XC90 2.5TVolvo OEM -- most common
8601692MHI TD04HL-13TB5254T2 2.5LVolvo S60/V70/XC70/XC90 2.5TVolvo OEM
8601456MHI TD04HL-13TB5254T2 2.5LVolvo S60/V70/XC70 2.5TVolvo OEM
8601691MHI TD04HL-13TB5254T2 2.5LVolvo S60/V70/XC70 2.5TVolvo OEM alternate
9471656MHI TD04HL-13TB5254T2 2.5LVolvo S60/V70/XC70/XC90 2.5TVolvo OEM alternate
8658098MHI TD04HL-13TB5254T2 2.5LVolvo XC90/S80 2.5TVolvo OEM
49131-05161MHI TD03B6294T 2.9L straight-six1999-2006 Volvo S80 T6 / 2003-2006 XC90 T6 (each turbo)Twin Turbo -- rebuild in matched pairs
49131-05150MHI TD03B6294T 2.9L straight-six1999-2006 Volvo S80 T6 / XC90 T6Twin Turbo -- earlier revision
30650210MHI TD03B6294T 2.9LVolvo S80 T6 / XC90 T6Volvo OEM
8602933MHI TD03B6294T 2.9LVolvo S80 T6 / XC90 T6Volvo OEM
8658624MHI TD03B6294T 2.9LVolvo S80 T6 / XC90 T6Volvo OEM
8602862MHI TD03B6294T 2.9LVolvo S80 T6Volvo OEM
8692170BorgWarner K24B5254T4 2.5L2004-2007 Volvo S60R / V70R / S60 T5 / V70 T5Volvo OEM -- with diverter valve
5324-988-7201BorgWarner K24B5254T4 2.5LVolvo S60R / V70RBorgWarner part number
53249887201BorgWarner K24B5254T4 2.5LVolvo S60R / V70RBorgWarner alternate format
Common Failure Modes

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 environment challenges. The BorgWarner K24 on the S60R is the toughest unit in the Volvo lineup.

01
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 have parked immediately after hard driving, heat soak still occurs when the coolant pump stops with the engine. Over years of hard shutdowns the bearing housing accumulates carbon deposits from baked oil that restrict oil passages. Volvo owners who drive their cars hard and park immediately are the most common turbo rebuild customers we see.
02
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 -- often the supply line fitting on the back of the turbo housing where it is most exposed to heat. A cracked coolant line that goes unnoticed removes the post-shutdown cooling protection entirely. The turbo continues to generate heat for minutes after the engine stops with no coolant circulation. We inspect coolant line connection condition on every Volvo TD04HL rebuild and flag any deterioration. The lines should be replaced on any turbo that has them cracked or hardened.
03
Extended Oil Intervals on the Five-Cylinder
Volvo's B5254T and B5234T five-cylinder engines are known for oil consumption -- particularly at higher mileage. An engine consuming oil between changes can drop below the minimum safe level without the owner noticing. Low oil level reduces oil pressure at the turbo bearing housing. Combined with any AVCS or VVT-related oil passage restriction (the B5254T has VVT similar in concept to Subaru's AVCS), the result is the same: starved bearings. Short synthetic oil change intervals are the single most important preventive maintenance item on any turbocharged Volvo five-cylinder.
04
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. Replacing only one turbo in a sequential twin system creates imbalanced boost delivery that the engine management cannot properly compensate for, and stresses the fresh unit with unequal loading. Both TD03 units must come out together and return rebuilt to the same specification. We rebuild S80 T6 pairs as a matched set, VSR balanced to matching spec.
05
TD04HL Angled vs Straight Housing Confusion
The 850 and early C70/S70/V70 use a straight compressor housing outlet. The 1998-onward models use an angled housing outlet. These are not interchangeable at the charge pipe. Installing a straight housing unit on an angled-housing application requires a charge pipe modification, and vice versa. This is the most common parts ordering mistake on Volvo TD04HL rebuilds. We ask about model year and current housing configuration before any rebuild proceeds -- confirming the housing type saves everyone time.
06
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 that have never been touched on high-mileage S60R and V70R cars are typically running with worn bearings and shaft seals that are weeping oil into the intake. The K24 is a proven rebuild-friendly design -- the same unit used on the Porsche 964 Turbo -- and the rebuild process is well established. If your R-chassis Volvo is blowing blue smoke or showing oil in the intercooler, the K24 is almost certainly the cause and a rebuild is the correct solution.
Common Questions

Frequently Asked

Look at the compressor housing outlet -- the metal pipe connection on the front of the turbo that connects to the charge pipe going to the intercooler. If that outlet points straight out parallel to the compressor housing face it is the straight flange housing used on 1993-1997 850s and early C70/S70. If it angles downward or away from the housing face it is the angled housing used from 1998 onward. You can also look at the Volvo OEM part number on the turbo tag -- 49189-013XX series is the straight housing family and 49189-052XX series is the angled housing family. Send us a photo of the housing outlet if you are unsure and we will confirm before the rebuild starts.
No. The S80 T6 uses a sequential twin turbo arrangement where both units operate under essentially identical thermal and load conditions. If one has failed from bearing wear or oil coking, the other has experienced the same environment and is close behind. Replacing one unit and leaving the other installed means the new unit enters a sequential system with a worn partner that cannot maintain matching boost response. The system runs poorly, the new turbo compensates and wears faster, and you are back to pulling the engine within a year or two. Ship both to us and we rebuild them as a matched pair.
The S60R/V70R K24 uses the same BorgWarner K24 frame as the Porsche 964 Turbo and 944 Turbo S -- they share the same fundamental KKK 5324 design. The housing configurations, wastegate actuators, and compressor/turbine wheel trims are calibrated differently for their respective applications, but the center section architecture is identical. This means the K24 rebuild process is well established and parts are available. The Volvo-specific BorgWarner part number is 5324-988-7201. If you have worked with Porsche K24 rebuilds before, the Volvo unit is the same turbo in a different dress.
The TD04HL-13T covers an enormous span of Volvo 2.5T LPT applications because Volvo used the same basic unit across S60, V70, XC70, S80, and XC90 from 1999 through 2009. The 49189-052XX family covers essentially all of them. There are minor revisions within the family (05200 vs 05201 vs 05211) but they are largely interchangeable within the application range. The most reliable approach is to match your existing Volvo OEM part number (8601692, 9454562, etc.) to the table above. If your car has engine code B5254T2 anywhere in the badge or emissions label you have the LPT 2.5T and the TD04HL-13T is your turbo.
Drain any residual oil from the oil inlet and outlet ports. Plug all ports including the coolant supply and return. Double-box with foam padding on all sides. Ship via UPS or FedEx to 37833 Pineapple Ave Unit A, Dade City, FL 33523. Include your model, model year, and the Volvo OEM part number from the turbo tag if visible. For S80 T6 and XC90 T6 twin turbo sets, ship both units in the same box. Contact us before shipping and we will send a receiving confirmation.
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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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sales@theboostlab.com theboostlab.com Dade City, FL