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Vectra Stage 2/3 Insignia VXR Turbo Upgrade

Overview Our goal with this upgrade was to improve the power spread across the rev range and remove the almost “diesel” like power band & delivery found in the existing stage 1 remaps, which is a direct result of the standard Vectra VXR turbo not being able to deliver sufficient boost, of any real value in the last third of the rev range. The development car used was already at stage 1 and equipped with our uprated water radiator, FM Intercooler and a 3” front pipe, in preparation for the upgrade. A Vectra VXR (whether standard or Stage 1) without these additional upgrades, as listed above, would still see a good power increase, with the Insignia’s Turbo, but the top end power would drop away due to flow restrictions through the exhaust and lack of inlet air cooling. We would still, however, recommend changing the water radiator, which can be an issue even for stage 1 cars when driven enthusiastically. Installing the Insignia Turbo is a fairly easy job, but requires patience to ensure that all components required to facilitate an easy installation are removed and car is taken to prevent any damage to both the new and existing components. Power Having installed the Turbo and started the car, we performed an initial run to review the results, running on the Stage 1 map. We found that the standard injectors were running out of duty cycle at circa 330 -335 bhp causing the mixture to become lean (as you will appreciate a weak mixture can cause some very serious damage and very quickly). If we were to continue on the development path, with standard injectors, the top end boost would have to be reduced for the injectors to stay within their threshold. As a result we would be back to the diesel like torque derived power curve, which was not our goal. Therefore we changed the injectors for the higher flowing Insignia VXR ones. This enabled us to hold the boost at the top end to produce a power curve that sustained good high RPM power levels (as can be seen from the graphs). It should be noted, even though we experimented with several different types of induction pipe work, the final results, were achieved using the standard induction pipes. Even opening up the air-box and changing the pipe work to 70mm all the way from the MAF to the turbo had no effect on the peak or through rev range power band. The only noticeable increase was turbo induction noise (which actually was quiet nice, but very subtle). Torque This turbo will produce massive torque figures. We saw 465 lbs ft (640nm) without really trying. However, common sense was telling us that with 2 wheel drive and the fact that the standard car can struggle at 400lbs ft this figure (465 lbs ft), whilst great for pub talk, would render the first 3 gears redundant. Also it would only serve to destroy the clutch and transmission in the remaining gears. As yet we are in 2 minds as to whether 430lbsft is still too much. However a little more time behind the wheel and the owner’s feedback will assist us in making a final decision. Graphs Looking at the graph below you can see that the big increase’s come from 4500 rpm, at which point the engine is producing an additional 40BHP, whilst at 5000 rpm there is producing an additional 52 bhp, and at 6500 rpm the engine is producing an impressive additional 62 bhp over the stage 1 remap. All this lends itself to a far more linear and sustained power delivery, feeling more like a traditional petrol engine.

Vectra VXR Tuning Packages

All our Vectra VXR  remapping is carried out serially, through OBD II/diagnostic port directly into the vehicle's ecu. All our maps are bespoke written for us to suit our requirements. If your car does not fit into the categories listed, for example you have a different exhaust configuration, we can and will write a bespoke map and tailor it to your vehicle.

Courtenay Sport Stage One We carry out a full engine diagnostic test first, we check and gap the spark plugs, then Exclusive Courtenay Sport software is installed raising the boost levels, whilst optimising the fuel and timing curves. A Rolling Road calibration, set up and testing session follows. Power and Torque Graph Print Outs.

+100 bhp mid range gain Peak Power Increase to 295-300bhp Torque: 400+ lb ft (540+ Nm) 140+ lb ft gain

£590 Fitted including Rolling Road Set Up

With our stage one ecu remap we can take the 255 and 280 bhp cars up to a peak of about 295 - 300 bhp (temperature and enviromental conditions dependent) which equates to a 40+ bhp gain on early cars and 15+ on later models but don't think that's all this is about or that our remap is not worth a second look. Whilst the peak gains are not that impressive it is not all about out and out peak power gains............. Our stage one remap gives a massive hike of about +100 bhp in the mid range at 3,700 rpm and a gain of around +140 lb ft torque which completely transforms this car's on road ability. Mid range performance is simply breath taking!

Power Graph for Stage One

Power graph for a Vectra 255 with our Stage One Remap.  Click to enlarge. Peak Power: 297.57 bhp. Maximum Torque: 403.56 lb ft. Cell Temperature: 19 degrees.

Courtenay Sport Stage Two We carry out a full engine diagnostic test first, then we fit a brand new Insignia VXR turbo assembly, change the oil anf filteer, check and gap the spark plugs and finally Exclusive Courtenay Sport software is installed raising the boost levels, whilst optimising the fuel and timing curves. A Rolling Road calibration, set up and testing session follows. Power and Torque Graph Print Outs.	Peak Power Increase to 315-320bhp	£1745 Fitted including Rolling Road Set Up
Courtenay Sport Stage Two+ We carry out a full engine diagnostic test first then we fit a brand new Insignia VXR turbo assembly along with our extra large water radiator, check and gap the spark plugs and finally Exclusive Courtenay Sport software is installed raising the boost levels, whilst optimising the fuel and timing curves. A Rolling Road calibration, set up and testing session follows. Power and Torque Graph Print Outs.	Peak Power Increase to 320-325bhp	£2562 Fitted including Rolling Road Set Up
Courtenay Sport Stage Three We carry out a full engine diagnostic test first then we fit a brand new Insignia VXR turbo assembly along with our extra large water radiator and intercooler assembly, fit a 3” Front pipe, 3” down pipe with Sports Cat, Uprated injectors, check and gap the spark plugs and finally Exclusive Courtenay Sport software is installed raising the boost levels, whilst optimising the fuel and timing curves. A Rolling Road calibration, set up and testing session follows. Power and Torque Graph Print Outs.	Power Graph Peak Power Increase up to 340bhp Torque: 430 lb ft (580+ Nm)	£4470 Fitted including Rolling Road Set Up
Insignia VXR Turbo Supplied and Fitted, includes parts, labour and oil & filter change - £1155.00 High Flow Panel Filter and Iridium Spark Plugs With any upgrade, we also suggest the addition of a High Flow re-useable K&N Panel Filter £45.95 Iridium Spark Plugs are also available (if not already fitted) at £60.00 set of six. Fitting FREE OF CHARGE as part of a Stage upgrade. Fuel: The use of Shell V-Power 99 RON, or a similar Super Unleaded fuel, is a requirement on all remapped vehicles.

Ryan McLeod and his team from Racer Industries in Australia have just successfully completed the Dubai 24 hour endurance race in their modified Astra VXR, which was competing against a field of some considerable machinery. The Astra 2.0 Turbo featured a number of Courtenay Sport components including our cast exhaust manifold, our VXRacing full height Intercooler, high flow plenum, lightweight LEH flywheel, race paddle clutch, brake cooling ducts and Courtenay Sport high flow panel filter. The car was fully race prepared and fitted with a Garrett turbocharger, which with Motec management was mapped to 380bhp running a maximum of 1.2 bar of boost revving to 7k rpm, the aircon was deleted, and the sump was spaced to allow for additional oil capacity. Ryan and the other 3 drivers Camilleri, Holdsworth and Nicholas took car number 67 to a 4th in class finish (in class A3T) and an excellent 26th overall out of 84 cars. Congratulations to Ryan, the drivers and the whole back up team who kept the car racing for the entire 24 hour period. A fantastic result. Links: www.24hdubai.com - - - www.racerindustries.com

Images courtesy of Creventic and Racer Industries

Specifications - Engine, Gearbox and Exhaust Z20LER engine, Forged Pistons, H-Beam Rods, Standard Cylinder Head, Balancer Shaft Deletion, Courtenay Sport LEH/M32 Lightweight Flywheel and 4 Paddle 'Race' Clutch, Courtenay Sport Cast Exhaust Manifold for Garrett Turbo, Disco Potato Turbo, Custom Exhaust Services twin Dump Pipe, 3" Stainless System, Courtenay Sport VXR Intercooler Kit, PWR Alloy Radiator, CDTi Air Box Conversion, M32 Stock Gearbox, Drexler LSD. Suspension MCA Front Struts, Bilstein Rear Dampers, Kings Springs, Whiteline Rear Sway Bar Engine Management Motec M800 ECU, Complete Custom Wiring Harness (no stock wiring), Motec SDL3 dash Logger, Motec ACL Logger, Motec PDM Power Management System, Motec Shift Light Module, System controls Factory ABS and Power Steering, Custom High Energy Ignition system Brakes Brembo Mono Block 4 piston front caliper, 330 x 32 Brembo Motorsport discs, Rear brake up grade from stock VE S" commodore, Interior and Safety 60 lt ancillary Fuel Cell with Twin pump/ reserve system, Body Tech crO Mo FIA cage, Racetech Carbon FIA Seat, Schroth Enduro Belts, Lifeline Z360 Fire system Wheels and Tyres 18 x 8 TD Pro Race II wheels, Dunlop 235 / 40 18 tyres Extensive weight reduction - 1140kg dry

Drive available for 2011 with Championship Winning Team.

Following a Dunlop Sport Maxx Championship winning season with Adrian Churchill and his Astra VXR, Courtenay Sport with Churchill Motors will be running a second fully prepared and supported Astra VXR to compete in the 2011 Dunlop Production Touring Car Trophy.

For more information please contact:

Jon Shield - Courtenay Sport - 01692 404313
Adrian Churchill - Churchill Motors - 01908 542087

We have released Silicone Engine Hoses for Astra 1.9 CDTi Diesel engines. 3 Ply Silicone Hoses with Fluoro lining for added durability and resistance to oil contamination Stock arriving January 2011.

Courtenay Sport to compete in 2011 Production Touring Car Trophy.

2010 Championship Winners to compete in 2011 New Championship Name Circuits and Dates Announced Second Car Available to Race

As the current 2010 Dunlop Sport Maxx Production Cup Champions, we have confirmed our intention to compete in the newly renamed 2011 Production Touring Car Trophy (formerly the Dunlop Sport Maxx Production Cup), following confirmation from Dunlop and the British Automobile Racing Club (BARC) of the 2011 dates and venues. New for 2011 is a round to be held at Silverstone, using the new GP circuit, the round being held at Donington Park is support to the only UK round of the World Touring Car Championship (WTCC), plus Croft has been reintroduced. Additionally for 2011, Courtenay Sport have a second car available to race either on a round by round basis, or for the entire season which will be fully supported at each race weekend. With a name change, the profile of this championship has again been raised, along with the introduction of Silverstone circuit plus running alongside the World Touring Cars. Furthermore to enhance the series, the use of slick and wet weather tyres has been introduced. For further details please contact us.

2011 Dates and Circuits:

March 26	Silverstone GP Circuit
May 7 / 8	Snetterton
June 11 / 12	Thruxton
July 2 / 3	Rockingham
July 16 / 17	Donington Park supporting WTCC
August 28 / 29	Brands Hatch
September 24 / 25	Croft