Archive for the ‘ Workshop ’ Category

Astra J VXR Front Pipe and Mapping

Another Astra J VXR in for front pipe fitting (shown centre front), followed by mapping and rolling road set up.

Astra J VXR Front Pipe Fitting

Astra J VXR Front Pipe Fitting

After mapping and set up, on 97RON fuel, this particular car achieved 324bhp and 357lb ft torque.

Astra J VXR Rolling Road

Astra J VXR Rolling Road

Astra H Handling and Stopping

We recently had the job of improving the stopping and handling on an Astra H.

This included supplying and fitting a D2 6 Pot 356mm front brake kit, complemented by a rear 292mm brake upgrade with vented rear 8G discs and new calipers.

Additionally a Premium Suspension package was also supplied and fitted: B8 dampers and DAP Road spec springs along with poly bushed Whiteline front wishbones, Powerflex poly rear beam bushes and a Whiteline rear anti roll bar.

 

Astra J VXR Stage 1+

Another Astra J VXR in for our increasingly popular Stage 1+ tuning package, comprising of front pipe fitting, ecu remap and rolling road set up. This car made a respectable 320bhp and 339 lb ft torque.

Astra J VXR

Astra J VXR

Corsa E VXR Mapping and Full Exhaust

This Corsa E VXR came to us to have a full turbo back 3″ exhaust fitted, followed by map optimisation to suit the exhaust and full rolling road set up.

Corsa E VXR

Corsa E VXR

Corsa E VXR Exhaust

Corsa E VXR Exhaust System

Once set up the results were an impressive 241bhp and 244 lb ft torque. We also carried out our own unique hardware fix and software recalibration to the air flow meter to allow it to read and fuel correctly above 222bhp, where it is known that the standard air flow meter maxes out.

Corsa E VXR

Corsa E VXR

We also have in development the CSR MaxAir Intake System for Corsa E VXR, which will feature an enlarged airflow meter housing and large AEM Dryflow cone filter.

Astra 1.9 CDTi Single Mass Flywheel

Astra H 888 CDTi

Astra H 888 CDTi

We recently had this lovely Astra H 888 CDTi (Z19DTH engine with M32 gearbox) in for a lighter single mass flywheel (removing the dual mass flywheel) and sprung clutch assembly due to slight clutch slip on the factory clutch. At the same time we also overhauled the gearbox fitting new bearings throughout and the later end case, which features larger diameter end case bearings and additional oil galleries in the end case for better end case bearing lubrication.

Insignia VXR Front Pipe and Mapping

This Insignia VXR came in to have our high flow front pipe (which removes the pre-cat or first cat) and Euro V compliant high flow sports cat fitted.

High Flow Front Pipe and Sports Car Fitting

High Flow Front Pipe and Sports Car Fitting

Once this was done in the workshop, the car was into the dyno cell for mapping and full rolling road set up.

Rolling Road Set Up

Rolling Road Set Up

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

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 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

M32 Gearbox Bearings and Late Endcase

Another M32 gearbox from an Astra H in for bearing replacement and upgrade to the later endcase with larger endcase bearings.

M32 Gearbox with Late Endcase

M32 Gearbox with Late Endcase

This gearbox had covered some 90,000 miles before need to have the bearings replaced, and whilst the box was off the car for overhaul the later endcase which features additional oil galleries and larger endcase bearings was fitted.

The box was refitted and filled with 3 litres of very high quality fully synthetic Amsoil MTG 75w-90 gearbox oil, and also the dual mass flywheel, clutch (cover and disc) and hydraulic slave cylinder were also replaced using genuine OE components.

1.9 CDTi Clutch and Dual Mass Flywheel Assembly

1.9 CDTi Clutch and Dual Mass Flywheel Assembly

Prices (to supply parts):
M32 Bearing Pack with late endcase £255.00
Genuine Vauxhall/Opel OE DMF £295.00/£335.00 (price according to chassis break)
Genuine Vauxhall/Opel OE Clutch Kit £150.00/£159.00 (price according to chassis break)
Genuine Vauxhall/Opel OE Slave Cylinder £108.00

Rear Brake Lines – Astra H/Zafira B

Some pictures for reference, in gallery form and in no particular order, showing our braided rear brake hoses fitted on Astra H VXR. These should offer some help with installation of the rear braided brake lines. The brackets from the factory brake lines can be reused to accept the new braided brake lines. Remove the factory brake pipes from the original brackets (you will need to drift them out), and carefully open up the holes in the brackets to accept the braided brake line stainless steel unions, which are a slightly larger diameter to the factory fittings.

Renault Clio Track Car

Some variety in our workshop.

The Renault Clio is a very popular option for a trackday car. This car came to us for some routine service work including a new alternator, R888R tyres, rear brake discs and pads and a check on the rolling road.

Renault Clio

Renault Clio

M32 Gearbox Overhaul – Astra H SRi 1.9CDTi

Another M32 gearbox overhaul, this time on an Astra H 1.9 CDTi 5 Door. Once the engine subframe and gearbox had been removed the gearbox could be stripped down, cleaned and inspected and then rebuilt with full bearing replacement (all 8 bearings) and new driveshaft oil seals.

Do not forget, even if you are unable to get your car to us to have the work carried out, we can supply bearing kits by mail order and ship worldwide.

M32 Gearbox Rebuild

M32 Gearbox Rebuild

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

3″ Full Exhaust System – Astra H VXR

Another Astra H VXR brought to us, this time to have a full 3″ Courtenay Piper exhaust system fitted. Where customers choose not to have a full ecu remap, part of our fitting process includes programming the ecu with factory spec software with the P0420 DTC (Cat System Efficiency Below Threshold) error code deleted, to eliminate the EML (engine management light) from coming on.

Astra H VXR 3" Exhaust

Astra H VXR 3″ Exhaust

Vectra C 1.9 CDTi DMF and Clutch Replacement

We do not just work on performance cars!

During routine servicing a knocking noise was identified on this Vectra C 1.9 CDTi which was only evident when the clutch was released. The noise was diagnosed as play within the dual mass flywheel assembly. Before it got too bad the customer asked for the appropriate repairs to be undertaken.

Once the engine bed and gearbox were removed, a replacement OEM dual mass flywheel and clutch assembly with new hydraulic slave cylinder were fitted.

Vectra C DMF and Clutch Replacement

Vectra C DMF and Clutch Replacement

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

The Courtenay Sport Blog

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