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Our Stage 4 Conversion for Astra & Zafira VXR (Z20LEH) builds on the Stage 3 hardware components that are:

. Full Exhaust System, preferably 3” (76mm) throughout
. Large Intercooler

To this we add the following:

. K06 Hybrid Turbo
. Klasen High Flow Inlet Manifold
. Stage 4 Software

With our Stage 4 we have addressed the main issue and negative comments we have read & heard regarding other versions of the Stage 4; that is the lack of torque when compared to a Stage 3 or Stage 3+ (with a KO6 turbo).

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Courtenay Sport 300bhp VX220 2.2 Supercharger Conversion.

Another big power supercharged VX220, this car features an engine rebuild, balancer shaft removal, high lift cams and uses the OE GM Eaton Supercharger.

Astra VXR with V Band Cast Manifold, External Wastegate, Garrett GT3076 Turbo, Courtenay Sport Full Height VXR Intercooler, Courtenay Sport High FLow Inlet Manifold, Full 76mm Exhaust System, 90mm Air Flow Meter, Steel Road, Factory ECU (Bosch 7.6.3 management) bespoke mapped by Courtenay Sport

For this conversion using our new V Band Cast Manifold the brief from our customer was as close to 500bhp as possible but with usable power. We opted for a Garrett GT3076 turbocharger. The car also has our full height VXR intercooler, steel rods, Courtenay Sport High Flow Inlet Manifold and 76mm full exhaust system.

V Band Cast Manifold Astra VXR

V Band Cast Manifold with GT3076

And finally the all important Power Graph:

Astra VXR Power Graph

Following the introduction of our V Band Cast Manifold with external wastegate, here is an example of afinished conversions and graph on a VX220 Turbo.

The manifold has been flow tested to 600bhp and the Tial V Band flanges are much more secure and allow for easier turbo fitment.

V Band Cast Manifold fitted to VX220Turbo

V Band Cast Manifold fitted to VX220Turbo

The VX220Turbo with this V Band Garrett Conversion and GT2871 has also had a full engine rebuild and has had a full 3″ exhaust system and chargecooler system fitted, 80mm air flow meter, high flow injectors, uprated map sensor and uprated clutch and flywheel.

The build spec was for up to 400bhp, the final power output was 398bhp.

VX220 Turbo Power Graph

Courtenay Sport VX220 Turbo with a bespoke Garrett Build, strengthened rebuilt engine, Pro Alloy Chargecooler, full 3 inch exhaust system and full Z20LET engine management mapped by Courtenay Sport….. 360bhp

Courtenay Sport’s latest Supercharged VX220 2.2 16v running Harrop Supercharger, strengthened rebuilt engine, 4 branch stainless steel manifold and full 3 inch exhaust system and full Z20LET engine management. 377bhp

VAUXHALL’S ALL-NEW 155MPH ASTRA VXR REVEALED

• First pics released of most powerful production Astra ever built
• Trailblazing 280PS and 400Nm outputs trounce those of key rivals
• Bespoke chassis with limited slip diff and Brembo brakes
• On sale in 2012

New Astra VXR

Luton – Hot on the heels of the recently launched GTC, these are the first official pics of the new Astra VXR, which goes on sale next year and is set to become one of the most powerful cars in its class and the fastest production Astra in Vauxhall’s history.

Based on the GTC’s platform and powered by a 2.0-litre turbocharged direct injection engine, the Astra VXR produces 280hp of power and a mighty 400Nm of torque, enough for it to achieve a top speed of 155mph.

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