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Astra VXR Development
 ZLEH Piston |
The Astra VXR engine (Z20LEH) is a development of the Astra G’s Z20LET power unit. Rather than simply diving straight in with remaps, we stripped an engine down to component form to examine its internals and get a real feel for what has been done. As you can see from the pictures the block has been equipped with oil spray jets. These jets cool the pistons by spraying oil at the underside of the piston. These oil spray jets were added for manufacturer's durability reasons because the LEH engine produces 240PS as standard (where the LET |  ZLEH Piston |
| engine only produced 200PS), and not because, contrary to internet myth, the factory Z20LEH engine runs lean. In fact the Z20LEL and Z20LER engines used in Astra H run at the same target lambda value from the factory as the Z20LEH engine, and the LEL/LER engines do not have under piston cooling. | ||
| The pistons themselves are high yield forged items with the skirts Teflon coated to reduce noise and wear. Gone are the Z20LET’s counter rotating balancer shafts. This sharpens response whilst helping the engine rev much more quickly. At the top end the inlet manifold is revised however this revision is across the whole of the MK5 engine range, the VXR though getting new larger injectors. |  ZLEH Block showing under piston cooling |
The turbo charger is a hybrid item, equipped with a better A/R ratio and stronger bearings. The manifold it has been built into is cast in a higher yield of material making it less prone to cracking. This unit has been available for a while now from Vaxuhall and we have already used many times on the Astra G and the VX220 with good results. |
| Once we had established the above we then under took mapping our first VXR. The results are very good, however we could not take the car any further than this on the standard intercooler. So extensive cooling modifications were investigate and developed for the next level of power, to ensure the longevity of the engine and surrounding components. |
 Vehicle parameters being checked and evaluated using Tech 2 prior to remapping. |
 Our Astra VXR on the dyno |
Astra VXR Tuning Packages
| All our Astra 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 our 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. |
| Courtenay Sport Stage 1 Driveability* Exclusive Courtenay Sport Stage 1 Software Upgrade, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs. |
Increases 20 - 25 bhp e.g. 240 becomes 260-265bhp Approx 280 lb ft torque |
£565 Fitted including Rolling Road Set Up |
| Courtenay Sport Stage 1.5 Exclusive Courtenay Sport Stage 1.5 Software Upgrade, Courtenay Front Pipe (pre-cat removal pipe) with 76mm Cat Back 2 Silencer System, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs. |
Increases 30 - 35 bhp e.g. 240 becomes 270-275bhp Approx 290 lb ft torque |
£1325 Fitted including Rolling Road Set Up £1220 1 Silencer |
| Courtenay Sport Stage 2 Exclusive Courtenay Sport Stage 2 Software Upgrade, 76mm (3") FULL Stainless Steel Sports Exhaust System (turbo downpipe pre-cat removal), Hi Flow Motorsport cat, Cat Back 2 Silencer System), Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs. |
Increases 40 - 45 bhp e.g. 240 becomes 280-285bhp Approx 300-320 lb ft torque |
£1730 Fitted including Rolling Road Set Up £1630 1 Silencer |
| For Astra VXR Nürburgring and cars already fitted with a full sports exhaust system. | £565 Fitted including Rolling Road Set Up | |
| Courtenay Sport Stage 3 Exclusive Courtenay Sport Stage 3 Software Upgrade, 76mm (3") FULL Stainless Steel Sports Exhaust System (turbo downpipe pre-cat removal), Hi Flow Motorsport cat, Cat Back 2 Silencer System), Extra Large VXRacing High Flow Front Mounted Intercooler, Uprated Actuator to replace VXR actuator, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs. |
Increases 50 - 55 bhp e.g. 240 becomes 290-295bhp with additional mid range power and torque over Stage 2 Approx 320-340 lb ft torque |
£2905 Fitted including Rolling Road Set Up £2805 1 silencer |
| For Astra VXR Nürburgring and cars already fitted with a full sports exhaust system. | £1745 Fitted including Rolling Road Set Up | |
| Courtenay Sport Stage 3'+' Exclusive Courtenay Sport Stage 3+ Software Upgrade, 76mm (3") FULL Stainless Steel Sports Exhaust System (turbo downpipe pre-cat removal), Hi Flow Motorsport cat, Cat Back 2 Silencer System), Extra Large VXRacing High Flow Front Mounted Intercooler, Uprated Actuator to replace VXR actuator, K06 Hybrid Turbo, Turbo Gaskets, Studs and Nuts, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs. |
Increases 65 - 70 bhp e.g. 240 becomes 305-310bhp additional power and torque over Stage 3 Approx 340+ lb ft torque |
£4310 Fitted including Rolling Road Set Up £4250 1 silencer |
| For Astra VXR Nürburgring and cars already fitted with a full sports exhaust system. | £3150 Fitted including Rolling Road Set Up | |
| Courtenay Sport Stage 4 Exclusive Courtenay Sport Stage 4 Software Upgrade, 76mm (3") FULL Stainless Steel Sports Exhaust System (turbo downpipe pre-cat removal), Hi Flow Motorsport cat, Cat Back 2 Silencer System), Extra Large VXRacing High Flow Front Mounted Intercooler, Uprated Actuator to replace VXR actuator, K06 Hybrid Turbo, Turbo Gaskets, Studs and Nuts, High Flow Inlet Manifold, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs. |
Increase 90 - 95 bhp e.g. 240 becomes 330-335bhp |
£5005 Fitted including Rolling Road Set Up £4905 1 silencer |
| For Astra VXR Nürburgring and cars already fitted with a full sports exhaust system. | £3840 Fitted including Rolling Road Set Up | |
| Note: 1 silencer 76mm exhaust systems are available with our tuning packages. Further Stages under development. Switchable Maps via Sport Button |
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Power and Torque Graphs
| Example Power and Torque Graphs for Stages 1, 2, 3, 3'+' and 4. |
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Garrett Upgrades. Garrett Upgrades, V Band Cast Manifold, Tubular and Cast Manifolds, High Flow Inlet Manifold, Engine Building, Pistons, Steel Rods. |
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Astra VXR - VXRacing Performance Intercooler Kit
| Following some extensive hot summer (26°C plus) testing and development both in the UK and Europe, Courtenay Sport and Triple Eight Race Engineering have revised their uprated VXRacing Intercooler for the Astra VXR. The cooler is still the same size, height and depth as the original VXRacing intercooler design, however for improved cooling efficiency it has now been mounted in front of and away from the other coolers to receive the major benefit of direct high pressure air at ambient air temperature. This removes all the problems caused by the interruption of air flow and heat dump caused by the air-conditioning condenser and front fan. |
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| The Intercooler package is also now installed lower. This is because air will always take the easiest flow route and with the original factory set up the air is able to escape underneath the intercooler rather than going through the core. By installing the cooler lower the air is no longer unable to take that route, but is directed through the core. An additional cooling benefit we have achieved by lowering the intercooler is that now 85% of the high pressure, ambient temperature air flow going in through the top grille panel gets directed on to the water radiator at its hottest point. This has addressed the issue of high and creeping engine water temps found on modified Astra VXR's. A third benefit of the new design and installation is that charge air from the cooler is now exiting out of the top left hand corner of the intercooler both shortening the pipe runs and making the intercooler core operate in the most efficient way by moving the air diagonally across the core rather than in and out at the bottom or the top. |
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 New Revision: Our Full Height Intercoller now with 60mm pipework throughout. This intercooler has always used 60mm pipework from the turbo to the intercooler and has now been revised to include a 60mm intercooler outlet with 60mm hard pipe up to and including the map sensor pipe - £825 including VAT. Polished Alloy or Stealth Finish Now Available  Or £1039.55 including VAT, fitting and software upgrade for cars already running Courtenay Stage 1 or Stage 2 software. (Dyno set up time extra)Important Note: Customers' with our existing intercooler set up are able to update it if required. Please contact us.  As used in the 2011 Dubai 24 Hour Race. |
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 60mm Pipework Stealth Finish |
 60mm Outlet Stealth Finish |
 60mm Outlet Stealth Finish |
Astra VXR K04 Turbo
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Genuine KKK Direct replacement K04 Astra VXR turbocharger. Turbocharger* and VXR Actuator (Special Mail Order*): £Check Shop Hybrid options are available |
| Z20LEH turbochargers fitted by Courtenay Sport will benefit from a 12 month/12,000 mile warranty. Turbocharger complete with VXR Actuator: £895 Fitted. Price includes warranty, turbocharger, gaskets, oil and filter change using fully synthetic oil Turbocharger* with Uprated Actuator and Bracket (Mail Order Price*): £Check Shop Turbocharger with Uprated Actuator and Bracket: £1037.95 Fitted. Price includes warranty, turbocharger, gaskets, oil and filter change using fully synthetic oil Uprated Actuator and Stainless Steel Bracket for Stage 3 Cars: £142.95 Fitting available. Fitting in our workshop includes required gaskets, Oil and Filter Change using Fully Synthetic 5w-40 API:SM specification oil * Vauxhall will only warrant these units for their intended purpose i.e. fitment to standard factory specification Astra/Zafira VXR. We are unable to extend a warranty onto these units when supplied by mail order due to the varied nature of fitment and application outside of these parameters. VXR Turbochargers supplied and fitted by us on our premises have our own 12 month/12,000 mile warranty. |
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 |
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 5 degrees earlier than the standard OE item (87 degrees instead of 92 degrees) and is fully open 5 degrees earlier. 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 .... £36.00 |
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Astra VXR Uprated Water Radiator
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All Aluminium high performance water radiator for improved cooling. Developed and tested on a 300+ bhp car. |
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Exhaust Systems. Details of exhaust systems we use and recommend for Astra VXR. |
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High Flow Plenum - 2.0T
 High Flow Plenum |
 Astra VXR 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 hose(s). As used in the 2011 Dubai 24 Hour Race.The plenum can be supplied on its own with stud and nut 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 VXR £122.05 including VAT. |
High Flow Inlet Manifold.
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High Flow Inlet Manifold - Gains from 30 bhp. More Information.... |
Uprated Fuel Pump
| For Astra VXR models running big horsepower and high boost levels, fuelling is critical. This replacement uprated fuel pump is ideal to take over from the original 'OE' fuel pump to mantain good fuel flow where the OE pump begins to struggle. This pump is capable of running at up to 2.9 litres per minute, which is good for cars running up to 500 bhp. Fits in place of original pump, with modification to the OE housing Uprated Fuel Pump £102.10 Convoluted Flexi Fuel Hose also available |
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Courtenay Sport Panel Filter
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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. 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. As used in the 2011 Dubai 24 Hour Race.Price £34.95 Filter Oil £4.05 |
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. Further plug upgrades also available. FREE fitting as part of a stage upgrade. |
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Uprated Actuator and Bracket
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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 used on Astra and Zafira VXR. Will also fit garrett units with modification. May require modified software to allow higher boost to be run. For use with Z20LEH cars running to 300+ bhp. As used in our Stage 3 Tuning Packs for Z20LEH Astra and Zafira VXR. Uprated Actuator and Stainless Bracket £142.95 including VAT. Uprated Actuator (No Bracket) £91.95 including VAT. |
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Brake Upgrades |  |
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Suspension and Chassis Tuning. |  |
| Details of suspension and chassis tuning options available including: Limited Slip Differentials, Springs, KW Coilovers, Premium Suspension Kits, Uprated Anti Roll Bars and Polyurethane Bushes. |
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Clutch Options and Lightweight Flywheel. |  |
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Turbo and Water Hose Kits. |  |
| Details of our silicone turbo and water hose kits which are available for Astra VXR, including the direct route hose kit and CDTi airbox. | ||
Direct Route Airbox Fitting Kit and CDTi Airbox.
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Direct Route Hose Kit and CDTi Airbox Modification. More Information.... |
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Recirculation and Dump Valves |  |
Power Fold Mirror Kit
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Details of our OE Power Fold Mirror Kit |
OPC Plug Cover
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OPC Plug Cover with New Style OPC Logo £13.25 |
Alloy Map Sensor Pipe
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Alloy Map Sensor Pipe. Direct replacement for the OE black plastic item.... £34.95 |
Stainless Steel Heatshield
| Stainless Steel Heatshield .... £30.60 Fitting available |
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27 Years of Vauxhall Tuning
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