Engine: TDI: Euro 4 D5 maximum power capability?

[Nathw9999]

So I've researched quite a lot into tuning the d5 engine, in a c30 in my case, and I am yet to find one making over 280hp/600nm

I have read about how the internals are good for 500+hp so they can theoretical make that much but the problem is how. Injectors seem to be a big issue when it comes to more power but should custom injectors be sourced along with suitable bolt ons such as intercooler and turbo that are capable over power in excess of 280hp what do we think these engines could truly produce or is there something I'm missing here? Also I am aware clutch and flywheel are an issue but u just want to know the possible power👍

My car currently has:
-Airtec intercooler with hardpipes
-BSR intake with extra cold air feed
-Straight through 3" inch exhaust
-EGR and swirl flap delete
-also looking at a stage 2 hybrid turbo from turbo zentrum that claims '320hp'

[Tannaton]

Not sure what the engine limit is, but in practice it's likely to be the gearbox. The E4 D5 already puts out very close to the maximum torque of the auto gearbox. Not sure what the limit is on the M66 manual but Focus owners with the Volvo engine complain that on tuned cars the gearbox gives up long before the engine.

[griston64]

https://www.volvoforums.org.uk/showthread.php?t=159608

Might be worth a read