Posts Tagged ‘ Vauxhall Tuning ’

PowerAlign Camber Bolts

Camber Bolts

Camber Bolts

Powerflex have announce a new ranged of PowerAlign products under the Powerflex umbrella.

The range of products will grow over the coming months. They will be more hardware based and offer innovative solutions to improve chassis geometry.

The first two products include a new range of camber bolt kits and a simple camber setting tool. By simply substituting the original upper bolts on two bolt suspension struts for PowerAlign Camber Bolts, this allows up to +/-1.75degs of camber change.

This offers an easy fix for camber issues and a perfect add-on for any suspension bush change, or for changes to camber required for a more ‘track focused’ set up.

The bolts are made using a 12.9 tensile, zinc plated high strength steel. These parts are also covered under the terms of the Powerflex lifetime warranty.

They are available in 5 sizes, to replace bolt diameters M12, M14, M15, M16 and M17 covering a wide range of vehicle makes and models.

Courtenay Sport currently stock the M12 bolts, suitable for the majority of the Vauxhall/Opel range.

M12 Camber Bolts £18.89 per pair

Camber Gauge

Camber Gauge

Along with the camber bolts, the PowerAlign Magnetic Camber Gauge, PFG-1001 measures the Camber angle on the wheel hub or brake disc and allows on-car adjustment to ensure correct wheel alignment.

This is a useful tool for setting Camber angles after dismantling and re-assembling of the suspension and is an ideal track day companion.

This easy to use magnetic gauge attaches to the hub or brake disc and graduates +/- 6 degrees and comes supplied in a durable storage case.A perfect addition to the PowerAlign range and a straightforward product to supply to customers allowing them to correctly set camber angles without expensive geometry equipment.

Camber Gauge £35.94 – Available to Order

Astra J VXR Remapping

We had another Astra J VXR in for mapping this week and it is good news that we are now seeing more and more of them. ECU remapping alone makes such a big improvement.

Otherwise a standard car, the ecu was treated to some enhancement offering much more mid range power and torque with good top end gains too, and the software was optimised, whilst the ecu was datalogged on the rolling road and a full set up carried out, checking AFR, boost pressure, inlet air temperatures, ignition time etc. A massive improvement all round, with mid range gains of between 10-40+bhp and torque with overall peak power at a shade over 300bhp.

Astra J VXR

Astra J VXR

Astra J VXR

Astra J VXR

Astra J VXR

Astra J VXR

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.

Vectra VXR Benefits from Bespoke ECU Remap

We were asked by a customer to diagnose a misfire on his Vectra VXR, which had occurred at around the same time as a set of spark plugs had been replaced.

Initially we checked which plugs were fitted in the front bank (as these are easy to check) and also to check the plug gap, which is critical on mapped cars. At this point all seemed well as the plugs were iridium ones, and they were correctly gapped.

Running the car on the rolling road (with full datalogging facilities) the car did indeed have a misfire running the ecu remap that was installed. As the plugs seemed fine, wondering if software had anything to do with the misfire we mapped back to standard (as the customer had brought his hand held unit with him) and ran the car again. The misfire had gone.

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Revised Astra VXR Intercooler

We have recently revised our Astra and Zafria VXR intercooler pipework, after requests from customers, to improve upon an already excellent design. From its existing design, the complete kit has been tested and proven to in excess of 420bhp (the intercooler core is good for 600bhp) with the intercooler utilising 60mm pipework from the turbo (the moment we can step it up from the OE 50mm turbo outlet we do) to the intercooler 60mm inlet. The intercooler outlet was 50mm, and stepped up to 60mm by the start of the OE map sensor pipe which we made use of in our original kit.
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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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Welcome…..

Courtenay Sport Astra VXR Race Car

Courtenay Sport Astra VXR Race Car

Welcome to Courtenay Sport’s new blog. This blog will serve as an additional resource alongside our main website to keep everyone updated on what we are up to on a daily basis. We hope you enjoy it.

The Courtenay Sport Blog

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