Tim's 2008 T5 RDesign Volvo C30

timbo

@240 nope but it doesn't seem to be causing any issues. Swing past the workshop one afternoon and I'll take you for a spin I put rego on the car yesterday

240

Sounds good I'd be keen

timbo

https://youtu.be/MaNWtJ2ZSOo

timbo

Since this is more than likely the first C30 in the world with functional standalone haldex control, I thought I should l document what parts you require for this to work.

-CRC performance mk3 haldex controller for Ford

-2012 Kuga mk4 haldex/AOC housing te model 2.5 petrol

-Canbus speed signal generator I used this one from soundlabs

https://www.soundlabsgroup.com.au/p/CANBUS-CB1/CANBUS+CB1+Speed+Interface

I had to swap the tailshaft flange from the S40/v50 gen2 haldex onto the mk4 haldex as the Kuga one is larger.

Wiring up is easy as the CRC performance controller just requires

- power (fuse tap from 12v socket fuse)

-handbrake (I spliced into the stock handbrake switch)

- 12v speed signal pulse (soundlabs product pulls this from the canbus)

CRC haldex controller allows you to calibrate the speed signal perfectly

-boost reference hose

I actually used a mk4 Volvo AOC housing because the 2nd hand Kuga one I got was filthy but i checked and the Kuga one will bolt to the Volvo diff.

Trex

hell yeah timmy. looks good!

timbo

Got to throw the c30 on the dyno today as part of boosters annual dyno day.

Made 203kw atw in AWD mode 100% lock.

Dyno guys said 30ish kw lost with AWD

K16 tunes are usually around 240atw

Afrs were rubbish ecu/tune is upset with the high flow fuel pump.

Interestingly with haldex controller @100% lock it's sending more power to the rear than the front, jumped in and we ran it up again while I adjusted it to 55% lock which had equal power front to rear.

This is a great result and shows this standalone controller is far superior to what you can achieve with any of the stock haldex modules

timbo

Since work is pretty quiet I got some "essential" work finished!

New larger/quieter compressors for airbag setup and polished barrels

TL_V70

Black and thoes Rims look really good especially when its dumped on its guts. Very nice C30 Timbo

timbo

Fitted new front hubs, bearing lock brackets textar rotors and project Mu pads.

I was able to borrow the tools for the front hub replacement from the local dealership which made the job easier

Need to see @AshDVS for some AWD braided brake lines and the mk3 RS rear brake upgrade

Also picked up some forged 8.5:1 wossner pistons for a good price so will slowly gather parts for a sleeved engine build. So far this engine has held up with just shims

AshDVS

Just reach out when you're ready.

242GT

Amazing

timbo

Rear LSD turned up today thanks to @VolvoMike

I'll drop a diff centre out to the machinist next week. The crown wheel has to be machined off the factory rear diff centre and is not a straightforward install

VolvoMike

Quaife sent me 7 of those boxes with nothing in them @timbo.... it might be a wifi LSD....

MattJ

Reading through your thread I saw you mention that you upgraded your fuel pump and added a 2nd for the LH side pickup.

I'm doing an AWD + k16 conversion and found as you did that the DW300 pump won't work in the AWD pump assembly. Can you give some details how you set up the additional LH pump.

timbo

@MattJ Ive since removed that setup and just running a stock setup for now. (Had fuel smell issue with the way I had run the wiring for auxillary pump) plus afrs we're all over the shop on dyno, since the ECU is chasing its tail trying to target fuel pressure with a 300% bigger pump.

The biggest issue I've found for upgrading fuel flow in these cars is actually the fuel reg in the tank. You can put the biggest pump you want in, but without upgrading the regulator it just dumps the extra fuel back in the tank.

I've since got a fuel sender unit out of a mk3 focus since they run a 6bar 250lph setup for the direct injection system (fairly similar to the fwd c30 setup may be direct fit), but I'm yet to muck around with that on my car. Was going to test the setup in @T3rrorbyt3 Amazon first since it's easier to get fuel pump in/out and don't have to worry about making fuel gauge work.

Biggest issue when changing the pumps is the corrugated fuel hose, I ended up changing to submersible rubber hose and running bulkhead fittings through the top of fuel sender.

Had mounted a 240 Volvo lift pump to level sensor on passenger side that fed the standard fuel pickup that runs to drivers side.

If you're still interested in how I did it I can take some photos when I'm back at work as it's out of the car.

MattJ

Thanks for your reply Tim

I found it interesting that you had issues with the setup. I was thinking about hanging the FWD pump on the LH sender and feeding it out through the top. Then "T"ing it into the fuel line, so it runs in paralleled to the stock pump. I was also going to set it up with a shut-off valve and cut-off switch so I can disable it if it causes issues.

the problem I relaise with this is I didn't think there was a regulator in the pump ASM as it works on a duty cycle from the pump control module. I'll have to look into it further.

The MK3 RS pump sounds like a good idea. I found a picture of one on Ebay. It looks like it has 2 pumps like the S60R.

I still have the tank out and the pump out of it, If you have one of these RS pumps not yet installed it would be good to get some measurements so I can see if the top is the same size as the S40 AWD one.

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