We recently had the Courtenay Sport backked DCE Motorsport run Time Attack Astra VXR back for set-up check, after a spot of bad luck at the previous round at Donington Park. Some gravel ingress into the cambelt area caused severe damage to the engine, resulting in a last minute engine swap for the car, to ensure it was up and running for the final round at Brands Hatch on Sunday 29th September.
So with a borrowed ‘spare’ engine, Will and his pit crew worked tirelessly over the weekend and once the engine swap had been completed and all the ancillaries, turbo, manifolds and such like had been refitted the car came to us for a mapping session just to check and alter the parameters, due to the fact this engine was running slightly different compression than previously.
After a few hours set up, all is now well again and we’re looking forward to Brands Hatch. Good Luck to Will and the whole team.
Further Development of this car has seen us change the turbo to a Garret GTx3076R along with a custom made 100mm diameter inlet pipe.
Target BHP was something on the right side of 500 BHP. With 99 octane UK pump fuel we saw 525 BHP but this was on the limit of our UK fuel quality; Stephan in Germany had seen well over 550 BHP with this turbo on 102 ocatane pump fuel available to them.
At this point we thought it might be fun to add some methanol to bring the octane value up; a stainless tank was fabricated and installed with an Aquamist pump in the spare wheel well, to sit alongside the already installed swirl pot and Pierburg pump. The spare wheel well has had a number of vents installed and a laser cut acrylic panel made and installed to protect the contents and seal the wheel well off from the car’s interior. With further mapping mostly based around a much more efficient timing curve we saw the power rise to a peak of 568 BHP and finally settled with a comfortable figure of 559 BHP.
Final testing on the road proved very interesting and memorable for Mark R when he found some additional work was needed to stop the meth from puddling in the inlet manifold, which occurred on part throttle when the throttle was being feathered due to wheel spin! Fortunately the functionality and adjustability of the Aquamist ECU made this quite straight forward to achieve.
Engine Spec features numerous Courtenay core products as follows:
Ported Cylinder head
Klasen Inlet Manifold
V Band Cast Manifold
Tial External Wastegate
Custom 3” front pipe mated to a Piper 3” exhaust System
GTx3076R Turbo with Tial Exhaust Housing & 100mm inlet
Courtenay Water Radiator
Paddle Clutch plate
Reworked Sach’s Uprated Clutch Cover
To name but a few items…
Hopefully this should keep the ever power hungry Wayne T content for a while. A thoroughly enjoyable conversion to do cheers Wayne…
Spare Wheel Well with Swirl Pot, Pierburg High Pressure Pump, Aquamist Pump and Methanol Tank
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.
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
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
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