Archive for the ‘ Vauxhall Tuning ’ Category

Mapping Session Astra H VXR

Rolling Road mapping session to optimise software settings on this Astra H VXR, which has had some hardware alterations since it was first mapped. Before and after mapping saw gains of between 12-34bhp and 5-20 lb ft torque.

Astra H VXR on the Rolling Road

Astra H VXR on the Rolling Road

Astra H VXR – PowerCool 180 Conversion

We had this very well speced Astra H VXR in with us recently for a full enhanced service, changing all the filters, fitting uprated NGK spark plugs, brake fluid change to DOT 5.1 and adding our high quality fully synthetic Valvoline SynPower 5w-40 oil. Already fitted with Team Dynamics Pro Race 1.2 Alloy Wheels, VXRacing AP 4 Pot 343mm Front Brakes, 285bhp upgrade with full 76mm exhaust system it is a great road car and can sometimes be seen making the odd appearance out on track from time to time.

In addition to the enhanced service, we also carried out a conversion from the traditional water based antifreeze to Evans Waterless PowerCool 180 Coolant with all the associated benefits that the waterless coolant brings.

Astra H VXR - Enhanced Service and PowerCool 180 Conversion

Astra H VXR – Enhanced Service and PowerCool 180 Conversion

Astravan Z20LEH 2.0 Turbo Conversion

A 294bhp Z20LEH engined Astravan in for a service, MOT and some additional TLC. This van has a huge spec including Quaife LSD, Astra H VXR brake set up (front and rear) with uprated discs, CSR Intercooler, 76mm Full exhaust system, 80mm AFM and VXR injectors, uprated clutch and flywheel, a B8 damper and Eibach spring kit, rear ARB and Revolution Millennium Alloy Wheels. We carried out the coversion on thsi van several years ago now and it is still kept in immaculate condition.

Z20LEH Astra Van

Z20LEH Astra Van

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

Zafira VXR 430bhp

Another big power Z20LEH engine undergoing mapping this week, this time in a Zafira VXR making it a pretty quick 7 seater! Pushing around 430bhp from a Garrett conversion, with 3″ exhaust, Courtenay Klasen Cams, Nortech tubular manifold, Owen Developments GT28 71 HTA turbo, 630cc injectors, steel rods, Pro Alloy alloy water radiator, 356mm K Sport brakes, Quaife LSD. A very respectable figure for a hot summer’s day on the rollers.

Zafira B VXR

Zafira B VXR 430bhp

Total Vauxhall Nov 2013

Mark Watts’ Astra H VXRs Trackday and Road Duo, from Total Vauxhall magazine November 2013 issue.

Astra H VXR - Track and Road Duo

Astra H VXR – Track and Road Duo

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

Revolution Millennium Alloy Wheels

Revolution Millennium Alloy Wheels 8Jx18; now also available in Anthracite (as well as White). Spec: 8Jx18, ET35mm, 5x110PCD, 65.1mmCB. Black finish due around August time.

 

Revolution Millennium Alloy Wheels

Revolution Millennium Alloy Wheels

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

Astra H VXR K06 Conversion + KW V3

Another Astra VXR K06 conversion with inlet manifold and steel rods (333bhp/350 lb/ft) leaves today, fitted with KW V3 Coilovers, K Sport 8 pot 356mm Front brakes, 292mm Rear Brake Upgrade, Alloy Water Rad, uprated VT engine mounts, poly bushes. Fully mapped and set up on the rolling road, this car has a huge spec.

Astra H VXR K06 + KW

Astra H VXR K06 + KW

Astra H VXR Intercooler Kit For Sale

We have a good used stealth black intercooler kit available for Astra H VXR. It is the latest spec with 60mm Inlet and Outlet and includes the hardpipe with map sensor boss and fan and mounting bracket.

The cooler has only done 2 dry races and looks very new and has all the fittings with it which are mainly new fittings. All the hose’s are new except for one, which is good but used. Hoses are blue.

The 2 main black brackets that  hold the intercooler on are used ones that are a little bit rusty around the edges, but nothing a wire brush and some fresh paint would not fix. Otherwise they are perfectly serviceable.

This Intercooler kit can be purchased for £650 inc vat. NOW SOLD

Uprated Enlarged Performance Intercooler – Astra J VXR

Astra J VXR Uprated Performance Intercooler

Astra J VXR Uprated Performance Intercooler

Once again we have joined forces with industry leaders Pro Alloy to develop our new enlarged, uprated performance intercooler kit for the Astra J VXR.

Our new intercooler is both larger in width and height than the standard unit with the core being twice as deep as the factory cooler. This represents a huge increase in available cooling area and volume and maximises the cooling available through the front of the car whilst also future proofing the cooler for use with high power large turbo setups.

The factory cooling set up has the air conditioning radiator in front of the intercooler so our first job was to remove the intercooler and then reposition the A/C radiator back, on to the water radiator. This is done so that the new intercooler is receiving the coolest air available. To further improve the efficiency we have included in the kit a lower air blade to stop the air washing away from the bottom of the intercooler.

Furthermore to maximise flow to and from the intercooler the kit comes complete with all the pipework which is enlarged to 60mm, paying particular attention to the restrictive section straight out of the turbo seen at the top rear of the engine bay. The Intercooler kit also comes complete with all the required hoses and laser cut brackets and fittings.

Price: £899

Oil Restrictor Bolt – K04 VXR Turbo

We thought we would share some information regarding oil restrictor bolts to help clarify our views on them…

Restricting the oil supply to Turbos is not a new idea or fad; turbo conversion companies have been doing this as instructed by Garret since the early 1990s.

It is true that a number of Vauxhalls have suffered from this smoking due to oil washing past the turbo oil seals.

It is true that changing the oil to a heavier weight of oil helps with this by allowing the oil to drain quicker as it is more resistant to any frothing or foaming (call it what you will) in the turbo core.

It is true that journal bearing turbos do need a very good supply of oil.

It is also true that too much oil can and will swamp the seals and in this case… the use of careful oil restriction will help; Vauxhall has also done this in production of the later K04 units.

Now we believe the original Vauxhall KO4 oil restrictor bolt was developed by Ian Percival AKA Percy (vxronline) before GM Modified the core. Ian is very knowledgeable by all accounts. He carefully calculated then made a restrictor as part of the bolt so it can be retro fitted to cure this lack of oil restriction in very early units. Our reluctance to recommend oil restrictor bolts comes not from what Ian did but from the fact that many other individuals and “ebayers” alike have jumped on the oil restrictor bolt bandwagon and produced some very inferior imitations. To this end we have been handed a number to fit, made of some very dubious soft material and we have seen some with a pressed in restrictor plug complete with a loose and rattling swarf built in, which would have killed a new turbo almost immediately! Plus we have removed many others that have been over restricted.

We hope people can now see why a number of suppliers, turbo manufactures and re-manufacturers are reluctant to recommend them. To be clear it’s not the principle or the original execution that is the problem but the others that have come along after, which when fitted can damage what was a perfectly good turbo unit, leaving the supplier / manufacture liable.

The later VXR turbochargers already have the oil flow control built into the oil gallery in the turbo itself, as is evident from the picture below centre:

Z20LEH Turbo Oil Gallery

Z20LEH Turbo Oil Gallery

If a turbocharger is smoking due to worn turbo oil seals, then the turbo already has a problem. A restrictor bolt will not repair worn turbo oil seals.

Corsa 1.6 Turbo VXR Aluminium Water Radiator

Due to increasing demand  we have once again joined forces with market leader’s Pro Alloy to fabricate an uprated aluminium water radiator for the VXR and 1.6 turbo engined Corsa D.

The new radiator had to be an all alloy construction featuring welded end tanks; this eliminates the common issue on Corsa D water radiators where they leak from the plastic end tanks.

Additionally the core depth has been increase from 26mm to 40mm, whilst the surface area has been increased by 7.7%. Furthermore by reconfiguring the tube layout and foil pitching we have increased the flow area by 67% making the radiator much more efficient in cooling and ambient airflow through the core.

Finally the bottom lower water connection on the right hand end tank has been make one piece, getting rid of the factory eclip/circlip configuration that also has been known to separate at high pressure.

It is available to order and can be finished raw in Natural Aluminium or powder coated in Stealth Black finish (at additional cost).

Ideal for direct replacement on any fast road or trackday car.

Price £558.00 including VAT.

It is also worthwhile considering an upgrade to Power Cool 180 Waterless Coolant at the same time. No Water, No Corrosion, No Pressure (less likelihood of leaks, less strain on hoses and other components) More BHP, No Hot Spots, No Overheating…….

Corsa D 1.6T Water Radiator Front

Corsa D 1.6T Water Radiator Front

Corsa D 1.6T Water Radiator Rear

Corsa D 1.6T Water Radiator Rear

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

 

 

How Waterless Coolant Works.

Water is an excellent fluid for cooling whilst in a liquid state, but when water turns to steam it has virtually no capacity for heat transfer. Evans is a superior fluid for transferring heat in engines because it remains in a liquid state until above 180°C. This article details the benefits of a significantly higher boiling point.

Within an engine cooling system the hottest surfaces are those adjacent to the combustion chamber, specifically the cylinder liners and cylinder head. In these hot spots water is likely to vaporise preventing efficient cooling and causing loss of performance and unnecessary engine damage. When the coolant fails in this way the engine becomes even hotter causing more hot spots and more steam.

Evans waterless coolants will not boil around these engine hotspots maintaining efficient cooling performance even when the engine is put under extreme conditions. When water turns to steam it pressurises the cooling system putting strain on hoses and other components. The significantly higher boiling point of Evans coolants means 75% less pressure than water resulting in a less stressed cooling system.

Water contains oxygen which causes corrosion and also allows electrolytic activity which further damages engine metals (chemical limitations of water). Evans waterless coolants eliminate corrosion and electrolytic activity significantly increasing the life of the engine.

Nucleate Boiling

Nucleate Boiling

Traditional water based coolants regularly cross the thermal boundary that separates efficient Nucleate Boiling (A) from inefficient Critical Heat Flux (CHF). CHF is synonymous with the condition ‘Departure from Nucleate Boiling’ (DNB). When DNB occurs, a layer of steam bubbles form adjacent to the engine hot spots (B).

Steam dissipates less than 1/30th of the heat that water does, rapidly over-heating local metal, causing premature detonation. The high boiling point of Evans Waterless Coolants, such as Power Cool 180, prevents DNB providing more efficient cooling in engine hot spots.

Convert your car to Waterless Engine Coolant:

Evans Waterless Engine Coolant

We are pleased to confirm that we are now testing Evans Waterless Coolant. Evan’s Power Cool 180 High Performance Waterless Coolant for performance & track cars is designed for high performance engines fabricated from a mixture of cast iron, copper, steel and aluminium components. It has a number of advantages over conventional coolant, which are listed below.

Power Cool

Power Cool

Conversion to Waterless Coolant is fairly straightforward, with using Evans Prep Fluid is formulated to hygroscopically absorb water whilst flushing loose dirt and scale from the cooling system prior to filling with Evans Waterless Coolant. The job can be completed in just a few hours by either a professional workshop or competent enthusiast.

Benefits of Waterless Over Water-Based Coolants:

Eliminates Overheating
Evans Waterless Coolants have a boiling point above 180°C and will not vapourise, thus eliminating overheating, boil-over and after-boil.

Reduces Pressure
Evans Waterless Coolants generate very low vapour pressures reducing strain on engine cooling system components.

Prevents Corrosion
Evans Waterless Coolants contain no oxygen effectively eliminating corrosion.

Increases BHP
Evans Waterless Coolants eliminate pre-ignition and detonation caused by overheating, thus improving combustion efficiency and delivering more power.

Stops Erosion
Evans Waterless Coolants prevent cavitation and eliminate liner and cooling pump erosion.

Freeze Protection
Evans Waterless Coolants freeze below -40ºC.

Non-Toxic
Evans Waterless Coolants are proven to be Non-Toxic. Standard anti-freeze is toxic and known to kill pets.

From what we have seen and heard about this product so far we are confident that it will outperform all expectations.

Prices for Power Cool range from £29.95 – £64.95 and £15.99 – £39.95 for Prep Fluid.

Available by Mail Order (Tel: 01692 404313) and online.

For further information on Evans waterless Engine Coolant visit: http://www.evanscoolants.co.uk/technical/questions-&-answers/38

Power Cool 180°Download Product Brochures 2 Page Data Sheet

4 Page Brochure

PowerAlign Camber Bolts

Camber Bolts

Camber Bolts

Powerflex have announce a new ranged of PowerAlign products under the Powerflex umbrella.

The range of products will grow over the coming months. They will be more hardware based and offer innovative solutions to improve chassis geometry.

The first two products include a new range of camber bolt kits and a simple camber setting tool. By simply substituting the original upper bolts on two bolt suspension struts for PowerAlign Camber Bolts, this allows up to +/-1.75degs of camber change.

This offers an easy fix for camber issues and a perfect add-on for any suspension bush change, or for changes to camber required for a more ‘track focused’ set up.

The bolts are made using a 12.9 tensile, zinc plated high strength steel. These parts are also covered under the terms of the Powerflex lifetime warranty.

They are available in 5 sizes, to replace bolt diameters M12, M14, M15, M16 and M17 covering a wide range of vehicle makes and models.

Courtenay Sport currently stock the M12 bolts, suitable for the majority of the Vauxhall/Opel range.

M12 Camber Bolts £18.89 per pair

Camber Gauge

Camber Gauge

Along with the camber bolts, the PowerAlign Magnetic Camber Gauge, PFG-1001 measures the Camber angle on the wheel hub or brake disc and allows on-car adjustment to ensure correct wheel alignment.

This is a useful tool for setting Camber angles after dismantling and re-assembling of the suspension and is an ideal track day companion.

This easy to use magnetic gauge attaches to the hub or brake disc and graduates +/- 6 degrees and comes supplied in a durable storage case.A perfect addition to the PowerAlign range and a straightforward product to supply to customers allowing them to correctly set camber angles without expensive geometry equipment.

Camber Gauge £35.94 – Available to Order

When is a 3″ Exhaust NOT a 3″ Exhaust?

We recently had a Corsa VXR in for mapping and rolling road set up. The car was previously fitted with (by another company) a Full 3″ Turbo Back Exhaust System and uprated intercooler – which should be ideal for performance.

Our K06 turbo, an 80mm air flow meter and some higher flow injectors were added into the mix (the engine had previously been strengthened with forged pistons and steel rods)…….

Imagine our surprise when no matter what we did software wise we could achieve more than 266bhp, when around 300bhp was the aim with the components we had.

So When is a 3″ Exhaust NOT a 3″ Exhaust??…..

When it looks like this:

Restrictive Centre Section

Restrictive Centre Section

You can see from the restriction caused by the baffles that narrow the bore of the exhaust through the centre pipe, that the bore size is greatly reduced. This obviously reduces flow, increases exhaust back pressure and hampers performance massively.

In fact when the car went from a Stage 1 Remap, to having this particular exhaust fitted the customer did report he thought that the car felt slower!

Not only was there a problem in the centre section, but the tail pipes had the same problem:

Restrictive Tail Pipe

Restrictive Tail Pipe

Needless to say once we had found the restriction we switched the cat back section for one of our Courtenay Piper developed 3″ systems, which does not feature restrictive internal baffles and finished off the mapping, successfully achieving 306bhp, gaining over 45bhp mid range, 40bhp peak to peak and 50 lbs ft torque mid range!

Corsa VXR Graph

Corsa VXR with K06 Turbo Before and After removing a poor flowing 3″ exhaust

The Courtenay Sport Blog

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