Corsa VXR Tuning

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Corsa VXR Tuning Packages

All our Corsa VXR remapping is carried out serially, through OBD II/diagnostic port directly into the vehicle's ecu. All our maps are bespoke written for us to suit our requirements. If your car does not fit into the categories listed, for example you have a different exhaust configuration, we can and will write a bespoke map and tailor it to your vehicle.
Courtenay Sport Stage 1* We carry out a full engine diagnostic test first. Then *Exclusive* Courtenay Sport software is installed raising the boost levels, whilst optimising the fuel and timing curves. A Rolling Road calibration, set up and testing session follows with full datalogging and map optimisation. Power and Torque Graph Print Outs.	Power Increases Click Torque Increases Click	£540 Fitted including Rolling Road Set Up
Courtenay Sport Stage 2 with 76mm exhaust First we carry out a full engine diagnostic test. The exhaust is then derestricted with a full turbo back 76mm (3") system. This comprises of a high flow downpipe and sports cat section that removes the pre cat which is not a legal requirement once the car is registered and adds a high flow sports cat. A performance exhaust with 2 silencers is also included for better gas flow whilst providing an improved sound track to drive to! Exclusive** Courtenay Sport Stage 2 Software is then installed, finishing with a Rolling Road calibration, set up and testing session with full datalogging and map optimisation. Power and Torque Graph Print Outs.	Power Increases Click Torque Increases Click	£1,860 Fitted including Rolling Road Set Up
Courtenay Sport Stage 3 with 76mm exhaust Following a full engine diagnostic test, we concentrate on maximising cooling efficiency of both inlet charge air temperature and water temperature with the fitment of our massive high flow intercooler. This intercooler features air guide blades to maximise the air flow back through to the water radiator. This stops the air that enters the bumper washing out through the easiest route, i.e. around past the fog lamps and away, thus utilising all the air that enters the bumper. A full turbo back 76mm (3") performance exhaust system is fitted featuring a motorsport catalyst, no pre cat and a 76mm cat back exhaust system with 2 silencers. Finally the Exclusive** Courtenay Sport Stage 3 Software is installed, finishing with a Rolling Road calibration, set up and testing session with full datalogging and map optimisation. Power and Torque Graph Print Outs.	Power Increases Click Torque Increases Click	£2,735 Fitted including Rolling Road Set Up
Courtenay Sport Stage 4 with 76mm exhaust and engine rebuild Following a full engine diagnostic test, we carry out a full engine rebuild to strengthen the 1.6 Turbo engine. The engine is removed, stripped down, rebored and rebuilt as necessary with Forged Pistons and Steel Rods renewing all gaskets and bearings as required. We then fit our Z16LEH cast manifold with Astra 2.0 VXR K04 turbo unit together with an 80mm VXR air flow meter, high flow direct fit injectors, larger map sensor, revised inlet pipework and uprated Sachs clutch cover. We then concentrate on maximising cooling efficiency of both inlet charge air temperature and water temperature with the fitment of our massive high flow intercooler. This intercooler features air guide blades to maximise the air flow back through to the water radiator. This stops the air that enters the bumper washing out through the easiest route, i.e. around past the fog lamps and away, thus utilising all the air that enters the bumper. A full turbo back 76mm (3") performance exhaust system is fitted featuring a motorsport catalyst, no pre cat and a 76mm cat back exhaust system with 2 silencers. Finally the Exclusive** Courtenay Sport Software is installed, finishing with a Rolling Road calibration, set up and testing session, with full datalogging and map optimisation. Power and Torque Graph Print Outs.	Power and Torque Increases Click	Package £7,640 Fitted including Rolling Road Set Up Price From £3,450 for cars with an engine build, intercooler and full exhaust
Courtenay Sport Stage 5 with 76mm exhaust and engine rebuild As Stage 4 above, plus 240mm Sachs uprated clutch and flywheel assembly and the K04 is replaced with the much larger K16 Turbo. To do this the manifold is reworked to accept the larger turbine K16 wheel and core whilst the shaft and bearing pack are much larger and thus very durable in high boost conditions. The K16 is used in many high powered cars e.g. Porsche, Bugatti to name a couple.	Power and Torque Increases Click	Package £9,495 Fitted including Rolling Road Set Up Price From £5,021 for cars with an engine build, intercooler and full exhaust
Stage One Remap with Front Pipe For customers wishing more from the Stage One Remap but who do not wish to opt for a full exhaust system, the addition of a high flow front pipe can be specified. We will remap to take full advantage of this which will give additional power and torque for further driveability enhancement. Front Pipe from £215.00 Fitted * Single silencer option available (Less £130). Nürburgring model requires a different exhaust tailbox. High Flow Panel Filter We also suggest the addition of one of our High Flow re-useable Panel Filters £34.95. FREE fitting as part of a Stage upgrade. Fuel: We recommend the use of Shell V-Power 99 RON, or a similar Super Unleaded fuel, on all remapped vehicles for optimum performance.

Power and Torque Graphs

For Power Graph Comparisons of our Conversions Click on the Images Below:
Power Graph Standard v Stage 1	Power Graph Standard v Stage 2	Power Graph Standard v Stage 3	Power Graph Stage 2 v Stage 3	Power Graph Std v St 2 v St 3
For Torque Graph Comparisons of our Conversions Click on the Images Below:
Torque Graph Standard v Stage 1	Torque Graph Standard v Stage 2	Torque Graph Standard v Stage 3	Torque Graph Stage 2 v Stage 3	Torque Graph Std v St 2 v St 3

80mm Air Flow Meter

For any stage of tune. More stable air flow meter than the standard 70mm item. Will require an ECU recalibration to run correctly on Corsa VXR because the 0-5v scale is different on the 80mm AFM to the standard 70mm AFM.

£149.95

High Flow Bosch Fuel Injectors

For any stage of tune, espeially for high power builds. Direct replacement for OE. OE spray pattern. Will require an ECU recalibration to run correctly on Corsa VXR. OE Flow rate 322cc at 3 bar.

395cc @ 3 bar (415cc - 3.3 bar 485cc - 4.5 bar) - £301.50

470cc @ 3 bar (495cc - 3.3 bar 575cc - 4.5 bar) - £352.50

Engine Components.
Forged Pistons, Lightweight Steel Rods for Z16LEx,
Z16LEH High Flow Exhaust Manifold.

Z16LEH Manifold and Turbo

Our Z16LEH cast manifold with Z20LEH turbo assembly. More details....

Iridium Spark Plugs

Ideal on standard or modified cars used for fast road or track use especially where engines may run warmer, we offer a spark plug upgrade. These iridium spark plugs are 'cooler running' and so able to dissipate more heat from the combustion chamber and produce a more efficient spark. £33 for a set of four.

FREE fitting as part of a stage upgrade.

Courtenay Sport Performance Intercooler Kit

Spot the Corsa VXR OE Intercooler!	Spot the Corsa VXR Courtenay Performance Intercooler
In our approach to the Corsa VXR intercooler we had to consider two areas; maximising the cooling efficiency through improved design and size whilst not detracting from the engine water temperature control capability. It's no big secret that the Corsa VXR’s engine runs quite hot. Typically on a 16 degree day it will cruise at 96/97 degrees. Whist this is fine for the standard car, it's not what we want from a more powerful, tuned engine. Heat is not good for power. The thermostat has an opening temperature of 92 degrees which is consistent with all performance Vauxhalls of the last decade, so the fact that the car will not maintain this 92 degrees at cruise suggest that we have an air flow issue. For the above reason it was imperative for us not to start by masking the water radiator (which is situated behind the intercooler) with any solid matter. This is why in this installation we have chosen to not to go with a diagonal flow intercooler as any minimal increase in performance would have been to the greater cost of water temperature control, through complicated solid pipes or air masking intercooler end tanks.
Corsa VXR Intercooler and Fitting Kit	Our Corsa VXR Performance Intercooler Shown above the standard intercooler.
The front end design lends itself well to a core that maximises frontal area, tall and wide, rather than short and deep. So this is the route we have taken. Furthermore, selecting a core that provides excellent intercooling heat transfer whist not being so dense to restrict onward air flow to water radiator was vital. The Corsa VXR remember is only a 1.6, so in order to achieve 192 bhp it requires quite a high boost pressure and once remapped the boost is higher still. With this in mind the kit comes with new silicone pipes increased in size from 50 to 60mm. These pipes are not only stronger but improve the air flow to and from the intercooler. Finally you will see from the pictures that we have also added air flow deflector guides to the bottom, sides and lower rear of the intercooler; the rear to seal where the original factory cooler has been removed. These guides are fitted to direct the air flow back through the radiator maximising its cooling effect, as air being air will always take the easier route which is in this case washing sideways past the back of the fog lamps and away under the bumper. The guides stop this from happening.

Intercooler Test Results: Standard Intercooler on a run from 40 to 106 mph^o Uprated Intercooler on a run from 40 to 106 mph^o	Avg Max Temp 61 ^oC 33 ^oC	Avg Temp Rise 37 ^oC 07 ^oC
The Courtenay Sport Intercooler comes complete with all the required fittings and hoses to suit. Intercooler - £690.00 including VAT. Fitted Price £869.00 including VAT.

Exhaust Systems.
Details of Exhaust Systems for Corsa VXR and Nürburging models

Courtenay Sport High Flow Front Pipe

The Z16LER turbo engine is fitted with 2 cats - a pre-cat and a main cat. Our performance front pipe replaces the original restrictive pre-cat. This is only required to be fitted to the vehicle up until the point of 1st registration, as the main cat still ensures the vehicle will meet all MOT emission regulations. The new front pipe is made in stainless steel, and by smoothing the bend radius and removing the cat, we have dramatically improved the flow through the unit. Our front pipe also features both a stainless steel 3 bolt flange and stainless steel spun end. Our performance front pipe will give a typical increase of around 6 - 8.

Courtenay Sport Pre-Cat Pipe for Z16LEx engines £182.85

Courtenay Sport Pre Cat Replacement Pipe

Courtenay Sport Panel Filter

Our high flow, high efficiency air filter uses a special foam which gives better airflow than even the most popular cotton gauze aftermarket filters. Our filters offer the very highest level of dirt retention and protection (Of course! After all we're engine builders!) and you can clean it and re-use it just like most other performance filters.

Each filter is supplied pre-oiled and ready for first use. For cleaning, simply wash out the underside of the filter using warm water and washing up liquid until clean, rinse through from the top to the bottom of the filter, allow to dry and lightly re-oil before re-fitting. Filter oil is available separately for subsequent re-oiling after cleaning.

Price: £34.95

Filter Oil £4.05

Large Bore Inlet Pipe

Large bore inlet pipe to ensure maximum air flow to the air box. Kit includes large inlet pipe, flexi air feed pipe to airbox, trumpet to port the airbox and locating screw and clip.

Price: £35.25

Fitting Information.

Image 1	Image 2	Image 3
Image 1 - Carefully drill 57mm hole in airbox front using a hole cutter. Cut down trumpet and bond in from the inside, to create a stub. Cut back original inlet pipe in airbox (if required) Image 2 - Fit air scoop behind front grill using supplied screw and spire clip. Image 3 - Run flexi pipe between scoop to stub of additional port at front of airbox.

Clutch and Lightweight Flywheel Options.

	Suspension and Chassis Tuning.
Details of suspension and chassis tuning options available including Limited Slip Differentials, DAP Springs, KW Coilovers and Premium Suspension Kits.

Brake Upgrades.

Courtenay Sport Silicone Hose Kit

The Courtenay Sport hose kit is designed as a direct replacement for the "OE" hoses. Superb integrity and superior performance reduces the risk of component failure whilst enabling higher temperature and pressures to be maintained. All hoses are made from 4-ply reinforced silicone so that the inlet hose (between the air filter & the turbo) will not "suck flat" as a result of high suction/vacuum during full boost. The inlet hose has been redesigned & enlarged for improved air flow whist the inside reducing lip has been removed along with the inset bump on the front edge.

Available in Blue, Red, Black, Orange, Green, Yellow, Purple or White.

Image Shows: Turbo Inlet Hose (Left) and Intercooler to Throttle Body Hose with Dump Valve Take Off Hose (Right)

Silicone Hose Kits:

Kit 1 - Turbo Inlet Hose and Intercooler to Throttle Body Hose - £100.60 (No DV Take-Off)
Kit 2 - Turbo Inlet Hose and Intercooler to Throttle Body Hose - £110.85 (With DV Take-Off)
Dump Valve £86.85

Silicone Hose Kits -

Silicone Hose for Dump Valve Fitment

Silicone Hose for dump valve fitment. Made from 4-ply reinforced silicone hose material. Available in Blue, Red, Black, Orange, Green, Yellow or Purple.

Silicone Dump Valve Take-Off Hose - £57.85

Dump Valve £86.85

Image Shows Dump Valve Take-Off Hose and Dump Valve on Right.

Silicone Turbo Inlet Hose

Available separately for cars already fitted with the dump valve take-off hose (as shown above).

Turbo Inlet Hose. Made from 4-ply reinforced silicone hose material. Available in Blue, Red, Black, Orange, Green, Yellow or Purple.

Turbo Inlet Hose - £56.65

Image Shows Inlet Hose at Front Left.

Coolant Hose Kit

Silicone Coolant Hose Kit for Corsa VXR. Hoses included are top and bottom radiator hoses, header tank to rad hose and both ancillary water hoses. Available in Blue, Red, Black, and to Special Order Orange, Green, Yellow or Purple.

Silicone Coolant Hose Kit - £109.95

Dump Valve

When fitting a Dump Valve, Courtenay only recommend the fitment of a Twin Piston Dump Valve as this will not affect air flow metering, where a single piston dump valve will cause running problems. The Dump Valve releases a volume of air to atmosphere producing an audible 'whooshing' sound!

Dump Valve without t-piece fitting kit (for use with our silicone hose with DV take-off) (Example Picture)

£86.85

Dump Valve Fitting information - >>>> Click Here <<<<

Uprated Recirculation Valve

Designed as a direct replacement for the OEM valve which is prone to failure when the engine has been tuned or had an upgrade to the engine management software.

This valve is complete and ready to install with no fitting kit required. It is available with 3 spring choices depending upon the state of tune of the engine.

Green Spring - For Standard Cars/Standard Boost.

Yellow Spring - For mapped/tuned cars running higher boost.

Blue Spring - Hybrid+ Turbo

Additional Springs available if required.

Recirculation Valve .... £122.50

Cool Running Thermostat

Our cool running thermostat reduces the engine's normal running temperature, protecting the engine by running it closer to it's optimum power temperature. The stat opens 10 degrees earlier than the standard OE item (82 degrees instead of 92 degrees) and is fully open 10 degrees earlier (97 degrees instead of 107 degrees). Ideal for modified cars for fast road and track work, they typically operate 4 - 5 degrees cooler thus reducing peak temperatures caused by sustained hard use. As used in Opel/GM products in warmer climates.

Cool 'Stat £25.50 Fitting £36.00

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