Join Today
Results 1 to 16 of 16
  1. #1
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts

    C30 D5 Tinkering

    I have decided to pep-up my C30 D5.

    The chosen bits & pieces are all gathered ready, now I just need to get them nailed on.

    I'm not deleting the cat or DPF, I like more power, yet like being quiet, green & legal too and these mods alone will be more than enough for the auto box to cope with.

    Here's my list of collected treasures.

    Focus ST front brake dust-guards.
    Focus ST Brembo 320mm discs.
    Focus ST refurbished OE front callipers.
    Focus ST calliper brake pad springs.
    Ferodo DS2500 pads - Focus ST front - C30 D5 rear.
    Volvo C50 T5 2.5 Turbo AWD Hel braided stainless steel brake flexi-hoses.
    Motul RBF600 DOT 4 brake fluid - 1 litre.
    K&N air filter.
    Airtec C30 D5 intercooler & fitting kit.
    Swirl flaps replacement kit with gaskets & O-rings.
    8 litres Titan 4400 ATF and a bottle of Lucas SS.
    Ford Focus E Transmission torque-mount.
    Jetex C30 T5 stainless steel cat back exhaust system.
    New DPF with tail-pipe removed and replaced with 2/1/2" id pipe to match exhaust.
    BSR PPC3 stage 1.
    Additional ATF cooler. (To be sourced?)

    I used to do all of my own tinkering, however, degenerative spine disease has put a stop to most of that.
    The first job will be to get the local Powerflow exhaust shop to sort out the DPF alteration and fit the exhaust system, the other jobs will get picked off when pals come to visit, Coronavirus & weather depending?

    After it has had a manual decoke of the induction system and all of these go faster bits fitted, I'll run it on a rolling road to see what numbers it achieves. Guessing around 240bhp and 340ftlb?
    Last edited by David P; Sunday 18th October 2020 at 10:51.

  2. The Following User Says Thank You to David P For This Useful Post:

    kmb (Wednesday 28th October 2020)

  3. #2
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    In no particular order of least resistance...

    The K&N air filter and BSR PPC3 stage 1 download are the first to get crossed off the job list.
    Considering that the induction system hasn't been decoked yet, I was pleasantly surprised just how much extra get up and grunt this gave.

    It's booked in next week for the DPF modification and fitting of the Jetex exhaust system.
    Spine permitting, I'll try and get the transmission serviced and the new torque mount fitted before then?

    Diminishing Projects List

    Service transmission
    Fit Ford Focus E Transmission torque-mount
    Upgrade Brakes
    Decoke induction system and fit new swirl flaps
    Fit Airtec intercooler
    Last edited by David P; Tuesday 20th October 2020 at 13:10.

  4. The Following User Says Thank You to David P For This Useful Post:

    kmb (Wednesday 28th October 2020)

  5. #3
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    Transmission serviced with two (3L) partial ATF changes.
    That's the third time in the last 1k miles and the fluid is getting closer to a healthy colour.

    Diminishing Projects List

    Upgrade Brakes
    Decoke induction system and fit new swirl flaps
    Fit Airtec intercooler

  6. The Following User Says Thank You to David P For This Useful Post:

    kmb (Wednesday 28th October 2020)

  7. #4
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    Good news is; the Jetex exhaust system is on.

    Not so good news is; one of the DPF pressure lines was broken in the process and the Volvo main Dealer didn't have one in stock.

    Bad news is; they weren't capable of doing a proper job with the DPF exit-pipe alteration.

    Preferring my glass to be half-full rather than half-empty. :/

    Whilst the car is grounded, I have asked them to fit the brakes, intercooler, swirl-flaps and give the induction a decoke.

    That will leave just a proper job to be done to the DPF and it can then be reduced to numbers on a rolling road.

  8. The Following User Says Thank You to David P For This Useful Post:

    kmb (Wednesday 28th October 2020)

  9. #5
    Senior Member
    Appreciative
    kmb's Avatar
    Join Date
    Oct 2014
    Location
    Suffolk & Rhone Alpes
    Posts
    1,358
    Thanks
    843
    Thanked 441 Times in 361 Posts
    Sounds like a decent overhaul, let us know how it goes!

  10. #6
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    Before

    Name:  20201112_151019.jpg
Views: 0
Size:  127.6 KB

    Name:  20201112_150814.jpg
Views: 0
Size:  132.4 KB

    Name:  20201112_143135.jpg
Views: 0
Size:  168.7 KB
    Last edited by David P; Thursday 19th November 2020 at 15:53.

  11. #7
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    After

    Name:  20201112_160429.jpg
Views: 0
Size:  155.8 KB

    Name:  20201113_112304.jpg
Views: 0
Size:  85.6 KB

  12. #8
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    All now nice and clean.

    Name:  20201113_112200.jpg
Views: 0
Size:  163.6 KB

    With a set of new flaps.

    Name:  20201113_112923.jpg
Views: 0
Size:  168.3 KB

    That should let a few more horses through.
    Last edited by David P; Thursday 19th November 2020 at 17:40.

  13. #9
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    The Ford Focus ST225 320mm front discs, callipers and backplates are on, Ferodo DS2500 pads and Hell braided flexi-hoses are fitted front & back and the lines flushed though with Motul 600 Dot 4.

    To help manage the extra going & stopping capabilities, I have treated the Old Girl to a set of Michelin Cross Climate + XL tyres.

    It now also has one of these intercoolers to temper the horses heated breath.

    Name:  C30 bumper off.jpg
Views: 0
Size:  144.2 KB

    And a 2.5" diameter pipe Jetex C30 T5 cat-back exhaust to let some additional horses out.

    Name:  Jetex exhaust.jpg
Views: 0
Size:  32.3 KB

    Just the DPF modification to be redone to my specification and it will then be ready to be reduced to numbers on a dyno.
    Last edited by David P; Thursday 19th November 2020 at 18:38.

  14. The Following User Says Thank You to David P For This Useful Post:

    kmb (Thursday 19th November 2020)

  15. #10
    Senior Member
    Appreciative
    kmb's Avatar
    Join Date
    Oct 2014
    Location
    Suffolk & Rhone Alpes
    Posts
    1,358
    Thanks
    843
    Thanked 441 Times in 361 Posts
    Some good improvements, be interested in how it runs now!

  16. #11
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    So am I.
    All being well, I pick it up tomorrow.
    Must remember to pay attention to bedding in the brakes first.

  17. #12
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    She's back.

    The decoke has eliminated the excessive turbo lag, the better exhaust and K&N filter have no doubt helped improve the throttle response too.

    Airtec intercooler, stealthy in black.

    Name:  IMG_1094.JPG
Views: 0
Size:  97.4 KB

    The new exhaust has a lower note, yet is even quieter than the stock system and has no drone.
    It is the T5 Jetex system that has a small resonator before the back box, but it really doesn't need this.
    I could have chosen the "sport pipe" version without this and saved myself 70.
    But I like it being quiet/discreet.

    Name:  IMG_1088.JPG
Views: 0
Size:  131.3 KB

    Along with the new tyres I had the geometry adjusted, which has noticeably improved the straight line stability and it is now nicer to drive.

    The brakes however, are very spongey and the pedal creeps almost to the floor, this combined with rush hour traffic and common sense, dictates that I'll be patient and wait until the extra stopping is happy before I trial the extra going.

    Stealthy in black.

    Name:  IMG_1092.JPG
Views: 0
Size:  123.4 KB


    Next job is a good wash.
    Last edited by David P; Sunday 22nd November 2020 at 16:35.

  18. #13
    Junior Member
    Keeping it Green
    David P's Avatar
    Join Date
    Oct 2020
    Location
    Northants UK
    Posts
    21
    Thanks
    2
    Thanked 7 Times in 7 Posts
    There's so much traffic about, you wouldn't believe we're in a Lockdown!

    Not even the B roads have been clear enough to play with my new brakes until after 2am.

    These are at last nicely bedded in, they are now more responsive and far more eager than they ever were. I am confident that I won't overcook this set up.

    The power delivery is now without turbo lag, but my bum dyno hasn't registered much gain from the Airtec intercooler and Jetex exhaust system, yet this is probably because the power delivery is way more linear than it previously was?

    It drives nicely at low speed and certainly has plenty of grunt when I ask for it.

    I have brimmed the tank with V-Power and added a bottle of injector cleaner to help clear a few more cobwebs.

    Next week is MOT time, so I am prepared with 6 litres of Fuchs TITAN SuperSyn LongLife Plus 0W-30 Ultra High Performance Engine Oil, a Mann oil filter and a Dimple magnetic drain plug to be added into the equation whilst she's up on the lift.

    Then just the DPF exit pipe mod remains to be refabricated and it will be ready to reduced to numbers a dyno.

    The additional transmission oil cooler is not yet fitted, that job was too challenging for the Garage Mechanic. So it can wait until warmer weather returns in the Spring and I'll do that job myself. I don't go far during the winter months and won't be challenging it much until the roads are warmer/drier, consequently, there's little chance of overheating the ATF during the interim cold Winter weather.
    Last edited by David P; Yesterday at 20:50.

  19. The Following User Says Thank You to David P For This Useful Post:

    kmb (Yesterday)

  20. #14
    Senior Member
    Appreciative
    kmb's Avatar
    Join Date
    Oct 2014
    Location
    Suffolk & Rhone Alpes
    Posts
    1,358
    Thanks
    843
    Thanked 441 Times in 361 Posts
    Definitely looking after the C30 in the best way!

  21. #15
    New Identity
    Back in an AWD....Oh the grip!
    Dangerous Dave's Avatar
    Join Date
    Dec 2006
    Location
    West Midlands
    Posts
    8,729
    Thanks
    2,430
    Thanked 2,516 Times in 1,993 Posts
    Quote Originally Posted by David P View Post
    There's so much traffic about, you wouldn't believe we're in a Lockdown!

    Not even the B roads have been clear enough to play with my new brakes until after 2am.
    Tell me about it! Bloody nightmare trying to get anywhere, and everyone seems to like dawdling along at 40mph
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.

  22. #16
    Gearbox Killer
    Proving the power of the
    15g....13.4@104.3mph
    MoleT-5R's Avatar
    Join Date
    Jun 2011
    Location
    Mid-Wales
    Posts
    5,421
    Thanks
    2,759
    Thanked 2,599 Times in 1,741 Posts
    Quote Originally Posted by Dangerous Dave View Post
    Tell me about it! Bloody nightmare trying to get anywhere, and everyone seems to like dawdling along at 40mph
    As you know we can have that problem here in Wales but you don't have to go too far to find a perfect drive around with limited holdups...

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
    Previous Volvo's 1987 745 gle 1989 745 GL 1995 855 Olive GLE 2001 V70 p2
    My Ebay Items http://www.ebay.co.uk/usr/quik.connection


 

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
ipv6 ready