Archive for the ‘ Fitting ’ 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

Astra H Handling and Stopping

We recently had the job of improving the stopping and handling on an Astra H.

This included supplying and fitting a D2 6 Pot 356mm front brake kit, complemented by a rear 292mm brake upgrade with vented rear 8G discs and new calipers.

Additionally a Premium Suspension package was also supplied and fitted: B8 dampers and DAP Road spec springs along with poly bushed Whiteline front wishbones, Powerflex poly rear beam bushes and a Whiteline rear anti roll bar.

 

Astra J VXR Stage 1+

Another Astra J VXR in for our increasingly popular Stage 1+ tuning package, comprising of front pipe fitting, ecu remap and rolling road set up. This car made a respectable 320bhp and 339 lb ft torque.

Astra J VXR

Astra J VXR

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

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 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

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

Rear Brake Lines – Astra H/Zafira B

Some pictures for reference, in gallery form and in no particular order, showing our braided rear brake hoses fitted on Astra H VXR. These should offer some help with installation of the rear braided brake lines. The brackets from the factory brake lines can be reused to accept the new braided brake lines. Remove the factory brake pipes from the original brackets (you will need to drift them out), and carefully open up the holes in the brackets to accept the braided brake line stainless steel unions, which are a slightly larger diameter to the factory fittings.

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

3″ Full Exhaust System – Astra H VXR

Another Astra H VXR brought to us, this time to have a full 3″ Courtenay Piper exhaust system fitted. Where customers choose not to have a full ecu remap, part of our fitting process includes programming the ecu with factory spec software with the P0420 DTC (Cat System Efficiency Below Threshold) error code deleted, to eliminate the EML (engine management light) from coming on.

Astra H VXR 3" Exhaust

Astra H VXR 3″ Exhaust

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.

Astravan 1.9 CDTi Gearbox Overhaul and Uprated Clutch

Another M32 gearbox overhaul.

Astravan M32 Gearbox Overhaul

Astravan M32 Gearbox Overhaul

Again we removed the gearbox to carry out a full strip down, inspection and clean of the components including the transmission case. It was then rebuilt with new bearings throughout and the revised end case was fitted which features additional oil galleries for better lubrication and larger end case bearings.

Prior to refitting the gearbox a new dual mass flywheel and uprated sachs clutch cover and disc were fitted with a new hydraulic slave cylinder.

Astravan 1.9 CDTi Gearbox Overhaul and Remap

This Astravan came to us for a gearbox overhaul and ecu remap and rolling road set up.

We remove the gearbox, and have it fully stripped down and all the internal components are cleaned and inspected. This also allows the transmission cases to be fully clean as well, something often overlooked if bearings are replaced with a gearbox in situ. The gearbox internals are then reassembled and refitted with new bearings throughout.

Once finished the van was on our dyno for full mapping and rolling road set up.

Astravan 1.9 CDTi Remap

Astravan 1.9 CDTi Remap

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.

Zafira GSi Turbo Clutch and Flywheel Replacement

A tuned Zafira GSi in our workshop for an uprated fast road clutch and lightweight billet steel flywheel assembly.

To cope with the higher power and torque figures, we have fitted this Zafria with an uprated clutch, and at the same time replaced the rear mail oil seal (behind the flywheel) and fitted a new Sachs hydraulic slave cylinder.

At the same time it has also benefitted from the addition of a lightweight flywheel which improves the engine’s willingness to rev and makes for faster acceleration through the gears. An upgrade well worth carrying out with clutch replacement.

Not only can we supply and fit but we can also send parts out mail order by courier for anyone unable to get to us.

Zafira GSi Clutch and Flywheel Replacement

Zafira GSi Clutch and Flywheel Replacement

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.

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

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

The Courtenay Sport Blog

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