The Courtenay Sport Blog

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 Actuator

Uprated Turbosmart Actuators are now in stock.

Uprated Turbosmart Internal Wastegate Actuators provide better turbo response and greater sensitivity when managing boost pressures, especially when bespoke mapping.

FEATURES:

• Silicone diaphragm with Nomex reinforcement to withstand high temperatures.
• High grade, billet aluminum construction.
• Stainless steel rods for corrosion resistance.
• Locking Collar design cap allows for quick spring changes.
• Actuator Base Pressure can be changed with internal springs.
• Anodised Black Finish
• Available with 10PSI Actuator Spring

APPLICATIONS:

This uprated Internal Wastegate Actuator is suitable for KKK factory turbos with an internal wastegate, such as K03, K04 (VXR) and K06 as used on 2.0 Petrol Turbo Z20LEx engines Astra G, Astra H, Zafira A, Zafira B including VXR models where an uprated actuator is required.

Can be used for all stages of tune/mapping with just spring changes if additional actuator clamping pressure is required during mapping.

Suits most 2.0 Turbo applications.

Available with or without mounting bracket From £120.00 – £168.00

Useful Gates Technical Information for Cambelt Timing on the Z20LEx 2.0 Turbo family of engines; Z20LET, Z20LEL, Z20LER and Z20LEH (Astra H VXR). This is not a ‘How To’ guide but additional technical information for those with enough mechanical competency to carry out a cam belt change.

Cambelt Change Cycle suggested by the manufacturer:
Z20LET :: 4 years* or 40,000 Miles*
Z20LEL :: 8 years* or 80,000 Miles*
Z20LER :: 8 years* or 80,000 Miles*
Z20LEH :: 8 years* or 80,000 Miles*
*Whichever occurs first.
Notes: The cambelt (timing belt), plastic inlet roller and tensioner are common between all the engines (i.e. the same parts). The only different is that the LEL/LER and LEH kits use a metal exhaust roller (LET uses a plastic exhaust roller). For this reason we suggest a 6 years* or 60,000 Miles* change cycle as best practice. Always use a new tensioner retaining bolt (torx head) with the LEL/LER/LEH engines.

What is Needed……
A good toolkit with a good selection of sockets, allen head sockets, male torx sockets, a 15mm spanner (or similar) to release tension on the auxiliary drive belt and a 17mm ½” drive socket and ratchet (makes turning the engine over to check tension much easier). For the later engines a very high quality T40 Male Torx ⅜” drive socket, and a ¼” drive E10 female torx socket (a slim one) is useful for removing the timing belt cover bolt next to the tensioner once the tensioner is in the ‘rest’ position.

Do not forget a suitable Camshaft Locking Tool (widely available).

On the later engines the cambelt tensioner retaining bolt has a very shallow torx head and if you are not careful the socket can slip and/or chew out the head of the bolt. We suggest akways replacing this bolt when fitting a new belt kit (often the kits are not supplied with the tensioner bolt!)

Remember the tensioner is tensioned ANTI-Clockwise!! We see far too many incorrectly tensioned cambelts.

Torque Settings (for reference):
Toothed belt tension roller to oil pump: 20Nm
Toothed belt guide roller to cylinder block (exhaust side): 25Nm
Toothed belt guide roller to cylinder block (inlet side): 25Nm
Toothed belt cover – upper part to rear toothed belt cover: 6Nm
Toothed belt cover – lower part to rear toothed belt cover: 6Nm

When changing the cam belt always check the water pump and replace if in any doubt, especially on later engines where the change cycle of the cam belt is longer.

Gates Technical Bulletin on how to time up the engine (for reference only):

PDF Timing Information

Note: You will need a PDF reader to read this file.

Timing Belt Diagram Z20LEx

Note: E&OE. The above Technical Guidelines are provided for information only. We accept no responsibility for any loss (consequential or otherwise), damage, injury howsoever caused relating to persons undertaking their own repairs. If unsure please seek the services of a professional.