Archive for the ‘ Rolling Road ’ Category

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

VX220 Turbo

One of last week’s jobs; After a CSR clutch upgrade and the addition of the Courtenay Pro Alloy charge cooler kit, a mapping session was carried out to boost the power and torque on this VX220 Turbo. The car was already fitted with a 63.5mm exhaust system and had a VXR turbo unit with OE actuator. Power was increased to a manageable and useable 280bhp.

VX220 Turbo

VX220 Turbo

Astra H 1.9 SRi CDTi 3 Door Mapping

Had a clean and very nice Astra H 1.9 CDTi Sporthatch in for a service followed by a remap on the rolling road today, achieving 183bhp and 333 lb ft torque.

Astra H 1.9 CDTi SRi 3 Door

Astra H 1.9 CDTi SRi 3 Door

VX220 Turbo Mapping

This Morning’s Rolling Road Job; a mild increase to 240bhp and 298 lb ft torque on this lovely VX220 Turbo, mapped and set up on the rolling road to suit the car.

VX220 Turbo

VX220 Turbo

K06 Astra H VXR

Another K06 conversion, with steel rods, Courtenay high flow inlet manifold, 3″ exhaust and CSR Intercooler being set up on our rolling road – bang on the money power and torque wise, and one of the cleanest and best prepared cars we’ve seen. We have also switched it to Evans Power Cool 180 Waterless Coolant.

 

Astra H VXR K06 Conversion

Astra H VXR K06 Conversion

 

 

K06 and Inlet Manifold Upgrade

The K06 Upgrade for Astra H VXR is an often overlooked conversion in favour of either a Garrett or Borg Warner EFR turbo, where the thinking is ‘the bigger the better’.

In a real world scenario, this is often not always the case, especially for fast road and trackday use where you want to retain driveability throughout the rev range, rather than wait for a huge hit  of power right at the top end.

Here is a graph showing the comparison between a Stage 2 Astra H VXR (ECU Remap and full exhaust system) compared to a K06 conversion:

Astra H VXR K06 Conversion

Astra H VXR K06 Conversion

In short the power gains of the K06 over the Stage 2 K04 are substantial, to say the least:

+20bhp @ 4,500 rpm
+30bhp @ 5,000 rpm
+50bhp @ 5,500 rpm
+70bhp @ 6,000 rpm
+90bhp @ 6,500 rpm

with much more mid range and top end torque as well, and still producing excellent power of 330bhp at 7,000 rpm and by 7,500 rpm still producing 320bhp, long after the Stage 2 car has faded by the wayside.

Notice also the power is still available from the mid range at 3,000 rpm, where a bigger ‘Garrett’ type turbo may not be fully on song until 4,000-4,500 rpm making the car less ‘on-road’ friendly for mid range road and trackday use.

So what exactly is involved?:

The full Stage 4 K06 conversion consists of a K06 turbocharger, a Courtenay Piper full stainless steel 76mm exhaust system, a Courtenay VXRacing full height front mounted intercooler, a Courtenay Klasen High Flow Inlet Manifold, steel rods, uprated arp rod bolts, new gaskets, exhaust valve spring shims, oil and filter, head bolts and a bespoke Courtenay ECU remap carried out and set up on the rolling road.

New pistons are not required due to the high quality nature of the factory fitted OE (Original Equipment) forged pistons, which are good for up to 500bhpm so they take this power easily in their stride.

The steel rods are fitted for strength, durability and safety. They also mean the engine can be revved much further, taking full advantage of the inlet manifold. Not fitting the rods simply means we have to turn the power down for safety!

The fully reworked K04 Turbocharger to K06 spec includes an uprated bearing pack and seals and billet K06 compressor wheel, meaning the turbo can produce and sustain more boost helped along with an uprated stronger actuator.

Our high flow Courtenay Klasen Inlet Manifold is designed to not only retain mid range power and torque (unlike some manifolds which sacrifice mid range power and torque for top end gains) but it also removes the restriction of the factory OE manifold at the top end. The improved flow means huge gains.

The full height intercooler keeps inlet air temperatures under control, and is available powder coated in stealth black, whilst the full 76mm exhaust system gives the required flow to obtain the maximum gains – a 70mm system will restrict power to 315-320bhp, due to its inability to flow at the top end as well as the 76mm system.

Finally the bespoke mapping and datalogging with map optimisation is carried out on the rolling road, making for a very useable, driveable fast road and trackday conversion not only retaining mid range power and torque but also increasing it.

Astra J VXR Stage 1 Remap

Courtenay Sport Stage 1 ECU Remap

Exclusive Courtenay Sport Stage 1 Software Upgrade. Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.

Our Stage 1 upgrade gives much better low end response combined with a smother and flatter torque curve, whilst at the top end we have managed to increase and sustain the power for longer. Alongside this you will also benefit from improved cruise fuel economy. We saw a peak power figure of 342.65 lb ft torque with power rising to 300.07 bhp. Our development car still has quite low miles so we would expect to see a few more bhp as the engine loosens further.

Like all our ECU upgrades the software is installed on your car whilst on our rolling road optimising fuelling, boost and Ignition maps. This enables us to see and rectify any underlying faults or problems and to ensure that the calibration is 100% accurate and safe for your car before handing it back over to you, along with the full power and torque print outs.

£565.00 including full map optimisation, datalogging and Rolling Road Set Up.

Courtenay Sport Stage 1 Remap Graph Astra J VXR

Courtenay Sport Stage 1 Remap Graph Astra J VXR

Cortina GT on Rolling Road

Had something a little different on the Rolling Road this morning……

A 1965 Cortina GT 1500 on twin webbers.

It was just being run up to check fuelling and power and made a respectable 100bhp at the flywheel.

Standard Astra GTC VXR Power Run

Courtenay Sport, as part of our development and testing, have run the new Astra GTC VXR on our Dynojet Rolling Road. This car is standard, and has been run as a benchmark. Mapping details will be released soon, along with full details of the 76mm performance exhaust system and intercooler.

Standard Astra GTC VXR Power Run on our Rolling Road

500bhp Astra VXR GTx3076R


Courtenay Sport mapped Garrett Conversion. The brief was to achieve 500bhp from the mapping and the customer had prepared the car with a Garrett GTx3076 turbo, tubular manifold, 76mm exhaust, 90mm air flow meter, 680cc injectors, High Flow Inlet Inlet Manifold, Courtenay Klasen cams, Forge Race Intercooler, Mocal Oil Cooler, Sachs Uprated Clutch and Uprated Cera Metallic Paddle Disc and Lightweight Flywheel.

Map Optimisation and Set Up Pays Off – Astra VXR

Another question we are constantly being asked is about remapping and correct set up and why this is better than a hand held unit.

Many people like the convenience of installing a map from a hand held unit (and are often ‘sold’ the same results as bespoke mapping, which invariably is not the case), but without checking it or seeing what it is doing for the car, the results are simply ‘hit and miss’. Put simply unless ecu software is properly checked and optimised to each car, you are unlikely to get the results you are expecting (or have been sold!)

Here’s a graph for an Astra VXR which we were asked to dyno which had a lower front mounted intercooler fitted, a full 70mm Remus Exhaust System and an unchecked map from a hand held unit. The resulting dyno figures show the map gave worse results than the factory software (where we have seen 270bhp on a car with exhaust and intercooler fitted):

Astra VXR Competitor Stage 3

Astra VXR Competitor Stage 3 : Before

This set up, correctly mapped should really have been producing at least 285bhp, not 252bhp!!

At the customer’s request, we changed the intercooler for one of our Full Height Front Mounted VXRacing Intercoolers and fitted a full 76mm system. Once properly remapped, datalogged and set up on the rolling road we achieved:

Astra VXR Courtenay Sport Stage 3 : After

Astra VXR Courtenay Sport Stage 3 : After

And finally here are the before and after graphs, showing the differences. Much more power and torque right across the rev range, which will totally transform the drive of the car:

Astra VXR Stage 3 Comparison

Astra VXR Stage 3 Comparison

The Benefits of a Good Exhaust System – Astra VXR

On more than one occasion we have extolled the virtues of a good, free flowing 76mm sports exhaust system for Astra VXR to get the best performance results out of remapping correctly.

Well here is another classic example……..

The car in question is an Astra VXR 2.0 Turbo which was fitted with a Stage 1.5 Hybrid K04 turbo (with exhaust wheel cut back), a large full height front mounted intercooler and a ‘one-off’ made to the car exhaust system which in places reduced to 50-57mm.

Once mapped the results were as follows:

Astra VXR Stage 3 : Poor Exhaust System : Before

Astra VXR Stage 3 : Poor Exhaust System : Before

Results: 278 bhp and 318 lb ft torque.

Upon examining all the evidence from the rolling road and datalogging, we concluded that the exhaust system was the limiting factor. Some might say it was easy for us to blame the exhaust (which we didn’t supply)….. why could it not be the installed software??

Well, we could comfortably rule out software based on the fact that all our maps are optimised on the rolling road and datalogged. so we knew we couldn’t get any more ignition timing into the software or take any more fuel out (without risking safety).

So we had the car back a couple of months later and fitted our full 76mm sports exhaust system, changed nothing else and ran the car back on the same rolling road, resulting in the following:

Astra VXR Stage 3 : 76mm Exhaust System : After

Astra VXR Stage 3 : 76mm Exhaust System : After

Yes, no word of a lie results of 305bhp and 348 lb ft torque, aided by the Stage 1.5 hybrid turbo, the full 76mm system and the cold February dyno cell temperatures.

Here is the before and after graph. The gains speak for themselves. Lots more power and torque right across the rev range:

Astra VXR Stage 3 - Good Exhaust vs Poor Exhaust : Before and After Results

Astra VXR Stage 3 - Good Exhaust vs Poor Exhaust : Before and After Results

So if you are trying to decide on which exhaust system to fit to your Astra VXR, we think we’ve just made the decision much easier for you. A good exhaust system may cost a little more, but you will get the benefits from fitting it.

Astra VXR Garrett GT3071 Video


Courtenay Sport Garrett Conversion. The brief was to achieve 420bhp with Garrett GT3071 turbo, tubular manifold, 76mm exhaust, 80mm air flow meter, 630cc injectors and Courtenay Sport Full Height Intercooler. The 80mm Astra VXR is maxxed out at around 420bhp so the achieved figure was the best achievable using the given components.

700bhp Klasen Speedster Turbo Video

Klasen Motors 700bhp Speedster (VX220) Turbo.

Another big power turbo conversion using the new V Band Cast Manifold.

300bhp Supercharged VX220 2.2 Video

Courtenay Sport 300bhp VX220 2.2 Supercharger Conversion.

Another big power supercharged VX220, this car features an engine rebuild, balancer shaft removal, high lift cams and uses the OE GM Eaton Supercharger.

V Band Cast Manifold Garrett GT3076 Astra VXR Video


Astra VXR with V Band Cast Manifold, External Wastegate, Garrett GT3076 Turbo, Courtenay Sport Full Height VXR Intercooler, Courtenay Sport High FLow Inlet Manifold, Full 76mm Exhaust System, 90mm Air Flow Meter, Steel Road, Factory ECU (Bosch 7.6.3 management) bespoke mapped by Courtenay Sport

New V Band Cast Manifold Astra VXR Conversion

For this conversion using our new V Band Cast Manifold the brief from our customer was as close to 500bhp as possible but with usable power. We opted for a Garrett GT3076 turbocharger. The car also has our full height VXR intercooler, steel rods, Courtenay Sport High Flow Inlet Manifold and 76mm full exhaust system.

V Band Cast Manifold Astra VXR

V Band Cast Manifold Astra VXR

V Band Cast Manifold with GT3076

V Band Cast Manifold with GT3076

And finally the all important Power Graph:

Astra VXR Power Graph

Astra VXR Power Graph

New V Band Cast Manifold VX220 Turbo Conversion

Following the introduction of our V Band Cast Manifold with external wastegate, here is an example of afinished conversions and graph on a VX220 Turbo.

The manifold has been flow tested to 600bhp and the Tial V Band flanges are much more secure and allow for easier turbo fitment.

V Band Cast Manifold VX220Turbo

V Band Cast Manifold fitted to VX220Turbo

V Band Cast Manifold VX220Turbo

V Band Cast Manifold fitted to VX220Turbo

The VX220Turbo with this V Band Garrett Conversion and GT2871 has also had a full engine rebuild and has had a full 3″ exhaust system and chargecooler system fitted, 80mm air flow meter, high flow injectors, uprated map sensor and uprated clutch and flywheel.

The build spec was for up to 400bhp, the final power output was 398bhp.

VX220 Turbo Power Graph

VX220 Turbo Power Graph

VX220 Turbo 360bhp Garrett Build Video

Courtenay Sport VX220 Turbo with a bespoke Garrett Build, strengthened rebuilt engine, Pro Alloy Chargecooler, full 3 inch exhaust system and full Z20LET engine management mapped by Courtenay Sport….. 360bhp

Supercharged 2.2 VX220 377bhp with Z20LET Management

Courtenay Sport’s latest Supercharged VX220 2.2 16v running Harrop Supercharger, strengthened rebuilt engine, 4 branch stainless steel manifold and full 3 inch exhaust system and full Z20LET engine management. 377bhp

The Courtenay Sport Blog

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