Posts Tagged ‘ K06 ’

Opel Speedster Turbo K06 and Inlet Manifold

This car had previously been in for a full engine rebuild with forged pistons and steel rods, strengthening the factory Z20LET engine and was running a K04 Z20LEH VXR turbocharger, Milltek 63.5mm exhaust system, Pro Alloy chargecooler and VXR injectors.

It returned to us to have some further enhancements which included a full 76mm Tullett exhaust system, a K06 turbocharger, Courtenay Klasen inlet manifold, uprated clutch and 80mm air flow meter.

After mapping and a full rolling road set up it is now producing 334bhp and 340lb ft torque, and is very at home on the track where it spends most of its ‘working’ life.

VX220 Turbo Mapping

VX220 Turbo Mapping

Astra H VXR Stage 4 K06 Coversion

Another fabulous conversion on an Astra H VXR.

This car first came to us for mapping to Stage 3 (hardware requirements are a full 3″ exhaust system and uprated intercooler). The car was fitted with a Forge lower front mount intercooler, but on the exhaust side only had a pre-cat removal pipe, and a Piper 3″ cat back exhaust system and was still running the factory main cat section. Obviously with this restriction in place it would be down on expected power, and upon checking on the rolling road this was found to be the case, but still making a respectable 283bhp.

Remedial action was simple; fit a 3″ front pipe and sports cat section. Once the mapping was finalised the results were a very good 299.99bhp and 332 lb ft torque on a cold January day.

In the hunt for more power, the car returned to us recently for a full K06 and inlet manifold upgrade.

ZRP steel rods and uprated ARP rod bolts were fitted, stem seals and retainers were done at the same time, and then when being put back together the K06 turbocharger, Courtenay Turbosmart uprated actuator, Courtenay Klasen high flow inlert manifold,thermal inlet gasket and high flow 340 fuel pump were all fitted. This was also the ideal opportunity to replace the cambelt and water pump and fit a lightweight allow bottom pulley.

Z20LEH engine being fitted with steel rods

Z20LEH engine being fitted with steel rods

An uprated CSRacing clutch kit and lightweight billet steel flywheel were also fitted, as a safeguard against the increase in power and torque, and to top it off a huge K Sport 8 Pot 356mm brake kit was also fitted, to bring everything safely to a halt. The car already had a Wavetrac LSD in the gearbox.

Rolling Road Mapping

Rolling Road Mapping

The end results after mapping 333bhp and 350 lb ft torque.

Astra H VXR – K06 Mapping

This Astra H VXR Nürburgring is a well loved and enjoyed example having covered some 110,000 miles, but it always gets regular 5,000 mile oil changes. It shows the durability of the engines as this car has been tuned to several levels, originally starting at Stage 3.

More recently it has benefitted from the addition of a K06 hybrid turbo and Courtenay Klasen Inlet manifold, a set of steel rods and with mapping and set up is currently making 316 bhp on the 70mm Remus exhaust system.

It is due back soon for a full 76mm exhaust system to release the additional power available from the fitted components, which is being held back by the Remus system.

Excellent results showing that mileage is not detrimental to the Z20LEH engine making good power, providing regular maintenacne is carried out.

Astra H VXR Mapping

Astra H VXR Mapping

Mapping on a Cold Day – K06 at 349bhp

This Astra H VXR has been with us before for mapping and has a K06 turbo, full 3″ exhaust, Courtenay Klasen inlet manifold, CSRacing intercooler, steel rods (plus all the other required components) and achieved a very respectable 329bhp and 350 lb ft torque when last seen in the July heat this year.

Astra H VXR K06 Conversion

Astra H VXR K06 Conversion

Previously running a standard actuator, the car came back to us for checking and additional mapping after a Courtenay Turbosmart uprated actuator and recirculation valve had been fitted. We were able to have some further changes made to the boost, fuelling and ignition timing after the replacement actuator had been fitted, but the biggest change was the colder November temperature, meaning the dyno cell was lovely and chilled.

Final mapping saw a recorded power figure of 349bhp and 370 lb ft torque with more boost through the mid range helped by the stronger actuator. It goes without saying that the car was running Shell V Power 99RON fuel.

K06 Graph

K06 Graph

We still quote expected gains for this conversion at 330-335bhp, becuase we see and map more cars during the hotter months, but it only goes to prove how much turbocharged cars love cold dense air!

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

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

K06 Astra H VXR

Another K06 conversion, with steel rods, Courtenay high flow inlet manifold, 3″ exhaust and CSR Intercooler being set up on our rolling road – bang on the money power and torque wise, and one of the cleanest and best prepared cars we’ve seen. We have also switched it to Evans Power Cool 180 Waterless Coolant.

 

Astra H VXR K06 Conversion

Astra H VXR K06 Conversion

 

 

Turbo Failure – The Truth About Dirty Oil………

…… and how it will kill your turbo.

All too often we hear of turbo failure of the K04 turbocharger, as used on the Z20LEx engines in Astra G and H, Zafira A and B, VX220 and all too frequently we hear the turbochargers being blamed as poor quality or ‘rubbish’ units, which is not the case.

In nearly all cases of turbo failure, the source of the problem is not down to the unit itself but usually due to oil contamination and/or incorrect fitting procedure. It is also important to carry out eliminating the initial cause of failure, if it was a failure caused by something other than old age/wear and tear. Additionally allowing oil to get dirty during use and poor or infrequent oil changes using poor quality oil will also contaminate the turbo causing failure.

The picture gallery below contains images from of a ‘failed turbo’ that was under 10,000 miles old which was dis-assembled and inspected and a report produced. The cause of the bearing failure in the turbo is down to contaminated dirty oil….. you cannot blame the turbo itself for the failure.

Here is the report, basically detailing how dirty oil has ‘scrapped’ the turbo:

Turbo Report

Turbo Inspection Report

The good news is the wastegate assembly and actuator are still in good condition!

Some pictures of the damaged components:

 

Oil Contamination Fact Sheet:

Oil Contamination Fact Sheet

Oil Contamination Fact Sheet

The Courtenay Sport Blog

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