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Installation Instructions
HD Turbo Control Valve
C30 all, V50 all, C70 2006-on,
S40 2005-on ipd #120154
SUGGESTED TOOLS
• Metric sockets • rachet • pliers
SAFETY WARNINGS
• Always support the vehicle with jack stands before working underneath
• Use only the parts supplied by ipd to install this kit
• Check ALL the fasteners for tightness before and after road testing the vehicle
• Do not use air impact wrench when re-installing bolts as stripped threads may resul
REMOVAL
1 Remove the 7 torx 30 bolts from the splash pan and remove it from the vehicle.
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PI-396 • 6/12
PI396
11744 NE Ainsworth Circle, Portland, OR 97220 • (503) 257-7500 • Fax (503) 257-7596
REMOVAL
2
Remove the 10mm bolt from the lower charge tube as shown.
3 Remove the two 10mm bolts from the lower charge tube forward bracket as shown.
4 Loosen the clamp holding the intercooler inlet coupler to the lower charge tube.
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5
REMOVAL
Loosen the clamp holding the turbo outlet coupler to the lower charge tube.
6 Remove the charge tube from the vehicle.
7 Lift the stock TCV off the factory mounting tab.
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REMOVAL
8 Remove the three lines from the stock TCV noting the color coding on each line. If the colors are not visible, be sure to mark each hose as it comes off referencing the color coding on the tcv itself.
9 Disconnect the electrical connector from the stock tcv and remove the tcv from the car.
INSTALLATION
10 Assemble your new HD TCV with the included screws/nuts and bracket as shown.
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INSTALLATION
11 Install the vacuum elbows into the valve as shown.
Note: Be sure not to over tighten the three elbows onto the TCV. Over tightening the elbows, especially on the center port (Labeled #3 that is going to the intake) can cause the TCV to not function properly as there is a screen over that port which can get crushed down into the unit.
Snug each elbow down by hand, having some threads showing on each elbow is normal.
12 Trim the molded cap so it’s overall length is approximately 1.5 inches.
13 Slide the molded cap into the bracket as shown.
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INSTALLATION
14 Connect the electrical connector on the TCV to the factory harness. Connect each of the factory vacuum lines to the TCV noting the color code of the line and the corresponding color mark on the
TCV. Use the included spring clamps to secure the vacuum lines.
15 Confirm the TCV, vacuum lines, and connector is free from any rotating or moving parts.
16 Reinstall the factory splash pan.
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Initial Drive Procedure and Warnings:
1 ipd recommends the use of a boost gauge for proper boost monitoring when installing any aftermarket parts that affect boost or power levels in a turbo charged vehicle. The ipd HD TCV is a high speed, high accuracy control solenoid intended for boost control and as such will expose any inconsistencies in the factory boost development system. This means that boost and power development issues you may not have been aware of may now come to your attention as they were previously masked by the factory TCV and its slower, less precise actuation. While a boost gauge is recommended, it is not required for this product. The ipd TCV operates in the same manner as the stock valve so it is well suited to stock cars as well as tuned cars. All the factory engine safety features such as knock control and boost limit are retained so the operation of the HD TCV is seamless.
2
Volvo engine control units feature ‘learning’ software, this means the on board programmed logic in the ECU can adapt to changing conditions in certain engine parameters. Boost development is one of the parameters that the ECU monitors and can adapt to a certain degree. It is possible to drive the vehicle in a specific manner to allow the ECU to adapt to the new TCV and its characteristics.
Adaptation of the ipd TCV is not as critical in stock cars as it is for tuned cars, however both will benefit from following the adaptation sequence.
3
After the installation of the ipd HD TCV drive the vehicle for 5 minutes without developing any boost pressure to allow the engine to warm up. In a safe and appropriate place, accelerate the vehicle to approx half of its maximum boost level and hold there for 5-7 seconds, then decelerate to below
30mph. Proper accelerator modulation will be necessary to control the boost level. Repeat this 4 times.
Turn the engine off and wait for 12 minutes. For optimum results the above procedure should be performed twice.
4 Once completed be sure to closely monitor boost pressure when reaching the maximum boost target.
If any inconsistencies or improper boost levels are reached, stop immediately and have a qualified technician inspect the vehicle for any of the following potential issues.
• Compressor bypass valve leakage
• Boost tubing leaks
• Vacuum line leaks, vacuum elbow leaks
• Incorrect waste gate setting
• Stored codes in the engine control module
• Proper installation of the TCV
5 Correct any problems and/or diagnose any on board trouble codes before continuing.
6
If you experience any inconsistencies or improper boost levels, re-install the factory TCV and call our customer service line at 800-444-6473 for assistance, we are happy to help you!
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WARRANTY
One Year Limited Warranty
ipd warrants to the original purchaser that the parts manufactured and/or sold by ipd (the Product) is free from defects in material and workmanship under normal use. ipd warrants that the Product will perform substantially in accordance with the specifications set forth in the documentation provided with it. The above express warranties are made for a period of the lesser of 12,000 miles or 12 months from the date the Product is installed in your vehicle.
Any improper use, operation beyond capacity, substitution of parts not approved by ipd in writing, any alteration or repair by others, or any removal, defacing or altering of the identification shall void this warranty. There is no warranty on high-performance or race related parts due to the nature of usage.
The purchaser shall notify ipd at 1-800-444-6473 of any defect within the warranty period no later than thirty (30) days after purchaser discovers the defect. Should any failure to conform to this warranty appear within the warranty period, ipd shall, on notification, correct the nonconformity at its option, either by repairing any defective part, or by making available, FOB ipd’s plant, a repaired or replacement part. The purchaser must insure any defective item being returned because ipd does not assume risk of loss or damage while in transit. No payment or reimbursement shall be made for installation, removal, transportation or other charges. The remedies set forth in this instrument are exclusive, and the liability of ipd with respect to any sale shall not exceed the price of the product on which the liability is based.
EXCEPT AS STATED OTHERWISE IN THIS WARRANTY, ipd MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. ipd shall not in any case be liable for special, incidental, consequential, indirect, or other similar damages arising from any breach of these warranties even if ipd or its agent has been advised of the possibility of such damages. Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you.
This warranty is governed by the laws of the State of Oregon.
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