Archive for the ‘ Vauxhall Tuning ’ Category

Astra J VXR Stage 1+

Another Astra J VXR in for a Stage1+ tuning package, which is proving to be a very popular option for many owners.

The first stage is to benchmarck the power of the standard car. It had already had a generic flash map installed via a well known hand held tuning box, so we first ran the car with the generic map installed, then using the hand held unit returned the car to factory standard software and ran it again. With the generic flash map loaded the car produced 287bhp and when returned to the standard map and run again the car made 281bhp.

It was then round onto the ramp so the pre cat removal pipe could be fitted, removing the restrictive factory pre cat.

Pre Cat Removal Pipe Fitting

Pre Cat Removal Pipe Fitting

Once the 76mm straight through pre cat removal pipe had been fitted it was back onto the rolling road for mapping and datalogging whilst the map is optimised on the rolling road, resulting in 328bhp and 373 lb ft torque.

Astra J VXR Mapping

Astra J VXR Mapping

Meriva VXR Tuning

This Meriva VXR had visited us before for a remap, and came back to have some further improvements carried out.

We removed the pre-cat and fitted a straight through pre-cat replacement pipe (downpipe) to remove the restrictive first cat, fitted a set of NGK iridium plugs and a high flow Courtenay Sport panel filter.

Then it was back onto the rolling road for map optimisation, datalogging and rolling road set up. The results were 216bhp and 243 lb ft torque.

Meriva VXR Mapping

Meriva VXR Mapping

Insignia VXR Remap

Another returning customer coming back to us this time with his 7,000 mile Insignia VXR for mapping, having previously has his Vectra VXR mapped by us.

Latest spec and an otherwise standard car, and a little under a year old we carried out the mapping, map optimisation, datalogging and full rolling road set up achieving 332 bhp and 380 lb ft torque, it will loosen up given a few more miles on its belt.

Insignia VXR Mapping on the Rolling Road

Insignia VXR Mapping on the Rolling Road

Astra J VXR Stage 3 Package

Courtenay Sport Stage 3: Remap, Front Pipe, Free Flowing Cat Section, Induction Kit, Intercooler
Stage 3 is the final stage upgrade using the standard factory K04 Turbo. This package consists of pre-cat deletion, replacing the OE factory front pipe and first cat first cat with our free flowing 3” cat-less front pipe (also used in our stage 1+ package). In the quest for further power we then turn to the next restriction which is the case of the Astra J VXR is the original equipment air intake/air box.

We completely remove this and replace it with a huge free flowing AEM non oiled Dry Flow Filter. This is mounted to a free flowing air flow meter housing which features a built in air straightener so correct air mass values are relayed to the ECU, finally this assembly sits within a heat deflector shield.

This particular car has also had our upgrade silicone inlet hose fitted.

Astra J VXR Stage 3

Astra J VXR Stage 3

With the Stage 3 package  we are looking to fully optimise everything around the turbo to fully maximise efficiency, so a huge Pro Alloy/Courtenay full height intercooler is installed complete with large bore pipe work and hoses, which whilst keeping the inlet air temperatures very cold also optimises the flow from the turbo through to the inlet manifold. The intercooler and pipework on the above car have been finish in stealth black finish.

Next a 3” free flowing cat section is fitted to compliment the high flow front pipe. With these parts installed the car is remapped on our rolling road optimising our Exclusive Courtenay Sport software to take full advantage to achieve maximum gains from these components.

Final power and torque figures are a very healthy 342bhp and 384 lb ft.

As an option to enhance the soundtrack, this car has also had our 3″ single sliencer cat back system fitted.

Astra J VXR Rolling Road Set Up

Astra J VXR Rolling Road Set Up

Corsa E VXR Stage 3 Mapping

Another Corsa E VXR which was brought to us for mapping and rolling road set up.

This car had already had a Cobra 3″ exhaust system and Airtec intercooler fitted to it by the customer and had previously been mapped. Prior to mapping we benchmarked the car on our rolling road to establish its base power and torque figues which were 227 bhp and 246 lb ft torque.

We then remapped the ecu and carried out a full rolling road set up with datalogging and optimised the software to suit the fitted components.

When finished the car is now producing 245 bhp and 259 lb ft torque with gains right across the rev range compared to the previous remap.

Corsa E VXR Rolling Road Set Up

Corsa E VXR Rolling Road Set Up

Corsa E VXR Front Pipe and Remap

In our workshop today was this 7,000 mile Corsa E VXR with the latest version of the 1.6 Turbo engine, B16LES. The first job was to remove the restrictive pre cat (first cat) and fit one of our straight through downpipes (pre cat removal pipe). Once fitted it was round into the dyno cell for remapping with full rolling road set up.

Corsa E VXR Pre Cat Removal

Corsa E VXR Pre Cat Removal

Running on Shell V-Power (99RON) fuel the results were 235bhp and 248 lb ft torque, with power and torque gains right across the rev range.

Corsa E VXR Remapping

Corsa E VXR Remapping

Astra H VXR Remap

Astra H VXR Nurburgring. Already fitted with a Remus 70mm stainless steel exhaust system and uprated intercooler this car came in recently for mapping and rolling road set up. Results: A very healthy 293bhp and 339 lb ft torque.

Astra H VXR Remap

Astra H VXR Remap

Courtenay Turbosmart Recirculation Valve 1.6 Turbo

New AND EXCLUSIVE to Courtenay Sport. NOW AVAILABLE: Courtenay Turbosmart Recirculation Valves for Z16LEx A16LEx B16LEx 1.6 Turbo engines.

Courtenay Turbosmart Recirculation Valve

Courtenay Turbosmart Recirculation Valve


Courtenay Sport, working with Turbosmart UK and Australia, have been involved with the development and testing of a new version of the popular Kompact Shortie Recirculation Valve specifically for the 1.6 turbocharger, used for Corsa D, Astra H, Astra J, Meriva A, Insignia, Zafira B and Zafira C 1.6 Turbo engines.

We are pleased to announce that an uprated recirculation valve is now available for the 1.6 Vauxhall/Opel turbocherged engine using the K03 turbocharger, following on from the success of the valve produced for K04/K06 applications.

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 using a single spring and increased reliabity over the factory valve.

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 than the factory fitted recirculation valve.

Included with each Kompact Shortie kit is:

  • 1 x Model Specific Valve
  • 1 x Straight Nipple
  • 1 x Banjo Nipple
  • 3 x Mounting screws

Finished Anodised 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:

  • Machined from Billet Alluminium.
  • Lightweight, brass/aluminium, two-piece piston.
  • More Reliable than the factory valve.
  • Substantial Construction.
  • Improved Boost Responsive.
  • Single Spring – No Requirement to Change when Tuning.
  • Finish: Anodised Black as shown.
  • Exclusive Courtenay Branding

Suitable for ALL BW EFR KKK (K03) Z16LEx/A16LEx/B16LEx.

Available at a special launch price of £108 inc VAT.

Here are some pictures showing the first valve we received to check fitment.

Features Cars – Astra H VXR Sprint and Corsa C Z20LET

The owners of these cars which we have mapped and supplied parts, help and advice to have had them featured in the latest April/May issue of Performance Vauxhall magazine.

Jason Anthony’s Astra H VXR Sprint, began life as a Triple8 modifed car at around 295bhp and since his ownership Jason has made a lot of changes to the car and turning it into something equally at home of the track as the road. Now with steel rods and a bespoke Courtenay Sport remap to mid 330bhp and mid 350 lb ft torque the car has also been treated to a K06 turbo, Courtenay Klasen Inlet Manifold, KW Clubsport Coilovers, Safety Devices Rear Cage, AP Front Brakes, 292mm Rear Brake Upgrade, TD Pro Race 1.2 alloys, LSD, Courtenay Intercooler and Water Rad, 3″ Piper Exhaust, Recaro Seats and Harnesses.

Wearing the Sprint badge, this is a fantastic conversion often seen at Snetterton track days.

Jack Scott’s Corsa C 1.8 SRi has changed massively since it left its birthplace in Spain. Wanting to achieve 300bhp, Jack and his Dad carried out a Z20LET engine transplant and also fitted abig intercooler and some other performance upgrades. Once up and running, the car came to us to have a few additional upgrades including performance clutch, Courtenay Klasen Inlet Manifold, 80mm VXR air flow meter and VXR injectors and was then treated to a full bespoke remap achiving 321bhp and 340 lb ft torque.

Astra J VXR – Stage 1+ Upgrade

This Astra J VXR came to us for a Stage1+ conversion. This was a lovely low mileage example which had covered under 4,000 miles and was finished in Buzz Blue paintwork.

The first part of the process was to check the vehicle on the rolling road and benchmark it. This car made 278 bhp and 319 lb/ft torque.

Astra J VXR

Astra J VXR

The second stage of the process was to remove the factory pre-cat and replace it with a high flow straight through front pipe, removing the restrictive catalyst.

OE Pre Cat (Left) Pre Cat Removal Pipe (Right)

OE Pre Cat (Left) Pre Cat Removal Pipe (Right)

Then it was back onto the rolling road for mapping, data logging, map optimisation and full calibration and set up. The results on 97RON fuel; 319.99 bhp and 366.84 lb/ft torque with a much greater spread of power and torque which can be seen on the graph.

Astra J VXR Standard and Stage1+

Astra J VXR Standard and Stage1+

Astra J VXR

Astra J VXR

Stage 3 Astra H VXR

Astra H VXR Stage 3 Upgrade and LSD (Limited Slip Differential).

This car spent a couple of days in our workshop and had a full 3″ exhaust system, CSRacing intercooler and a Quaife LSD fitted. Then it was onto the rolling road for mapping, datalogging and full rolling road set up making 290bhp and 350 lb/ft torque.

Astra H VXR Rolling Road Mapping

Astra H VXR Rolling Road Mapping

Stage 2 Astra H VXR

Astra H VXR is still a very popular vehicle for modifying, whenther it is a mild upgrade or something far more major.

This particular car came to us for a Stage 2 tuning pack. We fitted a full 3″ stainless steel turbo back exhaust system and it was then round to the dyno cell for mapping and a full set up on our rolling road. The resuting 280 bhp and 333 lb/ft torque completely transforms the car.

Astra H VXR Stage 2 Mapping

Astra H VXR Stage 2 Mapping

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

Astravan 1.9 CDTi Gearbox Overhaul and Remap

This Astravan came to us for a gearbox overhaul and ecu remap and rolling road set up.

We remove the gearbox, and have it fully stripped down and all the internal components are cleaned and inspected. This also allows the transmission cases to be fully clean as well, something often overlooked if bearings are replaced with a gearbox in situ. The gearbox internals are then reassembled and refitted with new bearings throughout.

Once finished the van was on our dyno for full mapping and rolling road set up.

Astravan 1.9 CDTi Remap

Astravan 1.9 CDTi Remap

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

Zafira GSi Turbo Clutch and Flywheel Replacement

A tuned Zafira GSi in our workshop for an uprated fast road clutch and lightweight billet steel flywheel assembly.

To cope with the higher power and torque figures, we have fitted this Zafria with an uprated clutch, and at the same time replaced the rear mail oil seal (behind the flywheel) and fitted a new Sachs hydraulic slave cylinder.

At the same time it has also benefitted from the addition of a lightweight flywheel which improves the engine’s willingness to rev and makes for faster acceleration through the gears. An upgrade well worth carrying out with clutch replacement.

Not only can we supply and fit but we can also send parts out mail order by courier for anyone unable to get to us.

Zafira GSi Clutch and Flywheel Replacement

Zafira GSi Clutch and Flywheel Replacement

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.

The Courtenay Sport Blog

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