Archive for the ‘ Courtenay Sport ’ Category

Corsa D VXR Engine Mounts

Due for imminent release, expected within the next 3 weeks, uprated engine mounts for Corsa D VXR models.

Corsa VXR Engine Mount Group

Corsa VXR Engine Mount Group

Pricing from £93.60 – £138.00 Further details to follow. Contact us now to pre-order yours.
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Corsa VXR Nürburgring Stage 2 Upgrade – Take 2

It has been a busy week for us for Corsa VXR tuning.

This Glacier White car is our second Corsa VXR Nürburgring Stage 2 Upgrade in a week. We fitted our full 3″ turbo back exhaust first:

Corsa VXR Nürburgring Exhaust Fitting

Corsa VXR Nürburgring Exhaust Fitting

Followed by custom mapping, datalogging (including ignition timing, knock retard, injectors, boost pressure, fuelling), map optimisation to suit the new exhaust and full rolling road set up:

Corsa VXR Nürburgring on the Rolling Road

Corsa VXR Nürburgring on the Rolling Road

Corsa VXR Mapping

A busy week for remapping Corsa VXRs on our rolling road with this A16 engined Corsa VXR in for mapping, injectors and set up earlier in the week, reaching a respectable 217bhp for a car with a 70mm cat back exhaust.

Corsa VXR on the Rolling Road

Corsa VXR on the Rolling Road

Garrett Built Astra G GSi Turbo 503bhp

Garrett Build Astra G GSi Turbo 503bhp

Garrett Build Astra G GSi Turbo 503bhp

Another Garrett build, with Garrett GT30 Turbo, V Band Manifold, Courtenay Klasen Cams and Inlet Manifold, Engine rebuild, 90mm AFM, injectors, 3″ exhaust; all the usual requirements for a Garrett conversion, previously mapped by us and making a respectable 490bhp; brought in for checking now its a little cooler. Up 13bhp to 503bhp due to the lower temperatures.

Another Garrett Build Astra H for Mapping

Astra H Van with Z20LEH VXR Engine

Astra H Van with Z20LEH VXR Engine

This Astravan with Z20LEH engine, steel rods and GTX2867 garrett build was brought in for mapping and full rolling road set up.

The map it was brought to us with (which was not our software) was checked first and shown to be running 320bhp, with some fuelling and ignition timing issues.

We switched to a 3 bar map sensor (from a standard 2.5 bar one) and recalibrated the map so the ecu could correctly read boost pressure as the 2.5bar map sensor will go out of range on capable of reading up to 22psi of boost, hence the change to a 3 bar sensor. Correctly recalibrated the ecu can then read up to 29.4psi boost presure.

Also changed were the 875cc injectors to a much more suitable 630cc injector for the required power, again with suitable ecu recalibration. 875cc injectors for the required power prove way too big, and cannot be controlled accurately enough for part throttle fuelling (essential on a fast road car) due to the spray pattern plus fuel consumption will be higher, again another consideration for a car with road manners. When checked and datalogged first this car was running at 0.88 lambda on cruise, so clearly the map needed some work at this point. This is too rich and can cause bore wash and potentially internal engine damage. Big injectors are fine for stand alone management and for race cars which do not run at part throttle or cruise, but were just incorrectly specced for this particular applcation.

With a couple of bits still to do and after mapping and set up the result for now is 390bhp and much better, more controlled fuelling at part throttle and cruise. Fuel consumption will improve as well as 630cc injectors control part throttle fuelling more accurately.

Why the change of injectors? For better road manners; in simple turns the bigger injector (875cc) does not atomise the fuel as efficiently at slow duty cycle/engine speeds. So a 630cc injector can provide more than enough fuel for the power but still return better fuel economy due to its ability to better atomise the fuel.

DAP Springs Astra J VXR

DAP Springs Astra J VXR

DAP Springs Astra J VXR

  • Manufacturered Exclusively for Courtenay Sport.
  • Probably the ultimate fast road springs for this chassis.
  • Lowers the VXR chassis by about 20-25mm.
  • For excellent road holding whilst maintaining good ride quality.

Priced at £183.95 per set.

Following our very successful and much acclaimed DAP R Astra H VXR spring kit we now have our DAP R Astra J VXR spring kit available.

Vauxhall set the bench mark very high with the original Astra J set up which didn’t make our job very easy however after an extensive period of development we have achieved what we feel is the ultimate fast road set up.

Visually the car now sits typically between 20-25mm lower. The straight line ride quality is slightly firmer but not at the detriment of ride quality and certainly does not feel crashy, however press hard into the corners and the suspension tightens, firming up giving more control through mind corner bumps and undulations whilst communicating with plenty of driver feel and feedback.

DAP Rs are wound from high tensile chrome silicone steel and are manufactured in a cold winding process for maximum durability in all weather conditions. They are powdered coated Diamond Black to give a very OE look and feel and have the DAP signature discreetly placed on them.

Corsa VXR Nürburgring Stage 2 Upgrade

This lovely 2012 Corsa Nürburgring in Lime Green Pearlescent was brought to us for a Stage 2 upgrade, so initially into the workshop and up in the air so the original exhaust could be removed to be replaced with the full 76mm (3″) turbo back stainless steel exhaust system:

Exhaust Fitting - Corsa Nürburgring

Exhaust Fitting – Corsa Nürburgring

and then onto the rolling road for custom mapping, datalogging (including ignition timing, knock retard, injectors, boost pressure, fuelling), map optimisation to suit the new exhaust and full rolling road set up:

Mapping on the Rolling Road - Corsa Nürburgring

Mapping on the Rolling Road – Corsa Nürburgring

Courtenay Sport at Trax 2014

A few pictures of our display at Trax 2014, Silverstone Circuit Sunday 7th September.
Thank you to everyone who came along on the day and for some fantatsic cars as part of the display.

Trax 2014 Video by Nankang Tyre UK

A short video from Trax 2014, by Nankang Tyre UK. Watch closely and you’ll spot Courtenay Sport in a couple of places.

Astra G GSi Turbo Z20LEH

We recently had this Astra G GSi Turbo in for a rolling road session. This car had previously had a Z20LEH Astra H VXR engine fitted (replacing the original Z20LET unit), running VXR turbo, injectors and 80mm Air Flow Meter. Additional upgrades now include steel rods for strength, high flow inlet manifold and 76mm full exhaust (upgraded from a 63.5mm exhaust system).

Astra G GSi with Z20LEH engine

Astra G GSi with Z20LEH engine

Mapping Session Astra H VXR

Rolling Road mapping session to optimise software settings on this Astra H VXR, which has had some hardware alterations since it was first mapped. Before and after mapping saw gains of between 12-34bhp and 5-20 lb ft torque.

Astra H VXR on the Rolling Road

Astra H VXR on the Rolling Road

Astra H VXR – PowerCool 180 Conversion

We had this very well speced Astra H VXR in with us recently for a full enhanced service, changing all the filters, fitting uprated NGK spark plugs, brake fluid change to DOT 5.1 and adding our high quality fully synthetic Valvoline SynPower 5w-40 oil. Already fitted with Team Dynamics Pro Race 1.2 Alloy Wheels, VXRacing AP 4 Pot 343mm Front Brakes, 285bhp upgrade with full 76mm exhaust system it is a great road car and can sometimes be seen making the odd appearance out on track from time to time.

In addition to the enhanced service, we also carried out a conversion from the traditional water based antifreeze to Evans Waterless PowerCool 180 Coolant with all the associated benefits that the waterless coolant brings.

Astra H VXR - Enhanced Service and PowerCool 180 Conversion

Astra H VXR – Enhanced Service and PowerCool 180 Conversion

Astravan Z20LEH 2.0 Turbo Conversion

A 294bhp Z20LEH engined Astravan in for a service, MOT and some additional TLC. This van has a huge spec including Quaife LSD, Astra H VXR brake set up (front and rear) with uprated discs, CSR Intercooler, 76mm Full exhaust system, 80mm AFM and VXR injectors, uprated clutch and flywheel, a B8 damper and Eibach spring kit, rear ARB and Revolution Millennium Alloy Wheels. We carried out the coversion on thsi van several years ago now and it is still kept in immaculate condition.

Z20LEH Astra Van

Z20LEH Astra Van

Astra H VXR – from Standard to Stage 3

Another one of our more recent jobs was to give this Astra H VXR Racing a much welcomed performance increase.

Booked in for a full Stage 3 conversion, the vehicle came to us as a standard spec car. We fitted our full 76mm (3″) turbo back exhaust system, our full height CSR front mounted intercooler, an uprated actuator with new bracket and finally a set of cooler running iridium spark plugs and a CS high flow foam panel filter were added. Mapping and set up saw a very respectable 289.5bhp and 336 lb ft torque, considering the heat at this time of year doing its best to reduce power.

For further details on the conversion, pricing and additional tuning information please visit our webpage on Astra H VXR Tuning >>>> HERE <<<<

Astra H VXR Stage 3

Astra H VXR Stage 3

Now Accepting AmEx and PayPal

Courtenay Sport are please to announce that we are now accepting American Express cards online and at our premises and PayPal for online purchases.

Now Accepting Online: Now Accepting On Our Premises:

American Express Logo

American Express

PayPal Logo

PayPal

American Express Logo

American Express

Zafira VXR 430bhp

Another big power Z20LEH engine undergoing mapping this week, this time in a Zafira VXR making it a pretty quick 7 seater! Pushing around 430bhp from a Garrett conversion, with 3″ exhaust, Courtenay Klasen Cams, Nortech tubular manifold, Owen Developments GT28 71 HTA turbo, 630cc injectors, steel rods, Pro Alloy alloy water radiator, 356mm K Sport brakes, Quaife LSD. A very respectable figure for a hot summer’s day on the rollers.

Zafira B VXR

Zafira B VXR 430bhp

Revolution Millennium Alloy Wheels

Revolution Millennium Alloy Wheels 8Jx18; now also available in Anthracite (as well as White). Spec: 8Jx18, ET35mm, 5x110PCD, 65.1mmCB. Black finish due around August time.

 

Revolution Millennium Alloy Wheels

Revolution Millennium Alloy Wheels

Uprated Enlarged Performance Intercooler – Astra J VXR

Astra J VXR Uprated Performance Intercooler

Astra J VXR Uprated Performance Intercooler

Once again we have joined forces with industry leaders Pro Alloy to develop our new enlarged, uprated performance intercooler kit for the Astra J VXR.

Our new intercooler is both larger in width and height than the standard unit with the core being twice as deep as the factory cooler. This represents a huge increase in available cooling area and volume and maximises the cooling available through the front of the car whilst also future proofing the cooler for use with high power large turbo setups.

The factory cooling set up has the air conditioning radiator in front of the intercooler so our first job was to remove the intercooler and then reposition the A/C radiator back, on to the water radiator. This is done so that the new intercooler is receiving the coolest air available. To further improve the efficiency we have included in the kit a lower air blade to stop the air washing away from the bottom of the intercooler.

Furthermore to maximise flow to and from the intercooler the kit comes complete with all the pipework which is enlarged to 60mm, paying particular attention to the restrictive section straight out of the turbo seen at the top rear of the engine bay. The Intercooler kit also comes complete with all the required hoses and laser cut brackets and fittings.

Price: £899

Oil Restrictor Bolt – K04 VXR Turbo

We thought we would share some information regarding oil restrictor bolts to help clarify our views on them…

Restricting the oil supply to Turbos is not a new idea or fad; turbo conversion companies have been doing this as instructed by Garret since the early 1990s.

It is true that a number of Vauxhalls have suffered from this smoking due to oil washing past the turbo oil seals.

It is true that changing the oil to a heavier weight of oil helps with this by allowing the oil to drain quicker as it is more resistant to any frothing or foaming (call it what you will) in the turbo core.

It is true that journal bearing turbos do need a very good supply of oil.

It is also true that too much oil can and will swamp the seals and in this case… the use of careful oil restriction will help; Vauxhall has also done this in production of the later K04 units.

Now we believe the original Vauxhall KO4 oil restrictor bolt was developed by Ian Percival AKA Percy (vxronline) before GM Modified the core. Ian is very knowledgeable by all accounts. He carefully calculated then made a restrictor as part of the bolt so it can be retro fitted to cure this lack of oil restriction in very early units. Our reluctance to recommend oil restrictor bolts comes not from what Ian did but from the fact that many other individuals and “ebayers” alike have jumped on the oil restrictor bolt bandwagon and produced some very inferior imitations. To this end we have been handed a number to fit, made of some very dubious soft material and we have seen some with a pressed in restrictor plug complete with a loose and rattling swarf built in, which would have killed a new turbo almost immediately! Plus we have removed many others that have been over restricted.

We hope people can now see why a number of suppliers, turbo manufactures and re-manufacturers are reluctant to recommend them. To be clear it’s not the principle or the original execution that is the problem but the others that have come along after, which when fitted can damage what was a perfectly good turbo unit, leaving the supplier / manufacture liable.

The later VXR turbochargers already have the oil flow control built into the oil gallery in the turbo itself, as is evident from the picture below centre:

Z20LEH Turbo Oil Gallery

Z20LEH Turbo Oil Gallery

If a turbocharger is smoking due to worn turbo oil seals, then the turbo already has a problem. A restrictor bolt will not repair worn turbo oil seals.

Corsa 1.6 Turbo VXR Aluminium Water Radiator

Due to increasing demand  we have once again joined forces with market leader’s Pro Alloy to fabricate an uprated aluminium water radiator for the VXR and 1.6 turbo engined Corsa D.

The new radiator had to be an all alloy construction featuring welded end tanks; this eliminates the common issue on Corsa D water radiators where they leak from the plastic end tanks.

Additionally the core depth has been increase from 26mm to 40mm, whilst the surface area has been increased by 7.7%. Furthermore by reconfiguring the tube layout and foil pitching we have increased the flow area by 67% making the radiator much more efficient in cooling and ambient airflow through the core.

Finally the bottom lower water connection on the right hand end tank has been make one piece, getting rid of the factory eclip/circlip configuration that also has been known to separate at high pressure.

It is available to order and can be finished raw in Natural Aluminium or powder coated in Stealth Black finish (at additional cost).

Ideal for direct replacement on any fast road or trackday car.

Price £558.00 including VAT.

It is also worthwhile considering an upgrade to Power Cool 180 Waterless Coolant at the same time. No Water, No Corrosion, No Pressure (less likelihood of leaks, less strain on hoses and other components) More BHP, No Hot Spots, No Overheating…….

Corsa D 1.6T Water Radiator Front

Corsa D 1.6T Water Radiator Front

Corsa D 1.6T Water Radiator Rear

Corsa D 1.6T Water Radiator Rear

The Courtenay Sport Blog

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