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Astra H Turbo and Zafira B Turbo Silicone HosesAstra H Turbo and Zafira B Turbo Siliocne Hoses

Silicone Hose Kits

Silicone 5 Piece Hose Kit The Courtenay Sport hose kit comprises of 5 silicone hoses with a lightweight polished aluminium transfer pipe and is designed as a direct replacement for the "OE" hoses. Superb integrity and superior performance reduces the risk of component failure whilst enabling higher temperature and pressures to be maintained. All hoses are made from 3-ply reinforced silicone so that the inlet hoses (between the air filter & the turbo) will not "suck flat" as a result of high suction/vacuum during full boost. The main boost pipes from the intercooler to the inlet manifold are also 3-ply reinforced and are joined by a lightweight polished aluminium transfer pipe. This set up will not swell or "suck flat" under boost or high vacuum yet remains flexible to compensate for engine movement against the intercooler.

ALL Courtenay Sport Hose kits are available in Blue, Red or Black, with Yellow, Green, Orange and Purple colour options available by Special Order, to suit all engine bays.
Hose Kit Options for 2.0 Turbo Models:

Silicone Hose Kit - 3 Hoses £91.95 Buy Now Click Here!

Intercooler to Plenum Hose Kit including Lightweight Polished Aluminium Transfer Pipe £91.95* Buy Now Click Here!

Full Hose Kit including Lightweight Polished Aluminium Transfer Pipe - 5 Hoses £183.75* Buy Now Click Here!

Full Hose Kit without Lightweight Polished Aluminium Transfer Pipe - 5 Hoses £164.35* Buy Now Click Here!

*Now avaiable with Dump Valve Take-Off £10.25 extra

All Hose Kits - Buy Now Click Here!

Intercooler to Plenum Hose Kit - 2.0 T

Astra Mark 5 2.0 Turbo Intercooler to Plenum Hose Kit with polished alloy transfer pipe and dump valve £91.95 Buy Now Click Here! Intercooler to Plenum 2 Hose Kit

Dump Valve Take Off Hose 2.0 Turbo

Dump Valve Take Off Hose with Dump Valve 3 ply silicone dump valve take off hose (Transfer pipe to Plenum) for 2.0 Turbo Models available separately at £57.05 Buy Now Click Here!

Requires a twin piston dump valve without fitting kit suitable for DV Take Off Hose. £88.85 Buy Now Click Here!

Image left shows Dump Valve Take Off Hose and Dump Valve (2.0 Turbo Model.)

Enlarged High Flow Plenum Hose - 2.0 Turbo

/images/uploads/EPH_Hose.jpg To suit our enlarged plenum for 2.0 turbo engines. Available with or without a dump valve take off spigot £61.25

Enlarged Plenum Hose (No DV Fitting) 

Enlarged Plenum Hose (With DV Fitting)

Direct Route airbox fitting kit - 2.0 Turbo.

Direct Route Airbox fitting kit
Black Inlet
Direct Route Airbox fitting kit
Full Engine Bay Image
Direct Route Airbox fitting kit
Blue Inlet
Direct Route inlet a pipe to remove the heavy transfer pipe fitted to Astra and Zafira Turbos. The pipe mimics the path first found and seen on the Cavalier & Calibra Turbo. It can be used with a cone filter, K&N Apollo, Viper or flowmaster Induction - style kit, or as shown with the 1.9 CDTi MK5 Astra airbox.
 
The hose kit consists of an inlet hose with integral moulded breather spigot, an airbox to air flow meter joiner hose, a breather hose and breather hose joiner. The inlet hose is 4 ply silicone for strength with a properly shaped fluoro lined breather hose. When being fitted to Astra H and Zafira B 2.0 Turbo you have 2 options on airflow meter. You can either retain your existing 70mm AFM and use our adapter sleeves to fit, or upgrade to an 80mm airflow meter. If upgrading to an 80mm AFM the ecu will require a remap to be re-calibrated for the 80mm air flow meter.

Hose Kit Only - £131.75
includes the items listed. If using the 1.9 CDTi airbox you will need to source your own and make the required modifications to the outlet to allow the 80mm AFM to fit.

Hose Kit with airbox and fitting for DIY modification - £218.20
includes the items listed above in the hose kit, plus an aluminium spigot and a 1.9CDTi airbox. You will need to modify the airbox by opening up the outlet and bonding in the aluminium spigot to the airbox top to allow the AFM to fit.

Hose Kit with ready modified airbox - £264.70
includes the hose kit and a 1.9 CDTi airbox already modified to fit straight on.

Can be used with the factory fitted 70mm Air Flow Meter.

Upgrade 80mm AFM - £149.95  Note: ECU Remap required to run 80mm AFM

Note: Fitting the direct route airbox will require the air flow meter wiring to be lengthened. We also offer a wiring loom extension to allow for easy fitment.

Direct Route Hose Kit (available with ot without CDTi Airbox): Blue  Black  Red

Direct Route (CDTi) Airbox Conversion Parts

The parts required to allow simple conversion of the standard Direct Route (CDTi) Airbox to accept an 80mm Air Flow Meter.

Once the top of the airbox has been opened up to accept the alloy joiner piece, it can be bonded into place in the airbox lid. The supplied black hose is fitted between the alloy joiner and the 80mm Air Flow Meter.

80mm Adapter Parts. £14.45

Turbo to Intercooler Hoses - 2.0 Turbo

Available for Astra H 2.0 Turbo models the turbo outlet to intercooler silicone hoses. This pipe run is made up of two hoses and includes an aluminium swaged joiner and two heavy duty stainless hose clips. The join sits just to the left of the radiator (when viewed from the front of the car) so makes it suitable for those with standard or side mount intercoolers and our lower front mounted intercooler.

Image (right) shows both hoses for turbo to side mount or standard intercooler.
Turbo to Lower Front Mount Intercooler Hose Both hoses - turbo outlet to intercooler including joiner and hose clips - Shown above - (for cars with 9 litre side mount or standard intercoolers) £131.75 Buy Now Click Here!

Single Hose from turbo to intercooler for cars with our Lower Front Mounted Intercooler - Shown Left - (joins to 90 degree elbow off intercooler) £45 Buy Now Click Here!

Dump Valve Take Off Hose 1.6 Turbo

3 ply silicone dump valve take off hose (Map Sensor to Plenum) for 1.6 Turbo Models available separately at £57.85 Buy Now Click Here!

Requires a twin piston dump valve without fitting kit suitable for DV Take Off Hose. £86.85 Buy Now Click Here!

Image right shows Dump Valve Take Off Hose (1.6 Turbo Model.). When installed Courtenay Sport logo is visible on top of the hose.
Dump Valve Take Off Hose - 1.6 Turbo

Inlet Hose - 1.6T

1.6T Inlet Hose

Reinforced 4 ply Silicone Inlet Hose

The inlet hose has been redesigned & enlarged for improved air flow whist the inside reducing lip has been removed along with the inset bump on the front edge. Designed as a direct replacement for the "OE" hose. Superb integrity and superior performance reduces the risk of component failure whilst enabling higher temperature and pressures to be maintained.

Made from 4-ply reinforced silicone so that the inlet hose (between the air filter & the turbo) will not "suck flat" as a result of high suction/vacuum during full boost.

Inlet Hose: £54.65 Buy Now Click Here!

Silicone Breather Hoses - 2.0T

Breather Hoses To compliment our range of silicone engine bay hose kits for Z20LEL/Z20LER 2.0 Turbo applications, we have manufactured a silicone breather hose. This hose is available in black, blue and red with other colours to special order and comes with the Courtenay Sport Logo. £13.25 Buy Now Click Here!

Courtenay Sport Turbo Dump Valve

Courtenay only recommend the fitment of a Twin Piston Dump Valve as this will not affect air flow metering. The Dump Valve is capable of releasing a higher volume of air than the standard GM Vauxhall fitted unit. It has the added benefit of producing an audible 'whooshing' sound!

£127.85 including fitting kit. Buy Now Click Here! Fitting from £36

Dump Valve without fitting kit (for use with silicone hose with DV take-off)
£86.95 Buy Now Click Here!
Dump Valve with T-piece Fitting Kit

 >>> 1.6 Click Here<<<     Dump Valve Fitting Information     >>> 2.0 Click Here<<<

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Courtenay Sport Vauxhall Tuning
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 Vauxhall Tuning

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