Posts Tagged ‘ Tuning ’

Corsa VXR Nürburgring Stage 2 Upgrade

This lovely 2012 Corsa Nürburgring in Lime Green Pearlescent was brought to us for a Stage 2 upgrade, so initially into the workshop and up in the air so the original exhaust could be removed to be replaced with the full 76mm (3″) turbo back stainless steel exhaust system:

Exhaust Fitting - Corsa Nürburgring

Exhaust Fitting – Corsa Nürburgring

and then onto the rolling road for 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:

Mapping on the Rolling Road - Corsa Nürburgring

Mapping on the Rolling Road – Corsa Nürburgring

K06 and Inlet Manifold Upgrade

The K06 Upgrade for Astra H VXR is an often overlooked conversion in favour of either a Garrett or Borg Warner EFR turbo, where the thinking is ‘the bigger the better’.

In a real world scenario, this is often not always the case, especially for fast road and trackday use where you want to retain driveability throughout the rev range, rather than wait for a huge hit  of power right at the top end.

Here is a graph showing the comparison between a Stage 2 Astra H VXR (ECU Remap and full exhaust system) compared to a K06 conversion:

Astra H VXR K06 Conversion

Astra H VXR K06 Conversion

In short the power gains of the K06 over the Stage 2 K04 are substantial, to say the least:

+20bhp @ 4,500 rpm
+30bhp @ 5,000 rpm
+50bhp @ 5,500 rpm
+70bhp @ 6,000 rpm
+90bhp @ 6,500 rpm

with much more mid range and top end torque as well, and still producing excellent power of 330bhp at 7,000 rpm and by 7,500 rpm still producing 320bhp, long after the Stage 2 car has faded by the wayside.

Notice also the power is still available from the mid range at 3,000 rpm, where a bigger ‘Garrett’ type turbo may not be fully on song until 4,000-4,500 rpm making the car less ‘on-road’ friendly for mid range road and trackday use.

So what exactly is involved?:

The full Stage 4 K06 conversion consists of a K06 turbocharger, a Courtenay Piper full stainless steel 76mm exhaust system, a Courtenay VXRacing full height front mounted intercooler, a Courtenay Klasen High Flow Inlet Manifold, steel rods, uprated arp rod bolts, new gaskets, exhaust valve spring shims, oil and filter, head bolts and a bespoke Courtenay ECU remap carried out and set up on the rolling road.

New pistons are not required due to the high quality nature of the factory fitted OE (Original Equipment) forged pistons, which are good for up to 500bhpm so they take this power easily in their stride.

The steel rods are fitted for strength, durability and safety. They also mean the engine can be revved much further, taking full advantage of the inlet manifold. Not fitting the rods simply means we have to turn the power down for safety!

The fully reworked K04 Turbocharger to K06 spec includes an uprated bearing pack and seals and billet K06 compressor wheel, meaning the turbo can produce and sustain more boost helped along with an uprated stronger actuator.

Our high flow Courtenay Klasen Inlet Manifold is designed to not only retain mid range power and torque (unlike some manifolds which sacrifice mid range power and torque for top end gains) but it also removes the restriction of the factory OE manifold at the top end. The improved flow means huge gains.

The full height intercooler keeps inlet air temperatures under control, and is available powder coated in stealth black, whilst the full 76mm exhaust system gives the required flow to obtain the maximum gains – a 70mm system will restrict power to 315-320bhp, due to its inability to flow at the top end as well as the 76mm system.

Finally the bespoke mapping and datalogging with map optimisation is carried out on the rolling road, making for a very useable, driveable fast road and trackday conversion not only retaining mid range power and torque but also increasing it.

Astra J VXR Stage 1 Remap

Courtenay Sport Stage 1 ECU Remap

Exclusive Courtenay Sport Stage 1 Software Upgrade. Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.

Our Stage 1 upgrade gives much better low end response combined with a smother and flatter torque curve, whilst at the top end we have managed to increase and sustain the power for longer. Alongside this you will also benefit from improved cruise fuel economy. We saw a peak power figure of 342.65 lb ft torque with power rising to 300.07 bhp. Our development car still has quite low miles so we would expect to see a few more bhp as the engine loosens further.

Like all our ECU upgrades the software is installed on your car whilst on our rolling road optimising fuelling, boost and Ignition maps. This enables us to see and rectify any underlying faults or problems and to ensure that the calibration is 100% accurate and safe for your car before handing it back over to you, along with the full power and torque print outs.

£565.00 including full map optimisation, datalogging and Rolling Road Set Up.

Courtenay Sport Stage 1 Remap Graph Astra J VXR

Courtenay Sport Stage 1 Remap Graph Astra J VXR

Astra VXR Dyno Revelation

A customer asked for his Astra VXR to have a run up on our rolling road the other day, as he had recently bought it and was curious about the power and torque output of the car which was running a full 2.5″ Milltek exhaust system and an off the shelf ecu flash.

The ecu reflash had been carried out by an authorised dealer however it had not been check on a rolling road (as the installer did not have one).
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VX220 Turbo Health Check

We had a VX220 Turbo booked in the other week as the customer had reported that the car seemed to be holding back on track. He thought it might be a fuelling issue and asked us to carry out a health check on the rolling road, datalog the ecu to see what the current map was doing and report back.

The car was running a ‘Stage 2′ ecu remap and has a full 2.5″ exhaust system. After our initial datalogging rolling road session we received a bit of a shock when we plotted the results ……..
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The Courtenay Sport Blog

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