The new Zafira VXR engine is a development of the Zafira A's Z20LET power unit. Rather than simply diving straight in with remaps, we stripped an engine down to component form to examine its internals and get a real feel for what has been done. As you can see from the pictures the block has been equipped with oil spray jets. These jets cool the pistons by spraying oil at the underside of the piston. These oil spray jets were added for manufacturer's durability reasons because the LEH engine produces 240PS as standard

The pistons themselves are high yield forged items with the skirts Teflon coated to reduce noise and wear. Gone are the Z20LET’s counter rotating balancer shafts. This sharpens response whilst helping the engine rev much more quickly. At the top end the inlet manifold is revised however this revision is across the whole of the MK5 engine range, the VXR though getting new larger injectors.

The turbo charger is a hybrid item, equipped with a better A/R ratio and stronger bearings. The manifold it has been built into is cast in a higher yield of material making it less prone to cracking. This unit has been available for a while now from Vaxuhall and we have already used many times on the Astra G and the VX220 with good results.

Once we had established the above we then under took mapping our first VXR. The results are very good, however we could not take the car any further than this on the standard intercooler. So extensive cooling modifications were investigated and developed for the next level of power, to ensure the longevity of the engine and surrounding components.

Switchable Maps via Sport Button
Our remaps make use of the Sport Mode button which offers two levels of driveability. With the Sport mode switched ON full power and torque are delivered, with near standard levels of power (240PS) and torque with Sport Mode switched Off.

*Stage One Remap with Front Pipe
For customers wishing more power from the Stage One Remap but not wishing to opt for a full exhaust system, the addition of a high flow front pipe, which we remap to take full advantage of, will give additional power and torque for further driveability enhancement.

High Flow Panel Filter and Iridium Plugs
We also suggest the addition of one of our High Flow re-useable Panel Filters £34.95 and cooler running Iridium Spark Plugs £33.00 set of four Fitting FREE OF CHARGE as part of a Stage upgrade.

Fuel:
We recommend the use of Shell V-Power, or a similar Super Unleaded fuel, on all remapped vehicles for optimum performance.

Following some extensive hot summer (26°C plus) testing and development both in the UK and  Europe, Courtenay Sport and Triple Eight Race Engineering have revised their uprated VXRacing Intercooler for the Astra and Zafira VXR.

The cooler is still the same size, height and depth as the original VXRacing intercooler design, however for improved cooling efficiency it has now been mounted in front of and away from the other coolers to receive the major benefit of direct high pressure air at ambient air temperature. This removes all the problems caused by the interruption of air flow and heat dump caused by the air-conditioning condenser and front fan.

The Intercooler package is also now installed lower. This is because air will always take the easiest flow route and with the original factory set up the air is able to escape underneath the intercooler rather than going through the core. By installing the cooler lower the air is no longer unable to take that route, but is directed through the core.

An additional cooling benefit we have achieved by lowering the intercooler is that now 85% of the high pressure, ambient temperature air flow going in through the top grille panel gets directed on to the water radiator at its hottest point. This has addressed the issue of high and creeping engine water temps found on modified Zafira VXR's.

A third benefit of the new design and installation is that charge air from the cooler is now exiting out of the top left hand corner of the intercooler both shortening the pipe runs and making the intercooler core operate in the most efficient way by moving the air diagonally across the core rather than in and out at the bottom or the top.