DIY Turbo Control Valve

[javaxc70]

So after browsing the web the last several days, I have found a way to build an HD turbo control valve that is identical to the iPd version for around $50 dollars. Here are the parts you need: 1) HD Solenoid Valve, 2) Bosch EV1 Connector, and 3) 1/8" vacuum connectors for solenoid valve. Throw in some teflon tape and some mounting tape and you are looking at the same HD TCV at a little over half price. Of course, you don't get the nifty mounting bracket, or a pre-assembled unit, but if you can work on your XC you can build this thing. You also need to find a rubber boot to cover connector. I have the parts coming in the mail and should have them this next week and will give a review! This is what a DIY version will look like in the end.

[Pennhaven]

Love that DIY initiative! Keep us posted.

[Aviator]

Post the plans if you wouldn't mind......that looks like something I might want to do!!!

Dave.

[javaxc70]

Once I get the parts, I will talk pictures and go through step by step on how to build. Apart from building the TCV, the install and computer learning time for the new solenoid valve are the same as the iPd HD TCV. Stand by for pictures and detailed instructions for this the next week!

[slowflyer]

That is cool. I didn't consider it. Good luck.

Actually, the mount is one part of iPD's TCV that I wasn't that impressed with. It is a piece of metal bent to form a back and an angle with a slot cut into the bend so it can slide onto the mount. You can easily build one with a bench vice and saw. It mounts to the TCV with bolts through the body of the TCV. You play with the gap until it mounts tightly enough.

[javaxc70]

I just got the fittings and solenoid in the mail today, but I am still waiting on the EV1 connector. I am contemplating just taking the connector from the working unit and using that. Here is a picture, as you can see, looks pretty similar to the iPd unit! I am still not sure 1/8" fittings will work, might have to go up to 1/4" to make work with hoses. I will install this weekend and give a review when done! [Edit: Looks like 1/4" fittings are the way to go, 1/8" are too small and won't work.]

[Allen]

Nice work, dude.

I bought one from iPD, and it really didn't make much difference. So I changed out two of the three vacuum lines with brand new silicon tubing. The one tube going to the bottom of the turbo I didn't change because I just couldn't get my hands up in there.

But changing just two of the three hoses brought the car to life. I wonder how much better it'll run when I pay the shop to swap out that last hose for me?

Old vacuum lines degrade from the constant heat, and will collapse under the negative pressure reducing the negative signal, especially on the Volvos with the plastic belly pan trapping all that heat in there for hours after shutdown. I took my belly pan off.

[howardc64]

it really didn't make much difference.

Ditto, built this thing and made little to no difference on my V70XC and V70T5. I'll be trying tubing next

[javaxc70]

I would definitely recommend replacing the vacuum hose. I replaced all my vacuum hoses well before the TCV and noticed a difference in everyday driving. I also replaced my CBV shortly before this upgrade which may have helped out. My XC has some higher mileage, so these upgrades together might have just brought me back to a nice stage 0!

[JayPinNC]

I'm thinking of going the DIY route for my TCV...but I'm looking for suggestions + pros/cons for the vacuum lines. I'm considering silicone, but what's a minimum wall thickness I should go for when I buy the lines? IPD says they're silicone tubing is great, but they don't even list the inside diameter of it...not that I could see anyway.

I see 2.5mm inside diameter on boostcontroller.com and I think that's a decent wall thickness, but I was looking for some input from people who've actually done this. Or should I just forget the silicone and stick with rubber?