Archive for the ‘ Rolling Road ’ Category

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

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

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.

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

Focus ST Remap

Just for a change we recently had a Focus ST here for remapping and rolling road set up. Already fitted with a cat back exhaust system (the standard downpipe and cat had not been changed) and an intercooler, we remapped the ecu and carried out a rolling road set up achieving 261bhp and 311 lb ft torque.

Focus ST on the Rolling Road

Focus ST on the Rolling Road

Astra H VXR K06 Conversion

One of our recent jobs was this Astra H VXR, brought in to have a K06 turbocharger fitted (complete with an uprated recirculation valve), along with our CSRacing Full Height Front Mounted Intercooler. Whilst in our workshop it was also converted to Evans Power Cool 180 Waterless Coolant.

Already fitted with a 70mm exhaust system it was onto the rolling road for mapping and full set up. During mapping the mid range and top end boost was reduced slightly due to the 70mm exhaust system giving more back pressure than a 76mm system and also because the engine did not have steel rods or uprated valve springs. Once the ignition timing and fuel were optimised we saw results of 304 point something bhp (so nearly 305bhp!) and 341 lb ft torque. With a 76mm system estimated gains are 305-310bhp so this particular car is making good power on a 70mm system.

There is still some in reserve to come for this car once it has a 76mm exhaust system to help with back pressure reduction as 310bhp+ is more than possible, with potentially even more should an inlet manifold, steel rods and uprated valve springs/shims be fitted.

Astra H VXR with K06 Conversion

Astra H VXR with K06 Conversion

Astravan 1.9 CDTi Stage 3+ Tuning Package

We had this Astravan 1.9CDTi here recently for a few days undergoing some fairly extensive upgrades to cover the engine, brakes  and chassis.

Performance:
A Stage 3+ conversion. The van was fitted with our hybrid turbo charger, full 2.5″ stainless steel exhaust system (turbo back), full height CSRacing Intercooler and 80mm Air Flow Meter with revised inlet air path. At the same time an oil and filter change was also carried out.

After the hardware had been fitted, it was round onto the rolling road for ecu remapping and a full set up, which achieved 223bhp and 377 lb ft torque.

Astravan 1.9CDTi 150

Astravan 1.9CDTi 150

Braking:
At the same time a K Sport big brake kit was fitted, under the 17″ wheels, to greatly improve the stopping ability over the original factory 308mm brake set up. Red 8 Pot calipers, 330mm x 32mm 8 grooved and ventilated front discs with EBC Yellow Ceramic Pads. The brake system was bled through with DOT 5.1 brake fluid.

K Sport 8 Pot 330mm Brake Kit

K Sport 8 Pot 330mm Brake Kit

To ensure adequate clearance between the wheel spokes and the calipers a TÜV approved 3mm spacer has been fitted with longer 28mm black wheel bolts.

Handling:
The van has also had our Courtenay Sport Clubman Plus fast road suspension upgrade which is a full kit that includes original equipment (OE) genuine Astra VXR dampers and a set of DAP Road springs, which drops the chassis significantly, as can be seen on the before and after pictures below. Ideal for fast road and light track day use.

Before:

Astravan 1.9CDTi Standard Suspension

Astravan 1.9CDTi Standard Suspension

After:

Astravan 1.9CDTi Clubman Plus Suspension

Astravan 1.9CDTi Clubman Plus Suspension

Insignia VXR Remap

We had this 2009 Insignia VXR with us recently for ecu remapping and full set up. It had covered about 55,000 miles and had already had the second cat removed by the owner, with the pre cat still in place.

Mapping and set up resulted in 348 bhp and 396 lb/ft torque, up on a car with a remap and standard exhaust with both cats still fitted, with gains of almost 100bhp and 100 lb/ft torque throught the mid range.

Insignia VXR

Insignia VXR

Stage 3 Corsa VXR

We had a lovely 40 something thousand mile Corsa VXR in with us recently which had been fitted with a full 3″ exhaust system, twin silencers and pre cat removed and also our high flow CSRacing full height intercooler.

Compressions were checked all found to be good, then the ecu was remapped and the car underwent a full rolling road set up with full ecu datalogging and the software was optimised to suit the fitted components resulting in 240bhp and 249 lb ft torque and running on 99 octane fuel.

As we are sure you all know what a Corsa VXR looks like by now, we will show you the power and torque graphs instead:

Corsa VXR Stage 3 Power and Torque Graph

Corsa VXR Stage 3 Power and Torque Graph

Mapping Session – Supercharged VX220

This VX220 was in for mapping following a self-install Stage 1 supercharger conversion and was mapped and set up on the rolling road making 210bhp and 190 lb ft torque.

Stage 1 Supercharged VX220

Stage 1 Supercharged VX220

Vectra VXR Mapping Session

This Vectra VXR came to us for mapping having already had an Insignia VXR Turbo unit and an intercooler fitted. The cats had also been removed prior to its visit. Once in our rolling road bay, a set of uprated injectors were fitted and then the car was mapped and set up on the rolling road, achieving excellent figures; 329bhp and 406 lb ft torque. These numbers were about what was expected from a car running a factory water radiator, in between our Stage2+ (320-325bhp) package and our Stage 3 (340bhp) package (which also adds an uprated water radiator) .

More details on Vectra VXR tuning on our >>>> main website <<<<.

Vectra VXR on the Rolling Road

Vectra VXR on the Rolling Road

Astra VXR Rolling Road Health Check

It is always useful to have a car checked from time to time on the rolling road, as it can show up potential running issues.

We had this Astra H VXR Nürburgring brought in for a health check on the rolling road this week, due to it feeling ‘down on power’ after a manifold swap by the owner, so running it up and datalogging it should highlight any issues.

We carried out an initial check over of the vacuum pipes, recirculation valve and actuator just to make sure nothing physical was at fault which could cause a problem. The ecu was also checked for any stored trouble codes, again to see if there was anything that could cause a running issue.

Running the car up on the rolling road whilst datalogging found the turbo to be down on boost, making less bosst pressure than expected  and resulting in 255bhp and 290 lb ft torque down on what is expected from a Nurburgring with a remap.

Additional checks were carried out to the boost hoses and intercooler fittings, which showed no leaks or issues.

After further runs, the turbo was shown only to be capable of making a maximum of 20psi overboost, and unable to make the required boost at peak power (around 5,700rpm), so identifying the root cause of the problem to be a failing turbocharger.

Astra VXR Health Check

Astra VXR Health Check

Supercharged VX220 Mapping Session

Supercharged VX220 2.2 16v

Supercharged VX220 2.2 16v

A recent mapping session on a VX220 2.2 with a self-install supercharger conversion. Initially brought in a while ago for mapping the car achieved 216bhp, lower than the expected Stage 2 power due to a restrictive exhaust system identified during the first mapping session.

Brought back to us with a derestricted 2.5″ front pipe and cat section, we were able to improve the mapping with changes to the ignition and fuelling now that exhaust flow had improved resulting in gains to 242bhp, with the graphs showing improved power and torque right across the rev range.

Corsa VXR Blue Edition – Stage 2

We had this lovely low mileage Corsa VXR Blue Edition with us recently.

Corsa VXR Blue Edition

Corsa VXR Blue Edition

If it was feeling ‘blue’ before it arrived, it certainly wasn’t when it left, after having a full 3″ exhaust system fitted, NGK iridium plugs, a panel filter, large bore inlet pipe and uprated recirculation valve followed by ecu remapping and a full set up on the rolling road with datalogging and map optimisation.

Corsa VXR 3" Exhaust Fitted

Corsa VXR 3″ Exhaust Fitted

Achieving 223 bhp and 238lb ft torque runing on 99 Octane V Power Nitro+.

Astra VXR Sprint K06

Built specifically for use as a track day car, this car was previously a Stage 3 car producing a useful 292bhp and had been fitted with our 3″ full exhaust, CSRacing Intercooler, Pro Alloy Water Rad, Wavetrac LSD, Alcon 4 Pot calipers with 356mm alloy belled discs, 292mm Rear Brake Upgrade, Whiteline Rear ARB, DAP Road Springs, direct route hose kit and Pro Race 1.2 alloys. Building on the track day specification, other modifications have included Recaro Pole Position Seats, Rear Cage and Sabelt Harnesses.

Astra VXR Sprint

Astra VXR Sprint

After a few engine changes including K06 turbo rework, Courtenay Klasen Inlet Manifold, Steel Rods, Turbosmart Actuator and Recirculation Valve and a few hours mapping on the rolling road we achieved a respectable 336bhp and 355 lb ft torque, all useable on track increases through the mid range and top end, with the ability to rev to 7,500 rpm.

Before and After Graph:

Stage 3 K04 v Stage 4 K06  Astra VXR

Stage 3 K04 v Stage 4 K06 Astra VXR

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.

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

The Courtenay Sport Blog

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