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DVS LT Vocus XR5 - 93% Volvo content

AshDVSAsh (@AshDVS) - Geelong, VIC
edited September 13 in Non-Volvo 3751 / 93joined Jul 2013
This is the project thread for our 2007 LT Ford Focus XR5.
Lots of placeholders here at the moment, because it's nice to have the key details back in the first post when you want to refer back to them later down the track.

Engine & Transmission -
B5254T3 2.5L (HYDA in Ford speak)
PumaSpeed R-Sport stage 2 intercooler. 650mm x 76 x 310
PumaSpeed aluminium inlet plenum
Snabb 3" intake pipe
Remote external engine oil cooler with braided lines and Airtec Motorsport sump adaptor
LV Focus RS ECU mount
LV Focus RS airbox with Pipercross filter
Volvo spark plug cover (replaces 'Ford Duratec ST' branded one)
Anembo Engineering billet front engine cover
M66 6 speed manual

Suspension -
Front -
Heico Coilovers
Whiteline Anti-lift/Anti-dive kit

Rear -
GAZ adjustable perches & springs
GAZ Gold Adjustable rear shocks
HardRace Adjustable rear toe arms
Mazda3 MPS 25mm rear swaybar (replaces Focus XR5 21mm swaybar)

Brakes -
Front -
DBA T3 4000 series slotted rotors
Project Mu NS400 pads
HEL braided brake lines

Rear -
Brembo slotted rotors
Project Mu NS400 pads
HEL braided brake lines

Wheels & Tyres -
LV Focus XR5 18x8 ET52.5, refinished in Nissan 'Precision Grey'
225/40/18 tyres

Interior -
Factory Recaro light grey/dark grey cloth seats
Factory Sony 6 stack CD and speakers (no way near as good as the stereo in the V70T5!)
USB charging socket
LV Focus XR5 carbon fibre dash inserts
LV Focus XR5 console
LV Focus XR5 door trims
LV Focus RS shift knob and boot
Mix of LT and LV Focus XR5 interior plastics
KAP Industries fire extinguisher mount

Body -
Tinted Windows
LV Focus tailgate
LV Focus tail lights
LV Focus XR5 rear bumper
LV Focus RS spoiler
UK-spec 'ST' guard badges
Zunsport lower mesh grille
Modified front bumper to incorporate airbox feed

Current pic -

Kekfz3e.jpg
Likes good coffee & motorsport. Builds stuff. Occasionally races stuff.
f: https://www.facebook.com/DvsPerformanceParts
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Comments

  • AshDVSAsh (@AshDVS) - Geelong, VIC
    edited March 2016 3751 / 93joined Jul 2013
    We'd been looking for a P1 platform car for a little while and the delayed sale of our V70 meant that the C30 we'd had our eye on didn't work out.

    So, we decided that, rather than pick up something neat, we'd sink our teeth into another project.
    The shared Volvo/Ford/Mazda P1 platform has a strong following, with lots of parts interchangability - particularly between Ford and Volvo variants - and a big scope for performance upgrades.

    The criteria list, this time around was short -
    * Must be Volvo 5cyl turbo powered
    * Must not have biege interior
    * Working heater and AC
    * No sunroof (applicable to Focus only)

    Preference too was that it would be manual.

    After a few non-returned phonecalls, voicemails and emails about some Volvo V50T5s, we stumbled across a filthy blue focus. I'd have settled for an auto if I could have had a V50T5, but it wasn't to be.

    It met the basic criteria, we agreed on a price and with our V70T5 having been sold, we had a free spot ready for it.

    Here's the starting point -
    It's a fairly untidy car but most of the issues will be easy to sort out.
    The current two big ones are -
    * Airbag light on the dash
    * I cant open the bonnet (common focus issue, and I could open the bonnet when I went and checked it out, pre purchase).

    7QOiuMt.jpg?1

    8Qv8Fgp.jpg?1

    CNRds0t.jpg?1

    It may be of interest due to the shared platform and all of the area's we're interested in are directly transferable to the Volvo C30/S40/V50T5 FWD models.
  • 8989 / 77joined Jul 2013
    /Me opens checkbook
    I think you need to add i was in an s80 with three wheels getting pulled backwards and was told to "hold on shit is about to get real".
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    3751 / 93joined Jul 2013
    /Me opens checkbook

    bahaha.
    I need to get the immediate issues sorted first and through the RWC process and then I'll start getting onto a few things.
  • 8989 / 77joined Jul 2013
    Airbag light is probobly the swirly wire behind the steering wheel
    Could be the module as well

    Good thing it's not a takata bag

    Is the trans a 5 speed or 6 speed?(lack on knowledge of foci on my part)

    You should get the plates "vocus" for it
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    edited March 2016 3751 / 93joined Jul 2013
    Airbag light is probobly the swirly wire behind the steering wheel
    Could be the module as well

    Good thing it's not a takata bag

    Is the trans a 5 speed or 6 speed?(lack on knowledge of foci on my part)

    You should get the plates "vocus" for it

    The clock-spring is a common airbag light cause on LS-LV Vocus (referred to as 'Vocus' from here on in) but in my case, it is 'Drivers seat open loop' - which, I think at this stage, is a pre-tensioner or seat wiring loom connector issue.
    I'll connect it to the Ford IDS software this week so should be able to pull more info and then start chasing it further.

    The Takata recall is scary. It's to the point where it'll hurt them financially, I'd think.

    trans is the trusty M66 as per manual Volvo C30/S40/V50T5 models.

    Interesting tidbit of info -
    The LV Focus RS actually uses the M66 AWD casing - not sure why, perhaps it's sturdier than the FWD version. I've never seen both variants side-by-side to see a difference.
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    3751 / 93joined Jul 2013
    Title changed.
  • Vee_QueVee_Que (@Vee_Que) South Eastern suburbs Melbourne.
    6943 / 36joined Jul 2013
    Doesn't look toooo bad!
  • 8989 / 77joined Jul 2013
    Iirc the only casing difference was the Mount points and the ability to bolt on the angle gear

    Ford might have gone with the awd case for packaging reasons alone
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    edited March 2016 3751 / 93joined Jul 2013
    Iirc the only casing difference was the Mount points and the ability to bolt on the angle gear

    Ford might have gone with the awd case for packaging reasons alone

    Quite possibly. The LV Focus RS is quite different from the XR5. It's 40mm wider in track all around and shares quite a few odds and ends from the Ford Kuga compact SUV.

    I'd think that due to sharing a bit with the Kuga, it might have just been easier to use the M66 AWD manual casing and related mounting systems, as per the Kuga as well.
    The Kuga is, interestingly, 40mm wider than a normal Focus.
  • PaddlerEdPaddler Ed (@PaddlerEd) New England Region, NSW
    2771 / 47joined Jul 2013
    How much wider is an XC60 than a normal Focus? They're all related IIRC...
    good old fArmidale, where money comes in both kinds; cash and grog
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    3751 / 93joined Jul 2013
    How much wider is an XC60 than a normal Focus? They're all related IIRC...

    Really good question. I don't know I wonder how close the wheelbase and track is on the XC60 vs the Kuga?
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    edited March 2016 3751 / 93joined Jul 2013
    I managed to get the bonnet open earlier. Not quite sure how, but managed to do it without breaking the grille, by applying pressure to the bonnet just above the latch and pushing the key inward and turning at the same time.

    I wont close it again until I've got a latch repair kit - hilariously, Ford is aware of how stupid the design is and has a service kit for this very task.
    I'm tempted to remove the latch and put bonnet pins in it. :)

    NMfErLw.jpg?1

    I also had Mark (from Berrys) send me out a Volvo spark plug cover. I'll swap that over post RWC inspection.

    YoameFS.jpg?1
  • 8989 / 77joined Jul 2013
    Needs a new expansion tank
    That one is scarry brown
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    3751 / 93joined Jul 2013
    Needs a new expansion tank
    That one is scarry brown

    Yep. Looks red/pink inside but I still don't like it.
    Radiator flush, new tank and refill with decent coolant is on the list, as is water pump, thermostat, timing belt, tensioners, serp belt and tensioners.
  • TzantushkaTrent (@Tzantushka) E. suburbs - Melbourne
    207 / 19joined Jun 2014
    I managed to get the bonnet open earlier. Not quite sure how, but managed to do it without breaking the grille, by applying pressure to the bonnet just above the last and pushing the key inward and turning at the same time.

    Looks like you have found the secret access door to the bonnet.
    Swivel the 'Ford' badge and the bonnet opens!
    2004 V70 R | 2008 V50 T5 AWD | 2015 V60 Polestar
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    3751 / 93joined Jul 2013
    I'm waiting for a few bits and pieces to arrive so I thought I'd dive in and take a look at some of the broken interior plastic stuff.

    My console is broken at the base where it mounts to the tunnel, I'm missing the gear shift boot and the shift knob is scratched and horrible.

    So, I've removed it and am having a look at it, side by side, with some other options -

    jdzpfqb.jpg

    Centre of picture is the one from my car. The armrest is ok but it has no storage. This is as per LS & LT XR5 and maybe Zetec and Ghia models too.

    Bottom of picture is from an LV base model (CL). LS & LT are identical, except they're a darker shade of grey.
    This will bolt in to my car.

    Top of picture is from an LV XR5. It is unique to LV XR5 and typically features the start button, 12V power source inside the (actually usable) storage compartment under the armrest and mounted to the underside is the keyless entry antenna.
    It needs a different bracket for the mount to the tunnel and different kick panels. The shifter boot, surround and knob are also different for LV XR5.

    I'm keen to use the LV XR5 console - I'll plug the hole for the start button and will splice the 12V power source into the existing cigarette lighter in the dash.
    I need to source the bracket to mount it to the trans tunnel, a shift knob, boot and surround.

    Hopefully some of the more important stuff I'm waiting on will arrive this week and I'll sink my teeth into some more serious tasks.
  • 8989 / 77joined Jul 2013
    Too bad P1 bits don't bolt in
    They would.look massively better
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    3751 / 93joined Jul 2013
    Too bad P1 bits don't bolt in
    They would.look massively better

    Some might as a lot of the mounting points in the floorpan will be the same, but the dash won't as the windscreen and A pillar location is massively different. eg. The windscreen rake on the focus is much greater, to the point where to change struts, you need to remove the windscreen scuttle panel.

    Interior plastic quality on the Volvo stuff is MUCH better, but I think this is to be expected.
  • 8989 / 77joined Jul 2013
    I remember the gearshift from the Mazda 3 of the same vintage being available in alloy in the sp23 or some such and looking quite good
    Maybe try and track one down and see if it gives it a better look than the ford unit

    Also what do you have planned for the steering wheel? Any retrimming like you did on the v70?
  • AshDVSAsh (@AshDVS) - Geelong, VIC
    edited April 13 3751 / 93joined Jul 2013
    I remember the gearshift from the Mazda 3 of the same vintage being available in alloy in the sp23 or some such and looking quite good
    Maybe try and track one down and see if it gives it a better look than the ford unit

    The shifter/knob from an LV Focus XR5 is a lot nicer looking, so I'm now going to go that way.
    I've got a gear knob from an LV Focus RS coming and I'll use a boot and surround from an LV XR5.
    Also what do you have planned for the steering wheel? Any retrimming like you did on the v70?

    I had the guys from Redline (who did the handbrake boot and console lid for the V70) sent out a gear shift boot and a handbrake boot in alcantara already. The handrake boot will fit the LT XR5 console, but as I'm changing to LV, it's now of no use to me.
    The shift boot they sent across doesn't fit any of the LS-LV Focus models. My guess is that it's for an LR model, so they're trying to work out what to do and they'll get back to me.

    I'll use the stock LV ones, until we work out whats happening or I may have a local trimmer make the right ones for me and I'll provide samples to use as a pattern.

    I've got a Steering wheel off being retrimmed. With the V70, I used Royal Steering wheels in the UK, so I did the same this time. Rather than send a steering wheel to the UK this time around (expensive), I bought a steering wheel via UK ebay and had the seller send it to them.
    I'll swap it over once I've got the airbag light issue resolved, so as not to confuse matters too much.

    In the UK, the XR5 is badged as the ST, so the UK-sourced steering wheel has a cool little ST logo on the lower spoke, which is kinda neat.
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