Archive for ‘ September, 2015 ’

Astra H 2.0 Turbo Mapping

We recently remapped this Astra H SRi 2.0 Turbo model. The 3 door model with the Z20LEL engine leaves the factory with 170PS and was booked in for a repalcement 70mm pre-cat removal pipe, a high flow panel filter, ECU remapping and full rollinh road set up.

Once on the rolling road after an initial inspection and run up a split factory recirculation valve was diagnosed which was causing a loss of boost, and if left can lead to turbo failure. This was replaced with one of our Courtenay TurboSmart uprated recirculation valves which are a much stronger and better made unit removing the rubber insert of the OE unit that tears causing the failure of the OE valve.

After full datalogging, bespoke mapping and optimisation the car produced a very respectable 224 bhp and 255 lb ft of torque, an excellent result from a 96,000 mile engine. The torque was been kept nice a smooth from 2,700 rpm – 5,000rpm without a peak mid range torque spike which can lead to  problems for the factory clutches causing them to slip.

Astra SRi 2.0 Turbo 3 Door

Astra SRi 2.0 Turbo 3 Door

K Sport Caliper Colours

Whilst K Sport calipers can be painted any colour from the factory, providing a recognised colour code is supplied, there are a selection of ‘default’ colours to chose from:

K Sport Caliper Colors

K Sport Caliper Colors

Routine Maintenance Service

Routine Maintenance for this lovely clean Golf GTi. In our workshop today for its annual maintenance service, including brake fluid change.

VW Golf GTi Service

VW Golf GTi Service

VIDEO STORY: Brit-Built Astra Flies The Flag For Great Britain

Ellesmere Port, 23rd September 2015 – Vauxhall has revealed how they built the Astra Union Jack flag through a film launched today.

Vauxhall Astra Union Jack

Vauxhall Astra Union Jack

To celebrate the launch of the all-new seventh generation Vauxhall Astra, workers at the Ellesmere Port manufacturing plant – home of the Astra for over 36 years – choreographed 128 new models to create the image of the Union Jack flag. Construction of the display was captured using a state-of-the-art drone giving a birds-eye view of the build.

Watch the footage of the Astra Union Jack film below or on YouTube https://youtu.be/aghmE8S8ln4.

Commenting on the launch at Ellesmere Port, Business Minister Anna Soubry said: “This is a proud day for Vauxhall and its workforce at Ellesmere Port. Manufacturing the seventh generation Astra onsite secures 2,000 jobs into the next decade, boosts productivity and further demonstrates the company’s ongoing commitment to the UK.”

Vauxhall’s seventh generation Astra is the eleventh major model-line to be built at Ellesmere Port and guarantees 2,000 jobs at the Cheshire plant over the next decade.  The plant secured a long-term contract in 2012 and a £140 million investment which further demonstrates the brand’s continued commitment to manufacturing the iconic car in Britain.

The image, orchestrated in under 24-hours, pays tribute to over 36 years of manufacturing the Brit-built best-seller, which has seen over five million cars roll off the Ellesmere Port production line. Three million have been sold in the UK alone – with 50,000 in the past 12 months and 2 million exported to 25 European markets. It is estimated that at full production in 2016, the plant will build approximately 680 Astras per day with further growth in subsequent years.

The British success story extends beyond the Astra itself – as for over 50 years, Ellesmere Port has been the manufacturing home of every compact class Vauxhall in the UK. With nearly 25 per cent of parts sourced locally from UK suppliers, the plant is a significant contributor the local economy and the continued investment at the facility is set to boost UK manufacturing, utilities, construction, transportation and storage companies by at least £70 million.

New Brit-built Vauxhall Astra – In Numbers:

  • One in four Britons has either owned or driven an Astra
  • 25% of a Vauxhall Astra is produced from British sourced materials
  • It takes approximately 24 hours to build an Astra, from sheet steel to the finished article – this is expected to reduce to just 22 hours as production grows
  • 3 million Astras have been sold over the past 36 years – 50,000 in the past 12 months
  • 5 million vehicles have been manufactured at Ellesmere Port, with 2 million exported to 25 European markets
  • £140m investment in the Ellesmere Port factory
  • The Ellesmere Port plant will build approximately 680 cars per day and 120,000 per year

The all-new Astra is in Vauxhall showrooms from October, priced from £15,295 on the road.

Enlarged Silicone inlet Hose for Astra J VXR

Enlarged Silicone Inlet Hose for Astra J GTC VXR.

A direct replacement for the factory inlet hose, this silicone hose has been enlarged throughout its length for improved air flow, tapering only at the end to fit onto the turbo. This hose is smoothed out removing all the steps and convolutes found in the factory hose. It also features a moulded spigot for the breather pipe.

£119.95 Available in Blue, Red or Black or Yellow, Green, Purple or Orange to Special Order.

Astra J Inlet Hose

Astra J Inlet Hose

K03 Hybrid Turbo 1.6

We have recently carried out some development work using a K03 Hybrid Turbo for the Corsa D 1.6 Turbo engine; Z16LEx/A16LEx/B16LEx

Featuring a reworked compressor wheel and shaft, an uprated bearing pack and a modified inlet elbow, we tested the unit on a Corsa 1.6 Turbo on which we had previously carried out a full engine rebuild with low compression pistons and steel rods. The car was also complemented by a full 76mm exhaust system and CSRacing Intercooler and achieved 258bhp once remapped and set up on our rolling road.

Price: £1140 inc VAT based on rework to a brand new core unit including a reworked inlet elbow.

K03 Hybird 1.6 Turbo

K03 Hybird 1.6 Turbo

K03 Hybrid 1.6 Turbo and Inlet Elbow

K03 Hybrid 1.6 Turbo and Inlet Elbow

Another Astra G Garrett Conversion

Brought in for a bottom end refresh with new bearings, crankshaft polish and mapping this conversion has a 3″ full exhaust, CSRacing full height front mounted intecooler, forged pistons, steel rods, external swirl pot and high pressure fuel pump set up and a Garrett GT3076R and TiAL external wastegate and hit 500bhp after mapping and rolling road set up. The Revolution Millennium wheels with Nankang NS-2R tyres finish the car off, and the power makes the K Sport 330mm 8 pot calipers work hard backed up by suspension from Weitec by KW and a full roll cage further stiffens the chasssis.

It now boasts Methanol injection and has been mapped to 540bhp and was the Class B winning car at Thunder Road 2015.

Astra G Garrett Conversion

Astra G Garrett Conversion

The Courtenay Sport Blog

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