Posts Tagged ‘ ECU Remapping ’

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

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 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

Astra J VXR Stage 2

Astra J VXR’s are becoming more and more popular for tuning now and here is another example. White seems to be a popular choice on this model.

This car was brought to us for a Stage 2 Tuning package which consists of a replacement 76mm downpipe to remove the restrictive pre-cat, a revised silicone inlet hose with a free flowing replacement air flow meter housing and large AEM DryFlow air filter assembly followed by custom ecu remapping, datalogging and full rolling road set up.

This car acheived 334bhp and 385 lb ft torque.

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

Lotus Europa Mapping

The Lotus Europa is fitted with a Z20LER engine, as used in the Astra H 2.0 Turbo (Non VXR) and has the M32 6 speed gearbox.

This particular car had been fitted with a VXR turbocharger, VXR injectors (both from the Z20LEH sister engine used in the Astra H VXR) and a Milltek exhaust and came in for ECU remapping and rolling road set up. To prevent clutch issues is also had an the uprated 240mm clutch and lightweight 240mm flywheel also used on Astra H VXR as an upgrade.

The Courtenay Sport Blog

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