- Mar 23rd. 2015
- By CourtenaySport
Upgrade work for this Astravan H CDTi included a new uprated clutch, new gearbox bearings and a Quaife Limited Slip Differential to help with the Stage 3 power and torque.
Upgrade work for this Astravan H CDTi included a new uprated clutch, new gearbox bearings and a Quaife Limited Slip Differential to help with the Stage 3 power and torque.
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.
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.
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.
Turbosmart Kompact Shortie Series Recirculation Valves have been specifically designed to suit BorgWarner EFR and KKK turbos.
Unlike the standard, plastic valves that use un-reinforced rubber diaphragms and are known to crack or split under increased boost, the new BW/KKK Kompact valves uses an O-Ring sealed piston which, coupled with their billet aluminium construction give them over 30PSI of boost handling capability.
Designed as a bolt-on direct replacement replacement for the factory valve on all BorgWarner EFR, KKK turbos, the Kompact Shortie Plumb Back provides better boost response and greater boost handling capability.
Included with each Kompact Shortie kit is:
Finished in Black as shown. This recirculation valve is a really nicely machined and finished item, with a quality look and feel about it.
Features and Benefits:
Suitable for ALL BW EFR KKK (K04/K06) Z20LEx and A20NFT Turbo units:
Astra G SRi/GSi 2.0 Turbo
Astra H SRi 2.0 Turbo including VXR
Astra J GTC VXR 2.0 Turbo
Zafira A GSi 2.0 Turbo
Zafria B SRi 2.0 Turbo including VXR
VX220/VXR220 2.0 Turbo
Coming soon for Z16LEx 1.6 Turbo Vauxhall Engines.
This Astra H VXR Nürburgring came to us for an uprated CSRacing clutch and lightweight billet steel flywheel, due to the fact the factory clutch had started to slip occasionlly.
The car had covered a shade over 91,000 miles and was originally modified to Stage 3 in 2008 at around 3,500 miles, virtually from new. So for nearly 7 years the car has been running at between 290-305bhp having had further changes made in later years, and the factory clutch and dual mass flywheel have given an exceptional service life considering the huge increase in power and torque to the car.
Replacing the original dual mass flywheel for a solid (single mass) lightweight billet steel one reduces the flywheel weight giving better acceleration due to the engine’s willingness to rev more freely as it is not having to rotate such a heavy mass. The CSRacing uprated clutch is a stronger unit, with an uprated cover with much more clamping pressure and an uprated sprung organic clutch disc to work with the single mass flywheel. The sprung disc is essential to fit if the dual mass flywheel is removed and replaced with a single mass item.
Also fitted at the same time was an uprated polyurethane gearbox mount insert as the original factory mount was starting to show signs of age related fatigue.
Don’t forget we can also fit standard original equipment (OE) replacement parts as well as uprated parts!
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.
We have recently fitted a KW Clubsport Coilover kit to our Astra H VXR track car, which was running a Bilstein B8 set up with Courtenay DAP Race Spec springs.
The Clubsport kit is the prefered choice for a track biased suspension for a car that is used predominantly on track (more than it is on the road) and is the next step up from the excellent KW V3 coilover kit, which is an ideal fast road kit also suitable for light light trackday use.
Full stainless steel dampers, height adjustable springs with helper springs, solid top mounts on the front struts and 2 way damper adjustment on both the front and the rear dampers for compression and rebound adjustment to fine tune the set up.
A reminder, this is the kit as supplied:
KW Clubsport coilovers were developed for customers who demand a better handling car when participating in track day events, but also require a setup that is still acceptable for road use such as to and from trackdays. The Clubsport kit was specifically designed for the Nordschleife using track day tires. The independently adjustable rebound and compression damping technology allow the suspension setup according to the vehicle load, tire characteristics and different track conditions. KW Clubsport meets every demand regarding a coilover for on road use but more importantly track use.
Here are some pictures of the fitted kit:
We prepared a second subframe and fitted the uprated bushes to it prior to fitting it to one of our track day cars.
Astra H Subframe with uprated purple road spec polyurethane subframe bushes fitted.
Astra H Subframe with uprated black track spec polyurethane subframe bushes fitted. This is due to be fitted to our track car. The front anti roll bar and power steering rack will be swapped over onto it.
And some close up shots:
6 complete bushes required per subframe. Kit includes 12 ‘top hat’ type bushes, 6 stainless steel sleeves/inserts, 12 zinc coated upper and lower washers and a grease sachet.
We recently had this Astra G GSi Turbo in with us to have a Quaife Limited Slip Differential fitted into the F23 gearbox and whilst the gearbox was off the car we had the opportunity to fit a lightweight billet steel flywheel and uprated clutch cover and 6 paddle disc, in preparation for some big horsepower upgrades.
Work In Progress:
Front End Improvement for Astra G/H and Zafira A/B.
Poweflex have engineered a solution to replace the factory engine bed/subframe bushes in Astra G/H and Zafria A/B which can be prone to failure and contribute to vague handling. These stiffer engine bed bushes help improve the front end feel of the car especially during turn-in and cornering. By removing the flex in the subframe bushes the handling is improved giving a more positive feel to the front end.
These Front Subframe Bushes feature two polyurethane top-hat style bushes that makes for simple installation and durability. The bushes house a stainless steel sleeve and are supported by zinc coated steel washers at each end for increased support under load.
Poly bushes will be resistant to corrosion and the addition of a stainless steel sleeve should help prevent the bed bolts from seizing into the bushes, which can happen with the factory bushes.
Suitable for Astra G, Astra H, Zafira A and Zafira B All Models.
These new bushes replace OE part numbers 90498689, 9223022, 9223023 and 13107328 used across the model ranges.
The application of corrosion resistant materials, robust design and the Powerflex Lifetime Warranty ensures the subframe need not be removed again once fitted, unless removal is required for other service work to be carried out.
These bushes are available in Purple Series 80 Shore Road Spec material for vehicles that are mainly used on the road and also Black Series 95 Shore Track Spec material that suits vehicles being used in Motorsport or predominantly on the track.
6 bushes required per subframe.
Professional installation is recommended. The ideal time is when the subframe is removed to allow access to the gearbox or clutch.
Now Available, we have direct replacement front wishbones for Astra G and H models. These front wishbones are brand new and come pre-fitted with uprated 85 Shore polyurethane wishbone bushes in black and a brand new high quality OEM ball joint.
This will make fitting uprated poly bushes far easier and much more straightforward. No need to spend hours knocking out existing bushes and fitting new ones, simply undo 3 bolts, drop the original arm off the car and fit the direct replacement wishbone.
Upgrading the suspension on this Astra G Turbo with a KW V3 inox line adjustable coilover kit.
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.
We have just taken delivery of a KW Clubsport 2 Way Coilover suspension kit for our Astra H Sprint track car, which will be fitted over the coming weeks and set up prior to its first outing in 2015.
Here’s a preview:
Enhancements being carried out to the brakes and suspension on an Astra H 1.9CDTi (150 PS) 3 door sport hatch.
To improve the chassis our Courtenay Sport Clubman Plus fast road suspension upgrade was fitted, which is a full kit that includes original equipment (OE) genuine Astra VXR dampers and a set of DAP Road springs, which not only improves road holding but also lowers the car by around 25-30mm.
The front and rear brakes were upgraded with EBC Turbo Grooved front and rear discs with EBC Red Ceramic (fast road) pads all round, and the system was bled with DOT 5.1 fluid.
Type 2120 – Turini. 8″x18″, 65.1mm, 5x110PCD ET38mm (possibly ET35mm) for Astra H VXR fitment.
We would like to have these Speedline Turini flow-formed 18″ wheels manufactured for Vauxhall/Opel fitment. If there is enough interest we will get a small batch of wheels made in 3 colours: Silver, Anthracite and Gold. The flowforming process makes these wheels extremely strong and light. They are fully heat treated up to motorsport specification and ideal for trackday use.
This would be a limited production run of wheels, meaning we do not need huge numbers of people to get this moving for delivery early 2015, and limited numbers would mean a certain level of exclusivity.
Target Price £936.00 per set of 4, depending upon the level of interest. (List Price £1008 inc VAT)
Please contact us as soon as possible to confirm interest giving your preferred colour. There is a contact form at the end of this post. If we achieve the desired numbers an order will be placed with Speedline upon receipt of payments from all participants.
Specification: 8″x18, 65.1mm, 5x110PCD ET38mm (possibly ET35mm) for Astra H VXR/OPC fitment. Will clear big brake kits such as AP 4 Pot and K Sport 8 Pot/D2 6 Pot.
These will not require a ‘fitting kit’ (spigot rings) or wobbly wheel bolts.
Gold suits White and Arden Blue cars.
Anthracite suits Silver, Red and White.
Silver suits most colours.
An iconic Speedline design, the Turini wheel is known for it’s classic good looks, durability and light weight.
The wheel comes with the ‘seal of approval’ from some of the worlds most important car manufacturers, as an original equipment option or line fitment. The 18″ version employ the world renowned Speedline patented Flowforming production technology, ensuring the ultimate marriage of low weight with high strength.
NOTE: These wheels are listed as available online on other suppliers’ websites, however having spoken directly to Speedline they have confirmed there is no stock of these wheels in a correct Vauxhall fitment, except by placing a minimum quantity special order.
FLOWFORMING – What is it and how does it differ?:
Speedline’s flowforming process is a unique solution to a common problem – how to make a wheel both light and strong.
Speedline’s flowforming method is unique within the wheel production industry, and patented.
This means that only Speedline can provide this precise technology.
The casting used to produce the wheel is much narrower than usual, but with the same amount of alloy that would be present in a conventional casting.
The casting is then placed in a specially designed machine within an additional mould. The hot casting is then spun at high rpm within the mould, and formed into the shape of the final wheel.
The resulting grain structure within the alloy of the wheel is linear, flowing in a single direction (see image below).
This grain structure pattern (shown above), combined with the exceptional quality of casting required for the process, gives the rim area of the wheel huge mechanical strength, and elongation. As a result of these mechanical characteristics, Speedline are able to reduce the thickness of the rim area resulting in reduced weight, without compromising strength and resistance to impact (see images below).
As can be seen from these images above, the flowformed wheel rim profile is much thinner that the usual cast wheel, resulting in lower weight and reduced inertia, making the wheel respond faster to acceleration and braking forces.
Note: Library Images
21mm Front Polyurethane Anti Roll Bar bushes have been added to our online catalogue for Astra H models inclduing OPC/VXR and CDTi 3 door and 5 door models.
These are designed to replace the original 2 piece factory anti roll bar bushes on Astra H models which run a 21mm bar and are available in either purple or black material. The models include VXR/OPC, SRi and CDTi 3 and 5 door models.
We had this Astravan 1.9CDTi here recently for a few days undergoing some fairly extensive upgrades to cover the engine, brakes and chassis.
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.
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.
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.
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.
The magnet is secured in place with a proprietary 2 step process and will never come out. Advancements in technology and materials means Gold Plug is continually evolving and at the forefront of technology.
The strong Neodymium magnet collects any swarf or wear particles missed by the oil filter. These particles are abrasive and potentially damaging to the engine. The magnet will hold any collected metal firmly, unaffected by temperature variation until the oil is changed.
Magnetic sump plugs are a proven product and even used by some manufacturers as standard, examples are available on the market today however few match the quality of Gold Plug and those that do are very expensive.
Some Vauxhall/Opel engines using M14x1.5 Sump Plugs:
X18XE X20XEV X25XE X30XE (FWD)
Z10XE Z12XE Z12XEP Z14XE Z18XE Z18XER Z32SE
1.6 Turbo: Z16LEL Z16LER Z16LET
2.0 Turbo: Z20LEL Z20LER Z20LET Z20LEH
1.6 Turbo: A16LER A16LET A16LES
If you are unsure on your particular fitment please check with us.
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.
We were asked recently to carry out rework to a pair (obviously) of 3.2 V6 cylinder heads; porting, polishing and gas flowing to improve the efficiency of the heads to maximise potential gains.
They were sent to us by the customer after they had been removed from the engine:
And after cleaning, rework and a reface to the heads:
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