Posts Tagged ‘ Astra H ’

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 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.

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.

KW Clubsport Coilover Kit for Astra H VXR

We have recently fitted a KW Clubsport Coilover kit to our Astra H VXR track car, which was running a Bilstein B8 set up with Courtenay DAP Race Spec springs.

The Clubsport kit is the prefered choice for a track biased suspension for a car that is used predominantly on track (more than it is on the road) and is the next step up from the excellent KW V3 coilover kit, which is an ideal fast road kit also suitable for light light trackday use.

Full stainless steel dampers, height adjustable springs with helper springs, solid top mounts on the front struts and 2 way damper adjustment on both the front and the rear dampers for compression and rebound adjustment to fine tune the set up.

A reminder, this is the kit as supplied:

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport coilovers were developed for customers who demand a better handling car when participating in track day events, but also require a setup that is still acceptable for road use such as to and from trackdays. The Clubsport kit was specifically designed for the Nordschleife using track day tires. The independently adjustable rebound and compression damping technology allow the suspension setup according to the vehicle load, tire characteristics and different track conditions. KW Clubsport meets every demand regarding a coilover for on road use but more importantly track use.

Here are some pictures of the fitted kit:

KW Clubsport Coilovers 2 Way Suspension

We have just taken delivery of a KW Clubsport 2 Way Coilover suspension kit for our Astra H Sprint track car, which will be fitted over the coming weeks and set up prior to its first outing in 2015.

Here’s a preview:

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

Astra VXR Rolling Road Health Check

It is always useful to have a car checked from time to time on the rolling road, as it can show up potential running issues.

We had this Astra H VXR Nürburgring brought in for a health check on the rolling road this week, due to it feeling ‘down on power’ after a manifold swap by the owner, so running it up and datalogging it should highlight any issues.

We carried out an initial check over of the vacuum pipes, recirculation valve and actuator just to make sure nothing physical was at fault which could cause a problem. The ecu was also checked for any stored trouble codes, again to see if there was anything that could cause a running issue.

Running the car up on the rolling road whilst datalogging found the turbo to be down on boost, making less bosst pressure than expected  and resulting in 255bhp and 290 lb ft torque down on what is expected from a Nurburgring with a remap.

Additional checks were carried out to the boost hoses and intercooler fittings, which showed no leaks or issues.

After further runs, the turbo was shown only to be capable of making a maximum of 20psi overboost, and unable to make the required boost at peak power (around 5,700rpm), so identifying the root cause of the problem to be a failing turbocharger.

Astra VXR Health Check

Astra VXR Health Check

VXRacing Door Sill Trims

VXRacing Sill Trim Cover

VXRacing Sill Trim Cover

VXRacing VXR Door Sill Trims Now Available. As fitted to Astra VXRacing Editon models

Only £28.00 per pair

Side Gearbox/Engine Mount Fitting – Astra G/H and Zafira A/B

Astra G/H 2.0 Petrol Turbo, Astra H 1.9 CDTi, Zafira A/B 2.0 Petrol Turbo and Zafira B 1.9 CDTi have a gearbox side mount that is rubber and prone to failure.

Courtenay Sport approached Powerflex to devise a solution to not only improve the original factory mount, but also give it some additional support and to help reinforce it. In some cases where the original factory mount is not too badly damaged or split, the polyurethane insert can be used to ‘save’ the failing factory mount and prevent further deterioration.

Two specifications of material are available for this mount: Yellow for road use (Shore Hardness 70) and Black (Shore Hardness 95) more aimed at trackday/competition use as it is much stiffer.

OE Factory Engine Mount and Yellow Poly Insert

OE Factory Engine Mount and Yellow Poly Insert

OE Factory Engine Mount and Black Poly Insert

OE Factory Engine Mount and Black Poly Insert

We recently fitted a yellow mount insert to an Astra H VXR which had covered just over 46,000 miles and the factory mount was already showing signs of weakening due to splitting which if left would ultimately deteriorate fully and  fail completely.

Once fitted there was no noticeable increase in NVH (Noise, Vibration, Harshness) into the vehicle. The vehicle used also had an uprated front engine mount insert fitted. Additionally it was noted that the gearchange had improved and became smoother due to the reduction in gearbox movement at gearchange, due to the uprated gearbox mount insert.

On vehicles with a full set of uprated engine mounts, some minor change in NVH may be experienced by fitting this additional mount.

Here is a brief fitting guide: Read more

The Courtenay Sport Blog

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