Developed in-house by Courtenay Sport.

In addition to our tubular manifold, we are also able to offer a high flow cast manifold for Z20LEx applications. This cast manifold has been developed for conversions up to 400 bhp and is a good alternative for the tubular manifold because a cast item is generally stronger and more durable plus it will not heat soak the engine bay in quite the same way. It also retains a degree of 'OE' look in the engine bay.

The cast manifold has been developed in such as was as to correctly orientate the turbo to give a constant radius 3" cast outlet for optimum flow and has been designed to allow air con to be retained.

Fully developed in house by Courtenay Sport this conversion can be specified with a newly developed garrett hybrid turbo unit for this manifold. The benefits of our new hybrid garret unit are that driveability is much improved. Power and torque is available from around 3,000 rpm making mid range driving a delight due to the turbos ability to spool up quickly.

Additionally, the turbo allows the use of original oil and water banjo bolts and the pick up points are in the same locations as the OE KKK turbo, making fitment easier. No more having to source fiddley oil and water feed pipes.

We can offer a range of turbo options to be used with this cast manifold to give a mild increase to around 320-330bhp, to 350bhp and up to around 400bhp.

Suitable for all Z20LEx engines, it is recommended that for durability and reliability additional strengthening of pistons and rods is carried out to non LEH engines, while LEH engines steel rods are recommended.

The graph shows a conversion specifically built to produce 330 bhp with 360 lb ft torque

Stephan Klasen, our partner and mapping engineer, has produced numerous high powered Z20LEx cars and for some time has had the most powerful Z20LEx engined car at 659BHP in his crazy Speedster. His various builds continually found that the standard inlet manifold starts flow inefficiently on high power applications over 350 BHP.

Using this knowledge gained from his Speedster and other builds, the high flow manifold is the culmination of a project Stephan started over 2 years ago. The aim was to design a manifold that fitted all versions & applications of the Z20LEx engine to produce good high end power whilst not sacrificing all the bottom and mid range end power.

Finished High Flow Manifold fitted up to an engine with our High Flow Plenum.
High Flow Manifold - £789.00
High Flow Plenum - £87.50

Courtenay Sport are pleased to launch their enlarged uprated intercooler kit for the Astra H 1.9 CDTi.

The kit consists of an extra large full height front mounted intercooler with thicker core, high flow repalcement fan and all the required fittings.

The intercooler is a direct replacement and results from testing have been excellent. Inlet air temperatures fall significantly and the fuelling is much cleaner. Full benefits can be made with additional ecu mapping to alter the fuelling to improve power and torque.

Intercooler Kit Price - £725.00

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