Archive for ‘ April, 2016 ’

Astra J VXR Stage 1+

Another Astra J VXR in for a Stage1+ tuning package, which is proving to be a very popular option for many owners.

The first stage is to benchmarck the power of the standard car. It had already had a generic flash map installed via a well known hand held tuning box, so we first ran the car with the generic map installed, then using the hand held unit returned the car to factory standard software and ran it again. With the generic flash map loaded the car produced 287bhp and when returned to the standard map and run again the car made 281bhp.

It was then round onto the ramp so the pre cat removal pipe could be fitted, removing the restrictive factory pre cat.

Pre Cat Removal Pipe Fitting

Pre Cat Removal Pipe Fitting

Once the 76mm straight through pre cat removal pipe had been fitted it was back onto the rolling road for mapping and datalogging whilst the map is optimised on the rolling road, resulting in 328bhp and 373 lb ft torque.

Astra J VXR Mapping

Astra J VXR Mapping

Meriva VXR Tuning

This Meriva VXR had visited us before for a remap, and came back to have some further improvements carried out.

We removed the pre-cat and fitted a straight through pre-cat replacement pipe (downpipe) to remove the restrictive first cat, fitted a set of NGK iridium plugs and a high flow Courtenay Sport panel filter.

Then it was back onto the rolling road for map optimisation, datalogging and rolling road set up. The results were 216bhp and 243 lb ft torque.

Meriva VXR Mapping

Meriva VXR Mapping

Insignia VXR Remap

Another returning customer coming back to us this time with his 7,000 mile Insignia VXR for mapping, having previously has his Vectra VXR mapped by us.

Latest spec and an otherwise standard car, and a little under a year old we carried out the mapping, map optimisation, datalogging and full rolling road set up achieving 332 bhp and 380 lb ft torque, it will loosen up given a few more miles on its belt.

Insignia VXR Mapping on the Rolling Road

Insignia VXR Mapping on the Rolling Road

Astra J VXR Stage 3 Package

Courtenay Sport Stage 3: Remap, Front Pipe, Free Flowing Cat Section, Induction Kit, Intercooler
Stage 3 is the final stage upgrade using the standard factory K04 Turbo. This package consists of pre-cat deletion, replacing the OE factory front pipe and first cat first cat with our free flowing 3” cat-less front pipe (also used in our stage 1+ package). In the quest for further power we then turn to the next restriction which is the case of the Astra J VXR is the original equipment air intake/air box.

We completely remove this and replace it with a huge free flowing AEM non oiled Dry Flow Filter. This is mounted to a free flowing air flow meter housing which features a built in air straightener so correct air mass values are relayed to the ECU, finally this assembly sits within a heat deflector shield.

This particular car has also had our upgrade silicone inlet hose fitted.

Astra J VXR Stage 3

Astra J VXR Stage 3

With the Stage 3 package  we are looking to fully optimise everything around the turbo to fully maximise efficiency, so a huge Pro Alloy/Courtenay full height intercooler is installed complete with large bore pipe work and hoses, which whilst keeping the inlet air temperatures very cold also optimises the flow from the turbo through to the inlet manifold. The intercooler and pipework on the above car have been finish in stealth black finish.

Next a 3” free flowing cat section is fitted to compliment the high flow front pipe. With these parts installed the car is remapped on our rolling road optimising our Exclusive Courtenay Sport software to take full advantage to achieve maximum gains from these components.

Final power and torque figures are a very healthy 342bhp and 384 lb ft.

As an option to enhance the soundtrack, this car has also had our 3″ single sliencer cat back system fitted.

Astra J VXR Rolling Road Set Up

Astra J VXR Rolling Road Set Up

Corsa E VXR Stage 3 Mapping

Another Corsa E VXR which was brought to us for mapping and rolling road set up.

This car had already had a Cobra 3″ exhaust system and Airtec intercooler fitted to it by the customer and had previously been mapped. Prior to mapping we benchmarked the car on our rolling road to establish its base power and torque figues which were 227 bhp and 246 lb ft torque.

We then remapped the ecu and carried out a full rolling road set up with datalogging and optimised the software to suit the fitted components.

When finished the car is now producing 245 bhp and 259 lb ft torque with gains right across the rev range compared to the previous remap.

Corsa E VXR Rolling Road Set Up

Corsa E VXR Rolling Road Set Up

Corsa E VXR Front Pipe and Remap

In our workshop today was this 7,000 mile Corsa E VXR with the latest version of the 1.6 Turbo engine, B16LES. The first job was to remove the restrictive pre cat (first cat) and fit one of our straight through downpipes (pre cat removal pipe). Once fitted it was round into the dyno cell for remapping with full rolling road set up.

Corsa E VXR Pre Cat Removal

Corsa E VXR Pre Cat Removal

Running on Shell V-Power (99RON) fuel the results were 235bhp and 248 lb ft torque, with power and torque gains right across the rev range.

Corsa E VXR Remapping

Corsa E VXR Remapping

M32 Gearbox Bearings and Late Endcase

Another M32 gearbox from an Astra H in for bearing replacement and upgrade to the later endcase with larger endcase bearings.

M32 Gearbox with Late Endcase

M32 Gearbox with Late Endcase

This gearbox had covered some 90,000 miles before need to have the bearings replaced, and whilst the box was off the car for overhaul the later endcase which features additional oil galleries and larger endcase bearings was fitted.

The box was refitted and filled with 3 litres of very high quality fully synthetic Amsoil MTG 75w-90 gearbox oil, and also the dual mass flywheel, clutch (cover and disc) and hydraulic slave cylinder were also replaced using genuine OE components.

1.9 CDTi Clutch and Dual Mass Flywheel Assembly

1.9 CDTi Clutch and Dual Mass Flywheel Assembly

Prices (to supply parts):
M32 Bearing Pack with late endcase £255.00
Genuine Vauxhall/Opel OE DMF £295.00/£335.00 (price according to chassis break)
Genuine Vauxhall/Opel OE Clutch Kit £150.00/£159.00 (price according to chassis break)
Genuine Vauxhall/Opel OE Slave Cylinder £108.00

The Courtenay Sport Blog

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