Archive for the ‘ General ’ 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.

More Astra J VXR Mapping

Another Astra J VXR in for mapping, in the ever popular blue, this time from another repeat customer who was more than pleased with work we carried out to his previous car a Vectra VXR.

Already fitted with an induction kit and our 3″ pre-cat removal pipe the car came in for mapping and full rolling road set up.

Astra J VXR Mapping Session

Astra J VXR Mapping Session

The final figures were up from 280bhp and 324 lb ft to 325 bhp and 365 lb ft torque.

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

 

M32 Gearbox Bearings and Late Endcase

Another M32 gearbox from an Astra H in for bearing replacement and upgrade to the later endcase with larger endcase bearings.

M32 Gearbox with Late Endcase

M32 Gearbox with Late Endcase

This gearbox had covered some 90,000 miles before need to have the bearings replaced, and whilst the box was off the car for overhaul the later endcase which features additional oil galleries and larger endcase bearings was fitted.

The box was refitted and filled with 3 litres of very high quality fully synthetic Amsoil MTG 75w-90 gearbox oil, and also the dual mass flywheel, clutch (cover and disc) and hydraulic slave cylinder were also replaced using genuine OE components.

1.9 CDTi Clutch and Dual Mass Flywheel Assembly

1.9 CDTi Clutch and Dual Mass Flywheel Assembly

Prices (to supply parts):
M32 Bearing Pack with late endcase £255.00
Genuine Vauxhall/Opel OE DMF £295.00/£335.00 (price according to chassis break)
Genuine Vauxhall/Opel OE Clutch Kit £150.00/£159.00 (price according to chassis break)
Genuine Vauxhall/Opel OE Slave Cylinder £108.00

Renault Clio Track Car

Some variety in our workshop.

The Renault Clio is a very popular option for a trackday car. This car came to us for some routine service work including a new alternator, R888R tyres, rear brake discs and pads and a check on the rolling road.

Renault Clio

Renault Clio

Astra H VXR Upgrades

Here we have a couple of Astra H VXRs in for upgrade.

The black car has had a K Sport 8 Pot 356mm front brake kit, CSRacing intercooler, full 3″ exhaust system and inlet plenum fitted and will be mapped and set up on the rolling road. It is also having a rear cage fitted along with eyelet provision for harnesses.

The blue car has had a Stage 3 package (CSRacing intercooler, full 3″ exhaust system), direct route hose kit and airbox, a Courtenay Turbosmart recirculation valve and a Quaife LSD and is also due to be mapped and set up on the rolling road.

Workshop Astra H VXRs

Workshop Astra H VXRs

Astra J VXR Stage 3

Another Astra J VXR in for mapping, fitted with all the right components for Stage 3; Full 3″ Turbo Back Exhaust with pre-cat removal, CSRacing Intercooler, enlarged inlet hose, Induction Kit.

Astra J VXR Mapping

Astra J VXR Mapping

 

Astra J VXR Engine Bay

Astra J VXR Engine Bay

K Sport Caliper Colours

Whilst K Sport calipers can be painted any colour from the factory, providing a recognised colour code is supplied, there are a selection of ‘default’ colours to chose from:

K Sport Caliper Colors

K Sport Caliper Colors

Enlarged Silicone inlet Hose for Astra J VXR

Enlarged Silicone Inlet Hose for Astra J GTC VXR.

A direct replacement for the factory inlet hose, this silicone hose has been enlarged throughout its length for improved air flow, tapering only at the end to fit onto the turbo. This hose is smoothed out removing all the steps and convolutes found in the factory hose. It also features a moulded spigot for the breather pipe.

£119.95 Available in Blue, Red or Black or Yellow, Green, Purple or Orange to Special Order.

Astra J Inlet Hose

Astra J Inlet Hose

K03 Hybrid Turbo 1.6

We have recently carried out some development work using a K03 Hybrid Turbo for the Corsa D 1.6 Turbo engine; Z16LEx/A16LEx/B16LEx

Featuring a reworked compressor wheel and shaft, an uprated bearing pack and a modified inlet elbow, we tested the unit on a Corsa 1.6 Turbo on which we had previously carried out a full engine rebuild with low compression pistons and steel rods. The car was also complemented by a full 76mm exhaust system and CSRacing Intercooler and achieved 258bhp once remapped and set up on our rolling road.

Price: £1140 inc VAT based on rework to a brand new core unit including a reworked inlet elbow.

K03 Hybird 1.6 Turbo

K03 Hybird 1.6 Turbo

K03 Hybrid 1.6 Turbo and Inlet Elbow

K03 Hybrid 1.6 Turbo and Inlet Elbow

Something Different

Something a little different……

Brought to us for an independent examination and mechanical inspection. The subject of an insurance claim (from a well known ‘local’ insurer) the car had suffered lower front end damage to the water radiator and dry sump set up. We were asked to carry out an inspection and to check that the engine was not seized.

Ferrari 575M

Ferrari 575M

Vauxhall Reveals Seventh-Generation Astra

  • First pictures of new Brit-built Astra ahead of Frankfurt unveil
  • Up to 200kg lighter than outgoing model
  • Smaller outside, bigger inside
  • New engine portfolio including 1.4-litre (145PS) petrol
  • First all-new Vauxhall with OnStar
  • IntelliLink R 4.0 compatible with Apple CarPlay and Android Auto

Luton – These are the first images of Vauxhall’s seventh-generation Astra, which will reach production later this year from the company’s Ellesmere Port manufacturing plant in Cheshire.

New Vauxhall Astra 2015

New Vauxhall Astra 2015

Based on an all-new lightweight vehicle architecture with a new design, powertrains and technology, Astra will receive its world premiere at the 2015 Frankfurt Motor Show (September 17-27).

One the UK’s top-selling and best-loved cars, the Astra is a household name for British car buyers with over 2.9 million sold in the UK over the last 36 years with over 50,000 last year.

Depending on the model and trim level it will be up to 200kg (130kg on average) lighter than its predecessor. The completely new vehicle architecture plays a major role in the weight reduction. Every component was checked for compact design and lightweight materials. The body shell weight alone was reduced by 20 per cent from 357kg to 280kg.

Additional, chassis-related measures resulted in a further 50kg weight loss. These include high-strength and ultra-high-strength low-weight steels, compact subframes as well as weight reductions to the front and rear axle.

Powertrains

The all-new Astra features a powertrain portfolio including petrol and diesel units ranging from 100PS to 200PS.

It is expected that a new GSi model (247bhp) and VXR model (296bhp) will also be announced.

Read more

Number Plates – Perspex and Pressed Steel

In addition to our Courtenay Sport perspex number plates we are now also able to supply pressed steel plates.

Both types are UK road legal with Courtenay Sport logo, supplied in pairs. Available with or without the EU/GB Logo, at no extra cost.

Perspex number plates have red line border, pressed steel number plates have a black border, as shown below.

Perspex: £30.00 per pair including VAT

Pressed Steel: £40.00 per pair including VAT

Please > Contact Us < to order.

Front Pressed Steel Number Plate

Front Pressed Steel Number Plate

Rear Pressed Steel Number Plate

Rear Pressed Steel Number Plate

Note: We will require proof of ID and entitlement to use any number plates ordered from us, as per DVLA guidelines.

New Advert June 2015

Our Latest Advert revealed in Evo and Performance Vauxhall magazines.

Courtenay Sport Advert

Courtenay Sport Advert

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.

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

The Courtenay Sport Blog

%d bloggers like this: