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CSR Intakes for Corsa E VXR

CSR Intake for OE 70mm Air Mass Meter

Corsa E VXR engine bay with CSR MaxAir Intake System 70mm Corsa E VXR engine bay with CSR MaxAir Intake System 70mm
CSR intake system for OE standard Air Mas meter consists of a AEM Dry Flow air filter, the CSR heat deflector shield complete with all the brackets and fittings with the option of our Courtenay Sport High flow inlet hose and adaptor.

Kit price to install onto the OE inlet hose. £159.00 (shown left)
Optional upgrade to high flow inlet hose and adaptor for OE 70mm AFM £84.50 (shown right in blue)

CSR MaxAir 80mm Intake System

CSR uprated intake system featuring our own 80mm high flow trumpeted air mas meter housing.

This housing has proven itself beyond compare in our Astra J VXR tuning program so we have introduced this in a package to suit the Corsa E VXR with exceptional results. The CSR housing is shaped to get the most air we can across the whole of the air mass meter without the need for the restriction of an inbuilt air straightener, to achieve the best flow possible. This combined with a large diameter AEM Dry Flow air filter give a massive increase in air flow potential.

The kit comes complete with a custom-made CSR heat deflector shield along with all the brackets and fittings and our own high flow reinforced inlet pipe down to the turbo.

Note: All cars fitted with the 80mm induction systems will need to have the cars ECU re-calibrated to scale the air mass meter correctly to take advantage of its larger size and to stop the EML coming on for to exceeding the 70mm air flow limits.

CSR MaxAir Intake System 80mm £335
Silicone Inlet Hose (shown in black) included in 80mm kit

Corsa E VXR MaxAir Intake System Corsa E VXR MaxAir Intake System Corsa E VXR MaxAir Intake System Corsa E VXR MaxAir Intake System

EBC – Know Your Brake Pad Compounds

Does exactly what it says on the tin. A guide to EBC brake pad compounds and their uses. Click on the image below to open up a PDF file (you will need a PDF reader such as Adobe or similar).

EBC Pad Compounds

EBC Pad Compounds

Corsa E VXR Mapping and Full Exhaust

This Corsa E VXR came to us to have a full turbo back 3″ exhaust fitted, followed by map optimisation to suit the exhaust and full rolling road set up.

Corsa E VXR

Corsa E VXR

Corsa E VXR Exhaust

Corsa E VXR Exhaust System

Once set up the results were an impressive 241bhp and 244 lb ft torque. We also carried out our own unique hardware fix and software recalibration to the air flow meter to allow it to read and fuel correctly above 222bhp, where it is known that the standard air flow meter maxes out.

Corsa E VXR

Corsa E VXR

We also have in development the CSR MaxAir Intake System for Corsa E VXR, which will feature an enlarged airflow meter housing and large AEM Dryflow cone filter.

Astra 1.9 CDTi Single Mass Flywheel

Astra H 888 CDTi

Astra H 888 CDTi

We recently had this lovely Astra H 888 CDTi (Z19DTH engine with M32 gearbox) in for a lighter single mass flywheel (removing the dual mass flywheel) and sprung clutch assembly due to slight clutch slip on the factory clutch. At the same time we also overhauled the gearbox fitting new bearings throughout and the later end case, which features larger diameter end case bearings and additional oil galleries in the end case for better end case bearing lubrication.

Courtenay Turbosmart Recirculation Valve 1.6 Turbo

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.

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

Enlarged Silicone inlet Hose for Astra J VXR

Enlarged Silicone Inlet Hose for Astra J GTC VXR.

A direct replacement for the factory inlet hose, this silicone hose has been enlarged throughout its length for improved air flow, tapering only at the end to fit onto the turbo. This hose is smoothed out removing all the steps and convolutes found in the factory hose. It also features a moulded spigot for the breather pipe.

£119.95 Available in Blue, Red or Black or Yellow, Green, Purple or Orange to Special Order.

Astra J Inlet Hose

Astra J Inlet Hose

Thermal Inlet Gasket Z16LEx/A16LEx/B16LEx

New Product, Now Available.

Thermal Inlet Gasket for 1.6 Turbo Z16LEx/A16LEx/B16LEx Engines.

Thermal Inlet Gasket Z16LEx/A16LEx/B16LEx

Thermal Inlet Gasket Z16LEx/A16LEx/B16LEx

Designed to reduce heat-soak from the cylinder head to the inlet manifold. Ideal for use with any engine, but especially big power builds.

Heat management is an area that is often ignored during engine modification. The Thermal Inlet Gasket will help prevent heat from conducting from the cylinder head casting into the inlet manifold, significantly reducing heat soak.

In theory, because of the cooler and denser inlet charge, a small and immediate power increase should be evident (if you can run a little more ignition timing before pre-ignition occurs then power should rise), but their main strength will be in helping to keep temperatures under control during and after prolonged engine use.

This 4mm thick high performance composite gasket, designed for optimal heat insulation, is available for Z16LEx/A16LEx/B16LEx engines and is paper coated on both sides to aid sealing.

£45.00

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: £40.00 per pair including VAT

Pressed Steel: £54.00 per pair including VAT

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.

Big Brake Kits

Big Brake Kits are becoming more and more popular, especially the offerings from D2 and K Sport due to their price point and build quality. They offer immense stopping ability and the most popular sizes are 330mm and 356mm designed to fit under 17″ and 18″ wheels respectively, although in some instances a narrow wheel spacer may be required, depending on the wheels fitted.

D2 kits feature 6 pot calipers with road seals and cross drilled belled discs, K Sport calipers are 8 pot and use 8 grooved discs and are available in a range of caliper colours at no extra cost; Black, Red, Yellow, Orange (K Sport only), Purple (D2 Only).

Prices range from £899 – £1122. Avaiable for Astra G, Astra H, Corsa D, Vectra C, Zafira A, Zafira B, Vectra B

D2 6 Pot Caliper in Purple

D2 6 Pot Caliper in Purple

K Sport 8 pot Caliper in Orange

K Sport 8 pot Caliper in Orange

D2 6 Pot Caliper in Purple

D2 6 Pot Caliper in Purple

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.

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.

EBC Yellow Pads for Astra J VXR

Astra J GTC VXR models, which have the Brembo 4 pot front calipers and 355mm brake discs now have available the choice of EBC Yellowstuff pads for front and rear.

Available for the front at £128.40 per set, this is a slightly less expensive option for the cost conscious to the currently favoured Brembo Sport HP2000 pad which is receiving excellent reviews and feedback.

The rear pad set is £64.00

Both options are available for online purchase from our website shop.

Poly Bushes for Vauxhall/Opel Adam

Polyurethane Bushes are available for Vauxhall/Opel Adam models to help stiffen the chassis.

Available is Purple Spec material for road use or Black Spec material for track use.

The front kit comprises Front Wishbone Front Bushes, Front Wishbone Rear Busehs and Front Anti Roll Bar Bushes at £220.80 (purple) and £250.80 (black) per set.

Rear Beam Mounting Bushes are £69 (purple) and £76.80 (black) per pair.

Also available is a Rear Lower Engine Mount Insert £21.60 (road) and £24.00 (black).

Vauxhall Adam

Vauxhall Adam

These bushes can be purchased by telephone for mail order and will be available for online purchase soon.

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

£108.00 inc VAT

Coming soon for Z16LEx 1.6 Turbo Vauxhall Engines.

Turbosmart Recirculation Valve

Turbosmart Recirculation Valve

Poly Engine Mount Additions – Astra H VXR and 1.9 CDTi

At our request, Powerflex have added a couple of new polyurethane engine mount inserts to their Astra H range.

Courtenay Sport supplied the relevant OE engine mounts and asked if a lower front engine mount insert for Astra H 1.9 CDTi models and an insert for the Right Hand Side Mount for Astra H VXR and 1.9 CDTi could be produced.

These engine mount inserts fit into and fill the voids in the original bushes and are recommended as a labour saving method of limiting engine movement to improve vehicle performance and reduce the likelihood of engine mount and downpipe failure caused by excessive movement. Some additional NVH may be experienced.

These mounts are now available in both road spec material to reduce engine movement but limit increased Noise, Vibrationand Harshness (NVH) and Black 95 Shore Track spec material, which due to its nature is much stiffer and will lead to significantly more NVH being transmitted.

Astra H 1.9 CDTi Front Engine Mount Poly Insert in Road Spec Material (below).
Road Spec £24.00:

Front Poly Mount Insert Astra H 1.9 CDTi

Front Poly Mount Insert Astra H 1.9 CDTi

Astra H 1.9 CDTi Front Engine Mount Poly Insert in Black Spec Track Material (below).
Track Spec £27.00:

Front Poly Mount Insert Astra H 1.9 CDTi in Black

Front Poly Mount Insert Astra H 1.9 CDTi in Black

Astra H 1.9 CDTi Right Hand Engine Mount Poly Insert in Road Spec Material (below).
Road Spec £22.50: Track Spec (Black) £26.10:

Right Hand Poly Mount Insert Astra H 1.9 CDTi

Right Hand Poly Mount Insert Astra H 1.9 CDTi

Astra H 2.0 Turbo inc VXR and Astra G 2.0 Turbo Right Hand Engine Mount Poly Insert in Road Spec Material (below).
Astra H 2.0 T inc VXR Road Spec £22.50: Track Spec (Black) £26.10:

Astra G 2.0 Turbo & Z22SE Road Spec £22.50: Track Spec (Black) £26.10:

Right Hand Poly Mount Insert Astra H 2.0T VXR

Right Hand Poly Mount Insert Astra H 2.0T VXR

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.

KW Suspension Reference Chart

This KW Product Selector image gives a representation of the KW product range and its intended application; a useful reference guide.

KW Product Finder

KW Product Finder

The Courtenay Sport Blog

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