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VXR Logo Zafira VXR Tuning Vauxhall Logo

Astra H and Zafira B VXR Development

Z20LEH Piston Full Size Image - Click Here
ZLEH Piston

The Zafira B 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

Z20LEH Pistons Full Size Image - Click Here
ZLEH Piston
(where the LET engine only produced 200PS), and not because, contrary to internet myth, the factory Z20LEH engine runs lean. In fact the Z20LER engine used in Zafira B runs at the same target lambda value from the factory as the Z20LEH engine, and the LER engine does not have under piston cooling.

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.

Oil Spray Jets Full Size Image - Click Here
ZLEH Block showing under piston cooling

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 Vauxhall 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.

Tech2 Diagnostic Check Full Size Image - Click Here
Vehicle parameters being checked and evaluated using Tech 2 prior to remapping.
Zafira VXR on the rolling road
Zafira VXR on the dyno

Zafira VXR Tuning Packages

All our Zafira 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. 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 Driveability*
Exclusive Courtenay Sport Stage 1 Software Upgrade, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
 
Increases 20 - 25 bhp

e.g. 240 becomes 260-265bhp

Approx 280 lb ft torque
£565 Fitted including Rolling Road Set Up

Courtenay Sport Stage 1.5
Exclusive Courtenay Sport Stage 1.5 Software Upgrade, Courtenay Front Pipe* (pre-cat removal pipe) with Milltek Cat Back System, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
*Milltek Front Pipe can be specified at £60 extra.
 
Increases 30 - 35 bhp

e.g. 240 becomes 270-275bhp

Approx 290 lb ft torque
£1535 Fitted including Rolling Road Set Up

Courtenay Sport Stage 2
Exclusive Courtenay Sport Stage 2 Software Upgrade, Milltek FULL Stainless Steel Sports Exhaust System (Milltek turbo downpipe (pre-cat removal), Milltek Hi Flow 200 cpi HJS Motorsport cat, Milltek Cat Back System), Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
 
Increases 40 - 45 bhp

e.g. 240 becomes 280-285bhp

Approx 300 lb ft torque
£2115 Fitted including Rolling Road Set Up

Courtenay Sport Stage 2 Remap For cars already fitted with a full exhaust system.
Exclusive Courtenay Sport Stage 2 Software Upgrade,  Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
 
Increases 40 - 45 bhp

e.g. 240 becomes 280-285bhp

Approx 300 lb ft torque
£565 Fitted including Rolling Road Set Up

Courtenay Sport Stage 3
Exclusive Courtenay Sport Stage 3 Software Upgrade, Milltek FULL Stainless Steel Sports Exhaust System (turbo downpipe (pre-cat removal), Hi Flow 200 cpi HJS Motorsport cat, 63.5mm Cat Back System), Extra Large High Flow Front Mounted Intercooler, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
Uprated CTS Actuator Fitted +£222.00
 
Increases 50 - 55 bhp

e.g. 240 becomes 290-295bhp
with additional mid range power and torque over Stage 2

Approx 320 lb ft torque
£3155 Fitted including Rolling Road Set Up
Courtenay Sport Stage 3'+'
Exclusive Courtenay Sport Stage 3+ Software Upgrade, FULL Stainless Steel Milltek Sports Exhaust System (turbo downpipe pre-cat removal), Hi Flow Motorsport cat, Cat Back 2 Silencer System), Extra Large VXRacing High Flow Front Mounted Intercooler, Uprated Actuator to replace VXR actuator, K06 Hybrid Turbo, Turbo Gaskets, Studs and Nuts, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
 
Increases 65 - 70 bhp

e.g. 240 becomes 305-310bhp
plus additional power and torque over Stage 3

Approx 340+ lb ft torque
£4763 Fitted including Rolling Road Set Up
Courtenay Sport Stage 4
Exclusive Courtenay Sport Stage 4 Software Upgrade, FULL Stainless Steel Milltek Sports Exhaust System (turbo downpipe pre-cat removal), Hi Flow Motorsport cat, Cat Back 2 Silencer System), Extra Large VXRacing High Flow Front Mounted Intercooler, Uprated Actuator to replace VXR actuator, K06 Hybrid Turbo, Turbo Gaskets, Studs and Nuts, High Flow Inlet Manifold, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
Note: 76mm system required for best results. Steel Rods recommended
 
Increases 70 - 75 bhp

e.g. 240 becomes 310-315bhp
£5368 Fitted including Rolling Road Set Up

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 Buy Now Click Here! and cooler running Iridium Spark Plugs £33.00 set of four Buy Now Click Here! 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.

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

Power and Torque Graphs

Example Power and Torque Graphs for Stage 1, 2 and 3

Power and Torque Graphs

Power and Torque Graphs

Power and Torque Graphs

Power and Torque Graphs

Zafira VXR - VXRacing Performance Intercooler Kit

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.

Zafira VXR VXRacing Performance Intercooler and Fitting Kit - Click for Full Size Image

 

Zafira VXR VXRacing Performance Intercooler - Click for Full Size Image

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.

 New Revision: Our Full Height Intercoller now with 60mm pipework throughout. This intercooler has always used 60mm pipework from the turbo to the intercooler and has now been revised to include a 60mm intercooler outlet with 60mm hard pipe up to and including the map sensor pipe - £825 including VAT. Polished Alloy or Stealth Finish Now Available  Or £1039.55 including VAT, fitting and software upgrade for cars already running Courtenay Stage 1 or Stage 2 software. (Dyno set up time extra)

Important Note: Customers' with our existing intercooler set up are able to update it if required. Please contact us.

As used in the 2011 Dubai 24 Hour Race.

60mm Pipework Stealth Finish

60mm Outlet Stealth Finish

60mm Outlet Stealth Finish

Courtenay Sport High Flow 70mm Front pipe

The Z20LEH engine is fitted with 2 cats - a pre-cat and a main cat. Our performance front pipe replaces the original restrictive pre-cat. This is only required to be fitted to the vehicle up until the point of 1st registration, as the main cat still ensures the vehicle will meet all MOT emission regulations. The new 70mm front pipe is made in stainless steel, and by smoothing the bend radius and removing the cat, we have dramatically improved the flow through the unit. Our front pipe also features both a stainless steel 3 bolt flange and stainless steel spun end. Our performance front pipe will give a typical increase of around 8 - 10 bhp.
Courtenay Sport 70mm Pre-Cat Pipe £169.98 Buy Now Click Here!

Astra VXR K04 Turbo

VXR Turbo Genuine KKK Direct replacement K04 Astra VXR turbocharger.

Turbocharger* and VXR Actuator (Special Mail Order*): £Check Shop Buy Now Click Here!

Hybrid options are available
Z20LEH turbochargers fitted by Courtenay Sport will benefit from a 12 month/12,000 mile warranty.

Turbocharger complete with VXR Actuator: £895
Fitted price includes warranty, turbocharger, gaskets, oil and filter change using fully synthetic oil

Turbocharger* with Uprated Actuator and Bracket (Mail Order Price*): £Check Shop Buy Now Click Here!

Turbocharger with Uprated Actuator and Bracket: £1063
Fitted price includes warranty, turbocharger, gaskets, oil and filter change using fully synthetic oil

Uprated Actuator and Stainless Steel Bracket for mapped cars: £168 Fitting available.

Fitting in our workshop includes required gaskets, Oil and Filter Change using Fully Synthetic 5w-40 API:SM specification oil

* Vauxhall will only warrant these units for their intended purpose i.e. fitment to standard factory specification Astra/Zafira VXR. We are unable to extend a warranty onto these units when supplied by mail order due to the varied nature of fitment and application outside of these parameters.

VXR Turbochargers supplied and fitted by us on our premises have our own 12 month/12,000 mile warranty.

How dirty oil will destroy a turbo - Check out info our blog

Hybrid Turbochargers - K04 and K06

We can also offer hybird turbo options allowing the turbo can achieve additional peak and top end boost pressure, providing yet more power and torque. K04 options include a stronger 360 bearing pack, double ring seals without compromising the bearing housing wall thickness, step gap oil seal and cut back turbine/exhaust wheel. The K06 option adds a billet K06 compressor wheel.
Hybrid Options cost from £795 - £1045  Buy Now Click Here!

How dirty oil will destroy a turbo - Check out info our blog

High Flow Plenum

High Flow Plenum
High Flow Plenum
High Flow Plenum
Zafira VXR Kit
High Flow Plenum
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 a stud and nut fitting kit, or with the required silicone hoses. For more information and images >>>> Click Here <<<<

High Flow Plenum £89.50 including VAT. Buy Now Click Here!
Kit including Hose for Zafira VXR £122.05 including VAT. Buy Now Click Here!

High Flow Inlet Manifold.

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

Uprated 340 Fuel Pump

Uprated Fuel Pump
Uprated 340 Fuel Pump, including Fitting Guidelines

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 seperately for subsequent re-oiling after cleaning.

Price £34.95 Buy Now Click Here! Filter Oil £4.05

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 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. FREE fitting as part of a stage upgrade. Buy Now Click Here!

Further plug upgrades available.
NGK Iridium Cooler Running Spark Plugs

Uprated Actuator and Bracket

We have a range of uprated actuators for Zafira B VXR suitable for standard power upwards for K04/K06 turbos to help offer smoother boost delivery, with a range of spring tensions to suit different mapping requirements.

>>>>> Read More ...... <<<<<
 
Brake Upgrades Brakes Discs and Pads
Suspension and Chassis Tuning.
Details of suspension and chassis tuning options available including:
Limited Slip Differentials, Springs, KW Coilovers, Premium Suspension Kits, Uprated Anti Roll Bars and Polyurethane Bushes.
Turbo Hose Kits - Click Here Turbo and Water Hose Kits. Turbo Hose Kits - Click Here
Details of our silicone turbo and water hose kits which are available for Zafira VXR, including the direct route hose kit and CDTi airbox.
Clutch Options and Lightweight Flywheel.
Alloy Bottom Pulleys

Direct Route Airbox Fitting Kit and CDTi Airbox.


Black Inlet
Direct Route Hose Kit and CDTi Airbox Modification. More Information....
Recirculation Valves
and Actuators

Cool Running Thermostats - 82 or 87 degree

Cooler running thermostat reduce the engine's normal running temperature, protecting the engine by running it closer to it's optimum power temperature. The stats open 5 or 10 degrees earlier than the standard OE item (87/82 degrees instead of 92 degrees) and is fully open 10/5 degrees earlier (97/102 degrees instead of 107 degrees). Ideal for modified cars for fast road and track work, they typically operate 5+ degrees cooler reducing peak temperatures caused by sustained hard use. Used in Opel/GM products in warmer climates.

Cool 'Stat 82o.... £25.50 Buy Now Click Here! 87o.... £36.00 Buy Now Click Here! Fitting .... £36.00

OPC Plug Cover

OPC Spark Plug Cover OPC Plug Cover with New Style OPC Logo Now Avalable! £13.25 Buy Now Click Here!

Stainless Steel Heatshield

Stainless Steel Heatshield .... £30.60 Buy Now Click Here! Fitting available

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