Author Archive

Audi TT 2.0 TFSi Rolling Road

This Audi TT was brought to us for rolling road checking after having been fitted with a full exhaust system. The car was previously runing a Stage 1 remap prior to the fitting of the exhaust and had been updated with a new piece of software from a hand-held flash tool and the customer wanted to see the results.

After checking on the rolling road it became evident that further enhancements are required to the software due to the throttle closing at higher rpm.

Audi TT on Rolling Road

Audi TT on Rolling Road

Astravan 1.9 CDTi Upgrades

Upgrade work for this Astravan H CDTi included a new uprated clutch, new gearbox bearings and a Quaife Limited Slip Differential to help with the Stage 3 power and torque.

Astra H 1.9 CDTi Van

Astra H 1.9 CDTi Van

EBC Yellow Pads for Astra J VXR

Astra J GTC VXR models, which have the Brembo 4 pot front calipers and 355mm brake discs now have available the choice of EBC Yellowstuff pads for front and rear.

Available for the front at £112.80 per set, this is a slightly less expensive option for the cost concious to the currently favoured Brembo Sport HP2000 pad which is receiving excellent reviews and feedback.

The rear pad set is £49.80

Both options are available for online purchase from our website shop.

Astra H VXR Routine Maintenance

Some people are under the impression that we only modify and tune Vauxhalls, but we do also carry out regular maintenance, servicing and repairs.

This modified Astra H VXR was brought to us for a full enhanced service which includes a thorough inspection, an oil and filter change, replacement of the air and pollen filters (or cleaning and re-oiling a high flow panel filter), replacement of the spark plugs with NGK iridiums and a brake fluid change to DOT 5.1 brake fluid. We use OE/OEM filters and high quality Valvoline 5w-40 fully synthetic engine oil.

Additionally at the customer’s request, the rocker cover gasket was replaced as it was leaking. We also replaced the oil filler cap seal which was also leaking and allowing oil to escape, which was picked up during inspection.

During the inspection it was also noted that the factory hydraulic gearbox mount had failed, which is not uncommom, splitting and leaking all its oil and causing the engine/gearbox to move excessively. The mount was replaced and additionally strengthened with a polyurethane insert to help reduce engine/gearbox movement and reduce the likelihood of the mount failing in the future.

Astra H VXR Enhanced Service

Astra H VXR Enhanced Service

Golf Mk 6 GTi Rolling Road Session

This low mileage VW Golf Mk6 GTi was brought to us for a health and power/torque check on our rolling road.

VW Golf Mk 6 Rolling Road

VW Golf Mk 6 Rolling Road

Poly Bushes for Vauxhall/Opel Adam

Polyurethane Bushes are available for Vauxhall/Opel Adam models to help stiffen the chassis.

Available is Purple Spec material for road use or Black Spec material for track use.

The front kit comprises Front Wishbone Front Bushes, Front Wishbone Rear Busehs and Front Anti Roll Bar Bushes at £220.80 (purple) and £250.80 (black) per set.

Rear Beam Mounting Bushes are £69 (purple) and £76.80 (black) per pair.

Also available is a Rear Lower Engine Mount Insert £21.60 (road) and £24.00 (black).

Vauxhall Adam

Vauxhall Adam

These bushes can be purchased by telephone for mail order and will be available for online purchase soon.

VX220 2.2 Upgrades

This very clean low mileage VX220 2.2 came to us for some pre trackday checks and upgrades prior to its owner getting involved in doing some UK track days.

VX220 2.2 16v

VX220 2.2 16v

Apart from the obvious fluid changes; oil (5w-40 Fully Synthetic) and filter, brake fluid and gearbox oil (75w-90 Fully Synthetic), the spark plugs were also replaced with NGK platinum plugs. A thorough inspection identified a few other areas that required some work. The rear spring seats/damper collars were corroding quite badly, which is not unusual over time and so were replaced, both side engine mounts had separated and were replaced and an uprated polyurethane insert was fitted to the front engine mount to help reduce engine movement. The header tank had started to crack and degrade, again another quite common issue, so to prevent premature failure on track a new one was fitted.

VX220 2.2 16v

VX220 2.2 16v

The brakes pads were getting low and so M1155 brakes pads were fitted front and rear as a starting point. Further attention will be paid to the brakes and suspension as the driver finds his ‘track legs’, so to speak.

To improve performance the ecu was remapped and a K&N Induction kit fitted. One a rolling road set up was carried out we saw results of 156bhp and 163 lb ft torque.

Finally front a rear towing eyes were fitted (essential for trackday use) and a set of Team Dynamics pro Race 1.2 alloy wheels with some trackday tyres finished off the package.

This should prove to be a very good and enjoyable track day car.

Golf Mk5 GTi Remap

A standard Golf Mk5 GTi brought to us for ECU remapping and rolling road set up achieving 240bhp.

Turbosmart Recirculation Valves Now Available

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Kompact Shortie Series Recirculation Valves have been specifically designed to suit BorgWarner EFR and KKK turbos.

Unlike the standard, plastic valves that use un-reinforced rubber diaphragms and are known to crack or split under increased boost, the new BW/KKK Kompact valves uses an O-Ring sealed piston which, coupled with their billet aluminium construction give them over 30PSI of boost handling capability.

Designed as a bolt-on direct replacement replacement for the factory valve on all BorgWarner EFR, KKK turbos, the Kompact Shortie Plumb Back provides better boost response and greater boost handling capability.

Included with each Kompact Shortie kit is:

  • 1 x Model Specific Valve
  • 1 x Straight Nipple
  • 1 x Banjo Nipple
  • 3 x Mounting screws

Finished in Black as shown. This recirculation valve is a really nicely machined and finished item, with a quality look and feel about it.

Features and Benefits:

  • Machined from Billet Alluminium.
  • Lightweight, brass/aluminium, two-piece piston.
  • More Reliable than the factory valve.
  • Substancial Construction.
  • Improved Boost Responsive.
  • Single Spring – No Requirement to Change when Tuning.
  • Finish: Anodised Black as shown.

Suitable for ALL BW EFR KKK (K04/K06) Z20LEx and A20NFT Turbo units:
Astra G SRi/GSi 2.0 Turbo
Astra H SRi 2.0 Turbo including VXR
Astra J GTC VXR 2.0 Turbo
Zafira A GSi 2.0 Turbo
Zafria B SRi 2.0 Turbo including VXR
VX220/VXR220 2.0 Turbo

£120.00 inc VAT

Coming soon for Z16LEx 1.6 Turbo Vauxhall Engines.

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Poly Engine Mount Additions – Astra H VXR and 1.9 CDTi

At our request, Powerflex have added a couple of new polyurethane engine mount inserts to their Astra H range.

Courtenay Sport supplied the relevant OE engine mounts and asked if a lower front engine mount insert for Astra H 1.9 CDTi models and an insert for the Right Hand Side Mount for Astra H VXR and 1.9 CDTi could be produced.

These engine mount inserts fit into and fill the voids in the original bushes and are recommended as a labour saving method of limiting engine movement to improve vehicle performance and reduce the likelihood of engine mount and downpipe failure caused by excessive movement. Some additional NVH may be experienced.

These mounts are now available in both road spec material to reduce engine movement but limit increased Noise, Vibrationand Harshness (NVH) and Black 95 Shore Track spec material, which due to its nature is much stiffer and will lead to significantly more NVH being transmitted.

Astra H 1.9 CDTi Front Engine Mount Poly Insert in Road Spec Material (below).
Road Spec £24.00:

Front Poly Mount Insert Astra H 1.9 CDTi

Front Poly Mount Insert Astra H 1.9 CDTi

Astra H 1.9 CDTi Front Engine Mount Poly Insert in Black Spec Track Material (below).
Track Spec £27.00:

Front Poly Mount Insert Astra H 1.9 CDTi in Black

Front Poly Mount Insert Astra H 1.9 CDTi in Black

Astra H 1.9 CDTi Right Hand Engine Mount Poly Insert in Road Spec Material (below).
Road Spec £22.50: Track Spec (Black) £26.10:

Right Hand Poly Mount Insert Astra H 1.9 CDTi

Right Hand Poly Mount Insert Astra H 1.9 CDTi

Astra H 2.0 Turbo inc VXR and Astra G 2.0 Turbo Right Hand Engine Mount Poly Insert in Road Spec Material (below).
Astra H 2.0 T inc VXR Road Spec £22.50: Track Spec (Black) £26.10:

Astra G 2.0 Turbo & Z22SE Road Spec £22.50: Track Spec (Black) £26.10:

Right Hand Poly Mount Insert Astra H 2.0T VXR

Right Hand Poly Mount Insert Astra H 2.0T VXR

Astra H VXR – Uprated Clutch and Lightweight Flywheel

This Astra H VXR Nürburgring came to us for an uprated CSRacing clutch and lightweight billet steel flywheel, due to the fact the factory clutch had started to slip occasionlly.

The car had covered a shade over 91,000 miles and was originally modified to Stage 3 in 2008 at around 3,500 miles, virtually from new. So for nearly 7 years the car has been running at between 290-305bhp having had further changes made in later years, and the factory clutch and dual mass flywheel have given an exceptional service life considering the huge increase in power and torque to the car.

Replacing the original dual mass flywheel for a solid (single mass) lightweight billet steel one reduces the flywheel weight giving better acceleration due to the engine’s willingness to rev more freely as it is not having to rotate such a heavy mass. The CSRacing uprated clutch is a stronger unit, with an uprated cover with much more clamping pressure and an uprated sprung organic clutch disc to work with the single mass flywheel. The sprung disc is essential to fit if the dual mass flywheel is removed and replaced with a single mass item.

Also fitted at the same time was an uprated polyurethane gearbox mount insert as the original factory mount was starting to show signs of age related fatigue.

Astra H VXR Nürburgring Clutch and Flywheel Replacement

Astra H VXR Nürburgring Clutch and Flywheel Replacement

Don’t forget we can also fit standard original equipment (OE) replacement parts as well as uprated parts!

VX220 Tuning

Recently in for some fairly extensive modifications were this brace of VX220s.

The 2.2 underwent a Stage 1 supercharger conversion, an uprated fuel pump with 48L alloy fuel tank and rolling road set up.

The turbo model had a chargecooler system fitted, along with uprated fuel pump and uprated clutch, 80mm air flow meter and 495cc injectors, followed by a full rolling road mapping session, to complement the already fitted VXR turbo and full exhaust system.

VX220s undergoing modification work

VX220s undergoing modification work

KW Clubsport Coilover Kit for Astra H VXR

We have recently fitted a KW Clubsport Coilover kit to our Astra H VXR track car, which was running a Bilstein B8 set up with Courtenay DAP Race Spec springs.

The Clubsport kit is the prefered choice for a track biased suspension for a car that is used predominantly on track (more than it is on the road) and is the next step up from the excellent KW V3 coilover kit, which is an ideal fast road kit also suitable for light light trackday use.

Full stainless steel dampers, height adjustable springs with helper springs, solid top mounts on the front struts and 2 way damper adjustment on both the front and the rear dampers for compression and rebound adjustment to fine tune the set up.

A reminder, this is the kit as supplied:

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport coilovers were developed for customers who demand a better handling car when participating in track day events, but also require a setup that is still acceptable for road use such as to and from trackdays. The Clubsport kit was specifically designed for the Nordschleife using track day tires. The independently adjustable rebound and compression damping technology allow the suspension setup according to the vehicle load, tire characteristics and different track conditions. KW Clubsport meets every demand regarding a coilover for on road use but more importantly track use.

Here are some pictures of the fitted kit:

Engine Bed/Subframe Bushes – Astra G/H and Zafira A/B

We prepared a second subframe and fitted the uprated bushes to it prior to fitting it to one of our track day cars.

Astra H Subframe with uprated purple road spec polyurethane subframe bushes fitted.

Astra Subframe with Poly Bushes Fitted

Astra Subframe with Poly Bushes Fitted

Astra H Subframe with uprated black track spec polyurethane subframe bushes fitted. This is due to be fitted to our track car. The front anti roll bar and power steering rack will be swapped over onto it.

Astra Subframe with Uprated Black Poly Bushes Fitted

Astra Subframe with Uprated Black Poly Bushes Fitted

And some close up shots:

Purple Spec: £22 each Black Spec: £24 each

6 complete bushes required per subframe. Kit includes 12 ‘top hat’ type bushes, 6 stainless steel sleeves/inserts, 12 zinc coated upper and lower washers and a grease sachet.

KW Suspension Reference Chart

This KW Product Selector image gives a representation of the KW product range and its intended application; a useful reference guide.

KW Product Finder

KW Product Finder

EBC GD Sport Discs

Over the next few months EBC GD Sport Discs will change from gold to black. The current gold coating is being phased out and will be replaced by a Black GEOMET coating, which is a new long lasting corrosion resistant finish.

This means that over the next few months the traditional gold finished EBC discs will be replaced with black coated discs. They will still be manufactured to the same high standards.

GD Discs - Gold and New Black Finish

GD Discs – Gold and New Black Finish

Astra G – LSD and Uprated Clutch and Flywheel

We recently had this Astra G GSi Turbo in with us to have a Quaife Limited Slip Differential fitted into the F23 gearbox and whilst the gearbox was off the car we had the opportunity to fit a lightweight billet steel flywheel and uprated clutch cover and 6 paddle disc, in preparation for some big horsepower upgrades.

Work In Progress:

Astra G GSi Turbo with engine bed and gearbox removed.

Astra G GSi Turbo with engine bed and gearbox removed.

Astra Subframe

Astra Engine Bed/Subframe Removed

F23 Gearbox

F23 Gearbox – LSD Fitted

Engine Bed/Subframe Bushes – Astra G/H and Zafira A/B

Front End Improvement for Astra G/H and Zafira A/B.

Poweflex have engineered a solution to replace the factory engine bed/subframe bushes in Astra G/H and Zafria A/B which can be prone to failure and contribute to vague handling. These stiffer engine bed bushes help improve the front end feel of the car especially during turn-in and cornering. By removing the flex in the subframe bushes the handling is improved giving a more positive feel to the front end.

These Front Subframe Bushes feature two polyurethane top-hat style bushes that makes for simple installation and durability. The bushes house a stainless steel sleeve and are supported by zinc coated steel washers at each end for increased support under load.

Poly bushes will be resistant to corrosion and the addition of a stainless steel sleeve should help prevent the bed bolts from seizing into the bushes, which can happen with the factory bushes.

Suitable for Astra G, Astra H, Zafira A and Zafira B All Models.

These new bushes replace OE part numbers 90498689, 9223022, 9223023 and 13107328 used across the model ranges.

The application of corrosion resistant materials, robust design and the Powerflex Lifetime Warranty ensures the subframe need not be removed again once fitted, unless removal is required for other service work to be carried out.

These bushes are available in Purple Series 80 Shore Road Spec material for vehicles that are mainly used on the road and also Black Series 95 Shore Track Spec material that suits vehicles being used in Motorsport or predominantly on the track.

Purple Spec: £22 each Black Spec: £24 each

6 bushes required per subframe.

Professional installation is recommended. The ideal time is when the subframe is removed to allow access to the gearbox or clutch.

Engine Bed Bushes - Purple Series

Engine Bed Bushes – Purple Series

Engine Bed Bushes - Black Series

Engine Bed Bushes – Black Series

Poly Bushed Front Wishbones – Astra G/H

Now Available, we have direct replacement front wishbones for Astra G and H models. These front wishbones are brand new and come pre-fitted with uprated 85 Shore polyurethane wishbone bushes in black and a brand new high quality OEM ball joint.

This will make fitting uprated poly bushes far easier and much more straightforward. No need to spend hours knocking out existing bushes and fitting new ones, simply undo 3 bolts, drop the original arm off the car and fit the direct replacement wishbone.

Priced at £90 each inc VAT.

Pre Bushed Front Arm Astra

Pre Bushed Front Arm Astra

Focus ST Remap

Just for a change we recently had a Focus ST here for remapping and rolling road set up. Already fitted with a cat back exhaust system (the standard downpipe and cat had not been changed) and an intercooler, we remapped the ecu and carried out a rolling road set up achieving 261bhp and 311 lb ft torque.

Focus ST on the Rolling Road

Focus ST on the Rolling Road

The Courtenay Sport Blog

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