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  1. #1
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    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.

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  3. #2
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    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.

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    kmb (Wednesday 28th October 2020)

  5. #3
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    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

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    kmb (Wednesday 28th October 2020)

  7. #4
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    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.

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  9. #5
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    Sounds like a decent overhaul, let us know how it goes!

  10. #6
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    Before

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    Last edited by David P; Thursday 19th November 2020 at 15:53.

  11. #7
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  12. #8
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    All now nice and clean.

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    With a set of new flaps.

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

  13. #9
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    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.

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

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    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.

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    Some good improvements, be interested in how it runs now!

  16. #11
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    So am I.
    All being well, I pick it up tomorrow.
    Must remember to pay attention to bedding in the brakes first.

  17. #12
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    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.

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    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.

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    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.

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

  18. #13
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    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; Thursday 26th November 2020 at 20:50.

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    Definitely looking after the C30 in the best way!

  21. #15
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    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.
    2004 Sapphire Black S60 D5 - The new daily hack.

  22. #16
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    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

  23. #17
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    Quote Originally Posted by MoleT-5R View Post
    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...
    You lucky guy

    I've started a new job in Telford so am communting 50-60 minutes each way now. The M54 has roadworks and the A roads are always blocked with muppets who don't know what their high beam is for.
    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.
    2004 Sapphire Black S60 D5 - The new daily hack.

  24. #18
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    Oil & filter change and MOT is scheduled for 15th December with the DPF exit pipe upgrade booked for the 22nd followed by a run on the rollers.

    The present Mestra wheels are looking tatty, so I have bought a set of Rexs', 3 of them are like new but one has been kerbed and in need of refurbishment, which makes it unlikely these will go on until after the Non Christmas Season has passed?

    It will then look as good as it goes.
    Last edited by David P; Friday 11th December 2020 at 14:33.

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  26. #19
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    The engine oil & filter change is done, the Dimple magnetic sump plug is fitted and it passed the MOT, but not without advisories.

    Apparently, during it's recent full geometry set up, the Monkey Nick used a gas torch to free up the track rods and doing so, also melted the N/S C.V. boot and both of the track rods are now blue from excessive heat.

    So now it needs a new C.V. boot, a pair of track rods and track rod end ball joints. I will make sure these new threads are liberally coated with Copperslip to prevent this from happening again. It's not Rocket Science, why can't Monkey Nicks understand this?

    The C.V. boot is not leaking grease yet, but it won't be long before it does.

    Whatever, this extra job will have to wait until after the DPF tailpipe rebuild (which is another extra job consequent to another Monkey Nick) and the dyno run that is scheduled for Tuesday, 22nd December.

    Monkey Nicks create as many jobs as they complete...
    Last edited by David P; Thursday 17th December 2020 at 03:27.

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  28. #20
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    Apparently, the dyno has a software issue, so the appointment has been rescheduled for Friday 8th January.

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