Posts Tagged ‘ VXR ’

Poly Engine Mount Additions – Astra H VXR and 1.9 CDTi

At our request, Powerflex have added a couple of new polyurethane engine mount inserts to their Astra H range.

Courtenay Sport supplied the relevant OE engine mounts and asked if a lower front engine mount insert for Astra H 1.9 CDTi models and an insert for the Right Hand Side Mount for Astra H VXR and 1.9 CDTi could be produced.

These engine mount inserts fit into and fill the voids in the original bushes and are recommended as a labour saving method of limiting engine movement to improve vehicle performance and reduce the likelihood of engine mount and downpipe failure caused by excessive movement. Some additional NVH may be experienced.

These mounts are now available in both road spec material to reduce engine movement but limit increased Noise, Vibrationand Harshness (NVH) and Black 95 Shore Track spec material, which due to its nature is much stiffer and will lead to significantly more NVH being transmitted.

Astra H 1.9 CDTi Front Engine Mount Poly Insert in Road Spec Material (below).
Road Spec £24.00:

Front Poly Mount Insert Astra H 1.9 CDTi

Front Poly Mount Insert Astra H 1.9 CDTi

Astra H 1.9 CDTi Front Engine Mount Poly Insert in Black Spec Track Material (below).
Track Spec £27.00:

Front Poly Mount Insert Astra H 1.9 CDTi in Black

Front Poly Mount Insert Astra H 1.9 CDTi in Black

Astra H 1.9 CDTi Right Hand Engine Mount Poly Insert in Road Spec Material (below).
Road Spec £22.50: Track Spec (Black) £26.10:

Right Hand Poly Mount Insert Astra H 1.9 CDTi

Right Hand Poly Mount Insert Astra H 1.9 CDTi

Astra H 2.0 Turbo inc VXR and Astra G 2.0 Turbo Right Hand Engine Mount Poly Insert in Road Spec Material (below).
Astra H 2.0 T inc VXR Road Spec £22.50: Track Spec (Black) £26.10:

Astra G 2.0 Turbo & Z22SE Road Spec £22.50: Track Spec (Black) £26.10:

Right Hand Poly Mount Insert Astra H 2.0T VXR

Right Hand Poly Mount Insert Astra H 2.0T VXR

Astra VXR Rolling Road Health Check

It is always useful to have a car checked from time to time on the rolling road, as it can show up potential running issues.

We had this Astra H VXR Nürburgring brought in for a health check on the rolling road this week, due to it feeling ‘down on power’ after a manifold swap by the owner, so running it up and datalogging it should highlight any issues.

We carried out an initial check over of the vacuum pipes, recirculation valve and actuator just to make sure nothing physical was at fault which could cause a problem. The ecu was also checked for any stored trouble codes, again to see if there was anything that could cause a running issue.

Running the car up on the rolling road whilst datalogging found the turbo to be down on boost, making less bosst pressure than expected  and resulting in 255bhp and 290 lb ft torque down on what is expected from a Nurburgring with a remap.

Additional checks were carried out to the boost hoses and intercooler fittings, which showed no leaks or issues.

After further runs, the turbo was shown only to be capable of making a maximum of 20psi overboost, and unable to make the required boost at peak power (around 5,700rpm), so identifying the root cause of the problem to be a failing turbocharger.

Astra VXR Health Check

Astra VXR Health Check

VXRacing Door Sill Trims

VXRacing Sill Trim Cover

VXRacing Sill Trim Cover

VXRacing VXR Door Sill Trims Now Available. As fitted to Astra VXRacing Editon models

Only £28.00 per pair

Turbosmart Recirculation Valve

We have been sent this lovely looking Turbosmart recirculation valve to try for the KKK K04/K06 turbocharger, which we rather like the look of. Once we’ve had a chance to evaluate it fully we’ll report back. In the meantime please enjoy this stylish piece of automotive add-on

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

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:

[nggallery id=20]

 

Oil Contamination Fact Sheet:

Oil Contamination Fact Sheet

Oil Contamination Fact Sheet

Side Gearbox/Engine Mount Fitting – Astra G/H and Zafira A/B

Astra G/H 2.0 Petrol Turbo, Astra H 1.9 CDTi, Zafira A/B 2.0 Petrol Turbo and Zafira B 1.9 CDTi have a gearbox side mount that is rubber and prone to failure.

Courtenay Sport approached Powerflex to devise a solution to not only improve the original factory mount, but also give it some additional support and to help reinforce it. In some cases where the original factory mount is not too badly damaged or split, the polyurethane insert can be used to ‘save’ the failing factory mount and prevent further deterioration.

Two specifications of material are available for this mount: Yellow for road use (Shore Hardness 70) and Black (Shore Hardness 95) more aimed at trackday/competition use as it is much stiffer.

OE Factory Engine Mount and Yellow Poly Insert

OE Factory Engine Mount and Yellow Poly Insert

OE Factory Engine Mount and Black Poly Insert

OE Factory Engine Mount and Black Poly Insert

We recently fitted a yellow mount insert to an Astra H VXR which had covered just over 46,000 miles and the factory mount was already showing signs of weakening due to splitting which if left would ultimately deteriorate fully and  fail completely.

Once fitted there was no noticeable increase in NVH (Noise, Vibration, Harshness) into the vehicle. The vehicle used also had an uprated front engine mount insert fitted. Additionally it was noted that the gearchange had improved and became smoother due to the reduction in gearbox movement at gearchange, due to the uprated gearbox mount insert.

On vehicles with a full set of uprated engine mounts, some minor change in NVH may be experienced by fitting this additional mount.

Here is a brief fitting guide: Read more

Rear Braided Brake Hose Fitting – Astra G/H and Zafira A/B

The factory/OE rear brake hose on these cars is a single piece with a rubber brake hose at each end and a solid metal joiner pipe which cannot be reused due to the way the rubber hoses are fitted into the metal pipe.

Our braided rear brake hose kit comes complete with 4 braided hoses (2 for each side) and 2 copper joiner hoses (again one for each side). Unlike some other supplied brake hose kits we do supply the copper joiner pipes with male unions pre-fitted, to make fitting braided rear brake hoses a much more straightforward job.

Additionally the brackets that are used on the factory rear brake hoses can be re-used with our rear brake lines, as this is often queried by people.  We’ve uploaded a few fitting images to show you how its done.
Read more

The Courtenay Sport Blog

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