Intercooler Kit Courtenay Sport - Astra H VXR / Zafira B VXR
1 x Full Height CSRacing Intercooler
1 x 60mm Alloy Intercooler Outlet Pipework with map sensor locating boss
1 x new slimline fan unit
1 x fan mounting bracket and heatsink/resistor location bracket
2 x intercooler mounting brackets
2 x aircon rad mounting brackets
2 x intercooler mounting bobbins
1 x 60mm Turbo Outlet 90 Silicone Hose
1 x 60mm 90 degree alloy joiner pipe
1 x 90 degree silicone hose
1 x straight silicone joiner
Required hose clips, nuts, bolts and washers
In house fitting from £237.60
VXR Intercooler Fitting Guide:Click on the below image for a guide to fitting a VXR intercooler. This fitting guide was produced for Total Vauxhall prior to the pipework change on our intercooler so should be used as a guide only, in conjunction with the above fitting guidelines.
Originally published in Total Vauxhall MagazinePlease Note: The information on this page is provided purely as a guide. This information is not intended to offer step by step fitting. Please ensure that before commencing any work you have the appropriate level of skill and knowledge to undertake any work safely and competently. Courtenay Sport Ltd accept no responsibility for any loss, damage, injury or consequential loss that may arise from individuals working on their own vehicles. If you are in any way unsure about how to proceed with anything, seek professional advice and help.
Proudly made in England by Pro Alloy Motorsport Exclusively for Courtenay Sport
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 H/Zafira B 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 in order 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 able 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 Astra H 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.
Black Hoses are the standard colour, Blue or Red Hoses available. Other hose colours are available on request/special order.
The cooler can be supplied in standard alluminium finish or stealth black upon request.
New Revision, now includes 60mm pipework throughout from turbo to intercooler and from the intercooler 60mm outlet up to and including the map sensor pipe.
Additionally, primarily intended for Track Use this intercooler is fitted with bosses to accept our Air Guide Blades to ensure maximum air flow through the intercooler core for maximum cooling.
As used in the 2011 Dubai 24 Hour Race.