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Astra G and Zafira A Turbo Tuning
Astra 2.0 SRi Turbo
The Astra G/Mark 4 Turbo - Hatchback, Coupe and Cabriolet. Providing responsive engines and a competent chassis, this is an excellent all round performer that responds well to the 'Courtenay Touch.' Mind you..... what Vauxhall doesn't?

Astra and Zafira Turbo Tuning Packages

The Astra (GSi, SRi, Coupe, Cabrio and OPC models) and Zafira (GSi and OPC models) are fitted with a Z20LET turbo charged engine. This power unit is equipped with Motronic M1.5.5 one of GM's more advanced engine management Systems. This engine management system is equipped with flash roms, rather than the conventional eprom chips that for example the Calibra and Cavalier Turbos used. The advantage of a flash rom is that the ECU can have the program changed/rewritten again and again with out ever having to break the ECU open. Zafira GSi
Remapping - Software Only Option:
Bespoke mapping using Courtenay Sport software as used in our CSS Tuning Packages is also available for cars already fitted with suitable parts. The software is tailored to individual requirements according to each application. Software price including datalogging, map optimising and rolling road set up from £495. This includes up to 1.5 hours rolling road time. Additional rolling road set up time £99/hr 'VXR Spec Remap £565.00
Courtenay Sport Stage 1**
Tech 2 Full Diagnostic Check. Factory Base Software Upgrade as required, Exclusive Courtenay Sport Software upgrade. Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
 
Increases up to 245 bhp** £495 Fitted

Courtenay Sport Stage 2**
Tech2 Full Diagnostic Check. Factory Base Software Upgrade as required, Exclusive Courtenay Sport Stage 2 Software upgrade, High Flow Large Lower Front Mounted Intercooler*, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
 
Increases up to 255 bhp £1,325 Fitted*

Courtenay Sport Stage 3**
Tech2 Full Diagnostic Check. Factory Base Software Upgrade as required, Exclusive Courtenay Sport Stage 3 Software upgrade, High Flow Lower Front Mounted Intercooler*, VXR (Z20LEH) turbocharger, VXR Actuator, Oil and Filter Change with Fully Synthetic oil (API:SM). The turbo, combined with our software, is the key to increasing power beyond the 260 bhp mark and producing a strong torque curve, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
 
Increases up to 265 - 270 bhp £2,240 Fitted*

Courtenay Sport Stage 4**
Tech2 Full Diagnostic Check, Factory Base Software Upgrade as required, Exclusive Courtenay Sport Stage 4 Software upgrade, High Flow Lower Front Mounted Intercooler*, VXR High Flow Injectors, VXR (Z20LEH) turbocharger, Uprated Actuator and Stainless Steel Bracket, Oil and Filter Change with Fully Synthetic oil (API:SM). The turbo, combined with our software, is the key to increasing power beyond the 260 bhp mark and producing a strong torque curve. Higher flow injectors ensure enough fuel is available mid range to ensure the engine does not run lean, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
Increases up to 285 - 290 bhp
up to 300 lb ft Torque
High Torque Map Available
320 + lb ft
 
£2,570 Fitted*
We recommend an Uprated Clutch when running the Stage 4 and Stage 4 High Torque Set Up.

K06 Hybird Turbo and High Flow Inlet Manifold
Further Enhancements can be made by fitting a K06 Hybrid Turbo (Power up to 310-315bhp)and our High Flow Inlet Manifold (Power up to 330bhp), however above 310bhp the Z20LET will require forged pistons and steel rods for strength and safety.

**VXR 80mm Air Flow Meter Upgrade Available on ANY Stage of Remap: AFM £149.95 Silicone Hoses £66.35. ECU requires recalibration to run 80mm AFM. If we are remapping this will be carried out at no additional cost.
As part of our Stage Tuning Packages we recommend Airbox modifications and a large bore inlet pipe.

*Fitted Price for our Stage packages on Astra SRi/GSi, Zafira and Coupe models with GSi front bumper. Additional cost of £110 on Coupe and Cabrio models, due to the extra time needed for fitment, which includes the bumper reworking on these models.

**Please note: For best results Z20LET engines require a full 76mm sports exhaust system to achieve maximum power increases. This is recommended for all our CSS Tuning Packages, but especially for the higher stages of tune. Upgrades can still be performed on cars running combination exhaust systems(e.g. cat back system and front pipe) or smaller bore systems, but as a minimum for a Stage One we recommend at least a front pipe is fitted. Maximum power increases will be achieved once a full system is in place. All our software upgrades are bespoke, tailored to your car on our rolling road to achieve the maximum power and torque increases to suit each individual application.

High Flow Panel Filter:
We also suggest the addition of one of our High Flow re-useable Panel Filters £34.95. Buy Now Click Here! FREE fitting as part of a Stage upgrade.

Fuel:
We recommend the use of Shell V-Power, or a similar Super Unleaded fuel, on all remapped vehicles for optimum performance.
Iridium Spark Plugs:
For customers who intend to use their cars for fast road or track use, where engines may run warmer, we can offer a spark plug upgrade. These iridium spark plugs are 'cooler running' and so able to dissipate more heat from the combustion chamber and produce a more efficient spark.

£33 for a set of four. Buy Now Click Here! FREE fitting as part of a stage upgrade.
NGK Iridium Cooler Running Spark Plugs
Garrett Upgrades.
Garrett Upgrades, Tubular and Cast Manifolds, High Flow Inlet Manifold, Engine Building, Pistons, Steel Rods.

Large Capacity High Flow Lower Front Mounted Intercooler

Lower Front Mounted Intercooler Our Lower Front Mounted Intercooler improves on the original 9 litre side mounted intercooler by the fact that in most applications over 95% of the frontal area is directly exposed to high pressure air, whereas with the original 9 litre side mounted cooler at least 40% is obstructed by the bumper. To this end on back to back testing at an ambient start temperature of 22 degrees the "OE" intercooler will exceed 74 degrees inlet air temperature, the 9 litre side mounted intercooler sees a respectable 55 degrees, however due to its position and therefore increased efficiency the new Lower Front Mounted Intercooler sees this inlet air temperature drop to 41 degrees.
As a result an Astra Coupe that was dyno tested running standard map, Courtenay front pipe and a Viper Induction Kit produced 205 bhp on the standard "OE" intercooler, and when tested after fitment of our New Lower Front Mounted Intercooler saw an increase of 18 bhp at best case and 15 bhp at worst. As used in our CS2, 3 and 4 Tuning Packages.

£615.00 including full fitting kit and instructions. Fitting in house from £190 Buy Now Click Here!

Turbochargers - Direct Replacement

Vauxhall/Opel have again used KKK to supply the turbocharger for the Z20LET engine. This unit has a fairly small A/R ratio which is why it is so quick to spin up onto boost, however the down side to this is the limit of power that the unit can produce. This is why we limit the peak torque of the Stage 2 package so as not to over rev the turbo, which in turn can dramatically shorten its life. For additional power and torque a turbo upgrade is required.

Direct Replacement: The K04 Astra VXR turbocharger is suitable as a direct replacement for a ZLET turbo unit that has failed and requires replacement. It is a direct fit and will work on a car with standard software. An ecu remap is not required if being fitted as a direct replacement to a standard mapped car.

Note: For Stage 1 or 2 mapped cars, if the VXR turbo is used to replace a standard ZLET unit we advise having the software checked to ensure boost and fuelling is still correct.

VXR Astra H Z20LEH K04 Turbo for Astra G/Zafira A

VXR Turbo From the extensive testing that we have carried out we use the Astra H VXR turbo as a great option for additional performance over the standard turbo.

Offering drivability like a manufacturer's standard unit, rather than a hybrid, and spooling up more quickly this is an ideal unit for those wanting to upgrade to the Stage 3 or 4 conversion with the appropriate remap.

Requires an uprated actuator and bracket if being used for Stage 4 mapping.
This unit not only features a better AR ratio but we also favour this turbocharger as it has a much stronger cast manifold providing extra durability and therefore can withstand greater temperatures, heat being an issue with turbo models. The standard ZLET turbo manifold has been known to crack and so this Z20LEH unit is preferred over a hybrid turbo which is rebuild into the original weaker manifold which is prone to cracking.

Z20LEH units fitted by Courtenay Sport will benefit from a 12 month/12,000 mile warranty.

Turbocharger* and VXR Actuator (Special Mail Order*): £Check Shop Buy Now Click Here!

Turbocharger complete with VXR Actuator (Price includes warranty when supplied and fitted in our workshop): £895 Fitted price includes turbocharger, gaskets, oil and filter change using fully synthetic oil

Turbocharger* with Uprated Actuator and Bracket (Mail Order Price*): £Check Shop Buy Now Click Here!

Turbocharger with Uprated Actuator and Bracket (Price includes warranty when supplied and fitted in our workshop): £1037.95 Fitted price includes turbocharger, gaskets, oil and filter change using fully synthetic oil

Uprated Actuator and Stainless Steel Bracket for Stage 4 Cars (already fitted with a VXR Turbo Unit): £189 Fitting available.

Fitting in our workshop includes required gaskets, Oil and Filter Change using Fully Synthetic 5w-40 API:SM specification oil

* As Vauxhall will only warrant these units for their intended purpose i.e. fitment to factory specification Astra/Zafira VXR, we are unable to extend a warranty onto them due to the varied nature of fitment and application outside of these parameters.
For units supplied and fitted by us on our premises we will offer our own 12 month/12,000 mile warranty.

How dirty oil will destroy a turbo - Check out info our blog

Hybrid Turbochargers - K04 and K06

We can also offer hybird turbo options allowing the turbo can achieve additional peak and top end boost pressure, providing yet more power and torque. K04 options include a stronger 360 bearing pack, uprated seals without compromising the bearing housing wall thickness, step gap rear seal and cut back exhaust wheel. The K06 option adds a billet K06 compressor wheel.
Hybrid Options cost from £795 - £1045 Buy Now Click Here!

How dirty oil will destroy a turbo - Check out info our blog
Turbo Installation Information - Click Here LEH Turbo Testing - Click Here
Read about our testing of the Z20LEH turbo unit against the TD Hybrid turbo on a Z20LET engine, from back in Summer 2005. Click on the above link.

Uprated Actuator and Bracket

An uprated actuator for Astra G Turbo suitable for Stage 4 where a stronger actuator is required to help offer smoother boost delivery. Spring tension can be altered to suit different mapping requirements if needed.

>>>>> Read More ...... <<<<<

VXR Injectors and 80mm Air Flow Meter

As used in all Stage 4 cars, where additional fuel is required above about 270 bhp. Set of 4 high flow VXR injectors (blue). ECU recalibration required to run these injectors (available at extra cost) £126.00 Buy Now Click Here!

80mm Air Flow Meter. Available as an upgrade on ALL stages of remap, this meter head is more stable than the OE 70mm item. ECU recalibration required to run this meter (available at extra cost)
80mm Air Flow Meter £149.95 Buy Now Click Here! Silicone Hoses to fit 80mm AFM £66.35 Buy Now Click Here!

High Flow Plenum

High Flow Plenum
High Flow Plenum
High Flow Plenum
Astra G/Zafira A Kit
High Flow Plenum
Next to OE Plenum
Our new High Flow Plenum is designed for all 2.0 Turbo Z20LEx engines. The plenum has been designed to allow more air flow through its enlarged housing, which has a 25% larger cross sectional area than OE (original equipment). It has been cast in alluminium specifically to give it an OE look, but leaving the option open to have the item polished or powder coated as necessary. This plenum has been proven up to 400 bhp, where on these engines the inlet manifold becomes a restriction and further major changes have to then be made to the inlet manifold, throttle body and associated pipework.

The plenum can be supplied on its own with a stud and nut fitting kit, or with the required silicone hoses with or without pre moulded dump valve take off piece. For more information and images >>>> Click Here <<<<

High Flow Plenum £89.50 including VAT. Buy Now Click Here!
Kit including Hoses for Astra G/Zafira A £173.15 including VAT. Buy Now Click Here!

High Flow Inlet Manifold.

High Flow Inlet Manifold - Gains from 30 bhp. More Information....
Z20LEH Engine Transplant.

Details of the Z20LEH (Astra VXR engine) engine transplant.
Z20LEH Transplant
Engine Rebuilding Options Engine Rebuilding and Components.

A separate page with details of our engine rebuilding services, high yield forged pistons, Steel Rods and Balancer Shaft Deletion Kit.

Z20LEH or Wossner Forged Pistons

 From £594 - £650 per Set. Details on our engine rebuild page. Click for Info

Uprated Lightweight Steel Rods and ARP Rod Bolt Kit

 From £360 per Set. Details on our engine rebuild page. Click for Info

Balancer Shaft Removal Kit

 £148.80 Details on our engine rebuild page. Click for Info

Uprated Fuel Pumps
Aeromotive and Walbro, including Fitting Guidelines
Clutch Options and Lightweight Flywheels

Details of Clutch Kits and Lightweight Billet Steel Flywheels.

F23 4.17 Final Drive Ratio

Lower Final Drive Components Lowers the final drive ratio of the Z2.2SE F23 gearbox by 5.8% and the Z2.0LET F23 gearbox by 14.9% for faster acceleration. £POA
Alloy Bottom Pulleys
 
Brake Upgrades
Exhaust Systems.

Details of exhaust systems we use and recommend for Astra G and Zafira A Turbo.
Turbo Hose Kits - Click Here Turbo Hose Kits. Turbo Hose Kits - Click Here
A separate page with details of our silicone hoses which are available for the Astra and Zafira Turbo models.

Direct Route Airbox and Fitting Kit (CDTi Airbox).


Direct Route Hose Kit and CDTi Airbox Modification. More Information....
Recirculation Valves
and Actuators
Suspension and Chassis Tuning - Click Here Suspension and Chassis Tuning. Suspension and Chassis Tuning - Click Here
Details of suspension and chassis tuning options available including springs, our premium suspension kits, uprated anti roll bars and polyurethane bush kits.

VXR and OPC Plug Covers

VXR Spark Plug Cover The VXR Plug Cover as used on the New Astra H VXR Z20LEH. Finished in painted metallic black with a silver fleck, and the VXR and Griffin logos. Suitable for Astra H (Z20LEL/Z20LER), Astra G Z20LET and Zafira Z20LET.
Only £10.15. Buy Now Click Here!
OPC Spark Plug Cover OPC Plug Cover with New Style OPC Logo (as shown left) Now Avalable! £12.95 Buy Now Click Here!

Blue OPC Plug Covers with Opel and orignal style OPC logo in Silver with yellow flash also available for this engine. £21.45 each Buy Now Click Here!

Courtenay Sport Turbo Boost Gauge

Courtenay Boost Gauge Whether you're running standard or increased boost pressure, keep a close eye on it with the Courtenay Turbo Boost Gauge. An excellent diagnostic tool. Available with a white face reading to 30 psi (markings in Black). The gauge can be illuminated with a 12v feed and earth to the supplied bulb. Comes complete with fitting kit (t-piece, rubber vacuum connectors and vacuum hose) to allow easy fitment.

Boost Gauge £72.00 Buy Now Click Here! Dash Mount Pod £8.40 Buy Now Click Here!
Fitting from £72.00

Cool Running Thermostat

Cool Running Thermostats Our cool running thermostat reduces the engine's normal running temperature, protecting the engine by running it closer to it's optimum power temperature. The stat opens 5 degrees earlier than the standard OE item (87 degrees instead of 92 degrees) and is fully open 5 degrees earlier (102 degrees instead of 107 degrees). Ideal for modified cars for fast road and track work, they typically operate up to 3 - 5 degrees cooler thus reducing peak temperatures caused by sustained hard use. As used in Opel/GM products in warmer climates.

Cool Stat .... £25.50 Buy Now Click Here! Fitting .... £36

Water Wetter

Helps to aid the heat transfer of the coolant for even greater cooling ability and head temperature reduction.

A 355ml bottle of Water Wetter suitable to treat one cooling system, which aids the heat transfer of the coolant for even greater cooling ability and head temperature reduction.

Water Wetter - £15.25 Buy Now Click Here!
Water Wetter

Courtenay Sport Air Filter and Large Bore Inlet Pipe

There are so many 'high performance' air filters on the market that it's difficult to know which one to choose. We have taken the guesswork out of it by producing our own - specially designed to work best with Vauxhall/Opel applications.

Our high flow, high efficiency air filter uses a special foam which gives better airflow than even the most popular cotton gauze aftermarket filters. Our filters offer the very highest level of dirt retention and protection (Of course! After all we're engine builders!) and you can clean it and reuse it just like most other performance filters. Supplied pre-oiled ready for first use.

Price £34.95 Buy Now Click Here! Large Bore Inlet Pipe £24 Buy Now Click Here!
Courtenay Sport High Flow Panel Filter
To get the most from your air filter and airbox we can modify the internals of your airbox to derestrict it to gain maximum flow
Airbox modifications - £25.50 Fitted in house

Air Flow Meter 70mm and Coil Pack

The Air Flow meter on the Z20LET engine has a tendency to fail, even on standard cars with no modifications. Replacement Bosch Unit £112.35 Buy Now Click Here!

The coil pack on the ZLET engine can be prone to failure over time, causing misfires and poor running. Replacement Bosch Unit £102.50 inc VAT Buy Now Click Here!

Do not use cheaper, non genuine copy parts. They often fail prematurely and lead to poor running and can cause more problems than they solve.

Traction Control Switch

A traction control switch to cars that haven't got one, just as it would have been fitted at the factory. This gives the driver the option of using the traction control, especially useful for when the traction control cuts in at the wrong moments, such as when out on track. £28.80 Loom and TC Switch Buy Now Click Here! Fitting from £108 (Astra) £144 (Zafria)

© Copyright Courtenay Sport Ltd


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Courtenay Sport Vauxhall Tuning
Courtenay Sport
 Vauxhall Tuning

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