Video tutorial on how to replace the turbo control valve on a Volvo C30 T5. The same procedure can also be found on the Volvo S40, V50, and C70 models from the same generation, this is a 2007 model. This car will also be getting a TCV upgrade thanks to IPDUSA. I am using IPD’s heavy duty turbo control valve for the P1 cars. A faulty turbo control valve will experience an increased fuel economy, a loss in high rpm power, over boosting in lower rpm which increases power, an irregular power band, and in a severe situation will be a check engine light and limp mode, meaning no turbo operation at while.
IPD HD TCV: https://www.ipdusa.com/products/9061/120154-ipd-heavy-duty-turbo-control-valve-hd-tcv-p1-s40-v50-c70-c30
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Elevate the car safely on ramps to access the TCV. Remove the plastic belly pan on your car. There will be two screws at the subframe, another two by the fender wells, and finally three along the bumper. Start with the rear and work your way forward, there are tabs which lock the pan into place on the subframe. Next you’ll need to remove the lower charge pipe for the turbo. There will be 3 10mm bolts in total, all the same length which holds the pipe in place. First is the lower one by the transmission. Next is the two remaining bolts at the front of the oil pan.
Using 7mm socket or standard screwdriver, loosen the gear clamps with connects the metal pipe to the rubber fittings. The rubber connections maybe stuck in place, twisting the connection does help break it free, then disconnect the pipe from it’s locations. Place it somewhere safe where dirt or debris won’t fall inside.
Next using the 7mm to disconnect the rubber connection on the turbo housing, then remove.
It can be a bit tough to remove, I find using a standard screwdriver to help expand the plastic, then push it off. If the old valve gets damaged, it’s not an issue here as it will be getting replaced and the old unit is faulty. Once removed, there will be an electrical connector on the TCV. Press the metal wire clip down, then remove the connector. There will be three hose clamps that need to be remove. I find it’s easiest to remove these clamps with smaller compact interlocking or slip joint pliers. The lines should be marked on the valve, however my markings did wear off. I did find some markings on the hoses. You can also follow the lines to their locations and determine each of their functions too.
IPD’s TCV has been designed to handle higher boost levels such as 16-17psi and is built for a harsh high heat environment and has viton seals. IPD includes all the items needed for the installation such as detailed instructions, new clamps, fittings, mounting bracket with fasteners, and the new HD TCV.
Assembly the TCV, first I install the nylon hose connections. Snug each fitting up using a wrench. Then using an allen wrench and wrench, install the bracket. With the supplied rubber sleeve, cut it to size for the bracket on the car. It will be about 1.5” in length.
One vacuum line did need to be extended by 2”. The best way to access this line is through the passenger side wheel well. There will be a plastic barrier that needs to be removed which provides a little extra room, there is a tab on the top, pull back and then slide down. This is for fitting number one for the turbo compressor. The line required for the replacement was 7/32” or 5mm will work as well. If all lines are being replaced, 3’ of rubber line should be all that’s needed.
I used a very light amount of rubber safe silicone spray to help install the hoses as they can be a tight fit. The hose hoses must be install past the hose barb, Then put the clamps into place. Cable ties maybe required to pull back the electrical connector or vacuum lines away from the axle or any other components which may damage the hose.
Reinstall parts in reverse of removal. In IPD’s detailed instructions, they do outline Volvo’s software learning procedure. Take the vehicle for a test drive to setup the ECU. Once the vehicle is performing correctly, reinstall the belly pan. Clip the rear side into the subframe first, then install the fasteners and tighten.
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