Posts Tagged ‘ Inlet Manifold ’

Opel Speedster Turbo K06 and Inlet Manifold


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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 H VXR Stage 4 K06 Coversion


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Another fabulous conversion on an Astra H VXR.

This car first came to us for mapping to Stage 3 (hardware requirements are a full 3″ exhaust system and uprated intercooler). The car was fitted with a Forge lower front mount intercooler, but on the exhaust side only had a pre-cat removal pipe, and a Piper 3″ cat back exhaust system and was still running the factory main cat section. Obviously with this restriction in place it would be down on expected power, and upon checking on the rolling road this was found to be the case, but still making a respectable 283bhp.

Remedial action was simple; fit a 3″ front pipe and sports cat section. Once the mapping was finalised the results were a very good 299.99bhp and 332 lb ft torque on a cold January day.

In the hunt for more power, the car returned to us recently for a full K06 and inlet manifold upgrade.

ZRP steel rods and uprated ARP rod bolts were fitted, stem seals and retainers were done at the same time, and then when being put back together the K06 turbocharger, Courtenay Turbosmart uprated actuator, Courtenay Klasen high flow inlert manifold,thermal inlet gasket and high flow 340 fuel pump were all fitted. This was also the ideal opportunity to replace the cambelt and water pump and fit a lightweight allow bottom pulley.

Z20LEH engine being fitted with steel rods

Z20LEH engine being fitted with steel rods

An uprated CSRacing clutch kit and lightweight billet steel flywheel were also fitted, as a safeguard against the increase in power and torque, and to top it off a huge K Sport 8 Pot 356mm brake kit was also fitted, to bring everything safely to a halt. The car already had a Wavetrac LSD in the gearbox.

Rolling Road Mapping

Rolling Road Mapping

The end results after mapping 333bhp and 350 lb ft torque.

Astra H VXR – K06 Mapping


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This Astra H VXR Nürburgring is a well loved and enjoyed example having covered some 110,000 miles, but it always gets regular 5,000 mile oil changes. It shows the durability of the engines as this car has been tuned to several levels, originally starting at Stage 3.

More recently it has benefitted from the addition of a K06 hybrid turbo and Courtenay Klasen Inlet manifold, a set of steel rods and with mapping and set up is currently making 316 bhp on the 70mm Remus exhaust system.

It is due back soon for a full 76mm exhaust system to release the additional power available from the fitted components, which is being held back by the Remus system.

Excellent results showing that mileage is not detrimental to the Z20LEH engine making good power, providing regular maintenacne is carried out.

Astra H VXR Mapping

Astra H VXR Mapping

Stage 4 Astra & Zafira VXR with K06 & Inlet Manifold

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).

Read more

The Courtenay Sport Blog


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