Hey everyone, i have recently purchased a 2003 volvo s60 2.5t awd. I'm having a weird issue when i accelerate full throttle after about 3.5-4K rpms the car feels like it gets a slight boost surge every few seconds. I don't know very much about volvo turbo systems so if anyone has experienced this before and might know the cause i would greatly appreciate any ideas.

 

You would need to look at live data and check stored codes to make sure what your feeling is what you think as these cars don't come with a boost gauge. This could be a lot of things.

 

Well shoot, guess i have to stop being lazy and figure it out myself.

 

No dude just change your tri motodiagrecher valve!

Or maybe if you think the boost is wonky - connect a boost gauge and tape it to the windshield (temporarily)

 

Boost gauge was the best "diagnostic tool" I installed on my old S60

 

Yeah bought a boost gauge today gonna connect it and see what it reads

 

So finally got around to installing a boost gauge and sure enough when I put my foot to the floor at almost any beginning speed, the turbo will spool steady and normally until 6-7 psi, which I was told is the factory max psi or something. It then surges to 9-12 psi every second or so. I would assume this is a boost controller issue but i don’t know much about the B5254T2 turbo system to say that confidently

 

#7 solenoid controls boost pressure - my techs have replaced a few, but not sure what other parameters might cause the valve to go to high or low. Or if the valve itself is simply sticking.

 

I have replaced this solenoid 3x in 2 years on my 06 S60 (granted it was running 12psi instead of stock) and other P2 owners replaced them a lot too. I think they run about $30 on fcp. Search Turbo Control Valve or by part # that hoonk provided.

I have also seen a lot of people install an inline air filter on the line coming from the turbo compressor. This will help keep it clean from oil vapors which can cause it to fail prematurely.

 

I just bought the heavy duty upgraded tcv from IPDUSA.com as i plan on pushing the boost limits in the future and don't want to replace it annually.

 

Let us know how you make out. I replaced the plastic elbows on that TCV with brass ones as I thought the plastic ones did not tighten up nicely. Worked out well for me. The plastic ones loosened up on me over time. I also used a ziptie to hold that TCV in place because of how it mounts to the air box.

 

Yeah im going to install it this weekend, 25-26th so once i finish I'll make a report about it and whether i solved my issue.

 

Alright so I basically did everything you said as well. As soon as I saw the supplied elbows I bought new brass ones at Ace hardware, the solenoid is good quality though and so is the pigtail for it. Install was fairly easy and painless, The hoses are color coded thank God. Ended up just not using the bracket it came with and zip tied it to the air box. Closed the hood fired it up and went and did some foot-to-the-floor pulls and my surge issue is fixed!!!! Hallelujah! No more surging from 6psi to 12psi at full throttle.

 

Awesome, glad it worked out for you. Did you do their break-in/adaption procedure?

The bracket that they put on the IPD TCV seems like it would work okay for an R, but not a T5 or a 2.5T

 

I did not, wasn't aware there was one. It seems to be running just fine none-the-less so I'll consider myself lucky.

 

It wasn't anything crazy, and was a recommendation, not required. Pretty much just held the car at 50% boost for a certain amount of time for a certain number of times, then full boost a few times. Then let the car sit at least 30min and do it again. I only did it once, no issues here.

Mine came with a sheet of paper with installation instructions and the adaption method.

 

Ok that's basically what i did with mine i held it at part throttle for a little bit then let it spool all the way a few times and then let it rest. Mine came with the same paper i just ignored it cause me being auto tech student didn't think I needed it

 

Step 1: Throw away instructions

I wouldn't start a project any other way