Archive for the ‘ Courtenay Sport ’ Category

Astra J VXR Front Pipe and Mapping

Another Astra J VXR in for front pipe fitting (shown centre front), followed by mapping and rolling road set up.

Astra J VXR Front Pipe Fitting

Astra J VXR Front Pipe Fitting

After mapping and set up, on 97RON fuel, this particular car achieved 324bhp and 357lb ft torque.

Astra J VXR Rolling Road

Astra J VXR Rolling Road

Corsa E VXR Mapping and Full Exhaust

This Corsa E VXR came to us to have a full turbo back 3″ exhaust fitted, followed by map optimisation to suit the exhaust and full rolling road set up.

Corsa E VXR

Corsa E VXR

Corsa E VXR Exhaust

Corsa E VXR Exhaust System

Once set up the results were an impressive 241bhp and 244 lb ft torque. We also carried out our own unique hardware fix and software recalibration to the air flow meter to allow it to read and fuel correctly above 222bhp, where it is known that the standard air flow meter maxes out.

Corsa E VXR

Corsa E VXR

We also have in development the CSR MaxAir Intake System for Corsa E VXR, which will feature an enlarged airflow meter housing and large AEM Dryflow cone filter.

Astra 1.9 CDTi Single Mass Flywheel

Astra H 888 CDTi

Astra H 888 CDTi

We recently had this lovely Astra H 888 CDTi (Z19DTH engine with M32 gearbox) in for a lighter single mass flywheel (removing the dual mass flywheel) and sprung clutch assembly due to slight clutch slip on the factory clutch. At the same time we also overhauled the gearbox fitting new bearings throughout and the later end case, which features larger diameter end case bearings and additional oil galleries in the end case for better end case bearing lubrication.

Insignia VXR Front Pipe and Mapping

This Insignia VXR came in to have our high flow front pipe (which removes the pre-cat or first cat) and Euro V compliant high flow sports cat fitted.

High Flow Front Pipe and Sports Car Fitting

High Flow Front Pipe and Sports Car Fitting

Once this was done in the workshop, the car was into the dyno cell for mapping and full rolling road set up.

Rolling Road Set Up

Rolling Road Set Up

Astra J VXR Stage 3

A change to the more common Astra J VXRs we see in Arden Blue, this time in the much less seen but equally stunning Power Red.

The car had already been fitted with a full 3″ Piper turbo back exhaust system and an Airtec cooler and induction kit when it arrived with us and when benchmarked produced 300bhp and 348 lb ft torque when benchmarked, although with a noticeably bouncing boost curve between 3-4,000 rpm due to the factory software, which was reflected inthe power and torque curves.

Once mapping was completed the results were a very respectable 340 bhp and 381 lb ft, after we had fitted our own air flow meter inlet housing and AEM dryflow cone filter which allowed the car to produce an extra 3 bhp and 10 lb ft torque over the original induction kit that had been fitted on the car.

Our free flowing air flow meter housing was specifically developed for the Astra J VXR on our rolling road and features a built in air straightener so correct air mass values which are relayed to the ECU, and able to help this car reach higher numbers.

Astra J VXR Mapping

Astra J VXR Mapping

Opel Speedster Turbo K06 and Inlet Manifold

This car had previously been in for a full engine rebuild with forged pistons and steel rods, strengthening the factory Z20LET engine and was running a K04 Z20LEH VXR turbocharger, Milltek 63.5mm exhaust system, Pro Alloy chargecooler and VXR injectors.

It returned to us to have some further enhancements which included a full 76mm Tullett exhaust system, a K06 turbocharger, Courtenay Klasen inlet manifold, uprated clutch and 80mm air flow meter.

After mapping and a full rolling road set up it is now producing 334bhp and 340lb ft torque, and is very at home on the track where it spends most of its ‘working’ life.

VX220 Turbo Mapping

VX220 Turbo Mapping

Astra J VXR Mapping

We are seeeing an ever increasing number of Astra J VXRs in for remapping and rolling road set up. As with Astra H VXR, blue seems to be a popular colour.

This car came to us with a pre cat removal pipe and Evoms kit already fitting. After mapping and rolling road set up the numbers were 333bhp and 376lb ft, which are within ther expected range.

Astra J VXR Mapping Session

Astra J VXR Mapping Session

CSR MaxAir Intake System

Early in testing the Astra J VXR it was discovered that the original factory airbox simply would not cut it even with the usual modifications. Porting it simply could not flow the required air, so some kind of induction system was required.

CSR MaxAir Intake System

CSR MaxAir Intake System

During initial induction testing it soon became apparent that a straight/parallel air MAF housing not unlike the Astra H 80mm MAF with a cone filter simply clamped on the end was not the answer. This parallel design created too much turbulence from the air turning from the sides of the filter into the housing and due to the lack of available space between the air filter and the MAF metering head, even with the addition of an air straightener, would not clean this turbulent air. The result was a restriction of air flow along the inside edges of the MAF and thus the air was

accelerated through the center of the MAF which in effect meant the engine was receiving less air than the mass meter was reading and reporting to the ECU. The target was therefore to create a trumpet with as long and smooth a progression of taper as space would allow in order to slowly turn and progress the air so smoothly that an air straightener was not even required. After testing a number of prototypes we achieved this goal.

Now we had to produce this. We looked at aluminium, however this was deemed too heavy with far too much wastage having the units moulded would make the product far too expensive so we turned to the relatively new dark art of plastic printing. We are able to make both the trumpet and the housing in one piece making it very clean looking on the outside and smoother for flow on the inside with a weight saving over an alloy version of a fraction under ½ a kilo. Not massive agreed but it all counts.

Attached to the new MAF housing we use a massive high flow AEM dry filter for very efficient filtration and breathing. This package is then housed in a powder coated heatshield assembly with the Courtenay Sport logo laser cut out of it.

So what does it do?
With the standard inlet air pipe just over 13bhp at peak power and with an enlarged silicone induction pipe 15 BHP. Also when compared to a parallel housing induction version it makes an extra 3 BHP at peak and a further 15 BHP from 5650 RPM! The MaxAir induction system is compatible for both mapped and standard cars.

CSR MaxAir Intake System £249 Silicone Inlet Hose (shown in blue) also available

 

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

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

Features Cars – Astra H VXR Sprint and Corsa C Z20LET

The owners of these cars which we have mapped and supplied parts, help and advice to have had them featured in the latest April/May issue of Performance Vauxhall magazine.

Jason Anthony’s Astra H VXR Sprint, began life as a Triple8 modifed car at around 295bhp and since his ownership Jason has made a lot of changes to the car and turning it into something equally at home of the track as the road. Now with steel rods and a bespoke Courtenay Sport remap to mid 330bhp and mid 350 lb ft torque the car has also been treated to a K06 turbo, Courtenay Klasen Inlet Manifold, KW Clubsport Coilovers, Safety Devices Rear Cage, AP Front Brakes, 292mm Rear Brake Upgrade, TD Pro Race 1.2 alloys, LSD, Courtenay Intercooler and Water Rad, 3″ Piper Exhaust, Recaro Seats and Harnesses.

Wearing the Sprint badge, this is a fantastic conversion often seen at Snetterton track days.

Jack Scott’s Corsa C 1.8 SRi has changed massively since it left its birthplace in Spain. Wanting to achieve 300bhp, Jack and his Dad carried out a Z20LET engine transplant and also fitted abig intercooler and some other performance upgrades. Once up and running, the car came to us to have a few additional upgrades including performance clutch, Courtenay Klasen Inlet Manifold, 80mm VXR air flow meter and VXR injectors and was then treated to a full bespoke remap achiving 321bhp and 340 lb ft torque.

Stage 2 Astra H VXR

Astra H VXR is still a very popular vehicle for modifying, whenther it is a mild upgrade or something far more major.

This particular car came to us for a Stage 2 tuning pack. We fitted a full 3″ stainless steel turbo back exhaust system and it was then round to the dyno cell for mapping and a full set up on our rolling road. The resuting 280 bhp and 333 lb/ft torque completely transforms the car.

Astra H VXR Stage 2 Mapping

Astra H VXR Stage 2 Mapping

Revised M32 Endcase and Larger Bearings

As part of our M32 gearbox repair service, we are now able to offer a new revised M32 gearbox endcase.

This later revised end case, introduced during 2012 for production vehicles, features additional oil galleries for improved lubrication of the end case bearings and also the end case bearings are of a larger diameter (62mm compared to 55mm); larger diameter bearings being able to deal with greater loads.

This upgrade is one that is well worth carrying out as part of an M32 gearbox refresh when new bearings are fitted, and proving extremely popular.

If you are unable to get to us for us to be able this service to be carried out, we are able to send out bearing packs complete with the revised endcase and larger endcase bearings, so if your chosen M32 gearbox repairer is unable to supply these parts we will send them directly to your repairer.

Astra H VXR Stage 4 K06 Coversion

Another fabulous conversion on an Astra H VXR.

This car first came to us for mapping to Stage 3 (hardware requirements are a full 3″ exhaust system and uprated intercooler). The car was fitted with a Forge lower front mount intercooler, but on the exhaust side only had a pre-cat removal pipe, and a Piper 3″ cat back exhaust system and was still running the factory main cat section. Obviously with this restriction in place it would be down on expected power, and upon checking on the rolling road this was found to be the case, but still making a respectable 283bhp.

Remedial action was simple; fit a 3″ front pipe and sports cat section. Once the mapping was finalised the results were a very good 299.99bhp and 332 lb ft torque on a cold January day.

In the hunt for more power, the car returned to us recently for a full K06 and inlet manifold upgrade.

ZRP steel rods and uprated ARP rod bolts were fitted, stem seals and retainers were done at the same time, and then when being put back together the K06 turbocharger, Courtenay Turbosmart uprated actuator, Courtenay Klasen high flow inlert manifold,thermal inlet gasket and high flow 340 fuel pump were all fitted. This was also the ideal opportunity to replace the cambelt and water pump and fit a lightweight allow bottom pulley.

Z20LEH engine being fitted with steel rods

Z20LEH engine being fitted with steel rods

An uprated CSRacing clutch kit and lightweight billet steel flywheel were also fitted, as a safeguard against the increase in power and torque, and to top it off a huge K Sport 8 Pot 356mm brake kit was also fitted, to bring everything safely to a halt. The car already had a Wavetrac LSD in the gearbox.

Rolling Road Mapping

Rolling Road Mapping

The end results after mapping 333bhp and 350 lb ft torque.

Astra J VXR Stage 2

Astra J VXR’s are becoming more and more popular for tuning now and here is another example. White seems to be a popular choice on this model.

This car was brought to us for a Stage 2 Tuning package which consists of a replacement 76mm downpipe to remove the restrictive pre-cat, a revised silicone inlet hose with a free flowing replacement air flow meter housing and large AEM DryFlow air filter assembly followed by custom ecu remapping, datalogging and full rolling road set up.

This car acheived 334bhp and 385 lb ft torque.

Astra J VXR Day

Returning after the Christmas and New Year break to work on more Astra J VXRs.

Mapping on a Cold Day – K06 at 349bhp

This Astra H VXR has been with us before for mapping and has a K06 turbo, full 3″ exhaust, Courtenay Klasen inlet manifold, CSRacing intercooler, steel rods (plus all the other required components) and achieved a very respectable 329bhp and 350 lb ft torque when last seen in the July heat this year.

Astra H VXR K06 Conversion

Astra H VXR K06 Conversion

Previously running a standard actuator, the car came back to us for checking and additional mapping after a Courtenay Turbosmart uprated actuator and recirculation valve had been fitted. We were able to have some further changes made to the boost, fuelling and ignition timing after the replacement actuator had been fitted, but the biggest change was the colder November temperature, meaning the dyno cell was lovely and chilled.

Final mapping saw a recorded power figure of 349bhp and 370 lb ft torque with more boost through the mid range helped by the stronger actuator. It goes without saying that the car was running Shell V Power 99RON fuel.

K06 Graph

K06 Graph

We still quote expected gains for this conversion at 330-335bhp, becuase we see and map more cars during the hotter months, but it only goes to prove how much turbocharged cars love cold dense air!

The Courtenay Sport Blog

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