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Software Upgrades - Astra H and Zafira B

The New Astra/Zafira Turbo, including the VXR, is fitted with the latest generation of the Vauxhall turbo charged engine. Three 2 litre petrol turbocharged engines were initially used in the Astra H model range, derived from the Z20LET power unit used in Astra G, Zafira A and VX220T.

From model launch until 2007, the Turbo Sport Hatch (3 door) utilised the Z20LEL (170PS) engine, the 5 Door hatch used the Z20LEL and Z20LER (200PS) engine, Zafira models have the Z20LER (200PS) engine and the Flagship VXR models (Astra and Zafira) use the Z20LEH (240PS) engine.
From 2007 onwards the Astra Sport Hatch and Astra 5 Door models received the Z16LET (180PS) 1.6 Turbo engine (similar to the Corsa VXR powerplant), in place of the 2.0 LEL and LER engines, which benefits from under piston cooling whilst the Zafira retained the use of the Z20LER engine and the VXR models kept the Z20LEH (240PS) engine.

The power units are equipped with one of GM's latest and most advanced engine management Systems, Bosch 7.6.x. This engine management system is equipped with flash roms which is what we are now familiar with from the the previous turbo charged unit. The advantage of a flash rom, as previously, is that the ECU can have the program changed/rewritten again and again with out ever having to break the ECU open.

This is why we refer to it as a software upgrade or remap and not a 'chip', as the ECU is reprogrammed with our software directly into the heart of the ECU, from our lap-top computer. The new programs are written so that the fuel, ignition, boost maps are all optimised to get the best driving experience from this power unit.

Our new maps are 100% accepted by the ECU so that they will not put the service or engine management light on for overboost etc and they are undetectable to diagnostic equipment.

We are able to offer on-site remapping direct into the ECU of the vehicle via the diagnostic port, without the need to remove the ecu from the vehicle for programming, so there is no evidence of reprogramming..... until driven!

Courtenay Sport's Exclusive new software, is customised to each car whilst being tested on our rolling road optimising fuelling, full boost and ignition maps. Power and torque graphs are provided with each conversion.

Tuning Packages - 2.0 Engines.

Courtenay Sport Stage 1 for Z20LEL and Z20LER
ECU Tech2 diagnostic check, 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.
Airbox modifications and fitment of large bore inlet air pipe included free of charge as part of the Stage 1 Remap.

Increases up to 225-230 bhp** and 260 lb ft (350 Nm) £565 Fitted including Rolling Road Set Up

Courtenay Sport Stage 2 for Z20LEL and Z20LER
ECU Tech2 diagnostic check, Full 2.5" stainless steel exhaust system, 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 235-245 bhp** and up to 300 lb ft (400 Nm) £1790 Fitted - Astra
£1750 Fitted - Zafira
including Rolling Road Set Up

**Please note: For best results the Z20LEL/LER engines require a full sports exhaust system to be in place in order to achieve maximum power increases. This is recommended for all our CS Stage 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, front pipe etc), 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 remaps tailored to your car on our rolling road to achieve the maximum power and torque increases to suit your individual application.

Iridium Spark Plugs and High Flow Panel Filter.
We also suggest a spark plug upgrade to iridium spark plugs which are 'cooler running' and so able to dissipate more heat from the combustion chamber and produce a more efficient spark £33.00 per set of four, and one of our High Flow re-useable Panel Filters £34.95.
Panel Filter and Iridium Plugs - £67.95. Fitting is free of charge with any Courtenay Sport Tuning Pack.

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

Further Stages are currently under development and durability testing.

Astra VXR software and Tuning Packages developed on our own car are shown on the Astra VXR Page.

Astra H 2.0 SRi Turbo undergoing final shakedown and dyno testing prior to software release.

Power and Torque Graphs.

Example Power Graph 2.0 SRi Turbo

Example Torque Graph 2.0 SRi Turbo

Power Graph
Torque Graph

Red - Remapped Car Sport Mode ON     Blue - Remapped Car Sport Mode OFF     Pink - Standard Car

Garrett Upgrades.
For 2.0T: Garrett Upgrades, Tubular and Cast Manifolds, High Flow Inlet Manifold, Engine Building, Pistons, Steel Rods.

Tuning Packages - 1.6 Engines.

Courtenay Sport Stage 1 for Z16LET
ECU Tech2 diagnostic check, 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.
Airbox modifications and fitment of large bore inlet air pipe included free of charge as part of the Stage 1 Remap.
Increases up to 210-215 bhp and 230+ lb ft (350 Nm)
This upgrade gives huge increases in mid range power and torque.
£565 Fitted including Rolling Road Set Up

Please note: For best results we suggest the fitment of a High Flow Stainless Steel Pre Cat replacement pipe.

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

Further Stages under development.

Turbochargers - Direct Replacement

The K04 Astra VXR turbocharger is suitable as a direct replacement for a ZLEL/R 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 Astra VXR turbo is used to replace a standard ZLEL/R unit we advise having the software checked to ensure boost and fuelling is still correct.

VXR Z20LEH Turbo - 2.0 LEL/LER

Z20LEH Turbo The Astra VXR K04 turbo unit is suitable as a performance upgrade for both Z20LEL and Z20LER (2.0 Turbo) engines and we have remaps suitable for both engines when used with the VXR unit.

With a different A/R ratio to the standard turbo this unit can produce and sustain more boost so producing more power and torque. It also features a stronger cast manifold.

Hybrid options are also available.
Turbocharger* and VXR Actuator (Special Mail Order*): £Check Shop

Turbocharger complete with VXR Actuator (Price including warranty when supplied and fitted in our workshop): £895 Fitted price including turbocharger assembly, gaskets, oil and filter change using fully synthetic 5w-40 Valvoline oil

Turbocharger* with Uprated Actuator and Bracket (Mail Order*): £Check Shop 

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

Uprated Actuator and Stainless Steel Bracket for Stage 4 Conversions: £142.95

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, double ring seals without compromising the bearing housing wall thickness (often missed by some turbo builders) and cut back exhaust wheel. The K06 option adds a billet K06 compressor wheel.
Hybrid Options cost from £295 - £545 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.

Uprated Actuator and Bracket

Courtenay Sport uprated wastegate actuators are designed to allow higher boost levels to be sustained through the mid range for increased torque for ZLET/LEL/LER/LEH KKK turbochargers. They have a much higher static break-off pressure. Our heavy duty stainless steel bracket will make for easy fitment as no drilling or cutting is required. Fits directly onto the KKK turbo units. Will also fit garrett units with modification. May require modified software to allow higher boost to be run.

For use with Z20LEL/R cars running to 300+ bhp. As used in our Stage 4 Tuning Packs.

Uprated Actuator and Stainless Bracket £142.95 including VAT.
Uprated Actuator (No Bracket) £91.95 including VAT.

80mm Air Flow Meter - 2.0T and 1.6T

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

£149.95 

VXR Injectors 2.0T

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) £114.95 Buy Now Click Here!

Other High Flow Injectors available for Big Power/Garrett Turbo Builds - 630cc Injectors Buy Now Click Here!

High Flow Bosch Fuel Injectors 1.6T

For any stage of tune. Direct replacement for OE. Will require an ECU recalibration to run correctly on Astra 1.6T. Available as 395cc and 470cc

395cc @ 3 bar (415cc - 3.3 bar 485cc - 4.5 bar) - £301.50 
Engine Components
and Rebuilds.

For 1.6T: Forged Pistons, Lightweight Steel Rods for Z16LEx,
Z16LEH High Flow Exhaust Manifold.

Z16LEH Exhaust Manifold

New from Courtenay Sport, a high flow Z16LEH exhaust manifold.

This cast manifold is manufactured in the same way as an Original Equipment (OE) manifold would be fabricated.

The result is a turbocharger assembly for the 1.6 Turbo engine that is capable of flowing more air, thus producing more boost and therefore more power and torque.

In fact our Z16LEH manifold has a 20% larger exhaust housing than the Z20LEH manifold and the wastegate aperture is also 20% bigger, so the Z16LEH manifold will offer much greater flow than the equivalent Z20LEH turbo manifold.

It has been designed for the Vauxhall/Opel 1.6 Turbo Z16LEx/A16LEx engines - Z16LET, Z16LEL, Z16LER, A16LET as fitted to Corsa D VXR/OPC and SRi Turbo, Astra H Turbo, Meriva VXR/OPC and Insignia 1.6 Turbo to allow the fitment of the core turbo charger from the Astra VXR Z20LEH engine.

It fits directly to the head as an OE 1.6 manifold will and the front pipe location is in the same location as the original - no exhaust adapter piece is required, so a standard pre-cat or a pre-cat replacement pipe will bolt straight on with no modification whatsoever. So this really is direct fit. Look closely at the images, and whilst this looks like a Z20LEH turbo, you will see the designation Z16LEH on the cast manifold for the 1.6 application.

We have also made provision for the addition of an EGT probe into the manifold if required.

Z16LEH Cast Manifold - £915.00
Z20LEH Turbo available built into manifold at additional cost of turbo

Z16LEH Exhaust Manifold
Z16LEH Cast Exhaust Manifold with Astra Z20LEH Turbocharger Fitted - Front View
Z16LEH Exhaust Manifold
Z16LEH Cast Exhaust Manifold with Astra Z20LEH Turbocharger Fitted - Rear View
Z16LEH Exhaust Manifold
Z16LEH Cast Exhaust Manifold with Z20LEH turbocharger fitted to Z16LEH engine

Iridium Spark Plugs 2.0T and 1.6T

For customers who intend to use their cars for fast road or track use, where engines may run warmer, we can offer an iridium spark plug upgrade. These NGK iridium spark plugs are 'cooler running' and so able to dissipate more heat from the combustion chamber and produce a more efficient spark. Suitable for 2.0T and 1.6T engines

£33 for a set of four.

Courtenay Sport 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 reuse it just like most other performance filters. Supplied pre-oiled for first use. Filter oil is available seperately for subsequent re-oiling after cleaning.

Price £34.95  Filter Oil £4.05
 
Courtenay Sport High Flow Panel Filter

Large Bore Inlet Pipe - 2.0 T

Large Bore Inlet Pipe for 2.0 Turbo models. Ensures maximum airflow into the airbox.

Large Bore Inlet Pipe.... £24.00

High Flow Plenum - 2.0T


High Flow Plenum

Astra H/Zafira B Kit

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. For more information and images >>>> Click Here <<<<

High Flow Plenum £89.50 including VAT.
Kit including Hose for Astra H/Zafira B £122.05 including VAT.

Cool Running Thermostat

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 10 degrees earlier than the standard OE item (82 degrees instead of 92 degrees) and is fully open 10 degrees earlier (97 degrees instead of 107 degrees). Ideal for modified cars for fast road and track work, they typically operate 4 - 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 Fitting .... £36

Stainless Steel Heatshield

Stainless Steel Heatshield for 2.0 Turbo Models £30.60 Fitting available

Front Mounted Intercooler - Astra H 2.0T/1.6T and Zafira B 2.0T

Building on the success of our Lower Front Mounted Intercooler for Astra G, we have an extra large front mounted intercooler for Astra H/Zafria B models. A larger frontal area and bigger core give reduced inlet air temperatures over the standard intercooler, with huge benefits to be had from a tuning perspective. £615.00 Buy Now Click Here!

High Performance 70mm Front Pipe - 2.0 Turbo - Astra and Zafira.

As with the Z20LEx turbo engines, the Astra H and Zafira B is fitted with 2 cats - a pre-cat and a main cat. Our performance front pipe replaces the original 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, we have dramatically improved the flow through the unit. The performance front pipe will give a typical increase of 6-8 bhp.

Pre Cat Pipe 2.0 Turbo £169.95 Fitting - £55 including VAT

High Performance Front Pipe - 1.6 Turbo.

As with the Z20LEx turbo engines, the Astra H Z16LET is fitted with 2 cats - a pre-cat and a main cat. Our performance front pipe replaces the original 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, we have dramatically improved the flow through the unit. The performance front pipe will give a typical increase of 6-8 bhp.

 Pre Cat Pipe 1.6 Turbo £182.85  Fitting - £55 including VAT

Exhaust System - Astra 2.0T/1.6T and Zafira 2.0T

A Full Milltek Stainless Steel exhaust system is available for Astra H and Zafira B 2.0 Turbo hatchback models. 2.5" system and available as a full system from the turbo back, or in component form as front pipe (also known as a turbo downpipe or pre-cat removal pipe), sports cat section and cat back system (centre section, link pipe and tailbox). A louder non-resonated system is also available.

A full system will give best results and maximum performance gains, however significant gains will be made by replacing the OE pre-cat and cat back system in the first instance.

Milltek Full System inc Sports Cat for Astra H 2.0 T: Resonated £1260.00 :: Non Resonated £1220.00
Milltek Front Pipe Astra H 2.0T: £280.00
Milltek Sports Cat Section Astra H 2.0T: £495.00
Milltek Cat Back System Astra H 2.0T: Resonated £485.00 :: Non-Resonated Louder System 2.0T: £445.00

Milltek Cat Back System Astra H 1.6T: Resonated £485.00 :: Non-Resonated Louder System 1.6T: £445.00

Milltek Full System inc Sports Cat for Zafira B 2.0 T: Resonated £1215.00 :: Non Resonated £1210.00
Milltek Front Pipe Astra H 2.0T: £280.00
Milltek Sports Cat Zafira B 2.0T: £495.00
Milltek Cat Back Zafira B 2.0T: Resonated £440.00 :: Non Resonated £435.00
 

Uprated Fuel Pumps

For Astra H running big horsepower and higher boost levels, fuelling is critical. The replacement Aeromotive 340 Stealth high output in-tank electric fuel pump offers the solution. 340 lph at 40psi. Offset Inlet, Inline with Outlet. Will fit into original in-tank housing with slight modification. Suitable for cars from 300bhp up to 450bhp. Features a vapour-purge port as on an OE pump, so less prone to fuel starvation at low fuel levels.

£180.00 Convoluted Flexi Fuel Hose also available
The Walbro replacement uprated fuel pump is ideal to take over from the original 'OE' fuel pump to maintain good fuel flow where the OE pump begins to struggle. This pump is capable of running at up to 350 bhp. Fits in place of original pump, with modification to the OE housing

£102.30

Convoluted Flexi Fuel Hose also available
Z20LEH Engine Transplant.

Details of the Z20LEH (Astra VXR engine) engine transplant.
Engine Rebuilding and Components - 2.0T.

A separate page with details of our engine rebuilding services, Cosworth Forged Pistons, Steel Rods and Balancer Shaft Deletion Kit.
Brakes Discs and Pads Stopping Power - Click for Brake Info.
Suspension and Chassis Tuning.
Details of suspension and chassis tuning options available including Limited Slip Differentials, KW Coilovers, Springs, Premium Suspension Kits, Uprated Anti Roll Bars and Polyurethane bushes.

Turbo Hoses - Dump Valve Fitment 2.0T and 1.6T

Astra 1.6T Dump Valve Hose

Astra 2.0T Dump Valve Hose

1.6T Inlet Hose

3 ply silicone dump valve take off hose (Map Sensor to Plenum) for Astra H 1.6 Turbo Models (Shown Above Left) £57.85 Buy Now Click Here!

3 ply silicone dump valve take off hose (Map Sensor to Plenum) for Astra H 2.0 Turbo Models (Shown Above Middle) £57.85 Buy Now Click Here!

Both DV hoses require a twin piston dump valve without fitting kit for DV Take Off Hose £86.85 Buy Now Click Here!

Inlet Hose for 1.6 Turbo (Shown Above Right) also available: £54.65 Buy Now Click Here!
Turbo Hose Kits.
A separate page with details of our silicone turbo hose kits which are available for Astra H 2.0 T, 1.6T and Zafira B Turbo.

Direct Route Airbox Fitting Kit (CDTi Airbox) - 2.0T


Black Inlet
Direct Route Hose Kit and CDTi Airbox Modification. More Information....

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

Uprated Recirculation Dump Valve - 2.0T and 1.6T

Designed as a direct replacement for the OEM valve which is prone to failure when the engine has been tuned or had an upgrade to the engine management software.

This valve is 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

Power Fold Mirrors Astra H 3dr

Power Folding Mirrors are available as an upgrade for Astra H models.

The kit, which uses OE components, consists of a new switch to operate the electric mirrors including the power folding and a pair of mirror housings and motors. The existing mirror covers and glass can be reused with the new components.

Some cars will also require an additional wiring loom for the operation of the power fold mirrors, which we can supply as part of the kit. It appears that later cars have this loom pre-fitted from the factory, so for these cars it is not required. The break point for cars with the loom fitted would appear to be vehicles that have Open and Start from the factory have the loom pre-installed, cars without do not. To be 100% sure it is worth checking before ordering a kit.
To check, remove the inner trim cover from one of the mirrors (you may wish to refer to our fitting guide for help here), and check to see if your car has the loom for power fold mirrors. If you have the loom pre-fitted there will be 2 wires in the middle of the connector - Black with a Green trace and Black with a Brown trace (see image right). If these 2 wires are not present you will need to order the kit with the loom.

Fitting instructions have been written to offer help with DIY fitment and can be found here, or we can offer a fitting service in our workshop. 



Kit Prices:
 

Check your mirror loom - Click to Enlarge
Kit 1: For cars with loom pre-fitted, consists of :
 
LH  Mirror Body with Power Fold Motor.
RH  Mirror Body with Power Fold Motor.
Combined Window and Folding Mirror Switch.
 
 
 
RRP:  £262.12        Our Price: £182.95
Kit 2: as Kit 1 but includes power folding door looms:
 
LH  Mirror Body with Power Fold Motor.
RH  Mirror Body with Power Fold Motor.
Combined Window and Folding Mirror Switch.
LH Door Loom with Power Folding Wiring.
RH Door Loom with Power Folding Wiring.
 
RRP:  £444.24        Our Price: £271.95

Alloy Bottom Pulley

Lightweight Billet Alloy Bottom Pulley - Z20LEx engine.

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 machined from solid billet alloy. Machined from 6082 T6 billet alloy, better balanced and 1 kilo lighter than the standard OE item. Multi V, 4 Bolt fixing. Available as Underdrive and OE size.

Price: Underdrive £97.50  OE Size £107.25

VXR and OPC Plug Covers

VXR Spark Plug Cover 2.0T 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.

Astra H (Z20LEL/Z20LER) - £10.15. Buy Now Click Here!

Astra H (Z16LET) - £12.20.
Blue OPC Plug Covers with Opel and orignal style OPC logo in Silver with yellow flash also available for 2.0T engine. £21.00 each Buy Now Click Here!
OPC Spark Plug Cover 2.0T OPC Plug Cover with New Style OPC Logo Now Avalable!

2.0 Turbo - £13.25 Buy Now Click Here!

1.6 Turbo - £10.15 each

© Copyright Courtenay Sport Ltd


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Courtenay Sport Vauxhall Tuning
Courtenay Sport
 Vauxhall Tuning

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