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VXR Logo

Corsa VXR Tuning

Vauxhall Logo
Corsa VXR
The Corsa D VXR is fitted with the Z16LER engine featuring Bosch Motronic 7.6.3 engine management. The engine is equipped with a turbo charger  from the German manufacture KKK, suppliers of the turbo units on the recent Vauxhall 2.0 turbo engines. The engine also features low compression pistons complete with under piston oil spray cooling jets.

Following a fairly lengthy and intense development program which involved a good deal of testing both here and in Germany (which gives us the opportunity of testing at sustained load for extended periods of time), we have developed a range of packages and components best suited to this application. These components are the result of numerous product versions, tests and variants over an extended development program, designed to optimise your car whilst maximising your enjoyment through enhanced performance and integrity.
 
Corsa VXR on Dyno - Full Size Image - Click Here
Our Corsa VXR on the dyno undergoing development work.
Corsa VXR on Dyno - Full Size Image - Click Here
Our Corsa VXR on Klasen's dyno prior to some hard autobahn shakedown runs.
Corsa VXR Diagnostic Check - Full Size Image - Click Here
Corsa VXR undergoing full Tech 2 diagnostic check prior to remapping.
EGT Monitoring - Full Size Image - Click Here
Corsa VXR turbo with EGT monitoring during development work.

Corsa D VXR Tuning Packages

All our Corsa 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 your 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.

NOTE: Injector Upgrades are Available with Stage 1, 2 and 3 Packages
Courtenay Sport Stage 1*
We carry out a full engine diagnostic test first. 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 with full datalogging and map optimisation. Power and Torque Graph Print Outs.
Injectors £295.00 Injector Information >> HERE <<

Power Increases Click

Torque Increases Click

£540 Fitted including Rolling Road Set Up

Courtenay Sport Stage 2 with 76mm exhaust
First we carry out a full engine diagnostic test. The exhaust is then derestricted with a full turbo back 76mm (3") system. This comprises of a high flow downpipe and sports cat section that removes the pre cat which is not a legal requirement once the car is registered and adds a high flow sports cat. A performance exhaust with 2 silencers** is also included for better gas flow whilst providing an improved sound track to drive to! Exclusive Courtenay Sport Stage 2 Software is then installed, finishing with a Rolling Road calibration, set up and testing session with full datalogging and map optimisation. Power and Torque Graph Print Outs.
Injectors £295.00 Injector Information >> HERE <<
Power Increases Click

Torque Increases Click
£1,977 Fitted including Rolling Road Set Up
Nürburgring £1,977

Courtenay Sport Stage 3 with 76mm exhaust
Following a full engine diagnostic test, we concentrate on maximising cooling efficiency of both inlet charge air temperature and water temperature with the fitment of our massive high flow intercooler. This intercooler features air guide blades to maximise the air flow back through to the water radiator. This stops the air that enters the bumper washing out through the easiest route, i.e. around past the fog lamps and away, thus utilising all the air that enters the bumper. A full turbo back 76mm (3") performance exhaust system is fitted featuring a motorsport catalyst, no pre cat and a 76mm cat back exhaust system with 2 silencers**. Finally the Exclusive Courtenay Sport Stage 3 Software is installed, finishing with a Rolling Road calibration, set up and testing session with full datalogging and map optimisation. Power and Torque Graph Print Outs.
Injectors £295.00 Injector Information >> HERE <<
Power Increases Click

Torque Increases Click
£2,867 Fitted including Rolling Road Set Up
Nürburgring £2,867

Courtenay Sport Stage 4 with 76mm exhaust and engine rebuild
Following a full engine diagnostic test, we carry out a full engine rebuild to strengthen the 1.6 Turbo engine. The engine is removed, stripped down, rebored and rebuilt as necessary with Forged Pistons and Steel Rods renewing all gaskets and bearings as required. We then fit our Z16LEH cast manifold with Astra 2.0 VXR K04 turbo unit together with an 80mm VXR air flow meter, high flow direct fit injectors, larger map sensor, revised inlet pipework and uprated Sachs clutch cover. We then concentrate on maximising cooling efficiency of both inlet charge air temperature and water temperature with the fitment of our massive high flow intercooler. This intercooler features air guide blades to maximise the air flow back through to the water radiator. This stops the air that enters the bumper washing out through the easiest route, i.e. around past the fog lamps and away, thus utilising all the air that enters the bumper. A full turbo back 76mm (3") performance exhaust system is fitted featuring a motorsport catalyst, no pre cat and a 76mm cat back exhaust system with 2 silencers**. Finally the Exclusive Courtenay Sport Software is installed, finishing with a Rolling Road calibration, set up and testing session, with full datalogging and map optimisation. Power and Torque Graph Print Outs.
Power and Torque
Increases Click
Package from
£7,640 Fitted
including Rolling Road Set Up
Price From £3,450
for cars with an engine build, intercooler and full exhaust

Courtenay Sport Stage 5 with 76mm exhaust and engine rebuild
As Stage 4 above, plus 240mm Sachs uprated clutch and flywheel assembly and the K04 is replaced with the much larger K16 Turbo. To do this the manifold is reworked to accept the larger turbine K16 wheel and core whilst the shaft and bearing pack are much larger and thus very durable in high boost conditions. The K16 is used in many high powered cars e.g. Porsche, Bugatti to name a couple.
Power and Torque
Increases Click
Package
£9,495 Fitted
including Rolling Road Set Up
Price From £5,021
for cars with an engine build, intercooler and full exhaust
*Stage One Remap with Front Pipe
For customers wishing more from the Stage One Remap but who do not wish to opt for a full exhaust system, the addition of a high flow front pipe can be specified. We will remap to take full advantage of this which will give additional power and torque for further driveability enhancement. Front Pipe from £237.00 Fitted

** Single silencer option available (Less £130). Nürburgring model requires a different exhaust tailbox.

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

Fuel:
We recommend the use of Shell V-Power 99 RON, or similar Super Unleaded fuel, on all remapped vehicles for optimum performance.

Power and Torque Graphs

For Power Graph Comparisons of our Conversions Click on the Images Below:
Power Graph Standard v Stage 1
Power Graph
Standard v Stage 1
Power Graph Standard v Stage 2
Power Graph
Standard v Stage 2
Power Graph Standard v Stage 3
Power Graph
Standard v Stage 3

Power Graph Stage 2 v Stage 3
Power Graph
Stage 2 v Stage 3
 

Power Graph Standard v Stage 2 v Stage 3
Power Graph
Std v St 2 v St 3
For Torque Graph Comparisons of our Conversions Click on the Images Below:
Torque Graph Standard v Stage 1
Torque Graph
Standard v Stage 1
Torque Graph Standard v Stage 2
Torque Graph
Standard v Stage 2
Torque Graph Standard v Stage 3
Torque Graph
Standard v Stage 3
Torque Graph Stage 2 v Stage 3
Torque Graph
Stage 2 v Stage 3
 
Torque Graph Standard v Stage 2 v Stage 3
Torque Graph
Std v St 2 v St 3

Aluminium Water Radiator

Due to increasing demand we have once again joined forces with market leader’s Pro Alloy to fabricate an uprated aluminium water radiator for the VXR and 1.6 turbo engined Corsa D.

The new radiator had to be an all alloy construction featuring welded end tanks; this eliminates the common issue on Corsa D water radiators where they leak from the plastic end tanks.

Additionally the core depth has been increase from 26mm to 40mm, whilst the surface area has been increased by 7.7%. Furthermore by reconfiguring the tube layout and foil pitching we have increased the flow area by 67% making the radiator much more efficient in cooling and ambient airflow through the core.

Finally the bottom lower water connection on the right hand end tank has been make one piece, getting rid of the factory eclip/circlip configuration that also has been known to separate at high pressure.

It is now available to order and can be finished raw in Natural Aluminium or powder coated in Stealth Black finish (at additional cost).

Ideal for direct replacement on any fast road or trackday car.

Price £558.00 including VAT

It is also worthwhile considering an upgrade to Power Cool 180 Waterless Coolant at the same time. No Water, No Corrosion, No Pressure (less likelihood of leaks, less strain on hoses and other components) More BHP, No Hot Spots, No Overheating…….
Corsa D 1.6T Water Radiator Front
Corsa D 1.6T Water Radiator Front
Corsa D 1.6T Water Radiator Rear
Corsa D 1.6T Water Radiator Rear

80mm Air Flow Meter

For any stage of tune. More stable air flow meter than the standard 70mm item. Will require an ECU recalibration to run correctly on Corsa VXR because the 0-5v scale is different on the 80mm AFM to the standard 70mm AFM.

£149.95

High Flow Bosch Fuel Injectors

For any stage of tune, especially for high power builds. Direct replacement for OE. OE spray pattern. Will require an ECU recalibration to run correctly on Corsa VXR. OE Flow rate 322cc @ 3 bar

395cc @ 3 bar :: 415cc @ 3.3 bar (310PS) :: 485cc @ 4.5 bar (360PS) - £295.00

650cc @ 3 bar :: 682cc @ 3.3 bar :: 750cc @ 4 Bar - £395.00
Not recommended for cars under 350PS

Uprated 340 In Tank Fuel Pump

For details >>> Click here <<<
Engine Rebuild Components
Hybrid Turbos
Garrett Conversions.

Forged Pistons, Lightweight Steel Rods,
Z16LEH High Flow Exhaust Manifold,
K03 Hybrid Turbo, Garrett Conversions.

Z16LEH Manifold with K04/K06/K16 Turbo

Our Z16LEH cast manifold with Z20LEH turbo assembly. More details....

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

K03 Turbo - Direct Replacement

Genuine direct replacement Original Equipment OE K03 Turbocharger for Corsa 1.6T inc VXR:
For Z16LEL/A16LEL/Z16LER/A16LER £499.00
For A16LES (Nurburgring) £499.00

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

K03 Hybrid Turbo

K03 Hybrid turbocharger reworked from a genuine brand new unit, features a reworked compressor wheel and shaft, an uprated bearing pack and a modified inlet elbow. Tested to 260bhp on low comp pistons.

£1140.00

Iridium Spark Plugs

Ideal on standard or modified cars used for fast road or track use especially where engines may run warmer, we 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. 
FREE fitting as part of a stage upgrade.

Courtenay Sport Performance Intercooler Kit

Corsa VXR OE Intercooler - Click for Full Size Image
Spot the Corsa VXR OE Intercooler!
Corsa VXR Courtenay Performance Intercooler - Click for Full Size Image
Spot the Corsa VXR Courtenay Performance Intercooler
In our approach to the Corsa VXR intercooler we had to consider two areas; maximising the cooling efficiency through improved design and size whilst not detracting from the engine water temperature control capability. It's no big secret that the Corsa VXR’s engine runs quite hot. Typically on a 16 degree day it will cruise at 96/97 degrees. Whist this is fine for the standard car, it's not what we want from a more powerful, tuned engine. Heat is not good for power. The thermostat has an opening temperature of 92 degrees which is consistent with all performance Vauxhalls of the last decade, so the fact that the car will not maintain this 92 degrees at cruise suggest that we have an air flow issue. For the above reason it was imperative for us not to start by masking the water radiator (which is situated behind the intercooler) with any solid matter. This is why in this installation we have chosen to not to go with a diagonal flow intercooler as any minimal increase in performance would have been to the greater cost of water temperature control, through complicated solid pipes or air masking intercooler end tanks.
Corsa VXR VXRacing Performance Intercooler and Fitting Kit - Click for Full Size Image
Corsa VXR Intercooler and Fitting Kit
Corsa VXR VXRacing Performance Intercooler - Click for Full Size Image
Our Corsa VXR Performance Intercooler Shown
above the standard intercooler.
The front end design lends itself well to a core that maximises frontal area, tall and wide, rather than short and deep. So this is the route we have taken. Furthermore, selecting a core that provides excellent intercooling heat transfer whist not being so dense to restrict onward air flow to water radiator was vital. The Corsa VXR remember is only a 1.6, so in order to achieve 192 bhp it requires quite a high boost pressure and once remapped the boost is higher still.

With this in mind the kit comes with new silicone pipes increased in size from 50 to 60mm. These pipes are not only stronger but improve the air flow to and from the intercooler. Finally you will see from the pictures that we have also added air flow deflector guides to the bottom, sides and lower rear of the intercooler; the rear to seal where the original factory cooler has been removed. These guides are fitted to direct the air flow back through the radiator maximising its cooling effect, as air being air will always take the easier route which is in this case washing sideways past the back of the fog lamps and away under the bumper. The guides stop this from happening.
Corsa VXR VXRacing Performance Intercooler - Click for Full Size Image Corsa VXR VXRacing Performance Intercooler - Click for Full Size Image

Intercooler Test Results:

Standard Intercooler on a run from 40 to 106 mpho
Uprated Intercooler on a run from 40 to 106 mpho

Avg Max Temp

61 oC
33 oC

Avg Temp Rise

37 oC
07 oC

The Courtenay Sport Intercooler comes complete with all the required fittings and hoses to suit.
Intercooler - £690.00 including VAT. Fitted Price £875.00 including VAT. Buy Now Click Here!
Exhaust Systems.
Details of Exhaust Systems for Corsa D VXR and Nürburging models

Courtenay Sport High Flow Front Pipe

The Z16LEx turbo engine is fitted with 2 cats - a pre-cat and a main cat. Our performance front pipe replaces the original restrictive pre-cat. This is only required to be fitted to the vehicle up until the point of 1st registration, as the main cat still ensures the vehicle will meet all MOT emission regulations. The new front pipe is made in stainless steel, and by smoothing the bend radius and removing the cat, we have dramatically improved the flow through the unit. Our front pipe also features both a stainless steel 3 bolt flange and stainless steel spun end. Our performance front pipe will give a typical increase of around 6 - 8. Also available for A16LEx

Pre-Cat Pipe £183.00 Z16LEx Buy Now Click Here! A16LEx Buy Now Click Here!
Courtenay Sport Pre Cat Replacement Pipe

Courtenay Sport Panel Filter

Courtenay Sport High Flow Panel Filter 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 re-use it just like most other performance filters.

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 separately for subsequent re-oiling after cleaning.

Price: £34.95  Filter Oil £4.05
Clutch and Lightweight Flywheel Options.
Corsa Chassis Tuning Suspension and Chassis Tuning.
Details of suspension and chassis tuning options available including Limited Slip Differentials, DAP Springs, KW Coilovers, Premium Suspension Kits and Poly Bushes.
Brake Upgrades Brake Upgrades.

Uprated Engine Mounts

Engine Mounts Uprated engine mounts from Vibra Technics. Significantly stiffer than the factory mounts, reduces engine movement. Ideal for fast road and track use.

Uprated Rear Engine Mount/Torque Link £90.00
Left Hand/Gearbox Side Engine Mount £124.80
Right Hand Side Engine Mount £138.00

Buy Now Click Here!

Courtenay Sport Silicone Hose Kit

The Courtenay Sport hose kit 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 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. 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.

Available in Blue, Red, Black, Orange, Green, Yellow, Purple or White.

Image Shows: Turbo Inlet Hose (Left) and Intercooler to Throttle Body Hose with Dump Valve Take Off Hose (Right)
Corsa VXR Engine Bay and Silicone Hoses
Silicone Hose Kits:

Kit 1 - Turbo Inlet Hose and Intercooler to Throttle Body Hose - £100.60 (No DV Take-Off)
Kit 2 - Turbo Inlet Hose and Intercooler to Throttle Body Hose - £110.85 (With DV Take-Off)

Silicone Hose Kits - Buy Now Click Here!

Silicone Hose for Dump Valve Fitment

Corsa VXR Engine Bay and Silicone Hose Silicone Hose for dump valve fitment. Made from 4-ply reinforced silicone hose material. Available in Blue, Red, Black, Orange, Green, Yellow or Purple.

Silicone Dump Valve Take-Off Hose - £57.85 Buy Now Click Here!

Image Shows Dump Valve Take-Off Hose and Dump Valve on Right.

Dump Valve Fitting information - >>>> Click Here <<<<

Silicone Turbo Inlet Hose

Available separately for cars already fitted with the dump valve take-off hose (as shown above).

Turbo Inlet Hose. Made from 4-ply reinforced silicone hose material. Available in Blue, Red, Black, Orange, Green, Yellow or Purple.

Turbo Inlet Hose - £56.65 Buy Now Click Here!

Image Shows Inlet Hose at Front Left.
Corsa VXR Engine Bay and Silicone Hose

Silicone Map Sensor to Throttle Body Hose

The hose that runs to the throttle body (OE plenum) from the map sensor pipe (right hand side of the engine bay) without the dump valve fitment/take-off.

£47.50 Buy Now Click Here!

Coolant Hose Kit

Coolant Hose Kit Silicone Coolant Hose Kit for Corsa VXR. Hoses included are top and bottom radiator hoses, header tank to rad hose and both ancillary water hoses. Available in Blue, Red, Black, and to Special Order Orange, Green, Yellow or Purple.

Silicone Coolant Hose Kit - £109.95 Buy Now Click Here!

Uprated Recirculation Valves

Developed in association with Turbosmart, this recirculation valve is designed as a direct replacement for the OEM rubber valve which is prone to failure when the engine has been remapped. One spring covers all stages of tune. Anodised Black. Includes 3 fitting screws, 1 straight and 1 banjo union.

CTS Recirculation Valve .... £108.00 Buy Now Click Here!
Uprated Turbosmart Recircultaion Valve
Forge recirculation valve. Complete and ready to install with no fitting kit required. It is available with 3 spring choices depending upon the state of tune of the engine.

Green Spring - For Standard Cars/Standard Boost.
Yellow Spring - For mapped/tuned cars running higher boost.
Blue Spring - Hybrid+ Turbo

Additional Springs available if required.

Recirculation Valve .... £122.50 Buy Now Click Here!
Uprated Recircultaion Valve

Cool Running Thermostat

Cool Thermostats Cooler running thermostat reduce the engine's normal running temperature, protecting the engine by running it closer to it's optimum power temperature. The stats open 5 or 10 degrees earlier than the standard OE item (87/82 degrees instead of 92 degrees) and is fully open 10/5 degrees earlier (97/102 degrees instead of 107 degrees). Ideal for modified cars for fast road and track work, they typically operate 5+ degrees cooler reducing peak temperatures caused by sustained hard use. Used in Opel/GM products in warmer climates.

Cool 'Stat 82o £25.50 Buy Now Click Here! 87o £36.00 Buy Now Click Here! Fitting £36.00

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Courtenay Sport Vauxhall Tuning
Courtenay Sport
 Vauxhall Tuning

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