Archive for the ‘ General ’ Category

Vauxhall Reveals Seventh-Generation Astra

  • First pictures of new Brit-built Astra ahead of Frankfurt unveil
  • Up to 200kg lighter than outgoing model
  • Smaller outside, bigger inside
  • New engine portfolio including 1.4-litre (145PS) petrol
  • First all-new Vauxhall with OnStar
  • IntelliLink R 4.0 compatible with Apple CarPlay and Android Auto

Luton – These are the first images of Vauxhall’s seventh-generation Astra, which will reach production later this year from the company’s Ellesmere Port manufacturing plant in Cheshire.

New Vauxhall Astra 2015

New Vauxhall Astra 2015

Based on an all-new lightweight vehicle architecture with a new design, powertrains and technology, Astra will receive its world premiere at the 2015 Frankfurt Motor Show (September 17-27).

One the UK’s top-selling and best-loved cars, the Astra is a household name for British car buyers with over 2.9 million sold in the UK over the last 36 years with over 50,000 last year.

Depending on the model and trim level it will be up to 200kg (130kg on average) lighter than its predecessor. The completely new vehicle architecture plays a major role in the weight reduction. Every component was checked for compact design and lightweight materials. The body shell weight alone was reduced by 20 per cent from 357kg to 280kg.

Additional, chassis-related measures resulted in a further 50kg weight loss. These include high-strength and ultra-high-strength low-weight steels, compact subframes as well as weight reductions to the front and rear axle.


The all-new Astra features a powertrain portfolio including petrol and diesel units ranging from 100PS to 200PS.

It is expected that a new GSi model (247bhp) and VXR model (296bhp) will also be announced.

Read more

Number Plates – Perspex and Pressed Steel

In addition to our Courtenay Sport perspex number plates we are now also able to supply pressed steel plates.

Both types are UK road legal with Courtenay Sport logo, supplied in pairs. Available with or without the EU/GB Logo, at no extra cost.

Perspex number plates have red line border, pressed steel number plates have a black border, as shown below.

Perspex: £27.00 per pair including VAT and UK mainland delivery

Pressed Steel: £37.00 per pair including VAT and UK mainland delivery

Please > Contact Us < to order.

Front Pressed Steel Number Plate

Front Pressed Steel Number Plate

Rear Pressed Steel Number Plate

Rear Pressed Steel Number Plate

Note: We will require proof of ID and entitlement to use any number plates ordered from us, as per DVLA guidelines.

New Advert June 2015

Our Latest Advert revealed in Evo and Performance Vauxhall magazines.

Courtenay Sport Advert

Courtenay Sport Advert

Vauxhall Drivers’ Club Rolling Road Day

Saturday 16th May.

We had a varied selection of cars turn out for the VxDC Rolling Road day on Saturday 16th May, 2.0 16v Turbo Z20LEx engines being the most popular offering due to the wide range of tuning options available for this popular engine.

We were fortunate to have good weather, with sunshine for the most part of the day and a very good turnout of cars and people.

Thank you to everyone who attended the day and made it an enjoyable one.

Look out for the feature in a forthcoming edition of Performance Vauxhall magazine.

Astra 1.9 CDTi 150 Gearbox Overhaul

We recently had this Astra 1.9CDTi SRi 150 brought to us for a gearbox overhaul with new bearings for the M32 gearbox, replacement 75w-90 fully sythetic gearbox oil and at the same time a new genuine dual mass flywheel and Genuine OE clutch:

Astra SRi 1.9 CDTi

Astra SRi 1.9 CDTi

AMSOIL MTG 75w-90 Fully Synthetic Gearbox Oil

We have recently received stock of AMSOIL MTG Fully Synthetic Manual Transmission & Transaxle Gear Lube 75W-90 again in the UK after supply issues from the UK distributor.

A very high quality gearbox oil formulated specifically for demanding manual transmission and transaxle applications.

Ideal for extreme use for modified cars such as those regularly subjected to track use, and high horsepower fast road applications.

£21.00 per US Quart 

Amsoil MTG 75w-90

Amsoil MTG 75w-90

KW Coilover Kit Vectra B

This Vectra B is now sporting a KW V2 Coilover kit as its latest addition and is sitting pretty.

Vectra B on KW V2 Coilover kit

Vectra B on KW V2 Coilover kit

D2 Brake Kits

We had a couple of cars in recently for D2 big front brake upgrades, both receiving D2 6 Pot kits with 330mm alloy belled discs to fit under 17″ Alloy Wheels:

Purple Calipers:

D2 6 Pot 330mm Brake Kit

D2 6 Pot 330mm Brake Kit

Red Calipers:

D2 6 Pot 330mm Brake Kit

D2 6 Pot 330mm Brake Kit

Also available with 356mm discs to fit under 18″ Alloy Wheels.

Kit prices start at £1022.00 including DOT5.1 braked fluid, discs, bells, calipers, brackets, bolts, shims and braided front brake hoses.

Astra H VXR Routine Maintenance

Some people are under the impression that we only modify and tune Vauxhalls, but we do also carry out regular maintenance, servicing and repairs.

This modified Astra H VXR was brought to us for a full enhanced service which includes a thorough inspection, an oil and filter change, replacement of the air and pollen filters (or cleaning and re-oiling a high flow panel filter), replacement of the spark plugs with NGK iridiums and a brake fluid change to DOT 5.1 brake fluid. We use OE/OEM filters and high quality Valvoline 5w-40 fully synthetic engine oil.

Additionally at the customer’s request, the rocker cover gasket was replaced as it was leaking. We also replaced the oil filler cap seal which was also leaking and allowing oil to escape, which was picked up during inspection.

During the inspection it was also noted that the factory hydraulic gearbox mount had failed, which is not uncommom, splitting and leaking all its oil and causing the engine/gearbox to move excessively. The mount was replaced and additionally strengthened with a polyurethane insert to help reduce engine/gearbox movement and reduce the likelihood of the mount failing in the future.

Astra H VXR Enhanced Service

Astra H VXR Enhanced Service

VX220 2.2 Upgrades

This very clean low mileage VX220 2.2 came to us for some pre trackday checks and upgrades prior to its owner getting involved in doing some UK track days.

VX220 2.2 16v

VX220 2.2 16v

Apart from the obvious fluid changes; oil (5w-40 Fully Synthetic) and filter, brake fluid and gearbox oil (75w-90 Fully Synthetic), the spark plugs were also replaced with NGK platinum plugs. A thorough inspection identified a few other areas that required some work. The rear spring seats/damper collars were corroding quite badly, which is not unusual over time and so were replaced, both side engine mounts had separated and were replaced and an uprated polyurethane insert was fitted to the front engine mount to help reduce engine movement. The header tank had started to crack and degrade, again another quite common issue, so to prevent premature failure on track a new one was fitted.

VX220 2.2 16v

VX220 2.2 16v

The brakes pads were getting low and so M1155 brakes pads were fitted front and rear as a starting point. Further attention will be paid to the brakes and suspension as the driver finds his ‘track legs’, so to speak.

To improve performance the ecu was remapped and a K&N Induction kit fitted. One a rolling road set up was carried out we saw results of 156bhp and 163 lb ft torque.

Finally front a rear towing eyes were fitted (essential for trackday use) and a set of Team Dynamics pro Race 1.2 alloy wheels with some trackday tyres finished off the package.

This should prove to be a very good and enjoyable track day car.

Turbosmart Recirculation Valves Now Available

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

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.

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.

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 in 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.
  • Substancial Construction.
  • Improved Boost Responsive.
  • Single Spring – No Requirement to Change when Tuning.
  • Finish: Anodised Black as shown.

Suitable for ALL BW EFR KKK (K04/K06) Z20LEx and A20NFT Turbo units:
Astra G SRi/GSi 2.0 Turbo
Astra H SRi 2.0 Turbo including VXR
Astra J GTC VXR 2.0 Turbo
Zafira A GSi 2.0 Turbo
Zafria B SRi 2.0 Turbo including VXR
VX220/VXR220 2.0 Turbo

£120.00 inc VAT

Coming soon for Z16LEx 1.6 Turbo Vauxhall Engines.

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Astra H VXR – Uprated Clutch and Lightweight Flywheel

This Astra H VXR Nürburgring came to us for an uprated CSRacing clutch and lightweight billet steel flywheel, due to the fact the factory clutch had started to slip occasionlly.

The car had covered a shade over 91,000 miles and was originally modified to Stage 3 in 2008 at around 3,500 miles, virtually from new. So for nearly 7 years the car has been running at between 290-305bhp having had further changes made in later years, and the factory clutch and dual mass flywheel have given an exceptional service life considering the huge increase in power and torque to the car.

Replacing the original dual mass flywheel for a solid (single mass) lightweight billet steel one reduces the flywheel weight giving better acceleration due to the engine’s willingness to rev more freely as it is not having to rotate such a heavy mass. The CSRacing uprated clutch is a stronger unit, with an uprated cover with much more clamping pressure and an uprated sprung organic clutch disc to work with the single mass flywheel. The sprung disc is essential to fit if the dual mass flywheel is removed and replaced with a single mass item.

Also fitted at the same time was an uprated polyurethane gearbox mount insert as the original factory mount was starting to show signs of age related fatigue.

Astra H VXR Nürburgring Clutch and Flywheel Replacement

Astra H VXR Nürburgring Clutch and Flywheel Replacement

Don’t forget we can also fit standard original equipment (OE) replacement parts as well as uprated parts!

VX220 Tuning

Recently in for some fairly extensive modifications were this brace of VX220s.

The 2.2 underwent a Stage 1 supercharger conversion, an uprated fuel pump with 48L alloy fuel tank and rolling road set up.

The turbo model had a chargecooler system fitted, along with uprated fuel pump and uprated clutch, 80mm air flow meter and 495cc injectors, followed by a full rolling road mapping session, to complement the already fitted VXR turbo and full exhaust system.

VX220s undergoing modification work

VX220s undergoing modification work

KW Clubsport Coilover Kit for Astra H VXR

We have recently fitted a KW Clubsport Coilover kit to our Astra H VXR track car, which was running a Bilstein B8 set up with Courtenay DAP Race Spec springs.

The Clubsport kit is the prefered choice for a track biased suspension for a car that is used predominantly on track (more than it is on the road) and is the next step up from the excellent KW V3 coilover kit, which is an ideal fast road kit also suitable for light light trackday use.

Full stainless steel dampers, height adjustable springs with helper springs, solid top mounts on the front struts and 2 way damper adjustment on both the front and the rear dampers for compression and rebound adjustment to fine tune the set up.

A reminder, this is the kit as supplied:

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport coilovers were developed for customers who demand a better handling car when participating in track day events, but also require a setup that is still acceptable for road use such as to and from trackdays. The Clubsport kit was specifically designed for the Nordschleife using track day tires. The independently adjustable rebound and compression damping technology allow the suspension setup according to the vehicle load, tire characteristics and different track conditions. KW Clubsport meets every demand regarding a coilover for on road use but more importantly track use.

Here are some pictures of the fitted kit:

Engine Bed/Subframe Bushes – Astra G/H and Zafira A/B

We prepared a second subframe and fitted the uprated bushes to it prior to fitting it to one of our track day cars.

Astra H Subframe with uprated purple road spec polyurethane subframe bushes fitted.

Astra Subframe with Poly Bushes Fitted

Astra Subframe with Poly Bushes Fitted

Astra H Subframe with uprated black track spec polyurethane subframe bushes fitted. This is due to be fitted to our track car. The front anti roll bar and power steering rack will be swapped over onto it.

Astra Subframe with Uprated Black Poly Bushes Fitted

Astra Subframe with Uprated Black Poly Bushes Fitted

And some close up shots:

Purple Spec: £22 each Black Spec: £24 each

6 complete bushes required per subframe. Kit includes 12 ‘top hat’ type bushes, 6 stainless steel sleeves/inserts, 12 zinc coated upper and lower washers and a grease sachet.

EBC GD Sport Discs

Over the next few months EBC GD Sport Discs will change from gold to black. The current gold coating is being phased out and will be replaced by a Black GEOMET coating, which is a new long lasting corrosion resistant finish.

This means that over the next few months the traditional gold finished EBC discs will be replaced with black coated discs. They will still be manufactured to the same high standards.

GD Discs - Gold and New Black Finish

GD Discs – Gold and New Black Finish

Engine Bed/Subframe Bushes – Astra G/H and Zafira A/B

Front End Improvement for Astra G/H and Zafira A/B.

Poweflex have engineered a solution to replace the factory engine bed/subframe bushes in Astra G/H and Zafria A/B which can be prone to failure and contribute to vague handling. These stiffer engine bed bushes help improve the front end feel of the car especially during turn-in and cornering. By removing the flex in the subframe bushes the handling is improved giving a more positive feel to the front end.

These Front Subframe Bushes feature two polyurethane top-hat style bushes that makes for simple installation and durability. The bushes house a stainless steel sleeve and are supported by zinc coated steel washers at each end for increased support under load.

Poly bushes will be resistant to corrosion and the addition of a stainless steel sleeve should help prevent the bed bolts from seizing into the bushes, which can happen with the factory bushes.

Suitable for Astra G, Astra H, Zafira A and Zafira B All Models.

These new bushes replace OE part numbers 90498689, 9223022, 9223023 and 13107328 used across the model ranges.

The application of corrosion resistant materials, robust design and the Powerflex Lifetime Warranty ensures the subframe need not be removed again once fitted, unless removal is required for other service work to be carried out.

These bushes are available in Purple Series 80 Shore Road Spec material for vehicles that are mainly used on the road and also Black Series 95 Shore Track Spec material that suits vehicles being used in Motorsport or predominantly on the track.

Purple Spec: £22 each Black Spec: £24 each

6 bushes required per subframe.

Professional installation is recommended. The ideal time is when the subframe is removed to allow access to the gearbox or clutch.

Engine Bed Bushes - Purple Series

Engine Bed Bushes – Purple Series

Engine Bed Bushes - Black Series

Engine Bed Bushes – Black Series

Astra H VXR K06 Conversion

One of our recent jobs was this Astra H VXR, brought in to have a K06 turbocharger fitted (complete with an uprated recirculation valve), along with our CSRacing Full Height Front Mounted Intercooler. Whilst in our workshop it was also converted to Evans Power Cool 180 Waterless Coolant.

Already fitted with a 70mm exhaust system it was onto the rolling road for mapping and full set up. During mapping the mid range and top end boost was reduced slightly due to the 70mm exhaust system giving more back pressure than a 76mm system and also because the engine did not have steel rods or uprated valve springs. Once the ignition timing and fuel were optimised we saw results of 304 point something bhp (so nearly 305bhp!) and 341 lb ft torque. With a 76mm system estimated gains are 305-310bhp so this particular car is making good power on a 70mm system.

There is still some in reserve to come for this car once it has a 76mm exhaust system to help with back pressure reduction as 310bhp+ is more than possible, with potentially even more should an inlet manifold, steel rods and uprated valve springs/shims be fitted.

Astra H VXR with K06 Conversion

Astra H VXR with K06 Conversion

KW Clubsport Coilovers 2 Way Suspension

We have just taken delivery of a KW Clubsport 2 Way Coilover suspension kit for our Astra H Sprint track car, which will be fitted over the coming weeks and set up prior to its first outing in 2015.

Here’s a preview:

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Clubsport 2 Way Coilover Kit

KW Salt Test

What makes KW so good? Apart from their build quality, assembly process, attention to detail and technical support?

Their durability and resistance to rust, meaning KW coilovers continue to work, unlike cheaper competitors where spring perches corrode onto the struts making adjustment impossible.

All KW coilovers are made using high quality and perfectly matching components and materials. So both their renowned racing applications for international motorsports benefit, but also your KW coilovers for the road.

All KW coilovers, Variant 1, Variant 2, Variant 3, Street Comfort and the adaptive KW DDC coilovers from the KW iSuspension range are made from stainless steel. Whether the strut or the trapezoid thread or the vehicle-specific connections – KW only use stainless steel. KW stainless steel “inox-line” coilovers in conjunction with corrosion-resistant springs and elastomers stand for a long-term driving pleasure.

  • Highly corrosion-resistant
  • Unsurpassed quality
  • No signs of wear at the adjustment mechanism – also during long use
  • Trapezoid thread in stainless steel eases height-adjustment
  • Perfect look – permanently
  • High load tolerance

How resistant to rust are the KW coilovers “inox line”?
KW wanted to know precisely and therefore worked together with the Fachhochschule (University of Applied Sciences) Esslingen. The chemists and engineers of the FH tested the KW coilover struts made of stainless steel. So in total nine coilover struts from six different manufacturers went through a quality check.

The image shows the results which speak for themselves:

KW Salt Test Comparison.

KW Salt Test Comparison.

The Courtenay Sport Blog

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