Archive for the ‘ Vauxhall Tuning ’ 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

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.

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!

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

Enlarged Silicone inlet Hose for Astra J VXR

Enlarged Silicone Inlet Hose for Astra J GTC VXR.

A direct replacement for the factory inlet hose, this silicone hose has been enlarged throughout its length for improved air flow, tapering only at the end to fit onto the turbo. This hose is smoothed out removing all the steps and convolutes found in the factory hose. It also features a moulded spigot for the breather pipe.

£119.95 Available in Blue, Red or Black or Yellow, Green, Purple or Orange to Special Order.

Astra J Inlet Hose

Astra J Inlet Hose

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.

Astravan 1.9 CDTi Upgrades

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.

Astra H 1.9 CDTi Van

Astra H 1.9 CDTi Van

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.

Turbosmart Recirculation Valves Now Available

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

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:

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

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:

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

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

£120.00 inc VAT

Coming soon for Z16LEx 1.6 Turbo Vauxhall Engines.

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Astra H VXR – Uprated Clutch and Lightweight Flywheel

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.

Astra H VXR Nürburgring Clutch and Flywheel Replacement

Astra H VXR Nürburgring Clutch and Flywheel Replacement

Don’t forget we can also fit standard original equipment (OE) replacement parts as well as uprated parts!

The Courtenay Sport Blog

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