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Astra J VXR Stage 3

A change to the more common Astra J VXRs we see in Arden Blue, this time in the much less seen but equally stunning Power Red.

The car had already been fitted with a full 3″ Piper turbo back exhaust system and an Airtec cooler and induction kit when it arrived with us and when benchmarked produced 300bhp and 348 lb ft torque when benchmarked, although with a noticeably bouncing boost curve between 3-4,000 rpm due to the factory software, which was reflected inthe power and torque curves.

Once mapping was completed the results were a very respectable 340 bhp and 381 lb ft, after we had fitted our own air flow meter inlet housing and AEM dryflow cone filter which allowed the car to produce an extra 3 bhp and 10 lb ft torque over the original induction kit that had been fitted on the car.

Our free flowing air flow meter housing was specifically developed for the Astra J VXR on our rolling road and features a built in air straightener so correct air mass values which are relayed to the ECU, and able to help this car reach higher numbers.

Astra J VXR Mapping

Astra J VXR Mapping

More Astra J VXR Mapping

Another Astra J VXR in for mapping, in the ever popular blue, this time from another repeat customer who was more than pleased with work we carried out to his previous car a Vectra VXR.

Already fitted with an induction kit and our 3″ pre-cat removal pipe the car came in for mapping and full rolling road set up.

Astra J VXR Mapping Session

Astra J VXR Mapping Session

The final figures were up from 280bhp and 324 lb ft to 325 bhp and 365 lb ft torque.

Opel Speedster Turbo K06 and Inlet Manifold

This car had previously been in for a full engine rebuild with forged pistons and steel rods, strengthening the factory Z20LET engine and was running a K04 Z20LEH VXR turbocharger, Milltek 63.5mm exhaust system, Pro Alloy chargecooler and VXR injectors.

It returned to us to have some further enhancements which included a full 76mm Tullett exhaust system, a K06 turbocharger, Courtenay Klasen inlet manifold, uprated clutch and 80mm air flow meter.

After mapping and a full rolling road set up it is now producing 334bhp and 340lb ft torque, and is very at home on the track where it spends most of its ‘working’ life.

VX220 Turbo Mapping

VX220 Turbo Mapping

Astra J VXR Mapping

We are seeeing an ever increasing number of Astra J VXRs in for remapping and rolling road set up. As with Astra H VXR, blue seems to be a popular colour.

This car came to us with a pre cat removal pipe and Evoms kit already fitting. After mapping and rolling road set up the numbers were 333bhp and 376lb ft, which are within ther expected range.

Astra J VXR Mapping Session

Astra J VXR Mapping Session

Astra J VXR Stage 1+

Another Astra J VXR in for a Stage1+ tuning package, which is proving to be a very popular option for many owners.

The first stage is to benchmarck the power of the standard car. It had already had a generic flash map installed via a well known hand held tuning box, so we first ran the car with the generic map installed, then using the hand held unit returned the car to factory standard software and ran it again. With the generic flash map loaded the car produced 287bhp and when returned to the standard map and run again the car made 281bhp.

It was then round onto the ramp so the pre cat removal pipe could be fitted, removing the restrictive factory pre cat.

Pre Cat Removal Pipe Fitting

Pre Cat Removal Pipe Fitting

Once the 76mm straight through pre cat removal pipe had been fitted it was back onto the rolling road for mapping and datalogging whilst the map is optimised on the rolling road, resulting in 328bhp and 373 lb ft torque.

Astra J VXR Mapping

Astra J VXR Mapping

Meriva VXR Tuning

This Meriva VXR had visited us before for a remap, and came back to have some further improvements carried out.

We removed the pre-cat and fitted a straight through pre-cat replacement pipe (downpipe) to remove the restrictive first cat, fitted a set of NGK iridium plugs and a high flow Courtenay Sport panel filter.

Then it was back onto the rolling road for map optimisation, datalogging and rolling road set up. The results were 216bhp and 243 lb ft torque.

Meriva VXR Mapping

Meriva VXR Mapping

Insignia VXR Remap

Another returning customer coming back to us this time with his 7,000 mile Insignia VXR for mapping, having previously has his Vectra VXR mapped by us.

Latest spec and an otherwise standard car, and a little under a year old we carried out the mapping, map optimisation, datalogging and full rolling road set up achieving 332 bhp and 380 lb ft torque, it will loosen up given a few more miles on its belt.

Insignia VXR Mapping on the Rolling Road

Insignia VXR Mapping on the Rolling Road

Astra J VXR Stage 3 Package

Courtenay Sport Stage 3: Remap, Front Pipe, Free Flowing Cat Section, Induction Kit, Intercooler
Stage 3 is the final stage upgrade using the standard factory K04 Turbo. This package consists of pre-cat deletion, replacing the OE factory front pipe and first cat first cat with our free flowing 3” cat-less front pipe (also used in our stage 1+ package). In the quest for further power we then turn to the next restriction which is the case of the Astra J VXR is the original equipment air intake/air box.

We completely remove this and replace it with a huge free flowing AEM non oiled Dry Flow Filter. This is mounted to a free flowing air flow meter housing which features a built in air straightener so correct air mass values are relayed to the ECU, finally this assembly sits within a heat deflector shield.

This particular car has also had our upgrade silicone inlet hose fitted.

Astra J VXR Stage 3

Astra J VXR Stage 3

With the Stage 3 package  we are looking to fully optimise everything around the turbo to fully maximise efficiency, so a huge Pro Alloy/Courtenay full height intercooler is installed complete with large bore pipe work and hoses, which whilst keeping the inlet air temperatures very cold also optimises the flow from the turbo through to the inlet manifold. The intercooler and pipework on the above car have been finish in stealth black finish.

Next a 3” free flowing cat section is fitted to compliment the high flow front pipe. With these parts installed the car is remapped on our rolling road optimising our Exclusive Courtenay Sport software to take full advantage to achieve maximum gains from these components.

Final power and torque figures are a very healthy 342bhp and 384 lb ft.

As an option to enhance the soundtrack, this car has also had our 3″ single sliencer cat back system fitted.

Astra J VXR Rolling Road Set Up

Astra J VXR Rolling Road Set Up

Corsa E VXR Stage 3 Mapping

Another Corsa E VXR which was brought to us for mapping and rolling road set up.

This car had already had a Cobra 3″ exhaust system and Airtec intercooler fitted to it by the customer and had previously been mapped. Prior to mapping we benchmarked the car on our rolling road to establish its base power and torque figues which were 227 bhp and 246 lb ft torque.

We then remapped the ecu and carried out a full rolling road set up with datalogging and optimised the software to suit the fitted components.

When finished the car is now producing 245 bhp and 259 lb ft torque with gains right across the rev range compared to the previous remap.

Corsa E VXR Rolling Road Set Up

Corsa E VXR Rolling Road Set Up

Corsa E VXR Front Pipe and Remap

In our workshop today was this 7,000 mile Corsa E VXR with the latest version of the 1.6 Turbo engine, B16LES. The first job was to remove the restrictive pre cat (first cat) and fit one of our straight through downpipes (pre cat removal pipe). Once fitted it was round into the dyno cell for remapping with full rolling road set up.

Corsa E VXR Pre Cat Removal

Corsa E VXR Pre Cat Removal

Running on Shell V-Power (99RON) fuel the results were 235bhp and 248 lb ft torque, with power and torque gains right across the rev range.

Corsa E VXR Remapping

Corsa E VXR Remapping

M32 Gearbox Bearings and Late Endcase

Another M32 gearbox from an Astra H in for bearing replacement and upgrade to the later endcase with larger endcase bearings.

M32 Gearbox with Late Endcase

M32 Gearbox with Late Endcase

This gearbox had covered some 90,000 miles before need to have the bearings replaced, and whilst the box was off the car for overhaul the later endcase which features additional oil galleries and larger endcase bearings was fitted.

The box was refitted and filled with 3 litres of very high quality fully synthetic Amsoil MTG 75w-90 gearbox oil, and also the dual mass flywheel, clutch (cover and disc) and hydraulic slave cylinder were also replaced using genuine OE components.

1.9 CDTi Clutch and Dual Mass Flywheel Assembly

1.9 CDTi Clutch and Dual Mass Flywheel Assembly

Prices (to supply parts):
M32 Bearing Pack with late endcase £255.00
Genuine Vauxhall/Opel OE DMF £295.00/£335.00 (price according to chassis break)
Genuine Vauxhall/Opel OE Clutch Kit £150.00/£159.00 (price according to chassis break)
Genuine Vauxhall/Opel OE Slave Cylinder £108.00

Rear Brake Lines – Astra H/Zafira B

Some pictures for reference, in gallery form and in no particular order, showing our braided rear brake hoses fitted on Astra H VXR. These should offer some help with installation of the rear braided brake lines. The brackets from the factory brake lines can be reused to accept the new braided brake lines. Remove the factory brake pipes from the original brackets (you will need to drift them out), and carefully open up the holes in the brackets to accept the braided brake line stainless steel unions, which are a slightly larger diameter to the factory fittings.

Astra H VXR Remap

Astra H VXR Nurburgring. Already fitted with a Remus 70mm stainless steel exhaust system and uprated intercooler this car came in recently for mapping and rolling road set up. Results: A very healthy 293bhp and 339 lb ft torque.

Astra H VXR Remap

Astra H VXR Remap

Courtenay Turbosmart Recirculation Valve 1.6 Turbo

New AND EXCLUSIVE to Courtenay Sport. NOW AVAILABLE: Courtenay Turbosmart Recirculation Valves for Z16LEx A16LEx B16LEx 1.6 Turbo engines.

Courtenay Turbosmart Recirculation Valve

Courtenay Turbosmart Recirculation Valve


Courtenay Sport, working with Turbosmart UK and Australia, have been involved with the development and testing of a new version of the popular Kompact Shortie Recirculation Valve specifically for the 1.6 turbocharger, used for Corsa D, Astra H, Astra J, Meriva A, Insignia, Zafira B and Zafira C 1.6 Turbo engines.

We are pleased to announce that an uprated recirculation valve is now available for the 1.6 Vauxhall/Opel turbocherged engine using the K03 turbocharger, following on from the success of the valve produced for K04/K06 applications.

Turbosmart Kompact Shortie Series Recirculation Valves have been specifically designed to suit BorgWarner EFR and KKK turbos.

Unlike the standard, plastic valves that use un-reinforced rubber diaphragms and are known to crack or split under increased boost, the new BW/KKK Kompact valves uses an O-Ring sealed piston which, coupled with their billet aluminium construction give them over 30PSI of boost handling capability using a single spring and increased reliabity over the factory valve.

Designed as a bolt-on direct replacement replacement for the factory valve on all BorgWarner EFR, KKK turbos, the Kompact Shortie Plumb Back provides better boost response and greater boost handling capability than the factory fitted recirculation valve.

Included with each Kompact Shortie kit is:

  • 1 x Model Specific Valve
  • 1 x Straight Nipple
  • 1 x Banjo Nipple
  • 3 x Mounting screws

Finished Anodised Black as shown. This recirculation valve is a really nicely machined and finished item, with a quality look and feel about it.

Features and Benefits:

  • Machined from Billet Alluminium.
  • Lightweight, brass/aluminium, two-piece piston.
  • More Reliable than the factory valve.
  • Substantial Construction.
  • Improved Boost Responsive.
  • Single Spring – No Requirement to Change when Tuning.
  • Finish: Anodised Black as shown.
  • Exclusive Courtenay Branding

Suitable for ALL BW EFR KKK (K03) Z16LEx/A16LEx/B16LEx.

Available at a special launch price of £108 inc VAT.

Here are some pictures showing the first valve we received to check fitment.

Renault Clio Track Car

Some variety in our workshop.

The Renault Clio is a very popular option for a trackday car. This car came to us for some routine service work including a new alternator, R888R tyres, rear brake discs and pads and a check on the rolling road.

Renault Clio

Renault Clio

Features Cars – Astra H VXR Sprint and Corsa C Z20LET

The owners of these cars which we have mapped and supplied parts, help and advice to have had them featured in the latest April/May issue of Performance Vauxhall magazine.

Jason Anthony’s Astra H VXR Sprint, began life as a Triple8 modifed car at around 295bhp and since his ownership Jason has made a lot of changes to the car and turning it into something equally at home of the track as the road. Now with steel rods and a bespoke Courtenay Sport remap to mid 330bhp and mid 350 lb ft torque the car has also been treated to a K06 turbo, Courtenay Klasen Inlet Manifold, KW Clubsport Coilovers, Safety Devices Rear Cage, AP Front Brakes, 292mm Rear Brake Upgrade, TD Pro Race 1.2 alloys, LSD, Courtenay Intercooler and Water Rad, 3″ Piper Exhaust, Recaro Seats and Harnesses.

Wearing the Sprint badge, this is a fantastic conversion often seen at Snetterton track days.

Jack Scott’s Corsa C 1.8 SRi has changed massively since it left its birthplace in Spain. Wanting to achieve 300bhp, Jack and his Dad carried out a Z20LET engine transplant and also fitted abig intercooler and some other performance upgrades. Once up and running, the car came to us to have a few additional upgrades including performance clutch, Courtenay Klasen Inlet Manifold, 80mm VXR air flow meter and VXR injectors and was then treated to a full bespoke remap achiving 321bhp and 340 lb ft torque.

M32 Gearbox Overhaul – Astra H SRi 1.9CDTi

Another M32 gearbox overhaul, this time on an Astra H 1.9 CDTi 5 Door. Once the engine subframe and gearbox had been removed the gearbox could be stripped down, cleaned and inspected and then rebuilt with full bearing replacement (all 8 bearings) and new driveshaft oil seals.

Do not forget, even if you are unable to get your car to us to have the work carried out, we can supply bearing kits by mail order and ship worldwide.

M32 Gearbox Rebuild

M32 Gearbox Rebuild

Golf TDi ECU Remap

This VW Golf TDi came in to us recently for an ecu remap, and it was a good job it did. Whilst it was being run up on the rolling road we found that the throttle body was loose on the inlet manifold and the seal had blown causing a boost leak and a significant loss of power.

Once this problem had been rectified we then proceeded to carry on and remap the ecu and set up the car on our rolling road. The end results: 173bhp and 355 lb/ft torque, up from 147bhp and 269 lb/ft torque and very repsectable for a car that had covered a shade over 100,000 miles.

VW Golf TDi Remap

VW Golf TDi Remap

Golf Mark 5 TDi Graph

Golf Mark 5 TDi Graph

Astra J VXR – Stage 1+ Upgrade

This Astra J VXR came to us for a Stage1+ conversion. This was a lovely low mileage example which had covered under 4,000 miles and was finished in Buzz Blue paintwork.

The first part of the process was to check the vehicle on the rolling road and benchmark it. This car made 278 bhp and 319 lb/ft torque.

Astra J VXR

Astra J VXR

The second stage of the process was to remove the factory pre-cat and replace it with a high flow straight through front pipe, removing the restrictive catalyst.

OE Pre Cat (Left) Pre Cat Removal Pipe (Right)

OE Pre Cat (Left) Pre Cat Removal Pipe (Right)

Then it was back onto the rolling road for mapping, data logging, map optimisation and full calibration and set up. The results on 97RON fuel; 319.99 bhp and 366.84 lb/ft torque with a much greater spread of power and torque which can be seen on the graph.

Astra J VXR Standard and Stage1+

Astra J VXR Standard and Stage1+

Astra J VXR

Astra J VXR

Stage 3 Astra H VXR

Astra H VXR Stage 3 Upgrade and LSD (Limited Slip Differential).

This car spent a couple of days in our workshop and had a full 3″ exhaust system, CSRacing intercooler and a Quaife LSD fitted. Then it was onto the rolling road for mapping, datalogging and full rolling road set up making 290bhp and 350 lb/ft torque.

Astra H VXR Rolling Road Mapping

Astra H VXR Rolling Road Mapping

The Courtenay Sport Blog

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