Courtenay Sport Website

Welcome Guest, Please Login Below:
Email: Password:
Create An Account   Forgotten Your Password? Remember Me

Search online shop for:
ONLINE SHOP
Shopping Basket
Your Basket is Empty.
0Items in Basket:
£0.00Total:
Sales Enquiries
Monday - Friday:
9am - 1pm  2pm - 5pm
Saturday:  9am - 12pm
 01692 404313
 01692 404060
Fax: 01692 404069
International Enquiries
 +44 1692 404313
Fax: +44 1692 404069
Email:  UK/EU/Worldwide
info@CourtenaySport.co.uk
Star Product
Featured Product
Secure Online
Secure Online Payments
Secure Payments by SagePay
Information
Products: 1141
Prices: British Pounds £GBP
Customers Online: 230
Mailing List
To subscribe to our mailing list please register with us online:

Courtenay Sport are pleased to be able to offer Diesel Vehicle Tuning Upgrades for a wide range of Vauxhall diesel engines. Due to the increasing popularity of diesel engined vehicles we have developed a range of software upgrades to enhance their performance and economy. Using specially developed software, these tuning upgrades are actually FULL remaps of your vehicle's engine management system to improve the performance characteristics throughout the vehicle's rev range, offering better driveability, more power and torque throughout the rev range and a reduction in fuel consumption, another added benefit.

There is no need to open up an ECU as our remapped software in installed via your car's engine diagnostic port and is totally invisible to engine diagnostics, ideal for any vehicle and in particular company car and van drivers wanting increased performance.

Our Diesel Tuning Upgrades cost from just £510 fully installed including a rolling road check and are fully reverseable at any time.

Courtenay Bespoke Diesel Remaps are available for the following vehicles:
Corsa C 1.3 CDTi

Astra H 1.9 CDTi
8v (120 PS) - Typical Gains to 155 - 160 bhp and up to 270 lb/ft
16v (120 PS) - Typical Gains to 180 - 185 bhp and up to 320 - 335 lb/ft
16v (150 PS) - Typical Gains to 180 - 185 bhp and up to 320 - 335 lb/ft

Astra J 2.0 CDTi:
A20DTH 160PS - Typical Gains up to +25/30bhp, and up to +60 lb ft
A20DTH 165PS - Typical Gains up to +20/25bhp, and up to +60 lb ft

Insignia 2.0 CDTi:
A20DTH 160PS - Typical Gains up to +25/30bhp, and up to +60 lb ft
A20DTH 170PS - Typical Gains up to +15/20bhp, and up to +60 lb ft

Vectra C/Signum 1.9 CDTi
8v 120PS - Typical Gains up to 150 bhp and 270 lb ft
16v 150PS - Typical Gains up to 180 - 185 bhp and 300 lb ft
Strapped Down and Ready to Go! - Click for Full Size
We cover a wide range of models, with more being added all the time. Should your vehicle not be listed then please do not hesiate to contact us for availability.

Courtenay Superchips Remaps for Diesel Engines from £395 (plus rolling road time if required), for models where we do not have our own bespoke software.
Click Here for Superchips Diesel Application List Search to see if your vehicle is listed.

Power and Torque Graph - Courtenay Diesel Remap - Astra H 1.9 CDTi 16v (150PS).

Power and Torque Graph Astra H 1.9 CDTi 150PS - Before and After Courtenay Sport Diesel Remap power and torque graph for the Astra H 1.9 CDTi 150PS (Z19DTH 16v engine) showing before and after graphs. Also applicable to Zafira 1.9 CDTi 16v (150PS).

The Astra/Zafira 1.9 CDTi 16v (120PS) engine will also achieve similar gains after an ecu remap.

Red - Before Blue - After

Results for this particular car:
Power - 186 bhp Torque - 325 lb ft

Click Image to Enlarge.

Power and Torque Graph - Courtenay Diesel Remap - Astra H 1.9 CDTi 8v (120PS).

Courtenay Sport Diesel Remap power and torque graph for the Astra H 1.9 CDTi 8v (120PS Z19DT 8v engine) showing before and after graphs.

Red - After

Results for this particular car:
Power - 157 bhp
Torque - 292 lb ft

Click Image to Enlarge.
Power and Torque Graph Astra H 1.9 CDTi 150PS - Before and After

Diesel Tuning Boxes.........

So why don't we use boxes?

Put simply all a tuning box does is increase the fuel pressure to the engine, so completely different to a remap which changes many parameters within the ecu. Your car's ecu does not know if a box has been fitted or not.

Yes boxes do give good power and torque, which can be shown on a rolling road but by increasing the fuel pressure the ecu loses its safety margins, because the ecu does not know the fuel pressure has been increased.

A diesel engine which runs excessive fuel (due to an big increase in fuel pressure) will lead to higher cylinder head and exhaust gas temperatures, which can ultimately cause damage internally. The reason for this is because the ecu does not know the fuel pressure has been increased with the box, and it has no way of defending against the higher temperatures.

A remap on the other hand, because it is an integral part of the ecu, means that if due to outside factors (e.g. high ambient air temperature, towing) the cylinder head/exhaust gas temperatures do rise, it can reduce the fuelling to be able to combat them for safety. The safety margins are still available with an ecu remap; they aren't there with a tuning box.

Power and Torque Graph - Diesel Tuning Box - Astra H 1.9 CDTi (150PS).

Diesel Tuning box power and torque graph for the Astra H 1.9 CDTi 150PS (Z19DTH engine).

Note from the graph how unstable the power and torque curves are between 2,000 - 3,000 rpm due the the fact the box just ramps up the fuel pressure, when compared with a remapped ecu.

Click Image to Enlarge.
Power and Torque Graph Astra H 1.9 CDTi 150PS with Diesel Tuning Box

Astra H 1.9 16v CDTi Tuning Packages

All our Astra H CDTi 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 our requirements. If your car does not fit into the categories listed we can and will write a bespoke map and tailor it to your vehicle.
Courtenay Sport Stage 1
Exclusive Courtenay Sport Stage 1 Software Upgrade, Software customising whilst on our rolling road optimising fuelling, timing and boost, Full Power and Torque Graph Print Outs.
 
Increases 25 - 35 bhp

up to 180 -185bhp

Approx 300 - 320 lb ft torque
£510 Fitted including Rolling Road Set Up
Courtenay Sport Stage 2
Extra Large Courtenay Sport High Flow Front Mounted Intercooler, Exclusive Courtenay Sport Stage 2 Software Upgrade, Software customising whilst on our rolling road optimising fuelling, timing and boost, Full Power and Torque Graph Print Outs.
 
Increases 40 - 50 bhp

up to 190 - 200bhp

Approx 320 - 350 lb ft torque
£1500 Fitted including Rolling Road Set Up
Courtenay Sport Stage 3
Extra Large Courtenay Sport High Flow Front Mounted Intercooler, 63.5mm (2.5") FULL Turbo Back Stainless Steel Milltek Sports Exhaust System with Hi Flow Motorsport cat and Cat Back 2 Silencer System, Hybrid Turbo, Oil and Filter Change, Exclusive Courtenay Sport Stage 3 Software Upgrade, Software customising whilst on our rolling road optimising fuelling, timing and boost, Full Power and Torque Graph Print Outs.
 
Increases 70 - 80 bhp

up to 215 - 220bhp

Approx 345 - 370 lb ft torque
Hatch: £POA
Van: £POA
Fitted
including Rolling Road Set Up
Courtenay Sport Stage 3+
Extra Large Courtenay Sport High Flow Front Mounted Intercooler, 63.5mm (2.5") FULL Turbo Back Stainless Steel Milltek Sports Exhaust System with Hi Flow Motorsport cat and Cat Back 2 Silencer System, Hybrid Turbo, Oil and Filter Change, Rework of the inlet system to incorporate a 80mm air flow meter housing (due to the 70mmm unit running of air mass value in the voltage range at stage 3), Exclusive Courtenay Sport Stage 3+ Software Upgrade, Software customising whilst on our rolling road optimising fuelling, timing and boost, Full Power and Torque Graph Print Outs.
 
Increases 70 - 80 bhp

up to 220 - 230bhp

Approx 345 - 370 lb ft torque
Hatch: £POA
Van: £POA
Fitted
including Rolling Road Set Up

High Flow Panel Filter
With any of our stage upgrades, we also suggest the addition of one of our High Flow re-useable Panel Filters
£34.95
Fitting FREE OF CHARGE as part of a Stage upgrade.

Fuel:
We recommend the use of Shell V-Power Diesel or similar for optimum performance.

EGR and EGR Cooler Laser Cut Stainless Steel Blanking Plates.

EGR Valve Blanking Plates

The advantage by blanking the EGR inlet is that all the dirty and sticky exhaust gas no longer gets into the EGR valve which will stop the build up that creates most EGR valve problems. Furthermore it will then stop all this muck getting into the inlet manifold and clogging the moving butterflies of the swirl flaps, because this clogging against the butterflies is what creates the majority of wear in the swirl flap linkage. Fitting the more square EGR plate between the inlet manifold and the inlet stops contaminated inlet manifold from feeding into the EGR valve and allowing it to gum up again.

EGR Valve Blanking plates: £11.95
EGR Blanking Plates
EGR Cooler Blank EGR Cooler Blanking Plate

In addition to the above we offer Stainless Steel Exhaust Manifold to EGR Cooler Pipe Blanking Plate, because we have seen on cars that are running high boost that the EGR cooler can fail. If this happens the symptoms can manifest themselves to look like a head gasket failure as the water system is suddenly pressurised by the exhaust gas coming through the EGR pipe in which the cooler is mounted. If you fit this plate combined with the EGR plates you can if you want completely remove the EGR cooler and join the water pipes which does help to declutter this area!
EGR Cooler Stainless Steel Blanking Plate & Bolts: £11.65

Uprated Intercooler Kit - Astra H 1.9 16v CDTi

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 replacement 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 - £745.00



Click on Image to enlarge >>>>>>>>>

Astra H 1.9 CDTi Intercooler Kit

Power and Torque Graph - Astra H 1.9 CDTi 16v (150PS) - Courtenay Diesel Remap and Intercooler.

Power and Torque Graph Astra H 1.9 CDTi 150PS - Before and After Courtenay Sport Diesel Remap on a 150PS Astra H also fitted with our uprated performance intercooler kit and exhaust. Power and torque graph for the Astra H 1.9 CDTi 150PS (Z19DTH 16v engine) showing before and after graphs.

Green - Before
Blue - After

Results for this particular car:
Power - 198 bhp
Torque - 371 lb ft

Click Image to Enlarge.

Intercooler Fitted

Uprated Intercooler Fitted Uprated Intercooler Fitted shown from above

Hybrid Turbo for 1.9 CDTi 16v

Hybrid Turbocharger for 1.9 CDTi 16v Z19DTH for Stage 3 and Stage 3+.

When fitted with our intercooler and sports exhaust system power up to 220-230bhp is achieved.

Price £630 On Exchange (subject to surcharge). Outright Brand New £1134

We can supply a genuine brand new OE turbo assembly £567.00
Courtenay Sport CDTi Hybrid Turbocharger

Stage 3 Power and Torque Graphs

Standard Power/Torque vs Stage 3 (Intercooler, Exhaust, Hybrid Turbo) Standard Power/Torque vs Stage 3 (Intercooler, Exhaust, Hybrid Turbo)
Power and Torque Graphs comparing a Standard Z19DTH Car to a Stage 3 car fitted with Intercooler, Full Exhaust and Hybrid Turbo (Left) and a Standard Car to a remapped car to a Stage 3 car fitted with Intercooler, Full Exhaust and Hybrid Turbo (Right).

Forge Uprated Intercooler Kit - Vectra C 1.9 16v CDTi

Vectra C 1.9 CDTi Intercooler Kit This Forge uprated intercooler for the Vauxhall/Opel Vectra 1.9CDTi uses a 40mm high performance tube and fin core with internal turbulation to maximise the cooling of the charge air. In the construction of the intercooler cast alloy end tanks have been used which are TIG welded to the core. This is to eliminate the common failure of the original design where the plastic end tank leaks or blows off the intercooler.

The intercooler is a direct replacement and for the original intercooler and has been made to ensure that it can be quickly and easily installed.

Full benefits can be made with additional ecu mapping to alter the fuelling to improve power and torque.

Intercooler Kit Price - £690.00

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. Supplied pre-oiled for first use. Filter oil is available separately for subsequent re-oiling after cleaning.

Available for most diesel applications.

Price £34.95  Filter Oil £4.05
Courtenay Sport High Flow Panel Filter

Astra 1.9 CDTi Silicone Engine Hoses

We have released Silicone Engine Hoses for Astra 1.9 CDTi Diesel engines.

3 Ply Silicone Hoses with Fluoro lining for added durability and resistance to oil contamination.

Will brighten up any engine bay.

Priced at £90.95 Buy Now Click Here!
Astra CDTi Engine Hoses

Diesel CDTi Airbox Conversion Parts to use 80mm Air Flow Meter

The parts required to allow simple conversion of the standard Diesel (CDTi) Airbox to accept an 80mm Air Flow Meter.

Once the top of the airbox has been opened up to accept the alloy joiner piece, it can be bonded into place in the airbox lid. The supplied black hose is fitted between the alloy joiner and the 80mm Air Flow Meter.

80mm Adapter Parts. £14.45

Replacement OE Dual Mass Flywheel and Clutch

We can supply replacement Genuine OE GM/Vauxhall dual mass flywheels and Genuine clutche kits.

Z19DTH DMF to Eng 17361103 - £295.20
Z19DTH DMF from Eng 17361104 - £294.00

Z19DTH Clutch to Eng 17361103 £150.00
Z19DTH Clutch from Eng 17361104 £162.00

Hydraulic Slave Cylinder Z19DTH/M32 £108.00

Late Clutch and Flywheel Package (will fit all Astra H 1.9 CDTi models when fitted as a package):
Genuine OE Clutch Cover and Disc, Dual Mass Flywheel £396

As above with Hydraulic Slave Cylinder and Flywheel Bolts £540

Uprated Sachs Clutch Cover and Disc

Uprated Sachs Cover and Disc; a stronger clutch for modified cars for use with OE DM Flywheel. £540

Single Mass Flwheeel

Lightweight Steel Billet Single Mass Flywheel.

Replacement for the Dual Mass Flywheel for Z19DTJ/Z19DTH applications. Requires sprung clutch disc.

8.2kgs

Clutches for Solid Flywheel

OE Cover and Sprung Disc Assembly £331.95
CSR Uprated Cover and Uprated Sprung Disc - £490.80

Back

Courtenay Sport Vauxhall Tuning
Courtenay Sport
 Vauxhall Tuning

Courtenay Sport - Find us on Facebook

Courtenay Sport - Follow us on Twitter
Latest News
Shopping Basket
Your Basket is Empty.
0Items in Basket:
£0.00Total:
Top Questions
Popular Products
Sale Items
Compatibility
Our website has been checked with most popular browsers. We advise using the latest version of your preferred browser.


About Us :: Privacy/Use of Cookies :: Credit Card Security :: FAQ :: Contact Us

© Copyright Courtenay Sport Ltd. Designed by Courtenay Sport Ltd
Find Courtenay Sport on Facebook

Switch to our Mobile Version