Archive for the ‘ Rolling Road ’ Category

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 H VXR – K06 Mapping

This Astra H VXR Nürburgring is a well loved and enjoyed example having covered some 110,000 miles, but it always gets regular 5,000 mile oil changes. It shows the durability of the engines as this car has been tuned to several levels, originally starting at Stage 3.

More recently it has benefitted from the addition of a K06 hybrid turbo and Courtenay Klasen Inlet manifold, a set of steel rods and with mapping and set up is currently making 316 bhp on the 70mm Remus exhaust system.

It is due back soon for a full 76mm exhaust system to release the additional power available from the fitted components, which is being held back by the Remus system.

Excellent results showing that mileage is not detrimental to the Z20LEH engine making good power, providing regular maintenacne is carried out.

Astra H VXR Mapping

Astra H VXR Mapping

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 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

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!

VW Scirocco R Mapping

Another VW brought in to us for mapping recenlty was this Scirocco R with the 2.0 Turbocharged EA113 engine (also used in VW Golf Mk5), which in standard trim is quoted at 261bhp and 258 lb ft torque.

The car was already fitted with a full 3″ exhaust system, upgraded air inlet pipework and RamAir foam filter and a Loba 2.0TFSI uprated high pressure fuel pump. After mapping and rolling road set up the end results were a shade over 350bhp and 326 lb ft torque.

VW Scirocco R Mapping

VW Scirocco R Mapping

Lotus Europa Mapping

The Lotus Europa is fitted with a Z20LER engine, as used in the Astra H 2.0 Turbo (Non VXR) and has the M32 6 speed gearbox.

This particular car had been fitted with a VXR turbocharger, VXR injectors (both from the Z20LEH sister engine used in the Astra H VXR) and a Milltek exhaust and came in for ECU remapping and rolling road set up. To prevent clutch issues is also had an the uprated 240mm clutch and lightweight 240mm flywheel also used on Astra H VXR as an upgrade.

Astra J VXR Development

This summer has seen a substantial increase in tuning demand for the A20NFT engine. This combined with the ECU’s use in the new Corsa E VXR has seen us spending many hours on the dyno looking at data with Stephan getting his teeth firmly into the intricacies, oddities, protocol and hidden depths of the Delco ECU required for example in bigger airflow and turbo applications.

With Stephan visiting us this week we took the opportunity carry out some further testing work on our own  Astra J VXR, already fitted with our Courtenay Sport Racing intercooler and full turbo back 3″ (76mm) twin silenced exhaust system. A lot of time was spent with the car on the rolling road and further updates were made to the software. One of the objectives this week was to further test and calibrate our soon to be released induction kit in order to to fully understand where the best gains are made. To do this a number of filter and air mass housing combinations were tested before finally settling on our preferred design for the A20NFT engine.

Corsa E VXR Development

We are pleased to announce that the tuning program for the Corsa E VXR has begun.

Stephan Klasen (our mapping engineer) has purchased a Corsa E VXR in ‘Shiny Rock’ Grey for a whole host of development work to compliment further existing on-going development on our own Astra J VXR, as the Corsa E shares the same GM – Delphi ECU with the Astra J VXR.

So far we have completed Stage 1 which is just a bespoke ecu remap to the standard car with full rolling road set up and optimisation and Stage 1.5 which has the addition of a front pipe complimented by the bespoke ecu remap.

The car had a number of runs to bench mark its base power as delivered from Opel. With the engine fresh out of the box and with less than 100 kilometres on the clock the standard power was recorded at 203 bhp and 208 lbs ft of torque. Following Stage 1 remapping the power increased to 223 bhp with 237 lbs ft of torque. As you can see from the graphs below this power and torque increase is across the whole of the rev range right up to the standard rev limiter.

A change of front pipe and the car was put back on the dyno. Following a good amount of recalibration and load testing runs the power further increased to 237 bhp and 238 lbs ft of torque. At this time Stephan wants to keep the toque at this level for the safety of the pistons. You can see from the Stage 1.5 graphs the rev limit has also been increased to complement its improved breathing and this the shift light function has also been lifted.

A full exhaust system has now been fitted to the car and mapping work for this will continue as soon as the car arrives back from KW who are currently using the car for suspension development; Watch this space……..

Click on the gallery images below to enlarge:

Astra H VXR Track Car Mapping

This track prepared (and more importantly track used) Astra H VXR came in for mapping to give it a performance improvement in the short term to compliment the other modifications which have been specifically aimed at making a good useable trackday car.

Lightweight Team Dynamics 18″ alloy wheels help with unsprung weight and improve acceleration and turn in and also allow the 356mm 8 pot K Sport brake kit to sit neatly behind. DAP springs and a Whiteline rear anti-roll bar are the current chassis upgrades. A full exhaust system has also been fitted to help with improving flow and compliment the ecu remap.

Turning to the interior, a rear half cage has been bolted in to enhance the structural rigidity of the body, which also improves the handling and offer the obvious safety benefits, the interior has been partially stripped to reduce weight, the heavy factory front seats have been replaced with Recaro Pole Positions, a massive weight saving and also allowing the use of front seat harnesses.

Astra H VXR Trackday Car Being Mapped

Astra H VXR Trackday Car Being Mapped

Astra H 2.0 Turbo Mapping

We recently remapped this Astra H SRi 2.0 Turbo model. The 3 door model with the Z20LEL engine leaves the factory with 170PS and was booked in for a repalcement 70mm pre-cat removal pipe, a high flow panel filter, ECU remapping and full rollinh road set up.

Once on the rolling road after an initial inspection and run up a split factory recirculation valve was diagnosed which was causing a loss of boost, and if left can lead to turbo failure. This was replaced with one of our Courtenay TurboSmart uprated recirculation valves which are a much stronger and better made unit removing the rubber insert of the OE unit that tears causing the failure of the OE valve.

After full datalogging, bespoke mapping and optimisation the car produced a very respectable 224 bhp and 255 lb ft of torque, an excellent result from a 96,000 mile engine. The torque was been kept nice a smooth from 2,700 rpm – 5,000rpm without a peak mid range torque spike which can lead to  problems for the factory clutches causing them to slip.

Astra SRi 2.0 Turbo 3 Door

Astra SRi 2.0 Turbo 3 Door

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

Another Astra G Garrett Conversion

Brought in for a bottom end refresh with new bearings, crankshaft polish and mapping this conversion has a 3″ full exhaust, CSRacing full height front mounted intecooler, forged pistons, steel rods, external swirl pot and high pressure fuel pump set up and a Garrett GT3076R and TiAL external wastegate and hit 500bhp after mapping and rolling road set up. The Revolution Millennium wheels with Nankang NS-2R tyres finish the car off, and the power makes the K Sport 330mm 8 pot calipers work hard backed up by suspension from Weitec by KW and a full roll cage further stiffens the chasssis.

It now boasts Methanol injection and has been mapped to 540bhp and was the Class B winning car at Thunder Road 2015.

Astra G Garrett Conversion

Astra G Garrett Conversion

Astra H VXR Garrett Mapping

Another Astra H VXR in for mapping that has had a Garrett installation fitted to it. V Band Cast Manifold, Garrett GT2871HTA Motorsport Spec Turbocharger with metal bearing cage, Tial External Wastegate, AEM Dryflow Filter, 90mm AFM, 630cc Injectors, Aeromotive Fuel Pump, 80mm Inlet Pipe, 3″ Courtenay Klasen Downpipe, 3″ Courtenay Piper Exhaust System and CSRacing Full Height Front Mounted Intercooler.

Astra H VXR Garrett Mapping Session

Astra H VXR Garrett Mapping Session

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.

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.

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.

The Courtenay Sport Blog

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