Posts Tagged ‘ Courtenay Mapping ’

Astra H VXR K06 Conversion

One of our recent jobs was this Astra H VXR, brought in to have a K06 turbocharger fitted (complete with an uprated recirculation valve), along with our CSRacing Full Height Front Mounted Intercooler. Whilst in our workshop it was also converted to Evans Power Cool 180 Waterless Coolant.

Already fitted with a 70mm exhaust system it was onto the rolling road for mapping and full set up. During mapping the mid range and top end boost was reduced slightly due to the 70mm exhaust system giving more back pressure than a 76mm system and also because the engine did not have steel rods or uprated valve springs. Once the ignition timing and fuel were optimised we saw results of 304 point something bhp (so nearly 305bhp!) and 341 lb ft torque. With a 76mm system estimated gains are 305-310bhp so this particular car is making good power on a 70mm system.

There is still some in reserve to come for this car once it has a 76mm exhaust system to help with back pressure reduction as 310bhp+ is more than possible, with potentially even more should an inlet manifold, steel rods and uprated valve springs/shims be fitted.

Astra H VXR with K06 Conversion

Astra H VXR with K06 Conversion

Insignia VXR Remap

We had this 2009 Insignia VXR with us recently for ecu remapping and full set up. It had covered about 55,000 miles and had already had the second cat removed by the owner, with the pre cat still in place.

Mapping and set up resulted in 348 bhp and 396 lb/ft torque, up on a car with a remap and standard exhaust with both cats still fitted, with gains of almost 100bhp and 100 lb/ft torque throught the mid range.

Insignia VXR

Insignia VXR

Stage 3 Corsa VXR

We had a lovely 40 something thousand mile Corsa VXR in with us recently which had been fitted with a full 3″ exhaust system, twin silencers and pre cat removed and also our high flow CSRacing full height intercooler.

Compressions were checked all found to be good, then the ecu was remapped and the car underwent a full rolling road set up with full ecu datalogging and the software was optimised to suit the fitted components resulting in 240bhp and 249 lb ft torque and running on 99 octane fuel.

As we are sure you all know what a Corsa VXR looks like by now, we will show you the power and torque graphs instead:

Corsa VXR Stage 3 Power and Torque Graph

Corsa VXR Stage 3 Power and Torque Graph

Mapping Session – Supercharged VX220

This VX220 was in for mapping following a self-install Stage 1 supercharger conversion and was mapped and set up on the rolling road making 210bhp and 190 lb ft torque.

Stage 1 Supercharged VX220

Stage 1 Supercharged VX220

Vectra VXR Mapping Session

This Vectra VXR came to us for mapping having already had an Insignia VXR Turbo unit and an intercooler fitted. The cats had also been removed prior to its visit. Once in our rolling road bay, a set of uprated injectors were fitted and then the car was mapped and set up on the rolling road, achieving excellent figures; 329bhp and 406 lb ft torque. These numbers were about what was expected from a car running a factory water radiator, in between our Stage2+ (320-325bhp) package and our Stage 3 (340bhp) package (which also adds an uprated water radiator) .

More details on Vectra VXR tuning on our >>>> main website <<<<.

Vectra VXR on the Rolling Road

Vectra VXR on the Rolling Road

Supercharged VX220 Mapping Session

Supercharged VX220 2.2 16v

Supercharged VX220 2.2 16v

A recent mapping session on a VX220 2.2 with a self-install supercharger conversion. Initially brought in a while ago for mapping the car achieved 216bhp, lower than the expected Stage 2 power due to a restrictive exhaust system identified during the first mapping session.

Brought back to us with a derestricted 2.5″ front pipe and cat section, we were able to improve the mapping with changes to the ignition and fuelling now that exhaust flow had improved resulting in gains to 242bhp, with the graphs showing improved power and torque right across the rev range.

Corsa VXR Blue Edition – Stage 2

We had this lovely low mileage Corsa VXR Blue Edition with us recently.

Corsa VXR Blue Edition

Corsa VXR Blue Edition

If it was feeling ‘blue’ before it arrived, it certainly wasn’t when it left, after having a full 3″ exhaust system fitted, NGK iridium plugs, a panel filter, large bore inlet pipe and uprated recirculation valve followed by ecu remapping and a full set up on the rolling road with datalogging and map optimisation.

Corsa VXR 3" Exhaust Fitted

Corsa VXR 3″ Exhaust Fitted

Achieving 223 bhp and 238lb ft torque runing on 99 Octane V Power Nitro+.

Astra VXR Sprint K06

Built specifically for use as a track day car, this car was previously a Stage 3 car producing a useful 292bhp and had been fitted with our 3″ full exhaust, CSRacing Intercooler, Pro Alloy Water Rad, Wavetrac LSD, Alcon 4 Pot calipers with 356mm alloy belled discs, 292mm Rear Brake Upgrade, Whiteline Rear ARB, DAP Road Springs, direct route hose kit and Pro Race 1.2 alloys. Building on the track day specification, other modifications have included Recaro Pole Position Seats, Rear Cage and Sabelt Harnesses.

Astra VXR Sprint

Astra VXR Sprint

After a few engine changes including K06 turbo rework, Courtenay Klasen Inlet Manifold, Steel Rods, Turbosmart Actuator and Recirculation Valve and a few hours mapping on the rolling road we achieved a respectable 336bhp and 355 lb ft torque, all useable on track increases through the mid range and top end, with the ability to rev to 7,500 rpm.

Before and After Graph:

Stage 3 K04 v Stage 4 K06  Astra VXR

Stage 3 K04 v Stage 4 K06 Astra VXR

Turbosmart Actuators

Turbosmart Actuator

Turbosmart Actuator

Uprated Turbosmart Actuators are now in stock.

Uprated Turbosmart Internal Wastegate Actuators provide better turbo response and greater sensitivity when managing boost pressures, especially when bespoke mapping.

FEATURES:

• Silicone diaphragm with Nomex reinforcement to withstand high temperatures.
• High grade, billet aluminum construction.
• Stainless steel rods for corrosion resistance.
• Locking Collar design cap allows for quick spring changes.
• Actuator Base Pressure can be changed with internal springs.
• Anodised Black Finish
• Available with 10PSI Actuator Spring

APPLICATIONS:

This uprated Internal Wastegate Actuator is suitable for KKK factory turbos with an internal wastegate, such as K03, K04 (VXR) and K06 as used on 2.0 Petrol Turbo Z20LEx engines Astra G, Astra H, Zafira A, Zafira B including VXR models where an uprated actuator is required.

Can be used for all stages of tune/mapping with just spring changes if additional actuator clamping pressure is required during mapping.

Suits most 2.0 Turbo applications.

Available with or without mounting bracket From £120.00 – £168.00

Corsa VXR Nürburgring Stage 2 Upgrade – Take 2

It has been a busy week for us for Corsa VXR tuning.

This Glacier White car is our second Corsa VXR Nürburgring Stage 2 Upgrade in a week. We fitted our full 3″ turbo back exhaust first:

Corsa VXR Nürburgring Exhaust Fitting

Corsa VXR Nürburgring Exhaust Fitting

Followed by custom mapping, datalogging (including ignition timing, knock retard, injectors, boost pressure, fuelling), map optimisation to suit the new exhaust and full rolling road set up:

Corsa VXR Nürburgring on the Rolling Road

Corsa VXR Nürburgring on the Rolling Road

Corsa VXR Mapping

A busy week for remapping Corsa VXRs on our rolling road with this A16 engined Corsa VXR in for mapping, injectors and set up earlier in the week, reaching a respectable 217bhp for a car with a 70mm cat back exhaust.

Corsa VXR on the Rolling Road

Corsa VXR on the Rolling Road

Garrett Built Astra G GSi Turbo 503bhp

Garrett Build Astra G GSi Turbo 503bhp

Garrett Build Astra G GSi Turbo 503bhp

Another Garrett build, with Garrett GT30 Turbo, V Band Manifold, Courtenay Klasen Cams and Inlet Manifold, Engine rebuild, 90mm AFM, injectors, 3″ exhaust; all the usual requirements for a Garrett conversion, previously mapped by us and making a respectable 490bhp; brought in for checking now its a little cooler. Up 13bhp to 503bhp due to the lower temperatures.

Another Garrett Build Astra H for Mapping

Astra H Van with Z20LEH VXR Engine

Astra H Van with Z20LEH VXR Engine

This Astravan with Z20LEH engine, steel rods and GTX2867 garrett build was brought in for mapping and full rolling road set up.

The map it was brought to us with (which was not our software) was checked first and shown to be running 320bhp, with some fuelling and ignition timing issues.

We switched to a 3 bar map sensor (from a standard 2.5 bar one) and recalibrated the map so the ecu could correctly read boost pressure as the 2.5bar map sensor will go out of range on capable of reading up to 22psi of boost, hence the change to a 3 bar sensor. Correctly recalibrated the ecu can then read up to 29.4psi boost presure.

Also changed were the 875cc injectors to a much more suitable 630cc injector for the required power, again with suitable ecu recalibration. 875cc injectors for the required power prove way too big, and cannot be controlled accurately enough for part throttle fuelling (essential on a fast road car) due to the spray pattern plus fuel consumption will be higher, again another consideration for a car with road manners. When checked and datalogged first this car was running at 0.88 lambda on cruise, so clearly the map needed some work at this point. This is too rich and can cause bore wash and potentially internal engine damage. Big injectors are fine for stand alone management and for race cars which do not run at part throttle or cruise, but were just incorrectly specced for this particular applcation.

With a couple of bits still to do and after mapping and set up the result for now is 390bhp and much better, more controlled fuelling at part throttle and cruise. Fuel consumption will improve as well as 630cc injectors control part throttle fuelling more accurately.

Why the change of injectors? For better road manners; in simple turns the bigger injector (875cc) does not atomise the fuel as efficiently at slow duty cycle/engine speeds. So a 630cc injector can provide more than enough fuel for the power but still return better fuel economy due to its ability to better atomise the fuel.

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

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

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

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

500bhp Astra VXR GTx3076R



Courtenay Sport mapped Garrett Conversion. The brief was to achieve 500bhp from the mapping and the customer had prepared the car with a Garrett GTx3076 turbo, tubular manifold, 76mm exhaust, 90mm air flow meter, 680cc injectors, High Flow Inlet Inlet Manifold, Courtenay Klasen cams, Forge Race Intercooler, Mocal Oil Cooler, Sachs Uprated Clutch and Uprated Cera Metallic Paddle Disc and Lightweight Flywheel.

Map Optimisation and Set Up Pays Off – Astra VXR

Another question we are constantly being asked is about remapping and correct set up and why this is better than a hand held unit.

Many people like the convenience of installing a map from a hand held unit (and are often ‘sold’ the same results as bespoke mapping, which invariably is not the case), but without checking it or seeing what it is doing for the car, the results are simply ‘hit and miss’. Put simply unless ecu software is properly checked and optimised to each car, you are unlikely to get the results you are expecting (or have been sold!)

Here’s a graph for an Astra VXR which we were asked to dyno which had a lower front mounted intercooler fitted, a full 70mm Remus Exhaust System and an unchecked map from a hand held unit. The resulting dyno figures show the map gave worse results than the factory software (where we have seen 270bhp on a car with exhaust and intercooler fitted):

Astra VXR Competitor Stage 3

Astra VXR Competitor Stage 3 : Before

This set up, correctly mapped should really have been producing at least 285bhp, not 252bhp!!

At the customer’s request, we changed the intercooler for one of our Full Height Front Mounted VXRacing Intercoolers and fitted a full 76mm system. Once properly remapped, datalogged and set up on the rolling road we achieved:

Astra VXR Courtenay Sport Stage 3 : After

Astra VXR Courtenay Sport Stage 3 : After

And finally here are the before and after graphs, showing the differences. Much more power and torque right across the rev range, which will totally transform the drive of the car:

Astra VXR Stage 3 Comparison

Astra VXR Stage 3 Comparison

The Courtenay Sport Blog

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