I am considering some significant performance upgrades for my 2001 Volvo S60 T5 (manual transmission), and I was hoping someone out there might be able to answer some questions for me. What I am looking for is a framework to develop my upgrade plans around.

At this stage, my particular concern is the strength of the engine and drivetrain. While I understand that any increase in power is going to reduce margins and increase the risk of breakage, I thought there might be someone here who would have a rough estimate of how much torque I could add before it became prudent to start beefing up the components.

I plan to keep using the car as my daily driver, so I won’t really be flogging it very often, or very hard. I just want to be able to, should the occasion arise. At worst, I might run a couple of passes down a dragstrip, just to see what it is capable of.

Continuing down that same path, once I start exceeding that “safe” level of torque, which parts need to be strengthened first? In other words, what are the weaker links in the chain, the connecting rods? The clutch?
Any insights you could provide would be enormously helpful, as would any guidance about where to find stronger versions of those parts.

[sm=shades.gif]Thanks for your assistance

For the most part unless you get to 400HP you should be fine.
They are pretty strong.

If your plan is to "go fast" then I would upgrade your brakes ASAP. "H" rated tyres may not be right for you either.