The VX220 Turbo

VX220 Turbo and VXR220 Tuning Packages

Iridium Spark Plugs: For customers who intend to use their cars for fast road or track use, where engines may run warmer, we can 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.

Garrett Upgrades. Garrett Upgrades, Tubular and Cast Manifolds, High Flow Inlet Manifold, Engine Building, Cosworth Pistons, Steel Rods.

VXR injectors and 80mm Air Flow Meter

VXR Injectors: As used in all Stage 4 cars, where additional fuel is required above about 270 bhp. Set of 4 high flow VXR injectors (blue). ECU recalibration required to run these injectors (available at extra cost) £114.95 80mm Air Flow Meter: Available as an upgrade on ALL stages of remap, this meter head is more stable than the OE 70mm item. ECU recalibration required to run this meter (available at extra cost). 80mm AFM - £149.95 Alloy intake pipe to fit 80mm AFM - £142.30   Silicone Hoses available separately for cars already fitted with the alloy intake pipe - £45.95

Chargecooler Kit

Mid engined turbocharged cars have to be the worst case scenario when it comes to cooling. Due to poor air flow in the engine bay temperatures soar as the power levels are raised, affecting both under bonnet and of course inlet air temperatures. On a standard VX220 Turbo (200 BHP) the tiny air to air intercooler already struggles - we saw temperatures in the region of 57 degrees C and climbing - you can feel this in the nature of the power delivery as the ECU struggles to protect the engine from imminent detonation by retarding the ignition and in some cases closing the throttle down! If this were a front engined saloon car the solution would be simple - we would simply add a front mount intercooler with a large surface area just as we do for the Astra VXR, but this simply cannot be done with the VX220 as the side scoop

Turbochargers - Direct Replacement

Z20LEH (Astra VXR) K04 Turbo

From the extensive testing that we have carried out we now offer the Z20LEH Astra H VXR turbo as an upgrade turbo unit. Offering driveability like a manufacturer's standard unit, rather than a hybrid, and spooling up more quickly this is an ideal unit for those wanting to upgrade to the Stage 4 conversion with Stage 4 remap. This unit not only features a better AR ratio but we also favour this turbocharger as it has a stronger cast manifold providing extra durability and therefore can withstand greater temperatures, heat being an issue with VX220 turbo models. The standard ZLET turbo manifold has been known to crack and so this Z20LEH unit is preferred over a hybrid turbo which is rebuild into the original weaker manifold which is prone to cracking.

Z20LEH units fitted by Courtenay Sport will benefit from a 12 month/12,000 mile warranty. Turbocharger* and VXR actuator (Special Price Mail Order*): £Check Shop Turbocharger complete with VXR Actuator (Price with warranty when supplied and fitted in our workshop). £925 Fitted including required gaskets, and Oil and Filter Change (using Fully Synthetic 5w-40 API:SM specification oil) Turbocharger* with Uprated Actuator and Bracket (Mail Order Price*): £Check Shop Uprated Actuator and Stainless Steel Bracket for Stage 4 Conversions: £142.95 Outright - No exchange Fitting available in our workshop from £295.00 including required gaskets plus Oil and Filter Change £51.50 (using Fully Synthetic 5w-40 API:SM specification oil) * As Vauxhall will only warrant these units for their intended purpose i.e. fitment to factory specification Astra/Zafira VXR, we are unable to extend a warranty onto them due to the varied nature of fitment and application outside of these parameters. For units supplied and fitted by us on our premises we will offer our own 12 month/12,000 mile warranty.

Hybrid Turbochargers - K04 and K06

Uprated Actuator and Bracket

Courtenay Sport uprated wastegate actuators are designed to allow higher boost levels to be sustained through the mid range for increased torque for ZLET/LEL/LER/LEH KKK turbochargers. They have a much higher static break-off pressure. Our heavy duty stainless steel bracket will make for easy fitment as no drilling or cutting is required. Fits directly onto the KKK turbo units used on VX220. Will also fit garrett units with modification. May require modified software to allow higher boost to be run. For use with Z20LET cars running to 300+ bhp. As used in our Stage 4 Tuning Packs for VX220 Turbo. Uprated Actuator and Stainless Bracket £142.95   Uprated Actuator (No Bracket) £91.95

High Performance Alloy Water Radiator

The standard water radiator on a VX220 has plastic end tanks which are prone to leaking especailly after time and where the cars are modified and used for sustained high speed work such as track days. This is a high performance alloy water radiator for enhanced cooling. It is a direct replacement unit, featuring a twin row 45mm thick high efficiency core. The radiator has rounded alluminium end tanks which are welded on for additional strength ideal for high pressure systems. Ideal for modified cars and for sustained speed use use e.g. track days As used in our Stage 4 VX220 Turbo. Price: £357.00 inc VAT

Z20LEH Engine Transplant. Details of the Z20LEH (Astra VXR engine) engine transplant.

Engine Rebuilding and Components. A separate page with details of our engine rebuilding options; Forged Pistons, Steel Rods, Balancer Shaft Deletion Kit, Rebuild Parts.

Balancer Shaft Removal Kit

£109.95 per kit. Save weight, Improve response. Details on our engine rebuild page. Click Here for Info

Alloy Bottom Pulley

Standard Size and Underdrive Lightweight Billet Alloy Bottom Pulleys have now been patterned up and are available for the Z20LET engine. Machined from 6082 T6 billet alloy, better balanced and 1 kilo lighter than the standard 'OE' item with no rubber core to perish and break away. Multi V, 4 Bolt fixing. Underdrive ideal for the 'Short Belt Mod' Underdrive £97.50  OE Size £107.25

Alloy Gearbox Breather Kit

Alloy breather tank and fitting kit designed to eliminate oil loss due to excessive gearbox breathing, especially when used on track. Breather tank catches oil from the gearbox preventing it from spilling onto the nearside rear wheel. Picks up from the breather point near the linkage assembly, plus takes a feed point from the gearbox filler plug using the conversion kit supplied. * Easy fitment - Full fitting kit included  * No further modifications necessary * Extensively tested on track Price: £115

Alloy Intake Pipe

All alloy intake pipe for the Vauxhall VX220 Turbo. The original intake pipe has reportedly experienced problems with the hose collapsing, and Vauxhall have certainly tried to minimise this by putting some stainless steel clips around the hose in a few places, however with all the heat around that part of the engine bay, the standard rubber hose gets very soft indeed. The original pipe also reduces in diameter immediately after the airflow meter from 70mm - 60mm. With the new polished alloy pipe we have maintained the larger diameter throughout the entire length of the pipe, with the reduction from 70mm to 60mm just taking place inside the hose which connects the pipe to the turbo thus reducing restriction. This pipe is a direct replacement for the original item and can be fitted in minutes. Supplied with all required hose clips and silicone hoses in black. Other colours available to order.

£101.95  Available in polished or stealth black finish. Hoses available in Black, Blue or Red 80mm VXR Air Flow Meter: For anyone wishing to fit a larger 80mm Astra VXR airflow meter, which is generally regarded as being a more robust item than the ZLET meter this set up can be used and can be supplied with the required silicone hoses to suit to large diameter air flow meter. This option also requires an ecu recalibration for air flow to ensure the engine does not run lean.

High Flow Plenum

High Flow Plenum

VX220 Turbo Kit

Next to OE Plenum

Our new High Flow Plenum is designed for all 2.0 Turbo Z20LEx engines. The plenum has been designed to allow more air flow through its enlarged housing, which has a 25% larger cross sectional area than OE (original equipment). It has been cast in alluminium specifically to give it an OE look, but leaving the option open to have the item polished or powder coated as necessary. This plenum has been proven up to 400 bhp, where on these engines the inlet manifold becomes a restriction and further major changes have to then be made to the inlet manifold, throttle body and associated pipework. The plenum can be supplied on its own with stud and nut kit, or with the required silicone hoses. For more information and images >>>> Click Here <<<< High Flow Plenum £89.50 including VAT. Kit including Hose for VX220 Turbo £152.15 including VAT.

High Flow Inlet Manifold.

High Flow Inlet Manifold - Gains from 30bhp. More Information....

Turbo Hose Kit

This three hose kit for VX220 Turbo manufactured by Samco Sport will tidy up your VX's engine bay. The hose kit comes in Blue as standard with six other colours to special order, to suit all tastes and is available either with or without a dump valve take off. £183.95 including VAT

Silicone Breather Hoses

To compliment the silicone engine bay hose kit, we have manufactured a silicone breather hose. This hose is available in blue, red and black with other colours to special order and comes with the Courtenay Sport Logo. Priced at £13.25 Long Breather Hose also available (rocker cover to inlet pipe) £40.80 unlined << OR >> £61.25 lined

Long Range Alloy Fuel Tank

Eliminate Fuel Surge - Increase Long Distance Range Anybody running a high powered VX220 Turbo on track will know that the standard tank arrangement allows the fuel to surge when making left hand corners when the tank contents falls below about half full. This can be a big problem on turbocharged cars where weak fuelling or fuel starvation can cause terminal engine damage. Developed and tested with Pro Alloy on their trackday cars, the long range alloy tank allows the car to be run right down to 3 litres without surge. Additionally an extra 10 litres capacity over standard adds to the car's long range capability by up to 25% on cruise. Longer Range 48 litre Capacity (Standard Tank: 38 litres) Internal collector - Assembly installed with Anti surge check valves. Safety Foam - Type IV FIA polyether Light weight - Alloy construction weighs 6.65kgs (Standard Tank: 10.8kgs) Alloy construction - Will not corrode like the standard steel tank Utilises Standard fuel pump and sender unit Eliminates the need for external fuel swirl pots and collectors Simple installation using all original fittings and brackets Price: £624.00

Fuel Collector

Tank Fitted

Uprated Fuel Pump

Uprated in-tank Fuel Pump. On modified cars fuelling is critical, and OE pumps are known to fail. Our pump is a direct replacement for OE and fits in the original housing. Ideal for standard and modified cars up to 500 bhp. Convoluted Flexi Plastic Fuel Hose Available Pump: £102.10

Fuel Filter

Exhaust Systems

Courtenay Sport Airbox Mods

Billet Steel 5.6 Kilo Flywheel

Our flywheel is precision cnc machined from billet steel, which due to its natural strength means we can lighten the unit further than simply reworking an original unit, reducing the overall weight by 3.9 kilos to 5.6 kgs. The clutch mounting height is identical to the standard OE unit to ensure that the clutch slave cylinder is not over extended and that a standard or uprated clutch can be used successfully. Billet Flywheel £254.50 (outright-no exchange required) Fitting £505.55

Uprated 'Competition' Clutch and Paddle Clutch

For cars with power well beyond 300 bhp and torque well into the mid 300 lbs ft, we can offer a 'competition' clutch which we also recommend for cars running about 270 bhp. Whilst some may offer a paddle clutch for such situations, these are really only suitable for true competition applications, as paddles clutches are often unsuitable when used in fast road applications offering very poor driveability in traffic and often causing damage to flywheels. This clutch features an uprated cover with far greater clamping pressure and an uprated organic disc which will withstand big increases in power and torque, yet will still retain good road manners often not associated with an uprated clutch. Price £429.95. Clutch Slave Cylinder £119.95 when bought with a clutch. Fitting £505.55

Paddle Clutch (Cera Metallic 4 or 6 Paddle Disc) and Uprated Cover £484.95/£494.95

Fast Road Clutch

As used in our own VX220T and ideal for any VX220T that has increased power and torque over a standard car. Our uprated clutch will withstand increases in power and torque without the slipping that may occur with a standard unit yet still retain the driveability of a standard clutch. Suitable as a direct replacement for the OE unit and for cars with running up to 270bhp Priced at £199.95. Clutch Slave Cylinder £119.95 when bought with a clutch. Fitting £505.55

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

Courtenay Turbo Boost Gauge

Whether you're running standard or increased boost pressure, keep a close eye on it with the Courtenay Turbo Boost Gauge. Available with a white face and black markings reading to 30 psi. Supplied complete with fitting kit (t-piece, rubber vacuum connectors and vacuum hose) to allow easy fitment. £72.00 including fitting kit. Gauge Pod £8.15

Vibra Technics Uprated Engine Mounts

Front Engine Mount VX220

High Performance Engine Mounts from Vibra Technics. Uprated Front, Rear and Side Engine Mounts. Details >>>> HERE <<<<

Uprated Poly Engine Mount

Uprated Polyurethane Engine Mounts for VX220 Turbo. Suitable for the front and rear engine mounts, these uprated items simply sleeve over the original rubber engine mounts making them extremely simple and easy to fit. They eliminate the the flex from the original rubber mounts removing the forward and backward motion of the engine on the over-run on lift off and under acceleration and will also relieve some of the strain put on the left and right engine mounts, which can be prone to failure. We have even had reported benefits from customers of an improved gearchange after fitment due to less engine/gearbox movement. One engine mount kit is ideal for road use, replacing both is better for those using the car for fast road or track day use, however this will give a little more resonance at lower rpm. Available at £20.45 per pair.  (One pair required for each engine mount.)

Brake Information

F23 4.17 Final Drive ratio

This lowers the final drive ratio of the F23 gearbox on the VX220 Turbo by 14.9% for faster acceleration. Price £POA

Cool Running Thermostat

As used on the VX220 Turbo Sprint. 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. Not recommended where Pro Alloy water rad is fitted (87 degree stat recommended) Thermostat £25.50 Fitting £36

Water Wetter

Water Wetter, suitable to treat one cooling system, aids the heat transfer of the coolant for even greater cooling ability and head temperature reduction. 355ml Bottle £15.25

Valvoline Fully Synthetic Engine and Gearbox Oil

Air Flow Meter 70mm and Coil Pack Z20LET

Courtenay VX220 Turbo at the Nürburgring - Nordschleife

What the press said about our VX220 Turbo: "A Courtenay chargecooler and engine management setup delivers a whacking punch and was felt as soon as I headed out onto the circuit during the out lap. I knew this was going to be quick. ....it reaches over 130mph which is very impressive along our main straight - there's not many track day stars that get over that figure. Because it was running standard suspension, the set of Courtenay 288mm grooved discs had me working hard on the brakes. If I did get it wrong on the entry the chassis was flexible enough to get it back while the huge lowdown torque figure had me very relaxed and composed." - Track and Race Car Magazine "Devastatingly quick in a straight line. The brakes are tops...." - Track and Race Car Magazine July 2004

VX220 Turbo Sprint

Courtenay Sport were delighted to have been involved in the Vauxhall/Lotus development of the VX220 Turbo Sprint, and this exciting car had a number of our components fitted to it. We were the ONLY UK tuner to work with Lotus on this project. Throughout the project working closely with Vauxhall and Lotus, we learnt what would and would not work consistently on this engine, particularly in this installation and where the limits lie.

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