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Non Turbo Tuning

Welcome to our Atmo Tuning page. This page covers most aspects for tuning normally aspirated, or non turbo charged engines. It covers everything from panel filters to uprated sports cams to cylinder head re-working to a complete engine rebuild. In fact anything to improve the performance of your vehicle for fast road use. Whilst we can fit any of these tuning items in our own workshops, we can also supply many of them via mail order.

We have listed our Tuning Packages for the most popular engines first, with information further on regarding other tuning items that are available, either separately or as part of a tuning package.

Tuning Packages for 1.8 16v Engines

Suitable for Z18XE and X18XE1 engines - Corsa C, Astra G, Vectra B
CS Stage 1
Remap, Airbox modifications, High Flow Sports Panel Filter
Increases up to +9 bhp £369 Fitted
CS Stage 2
Remap, Airbox modifications, High Flow Sports Panel Filter, Sports Cams
Increases up to +20 bhp £1445 Fitted
CS Stage 3
Remap, Airbox modifications, High Flow Sports Panel Filter, Sports Cams, High Flow 200 cpi Motor Sport Cat
Increases up to +26 bhp £1955 Fitted
CS Stage 4
Remap, Airbox modifications, High Flow Sports Panel Filter, Sports Cams, High Flow 200 cpi Motor Sport Cat, Modified Cylinder Head, Oil and Filter change
Increases up to +35 bhp £2,835 Fitted
Optional - Lightweight Flywheel, for lightening throttle response and improved acceleration - £410 Fitted when fitted with any CS Stage package listed above.

Courtenay Sport recommend a good free flowing sports exhaust system, such as a Milltek where available, is fitted for best results from all engine tuning.

Tuning Packages for 2.0 XEV engines

Suitable for X20XEV engines - Astra G, Vectra B, Cavalier, Calibra
CS Stage 1
Remap, Airbox modifications, High Flow Sports Panel Filter
Increases up to +9 bhp £369 Fitted
CS Stage 2
Remap, Airbox modifications, High Flow Sports Panel Filter, Sports Cams
Increases up to +20 bhp £715 Fitted
CS Stage 3
Remap, Airbox modifications, High Flow Sports Panel Filter, Sports Cams, High Flow 200 cpi Motor Sport Cat
Increases up to +26 bhp £1115 Fitted
CS Stage 4
Remap, Airbox modifications, High Flow Sports Panel Filter, Sports Cams, High Flow 200 cpi Motor Sport Cat, Modified Cylinder Head, Oil and Filter change
Increases up to +35 bhp £1,995 Fitted
Optional - Lightweight Steel Billet Flywheel, for lightening throttle response and improved acceleration - from £550 Fitted when fitted with any CS Stage package listed above.

Courtenay Sport recommend a good free flowing sports exhaust system, such as a Milltek where available, is fitted for best results from all engine tuning.

Astra G/Vectra B 2.2 16v Tuning Packages

Our CS 3, CS 4 and CS 5 Tuning packages now include a Rolling Road Tune.
CS Stage 1
Remap
 
Increases to +8 bhp £365 Fitted
CS Stage 2
Remap, Airbox Mods, Sports Air Filter
 
Increases to +10 bhp £425 Fitted
CS Stage 3
Remap, Airbox Mods, Sports Air Filter, Pre-cat removed, 200 cell per inch Sports Cat, Rolling road Tune
 
Increases to +18 bhp £1208 Fitted
CS Stage 4
Airbox Mods, Sports Air Filter, Pre-cat removed, 200 cell per inch Sports Cat, Modified Cylinder Head, Remap, Oil and Filter change, Rolling Road Tune
 
Increases to +25 bhp £3,075 Fitted
CS Stage 5*
Airbox Mods, Sports Air Filter, Pre-cat removed, 200 cell per inch Sports Cat, Uprated Schrick Camshafts with double valve springs and collets, Modified Cylinder Head**, Remap, Oil and Filter change, Rolling Road Tune
*Vectra B +£240 for additional camshaft re-work
**Additional head work may be required to allow double valve springs to seat correctly.
Increases to +35 - 40 bhp £POA Fitted*
Optional - Lightweight Steel Billet Flywheel, for lightening throttle response and improved acceleration - from £615 Fitted when fitted with any CS Stage package listed above.

Courtenay Sport recommend a good free flowing sports exhaust system, such as a Milltek where available, is fitted for best results from all engine tuning.

Courtenay Sport Air Filter

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.
Courtenay Panel Filter
Each filter is supplied pre-oiled and ready for first use. For cleaning, simply wash out the underside of the filter using warm water and washing up liquid until clean, rinse through from the top to the bottom of the filter, allow to dry and lightly re-oil before re-fitting. Filter oil is available seperately for subsequent re-oiling after cleaning.

To fit most Vauxhall models from Astra to Zafira. Priced at £34.95  Filter Oil £4.05

Courtenay Sport Cylinder Heads

Cylinder Head Courtenay have been performance tuning Vauxhalls since 1984. The feature that sets Courtenay's work apart, however, is that it has always been intended for road use from the beginning rather than being competition derived technology transferred directly to the road.

Road cars need torque across the 2000-5000rpm range (where we do 95% of our driving) more than they need top-end brake horsepower at 6000-7000rpm (where we hardly ever go). Race drivers are only interested in top-end power and will accept a lack of torque in the mid range as a necessary consequence of maximising horsepower.
So we believe that if we really are to do the best job for you as a Road Engine Tuner we should concentrate on the mid range torque as priority and accept as much - or as little - extra top-end brake horsepower (at zillions of rpm!) as we can get at the same time. Astra G
Extensive development has revealed a method of reprofiling and finishing the ports and combustion chamber surfaces to produce what must be the "perfect" result: virtually the same percentage horsepower increase at the top end as the torque is increased in mid range - in tuning that's having your cake and eating it!
VX220 2.2 16v Courtenay Sport cylinder heads are offered on an exchange basis (subject to a returnable deposit, of course) for the more popular applications or otherwise we will rework your own head for you, which many of our customers prefer. They may either be fitted in our own workshops or supplied by mail order. We do not call our heads "Stage 1" or "Stage 2" since this is quite meaningless: rather, we prefer to call them by the level of benefit they offer.

CS 10 Heads

Courtenay Sport CS10 will give approximately a 10% improvement in both torque and brake horsepower - right across the board! It comprises of a head, which has been overhauled, with new stem seals. The valves are reprofiled in the stem and the head. The ports are reprofiled (not merely opened out) and the seats recut with compound angles. The ports and combustion chambers are then not polished, but sandblasted specifically to take away the polishing effects of the machining work. This has a major influence on improving the torque and fuel economy (another bonus we did not mention before!).

CS 10 Head Prices

Application (Exchange) Price from
Fitting
All 4 Cyls (except below) £445 £360
4 Cyl CIH Heads £445 £425
4 Cyl 16v Heads £615 £595
6 Cyl 12v Heads £615 £595
6 Cyl 24v Heads £1055 £625
V6 2x12v Heads
(consists of both heads, reworked inlet section and front cast exhaust manifold)
£975 £845
4 Cyl 16v 2.2 (Z22SE Alloy Engine) £800 From £864

CS 15 Heads

Courtenay Sport CS15 will give approximately a 15% improvement in both torque and brake horsepower. Its composition is essentially the same as the CS10 except that the larger inlet valves are specified and in some cases (post 1987, 1800 and 2000 8v OHC engines) the inlet manifold is also reworked to suit. Otherwise the essential philosophy is the same.

CS 15 Head Prices

Application (Exchange) Price Fitting
All 4 Cyls (except below) from
£615 £POA
4 Cyl CIH Heads £615 £POA
4 Cyl 16v Heads N/A N/A
6 Cyl 12v Heads £895 £POA
6 Cyl 24v Heads N/A N/A
V6 2x12v Heads (pair) N/A N/A

C20XE Porous head repair

The 2.0 16V XE heads suffer an internal oil gallery problem. The gallery is the cross feed that links the 2 camshaft oil feeds, this cracks/goes porous, the oil then leaks into a water gallery and the result is oil in your water and a header tank full of emulsified oil. To fix this we drill into the head and completely blank this problem gallery from both ends. Having done this we then run an oil link tube externaly through an aeroquip pipe thus completly by passing the problem area. This is a 100% fix and as yet we have never seen a recurrence of the problem.

£NLS

Uprated Sports Camshafts

Sports Camshafts As a by-product of our advanced turbo development programme we have managed something we didn't ever think could be done. We have come up with a camshaft specification which betters the GM originals for torque delivery - even on a non-turbo engine. This is a real breakthrough; previous experience had invariably shown disastrous mid-range torque reductions with so-called "Performance" camshafts fitted to GM engines. We can now offer Courtenay Uprated Sports Camshafts for most engines from 1.4 to 3.0, pre-Ecotec and Ecotec: "straight" and "vee".

Buy Now Click Here!

Uprated Sports Camshafts - Prices

Application
(Exchange Cams)
Typical Power Gain Price Fitting
4 Cylinder 16v's
(2.0 16v XE, XEV, CLET)
From +8bhp £276.00 £245
2.5 V6 24v's (All four cams) +15bhp £390.00 £430
3.0 V6 24v's (All four cams) +18bhp £390.00 £430
       
Application
(New Cams NOT Exchange)
Typical Power Gain Price Fitting
All 4 Cylinder 8v's (1.3,1.4,1.6,1.8,2.0) From +10bhp £240 £155
1.4, 1.6 16v (Not Z engine)
From +7bhp £710 £245
1.8 16v Smallblock From +15bhp £710 £245
2.0 16v XE, LET, XEV From +8bhp £540 £245
Z22SE 2.2 16v Alloy Engine* Increases to +15bhp £POA From £625
*2.2 cams include double valve Springs and collets and may require head machining work to fit. Vecta B +£200 to include additional camshaft re-work required for PAS pump drive.

Z22SE 2.2 16v Alloy Engine - Tuning

Remap to standard ECU. Increases to +7 bhp £310 Fitted

High Flow Sports Air Filter £34.95 Buy Now Click Here!

Air Box Modifications (RWD - Fitted in house) £54

Air Box Modifications - Astra G/Zafira A (Fitted in house) £25.50

Cool running thermostat £25.50 Buy Now Click Here!

Uprated Sports Camshafts. (Outright) Increases to +15 bhp - Astra G/VX220 £1247 Vectra B £1487

Modified Cylinder Head. Increases to +10 bhp £POA
Fitting includes new valve seats from £POA
GM Z22SE Engine

VX220 2.2 16v Tuning. Click Here For More Information

For more details on tuning and full details of our Tuning Packages for
VX220 2.2 16v Click Here.

2.4 Inlet Manifold for Z22SE

2.4 Inlet Manifold for Z22SE

2.4 Inlet manifold for Z22SE 2.2 16v engine. Fits as a direct replacement to the original manifold - £NLS

Additional Useful Fitting Parts - £NLS

No Longer Seviced.

Useful Fittings

Z22SE Supercharger Conversion

Our Supercharger Conversion was originally developed for the VX220 2.2 16v and features several components from the GM 2.0 supercharged LM850 engine, which was developed by Lotus, and is used by GM in the Saturn Ion Redline and the Chevy Cobolt SS in the USA. One major benefit of this is that the components are ‘OE’ fitment and durability tested, another being an inlet manifold featuring the laminova charge cooler fitted as standard.

We have successfully developed our second generation supercharger conversion from the original application in the VX220 for use in the Vectra B 2.2 16v and now also for the Astra G.

This is not simply a bolt-on addition but a fully engineered conversion. The most evident components being the supercharger (which is modified from the GM standard unit) and the inlet manifold. The laminova chargecooler is retained to keep inlet air temperatures as low as possible with an additional charge cooler water radiator fitted in front of the car’s original radiator, with its own pump. The head is removed to allow for the compression to be lowered down to 8.5:1, additional injectors are added to deliver additional fuel when on boost and an additional fully mapable ecu is fitted and wired into the map sensor to take control of the on boost fuelling. Re-work to the driven side of the supercharger assembly also had to be done to ensure that the drive belt is not fouled by the alternator or aircon housing. The OE ecu has to be moved from its original location on top of the OE inlet manifold (it can no longer remain in its original location as the supercharger assembly now occupies this space) and a new bracket mounts the OE ecu. This ecu relocation also involves having to extend the wiring loom to the ecu, the injectors, the OE map sensor, the throttle body and the injectors. Once everything is fitted the car is mapped on the dyno.

The development for Vectra B included re-routing of the aircon pipework to ensure that we kept the aircon on the vehicle and additional other re-work was carried out allowing clearance of the map sensor under the bonnet.

Further development of the coversion has taken place for the Astra G installation.  This ensures that the aircon is retained, running off a longer belt than origianally used along with careful re-alignment of both the aircon compressor and the alternator. Also a smaller, lighter motorsport battery is installed on the oposite side of the engine bay, with associated wiring and terminals which allows for a large K & N filter to be fitted for good airflow into the supercharger. An extra large water pre-radiator is fitted as part of the charge cooler set up with a separate pump and the fuel hoses are changed to allow clearance under the bonnet. The ecu is relocated as with the VX220 conversion, with all the associated wiring modifications and the radiator top hose is re-routed.

Driveability of the supercharger conversion is ‘OE’ with the car performing more like a modified 3.0 V6, but with the scream of the supercharger to ensure you don't forget its there. Bundles of useable torque pulls the car smoothly from 2,000 rpm right up to the red line and completely transforms the vehicle.

Fitting including mapping and setting up takes approximately 5-7 days, and for the Stage 2 conversion. A good high flow sports exhaust system is required for Stage 2.

With 240+ bhp and 220+ lb ft torque available from the Stage 2 conversion this offers a massive performance boost to the all alloy Z22SE engine.

Stage 3 conversion under development and testing, which includes spearate management, re-worked cylinder head, cams, pistons and rods.

Available for VX220, Astra G and Vectra B.

VX220..... Full details on our VX220 page.

Vectra B 2.2 16v Supercharger Conversion Stage 2 - 240 bhp and 220 lb ft torque £6125 fitted (requires Sports Exhaust System including Sports cat and pre-cat removal).

Astra G 2.2 16v Supercharger Conversion - Price £6125.00. 240+ bhp and 220+ lb ft torque. Requires Full Sports Exhaust (we have used a 2.5" system from manifold to the tailbox with the pre-cat removed on our car).
Our Car - Specification and Power/Torque Graphs

Uprated Clutch for Z22SE

Sports Clutch - Cover and Disc Our uprated clutch will withstand increases in power and torque without the slipping that may occur with a standard unit, yet still retain the drivability of a standard clutch. Coverplate and disc.

Priced at £199.5. Buy Now Click Here!

Fitting available. Why not combine this item with a lightweight flywheel at the same time?

Hydraulic Slave Cylinder £120 Genuine/£99 Sachs when bought with a clutch

Modified original equipment throttle bodies

Modified Throttle Body
To a large extent, the power and torque out put on any engine is dependent on the volume of air its capable of drawing in. Research shows that the standard GM throttle bodies fitted to most Vauxhall engines are undersized and act as a bottle-neck to the inlet charge, pegging back power and torque. To over come this we dismantle the throttle body and use a CNC lathe to enlarge the diameter of the unit, as well as installing a new, bigger throttle disc and low profile spindle to suit. Typically, this results in an increase in full throttle cross sectional area of between 10 and 20%. The result? Improved torque and power outputs usually in the order of 4 to 7 bhp, as well as superior throttle response and a sharper feel to the engine. All throttle body reworking is carried out on an exchange basis.
Corsa 1.4, 1.6
Astra 2.0 8V, 2.0 16v (XE & XEV)
Cavalier, Calibra 2.0 16v inc Turbo (XE & LET)
Cavalier, Calibra 2.5 V6
Vectra V6 2.5

All the above .... £265 on exchange

Omega 2.5 & 3.0 Twin butterfly .... £355 on exchange
Courtenay Modified Throttle Body

Courtenay Engine Management and Throttle Bodies Kit

C20XE Throttle Body Kit Courtenay’s have announced a complete engine management and fuelling system for the Vauxhall/Opel 2.0 16v engine. The multi throttle Alpha Engine Management System controls both the fuel injection and ignition requirements in a fully integrated package. The kit includes two Alpha throttle bodies, lambda sensor, air filters, inlet manifold and a complete fitting kit.
The kit will increase the original 150 bhp output to 180 bhp, but the benefits go far further than just extra power. The car will be perfectly suited for day to day driving on the road even if a wild cam is fitted thanks to an excellent idle control valve. The car will be docile and reliable around town, but with power to spare on the open road or on track days and during winter months too, cold starting won’t be a problem. This highly tuned car will start just like a standard model.
The Courtenay Alpha Performance Kit can be supplied by Mail Order or Supplied and Fitted - POA

Billet Alloy Bottom Pulley

The standard bottom pulley is constucted around a rubber centre donut which is bonded to a steel centre section. Over time the rubber can split, which causes the pulley to wobble. This can throw the fan belt particularly on engines that are operating at high RPM.
Our alloy pulley cures this problem and is available in single format (ideal when the engine is installed in a Nova or Corsa), power steering double format and Multi V format. They come machined from 6082 T6 solid billet alloy, with superior design featuring a deeper V to add extra stability to the fanbelt at high revs.
These pulleys are available for C2.0XE, C2.0LET, 2.0 8V and V6.

 
Lightweight Alloy Bottom Pulley
Alloy Bottom Pulley 2.0 XE Single .... £111.95
Alloy Bottom Pulley 2.0 8v 4 bolt Single .... £111.95
Alloy Bottom Pulley 2.0 8v 4 bolt Double .... £123.95
Alloy Bottom Pulley 2.0 XE Double .... £123.95
Alloy Bottom Pulley C20XE Multi V .... OE Size £107.25 Underdrive £97.50
Alloy Bottom Pulley V6 Multi V .... £153.15
Alloy Bottom Pulley Z22SE Multi V .... £NLS

Buy Now Click Here!

Courtenay Group N Chip (2.0 XE)

Courtenay Group N Chip (2.0 XE). Additional power from this engine with the Group N remap. Changes to fuelling and ignition help to improve engine power - £NLS

Superchips - Click Here

Superchips Logo We are Superchips dealers and can offer chip upgrades and remaps for both Vauxhall/Opel models and other makes. Click on the logo or above link for more details.

 

Induction kits for Vauxhalls

For many years now, we have been recommending that induction kits are not fitted to performance Vauxhalls, especially turbo models. This has been because the induction kit would run close to the engines heat sources and the cold air charge would be heated before it reached the manifold thus negating any beneficial effect.

But now things have changed. We have teamed up with leading air induction specialists Pipercross, to develop a version of the Viper carbon fibre cold air induction kit to suit popular Vauxhall models.
Piper Viper Kit
The design incorporates a carbon fibre heat shield to protect the air charge from under bonnet heat, keeping it cool - and therefore more dense - thus introducing more oxygen into the combustion mixture, giving increased power.
Viper carbon fibre induction kit retails for £259 including VAT.

NGK Iridium Spark Plugs

Iridium NGK cooler running spark plugs offer an enhanced spark over the standard plugs. Suitable for many normally aspirated engines including Z14XE, Z16XE, Z18XE, C20XE, X20XEV, X25XE, Y26SE, X30XE, Y32SE.

£33 for 4 cylinder engines. £49.50 for 6 cylinder engines. Buy Now Click Here!

Cool Running Thermostats

Cool Stats Our cool running thermostats reduce the engine's normal running temp by 10 degrees protecting the engine and running it closer to it's optimum power temperature. Mail order available. Buy Now Click Here!

Application

Price  

Corsa 1.4, 1.6, 1.8 16v's

£25.50  

Astra 2 - 2.0

£25.50  

Astra 3 - 1.8, 2.0

£25.50  

Astra G - 2.0, 2.2

£25.50  

Vectra B - 1.8, 2.0, 2.2

£25.50  

2.2 16v - Astra, Vectra, VX220

£25.50  

V6 - 2.5, 2.6, 3.0, 3.2

£25.50  

Water Wetter

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. £15.25 Buy Now Click Here!

Power Boost Valves

Power Boost Valves are an adjustable fuel pressure regulator for use when tuning a car where additional fuel is called for. Available from £NLS.

 

Lightweight Flywheels

Application Price Fitting
1.6 8v (Nova) Supplied on exchange £179 £295
1.4/1.6 16v (3kg weight reduction) Supplied on exchange £179 £295
2.0 16v XE (flat type flywheel i.e. distributor engine) Supplied on exchange £179 £295
2.0 8v (20SE/SEH/NE/SER) Supplied on exchange £179 £295

Lightweight Steel Billet Flywheels

Application Price Fitting
2.0 16v XE X dis 92 on (3.9 Kg weight reduction) £255 £360
2.0 16v Ecotec (3.9 kg weight reduction) £255 £360
2.2 16v VX220 (3.9 kg weight reduction) £255 £504
2.2 16v Astra/Zafira/Vectra (3.9 kg weight reduction) £255 £360
2.5 V6 24v (9.4 kg weight reduction) Vectra B £301.50 £360
3.0/3.2 V6 24v (9.4 kg weight reduction) Vectra B £301.50 £360

Buy Now Click Here!

Uprated Clutch For 20XE engines.

Our uprated clutch will withstand increases in power and torque without the slipping that may occur with a standard unit, yet still retain the drivability of a standard clutch. Coverplate and disc. Priced at £185 including new Thrust Bearing. Fitting available. Why not combine this item with a lightweight flywheel at the same time?

F23 4.17 Final Drive Ratio

F23 Lower Final Drive Suitable for the F23 gearbox. It lowers the Z22SE F23 (Astra G/VX220) by 5.8% and the Vectra B 2.5 V6 F23 by 8.7%. Also available for F23 for VX220 Turbo. Price: £POA Fitting available.

8.5mm Magnecor Leads

We have a range of 8.5mm Magnecor Leads available for the most popular engines. Please telephone if your vehicle is not listed here.
Application Price  
Nova GTE £87.00  
Corsa B 1.4 8v £89.10  
Corsa B 1.4, 1.6 16v Sport £148.80  
Astra 2.0 XE 16v £156.00  
Astra GSi 93> 2.0XE (x-dis) £146.50  
Astra/Cavalier/Calibra 2.0 XEV Ecotec £141.00  
Cavalier 2.0XE 16v £146.50  
Cavalier 2.5 V6 £192.00  
Calibra 2.0XE 16v £146.50  
Calibra 2.5 V6 £192.00  
Vectra B 2.0 XEV £141.00  
Vectra B 2.5 V6/3.0V6/3.2 V6 £192.00  
Omega 2.5 V6, 3.0 V6 £192.00  

Buy Now Click Here!

Uprated Lightweight Steel Rods and ARP Rod Bolt Kit

These uprated steel roads are manufactured from Certified SAE 4340 chrome-moly steel vacuumed to remove impurities, are shot peened to stress relieve the metal and have bronze gudgeon pin bushings are made to withstand higher impact force. They are far stronger and lighter than the standard ‘OE’ items and are packaged in weight matched sets balanced end to end +/- 1 gram. Ideal for all modified engines for fast road and track use, they are supplied with uprated ARP rod bolts.

Available for 2.0 16v C20XE/20XE, C20LET and Z20LET Turbo

Price - £360 including VAT

ARP Uprated Bolts

ARP Uprated Conrod Bolt Kit - 20XE/X20XEV £66.95

ARP Uprated Head Bolt Kit - 20XE £129.95

ARP Uprated Main Bearing Stud Kit - 20XE £111.95

Buy Now Click Here!

Engine Bay Hose Kits - Click for details

A range of engine bay hose kits for nova 1.3/1.4 SR, 1.6 GTE, Corsa B 1.4 SRi, Corsa B 1.6 GSi (early), Astra 2.0 8v GTE and Cavalier/Calibra 2.0 16v (C20XE).

Silicone Breather Hose

We have manufactured a silicone breather hose to suit 1.8 XE and 2.0 XEV engines. This hose is available in black, blue and red with other colours to special order and comes with the Courtenay Sport Logo. Priced at £13.25 Buy Now Click Here!

Courtenay Sport Vauxhall Tuning
Courtenay Sport
 Vauxhall Tuning

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