Posts Tagged ‘ ECU Remap ’

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

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 3

A change to the more common Astra J VXRs we see in Arden Blue, this time in the much less seen but equally stunning Power Red.

The car had already been fitted with a full 3″ Piper turbo back exhaust system and an Airtec cooler and induction kit when it arrived with us and when benchmarked produced 300bhp and 348 lb ft torque when benchmarked, although with a noticeably bouncing boost curve between 3-4,000 rpm due to the factory software, which was reflected inthe power and torque curves.

Once mapping was completed the results were a very respectable 340 bhp and 381 lb ft, after we had fitted our own air flow meter inlet housing and AEM dryflow cone filter which allowed the car to produce an extra 3 bhp and 10 lb ft torque over the original induction kit that had been fitted on the car.

Our free flowing air flow meter housing was specifically developed for the Astra J VXR on our rolling road and features a built in air straightener so correct air mass values which are relayed to the ECU, and able to help this car reach higher numbers.

Astra J VXR Mapping

Astra J VXR Mapping

More Astra J VXR Mapping

Another Astra J VXR in for mapping, in the ever popular blue, this time from another repeat customer who was more than pleased with work we carried out to his previous car a Vectra VXR.

Already fitted with an induction kit and our 3″ pre-cat removal pipe the car came in for mapping and full rolling road set up.

Astra J VXR Mapping Session

Astra J VXR Mapping Session

The final figures were up from 280bhp and 324 lb ft to 325 bhp and 365 lb ft torque.

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

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 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.

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

Golf Mk5 GTi Remap

A standard Golf Mk5 GTi brought to us for ECU remapping and rolling road set up achieving 240bhp.

The Courtenay Sport Blog

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