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Astra J VXR Tuning
Courtenay Sport Astra J VXR
Courtenay Sport Astra J VXR
The Astra J GTC VXR is powered by a GM developed 2.0 turbocharged direct injected engine. Originally developed for the American market, the current development of this 2.0 engine is a higher power unit, known in Europe as A20NFT (LHU).
Astra J VXR Engine A20NFT
A20NFT Engine
Click to Enlarge
Standard Astra J VXR Power and Torque Graph
Standard Power and Torque Graph
Click to Enlarge
This engine, in standard guise, develops 280PS (276bhp) and 295 lb ft torque, featuring an all alluminium block and cylinder head; the latter being unique to the Astra VXR.
Specification wise the 2.0 engine is a 1998cc 16v (4 valves per cylinder) engine, with a 9.3:1 compression ratio, has an 86mm bore and stroke with Variable Valve Timing, under-piston cooling and a twin-scroll turbocharger.
Our Testing - Standard Power:
When testing standard factory cars which are quoted at 276bhp we have seen power outputs as low as 265bhp through to 285bhp. This variation can carry through when modified and subsequently we have seen some low power cars improve (aside from the usual climatic conditions) as the mileage climbs and the car loosens up. This is why we show a broader range of expected power than perhaps we have seen previously with other VXR models.
Our power figures quoted have been achieved with the same car, always using Shell V- Power Nitro+

Astra J VXR Tuning Packages

All our Astra J 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 your requirements.
All our ECU upgrade software is installed on your car whilst on our rolling road optimising fuelling, boost and Ignition maps.
This enables us to see and rectify any underlying faults or problems and to ensure that the calibration is 100% accurate and safe for your car before handing it back to you, along with the full power and torque print outs.
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: ECU Remap
Our Stage 1 upgrade gives much better low end response combined with a smother and flatter torque curve, whilst at the top end we have managed to increase and sustain the power for longer. Alongside this you will also benefit from improved cruise fuel economy.

As with all our ECU upgrades our Exclusive Courtenay Sport Stage 1 software is installed whilst your car is on our rolling road optimising fuelling, boost and ignition maps. This enables us to see and rectify any underlying faults or problems and to ensure that the calibration is 100% accurate and safe to suit both your car and the grade of super unleaded fuel you use, before handing it back over to you complete with the full power and torque print outs.
 
Stage 1 Remap Power and Torque Graph
Power and Torque Graph
Click to Enlarge


Power Gains to 305-310bhp
Torque: 350lb ft
£565 Fitted including Rolling Road Set Up
Courtenay Sport Stage 1+: Front Pipe and ECU Remap
To meet the stringent Euro 5 emissions regulations the engine prior to registration has to be fitted with a very restrictive 600 cell per inch cat which is mounted in not the best flowing pipework, however once registered the factory fitted 2nd catalyst (fitted in the next section back) is fully capable of passing MOT requirements.

So for stage 1+ we remove the factory front pipe complete with its restrictive catalyst and install a free flowing 3” front pipe featuring far smoother flowing bends. Once fitted we install and optimise our Exclusive Courtenay Sport software on our rolling road to take full advantage of the much improved flow and output due to the engine's vastly improved breathing, and provide full power and torque graphs.
 
Stage 1+ Remap Power and Torque Graph
Power and Torque Graph
Click to Enlarge


Power Gains to 320bhp
£915 Fitted including Rolling Road Set Up
Courtenay Sport Stage 2: Remap, Front Pipe and Induction Kit
Stage 2 consists of the factory front pipe with catalyst deletion, replacing with the free flowing 3” cat-less front pipe as found above in the stage 1+ package. In the quest for further power we then turn to the next restriction which is the case of the Astra J VXR is the original equipment air intake/air box. We completely remove this and replace it with a huge free flowing AEM non oiled Dry Flow Filter. This is mounted to a free flowing air flow meter housing which features a built in air straightener so correct air mass values are relayed to the ECU, finally this assembly sits within a heat deflector shield. Once fitted we install and optimise our Exclusive Courtenay Sport software on our rolling road to take full advantage of the improvements and provide full power and torque graphs.
 
Stage 2 Remap Power and Torque Graph
Power and Torque Graph
Click to Enlarge


Power Gains to 330-340bhp
£1175 Fitted including Rolling Road Set Up
Courtenay Sport Stage 3: Remap, Front Pipe, Free Flowing Cat Section, Induction Kit, Intercooler
Stage 3 is the final stage using the standard factory K04 Turbo. Over and above the Stage 2 parts (Front Pipe and Induction kit), with the Stage 3 we are looking to fully optimise everything around the turbo to fully maximise efficiency, so a huge Pro Alloy/Courtenay full height intercooler is installed complete with large bore pipe work and hoses, which whilst keeping the inlet air temperatures very cold also optimises the flow from the turbo through to the inlet manifold. Next a 3” free flowing cat section is fitted to compliment the high flow front pipe. With these installed the car is remapped on our dyno optimising our Exclusive Courtenay Sport software to take full advantage to achieve maximum gains from these components. Power and torque graphs.
 
Stage 3 Remap Power and Torque Graph
Power and Torque Graph
Click to Enlarge

Power Gains to 340-350bhp
plus additional torque
£2135 Fitted*
(full cat delete track use only)
£2637 Fitted*
(Euro 5 sports cat section)
including Rolling Road Set Up
*Stage 3 Option of a 3” cat back system for better flow
Add £748 for a single box system or £780.90 for twin box system

Stage 4 - In development

With Stage 4 we turn our attention to the next restriction this being the factory K04 turbo we are currently testing a version the features a number of up-grades, larger compressor wheel, better & stronger bearing pack complete with improved oil supply.

Target gains circa 370-380 Bhp

High Flow Panel Filter and Iridium Spark Plugs
With any of our stage upgrades, we also suggest the addition of one of our High Flow re-useable Panel Filters
£34.95 and a set of cooler Laser Iridium Spark Plugs £48.00 set of four.
Fitting FREE OF CHARGE 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 vehicles for optimum performance.

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 laser iridium spark plugs are 'cooler running' and so able to dissipate more heat from the combustion chamber and produce a more efficient spark. £48 for a set of four.

FREE fitting as part of a stage upgrade.

Enlarged Silicone Inlet Hose

Astra J VXR engine bay with inlet hose Enlarged Silicone Inlet Hose.

A direct replacement for the factory inlet hose, this silicone hose has been enlarged throughout its length for improved air flow, tapering only at the end to fit onto the turbo. This hose is smoothed out removing all the steps and convolutes found in the factory hose. It also features a moulded spigot for the breather pipe.

£119.95 Available in Blue, Red or Black. Yellow, Green, Purple or Orange to Special Order.

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 reuse 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

CSR MaxAir Intake System

Astra J VXR engine bay with CSR MaxAir Intake System Early in testing the Astra J VXR it was discovered that the original factory airbox simply would not cut it even with the usual modifications. Porting it simply could not flow the required air, so some kind of induction system was required.

During initial induction testing it soon became apparent that a straight/parallel air MAF housing not unlike the Astra H 80mm MAF with a cone filter simply clamped on the end was not the answer. This parallel design created too much turbulence from the air turning from the sides of the filter into the housing and due to the lack of available space between the air filter and the MAF metering head, even with the addition of an air straightener, would not clean this turbulent air. The result was a restriction of air flow along the inside edges of the MAF and thus the air was
accelerated through the center of the MAF which in effect meant the engine was receiving less air than the mass meter was reading and reporting to the ECU. The target was therefore to create a trumpet with as long and smooth a progression of taper as space would allow in order to slowly turn and progress the air so smoothly that an air straightener was not even required. After testing a number of prototypes we achieved this goal.

Now we had to produce this. We looked at aluminium, however this was deemed too heavy with far too much wastage having the units moulded would make the product far too expensive so we turned to the relatively new dark art of plastic printing. We are able to make both the trumpet and the housing in one piece making it very clean looking on the outside and smoother for flow on the inside with a weight saving over an alloy version of a fraction under ½ a kilo. Not massive agreed but it all counts.

Attached to the new MAF housing we use a massive high flow AEM dry filter for very efficient filtration and breathing. This package is then housed in a powder coated heatshield assembly with the Courtenay Sport logo laser cut out of it.

So what does it do?
With the standard inlet air pipe just over 13bhp at peak power and with an enlarged silicone induction pipe 15 BHP. Also when compared to a parallel housing induction version it makes an extra 3 BHP at peak and a further 15 BHP from 5650 RPM! The MaxAir induction system is compatible for both mapped and standard cars.

CSR MaxAir Intake System £249 Silicone Inlet Hose (shown in blue) also available
Astra J VXR MaxAir Intake System Astra J VXR MaxAir Intake System Astra J VXR MaxAir Intake System
Exhaust Systems.

Details of exhaust systems we use and recommend for Astra J VXR.
Full System.

For the Astra J we have developed a full 3” exhaust system that comprises of a full turbo back 76mm system, including sports cat which integrates itself perfectly with the car right through to the stainless steel trims that sit inside the bumper replicating the offset original "Fish Tail" shape of the factory trims.

The exhaust system in single box mode provides a true VXR soundtrack at full throttle whilst retaining low noise level at cruise with the associated booming that comes with many aftermarket systems.

We also offer a twin box system that is for those who want a less sporty / more stealth like sound track at full throttle.

Full System Non Resonated Single Silencer - £1695.00

Full System Resonated Twin Silencer - £1872.00
Astra J VXR 76mm Sports Exhaust Astra J VXR 76mm Sports Exhaust Astra J VXR 76mm Sports Exhaust Astra J VXR 76mm Sports Exhaust
Astra J VXR 76mm Sports Exhaust Astra J VXR 76mm Sports Exhaust Astra J VXR 76mm Sports Exhaust Astra J VXR 76mm Sports Exhaust Astra J VXR Fish Tail trims
Front Pipe

The standard front pipe houses the first factory catalyst. Replacing the front pipe will increase the pressure drop across the turbo vastly improving response and also increasing power. It also saves around 2kg in weight. Removing this catalyst will require either a software update to factory software or a full ecu remap to remove the catalyst efficiency error code.

Front Pipe Price £252
Front Pipe & Sports Cat Section

The standard front pipe houses the factory cat, replacing the front pipe and removing the factory cat will increase the pressure drop across the turbo vastly improving response and also increasing power. A sports cat is then fitted in this next section of pipe which has a lower cell count which increases the gas flow through it. This combination will also keep your car legal & MOT compliant.

Front Pipe and Sports Cat Section £960

Uprated Enlarged Full Height Performance Intercooler

Once again we have joined forces with industry leaders Pro Alloy to develop our new enlarged, uprated performance intercooler kit for the Astra J VXR.

Our new intercooler is both larger in width and height than the standard unit with the core being twice as deep as the factory cooler. This represents a huge increase in available cooling area and volume and maximises the cooling available through the front of the car whilst also future proofing the cooler for use with high power large turbo setups.

The factory cooling set up has the air conditioning radiator in front of the intercooler so our first job was to remove the intercooler and then reposition the A/C radiator back, on to the water radiator. This is done so that the new intercooler is receiving the coolest air available. To further improve the efficiency we have included in the kit a lower air blade to stop the air washing away from the bottom of the intercooler.

Furthermore to maximise flow to and from the intercooler the kit comes complete with all the pipework which is enlarged to 60mm paying particular attention to the restrictive section straight out of the turbo seen at the top rear of the engine bay. The Intercooler kit also comes complete with all the required hoses and laser cut brackets and fittings.

Price: £749
Astra J VXR Uprated Full Height Intercooler Astra J VXR Uprated Full Height Intercooler Kit Astra J VXR Uprated Intercooler - Engine Bay with Pipework
Astra J VXR Uprated Full Height Intercooler Astra J VXR Uprated Full Height Intercooler Astra J VXR Uprated Full Height Intercooler - Engine Bay
Suspension and Chassis Tuning.
We have bespoke lowering springs available for the new Astra J VXR and KW coilover kits. A rear anti roll bar and other suspension and chassis tuning items are also in development.

KW Suspension - V1 and V3 Coilover Kits

Full Stainless Steel Damper Bodies, Height Adjustable Coilover Suspension.

KW V1 Coilover Kit - £1115.00
Height Adjustable, Fixed Rate Damping

KW V3 Coilover Kit - £1715.00
Height Adjustable, Adjustable Rebound and Compression
Note: EDC must be deactivated; required parts included in kit.
Astra J VXR on KW
Astra J VXR KW Coilovers Astra J VXR KW Coilovers Astra J VXR KW Coilovers Astra J VXR KW Coilovers Astra J VXR KW Coilovers

DAP Springs

Astra J VXR on DAP Springs
  • Manufacturered Exclusively for Courtenay Sport.
  • Probably the ultimate fast road springs for this chassis.
  • Lowers the VXR chassis by about 20-25mm
  • For excellent road holding whilst maintaining good ride quality.


  • £183.95 per set
Vauxhall set the bench mark very high with the original Astra J set up which didn’t make our job very easy however after an extensive period of development we have achieved what we feel is the ultimate fast road set up.

Visually the car now sits typically between 20-25mm lower. The straight line ride quality is slightly firmer but not at the detriment of the overall ride quality and certainly does not feel crashy, however press hard into the corners and the suspension tightens, firming up giving more control through mind corner bumps and undulations, whilst communicating with plenty of driver feel and feedback.

DAP Rs are wound from high tensile chrome silicone steel and are manufactured in a cold winding process for maximum durability in all weather conditions. They are powdered coated Diamond Black to give a very OE look and feel and have the DAP signature discreetly placed on them.

ST Coilover Kits

ST X Coilover Kit - Height Adjustable, Fixed Rate Damping £708.00

Brake Pads and Replacement Discs

The 4 Pot Brembo brake set up with 4 pot calipers and 355mm x 32mm belled discs offers excellent stopping ability. We can offer upgraded direct replacement brake pads from Brembo, EBC and Pagid.

Brembo HP2000 Sport Pads £147 EBC Yellow Pads £112.80 Pagid RS29 Pads £312.00

We are also able to supply Genuine replacement disc and bell assemblies - £375 each

Braided Brake Lines

Courtenay Sport braided brake lines for front and rear. Made with stainless steel unions. For maximum brake feel under heavy braking. Front Set: Rear Set:

Clutch and Dual Mass Flywheel

Genuine Clutch Kit (Cover and Disc) £192.00
Genuine Dual Mass Flywheel £364.50
Genuine Hydraulic Slave Cylinder F40 £81.00
Clutch Pipe £9.60
Sachs Motorsport Clutch £662.40

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