Posts Tagged ‘ Rolling Road ’

Astra J VXR Stage 1+

Another Astra J VXR in for a Stage1+ tuning package, which is proving to be a very popular option for many owners.

The first stage is to benchmarck the power of the standard car. It had already had a generic flash map installed via a well known hand held tuning box, so we first ran the car with the generic map installed, then using the hand held unit returned the car to factory standard software and ran it again. With the generic flash map loaded the car produced 287bhp and when returned to the standard map and run again the car made 281bhp.

It was then round onto the ramp so the pre cat removal pipe could be fitted, removing the restrictive factory pre cat.

Pre Cat Removal Pipe Fitting

Pre Cat Removal Pipe Fitting

Once the 76mm straight through pre cat removal pipe had been fitted it was back onto the rolling road for mapping and datalogging whilst the map is optimised on the rolling road, resulting in 328bhp and 373 lb ft torque.

Astra J VXR Mapping

Astra J VXR Mapping

Meriva VXR Tuning

This Meriva VXR had visited us before for a remap, and came back to have some further improvements carried out.

We removed the pre-cat and fitted a straight through pre-cat replacement pipe (downpipe) to remove the restrictive first cat, fitted a set of NGK iridium plugs and a high flow Courtenay Sport panel filter.

Then it was back onto the rolling road for map optimisation, datalogging and rolling road set up. The results were 216bhp and 243 lb ft torque.

Meriva VXR Mapping

Meriva VXR Mapping

Insignia VXR Remap

Another returning customer coming back to us this time with his 7,000 mile Insignia VXR for mapping, having previously has his Vectra VXR mapped by us.

Latest spec and an otherwise standard car, and a little under a year old we carried out the mapping, map optimisation, datalogging and full rolling road set up achieving 332 bhp and 380 lb ft torque, it will loosen up given a few more miles on its belt.

Insignia VXR Mapping on the Rolling Road

Insignia VXR Mapping on the Rolling Road

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

Corsa E VXR Stage 3 Mapping

Another Corsa E VXR which was brought to us for mapping and rolling road set up.

This car had already had a Cobra 3″ exhaust system and Airtec intercooler fitted to it by the customer and had previously been mapped. Prior to mapping we benchmarked the car on our rolling road to establish its base power and torque figues which were 227 bhp and 246 lb ft torque.

We then remapped the ecu and carried out a full rolling road set up with datalogging and optimised the software to suit the fitted components.

When finished the car is now producing 245 bhp and 259 lb ft torque with gains right across the rev range compared to the previous remap.

Corsa E VXR Rolling Road Set Up

Corsa E VXR Rolling Road Set Up

Astra H VXR Remap

Astra H VXR Nurburgring. Already fitted with a Remus 70mm stainless steel exhaust system and uprated intercooler this car came in recently for mapping and rolling road set up. Results: A very healthy 293bhp and 339 lb ft torque.

Astra H VXR Remap

Astra H VXR Remap

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 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

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

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!

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.

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

Audi TT 2.0 TFSi Rolling Road

This Audi TT was brought to us for rolling road checking after having been fitted with a full exhaust system. The car was previously runing a Stage 1 remap prior to the fitting of the exhaust and had been updated with a new piece of software from a hand-held flash tool and the customer wanted to see the results.

After checking on the rolling road it became evident that further enhancements are required to the software due to the throttle closing at higher rpm.

Audi TT on Rolling Road

Audi TT on Rolling Road

Golf Mk 6 GTi Rolling Road Session

This low mileage VW Golf Mk6 GTi was brought to us for a health and power/torque check on our rolling road.

VW Golf Mk 6 Rolling Road

VW Golf Mk 6 Rolling Road

Golf Mk5 GTi Remap

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

Focus ST Remap

Just for a change we recently had a Focus ST here for remapping and rolling road set up. Already fitted with a cat back exhaust system (the standard downpipe and cat had not been changed) and an intercooler, we remapped the ecu and carried out a rolling road set up achieving 261bhp and 311 lb ft torque.

Focus ST on the Rolling Road

Focus ST on the Rolling Road

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

The Courtenay Sport Blog

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