Author Archive

Garrett Conversion Astra G 2.0 Turbo

Brought to us for a full conversion, this car now features a VXR engine with LEH forged pistons and ZRP Steel Rods, our V Band Cast Manifold, Garrett GT2871HTA turbo with 4″ inlet pipe, Tial External Wastegate, 3″ Courtenay Klasen Downpipe, 3″ Courtenay Piper Exhaust System, Courtenay Klasen Camshafts, CSRacing Full Height Front Mounted Intercooler, 90mm Air Flow Meter, 90mm AEM Dryflow Cone Filter and Courtenay Enlarged Plenum. Producing around 457bhp and 380 lb ft torque….. Nice.

Vauxhall Drivers’ Club Rolling Road Day

Saturday 16th May.

We had a varied selection of cars turn out for the VxDC Rolling Road day on Saturday 16th May, 2.0 16v Turbo Z20LEx engines being the most popular offering due to the wide range of tuning options available for this popular engine.

We were fortunate to have good weather, with sunshine for the most part of the day and a very good turnout of cars and people.

Thank you to everyone who attended the day and made it an enjoyable one.

Look out for the feature in a forthcoming edition of Performance Vauxhall magazine.

Big Brake Kits

Big Brake Kits are becoming more and more popular, especially the offerings from D2 and K Sport due to their price point and build quality. They offer immense stopping ability and the most popular sizes are 330mm and 356mm designed to fit under 17″ and 18″ wheels respectively, although in some instances a narrow wheel spacer may be required, depending on the wheels fitted.

D2 kits feature 6 pot calipers with road seals and cross drilled belled discs, K Sport calipers are 8 pot and use 8 grooved discs and are available in a range of caliper colours at no extra cost; Black, Red, Yellow, Orange (K Sport only), Purple (D2 Only).

Prices range from £899 – £1122. Avaiable for Astra G, Astra H, Corsa D, Vectra C, Zafira A, Zafira B, Vectra B

D2 6 Pot Caliper in Purple

D2 6 Pot Caliper in Purple

K Sport 8 pot Caliper in Orange

K Sport 8 pot Caliper in Orange

D2 6 Pot Caliper in Purple

D2 6 Pot Caliper in Purple

Classic 911 in for MOT

There is just something about the lines of a classic 911…. we had this immaculte car in recently for headlight bean alignment and MOT.

Porsche 911 Targa

Porsche 911 Targa

Astra 1.9 CDTi 150 Gearbox Overhaul

We recently had this Astra 1.9CDTi SRi 150 brought to us for a gearbox overhaul with new bearings for the M32 gearbox, replacement 75w-90 fully sythetic gearbox oil and at the same time a new genuine dual mass flywheel and Genuine OE clutch:

Astra SRi 1.9 CDTi

Astra SRi 1.9 CDTi

AMSOIL MTG 75w-90 Fully Synthetic Gearbox Oil

We have recently received stock of AMSOIL MTG Fully Synthetic Manual Transmission & Transaxle Gear Lube 75W-90 again in the UK after supply issues from the UK distributor.

A very high quality gearbox oil formulated specifically for demanding manual transmission and transaxle applications.

Ideal for extreme use for modified cars such as those regularly subjected to track use, and high horsepower fast road applications.

£21.00 per US Quart 

Amsoil MTG 75w-90

Amsoil MTG 75w-90

KW Coilover Kit Vectra B

This Vectra B is now sporting a KW V2 Coilover kit as its latest addition and is sitting pretty.

Vectra B on KW V2 Coilover kit

Vectra B on KW V2 Coilover kit

D2 Brake Kits

We had a couple of cars in recently for D2 big front brake upgrades, both receiving D2 6 Pot kits with 330mm alloy belled discs to fit under 17″ Alloy Wheels:

Purple Calipers:

D2 6 Pot 330mm Brake Kit

D2 6 Pot 330mm Brake Kit

Red Calipers:

D2 6 Pot 330mm Brake Kit

D2 6 Pot 330mm Brake Kit

Also available with 356mm discs to fit under 18″ Alloy Wheels.

Kit prices start at £1022.00 including DOT5.1 braked fluid, discs, bells, calipers, brackets, bolts, shims and braided front brake hoses.

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

The Courtenay Sport Blog

%d bloggers like this: