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Astra H VXR Development


ZLEH Piston
The Astra H VXR engine (Z20LEH) is a development of the Astra G’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 (where the LET
ZLEH Piston
engine only produced 200PS), and not because, contrary to internet myth, the factory Z20LEH engine runs lean. In fact the Z20LEL and Z20LER engines used in Astra H run at the same target lambda value from the factory as the Z20LEH engine, and the LEL/LER engines do 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.
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 investigate and developed for the next level of power, to ensure the longevity of the engine and surrounding components.

Vehicle parameters being checked and evaluated using Tech 2 prior to remapping.

Our Astra VXR on the dyno

Astra H VXR Tuning Packages

All our Astra H 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 76mm Cat Back 2 Silencer System, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
 
Increases 30 - 35 bhp

e.g. 240 becomes 270-275bhp

Approx 290-300 lb ft torque
£1375 Fitted including Rolling Road Set Up
£1275 1 Silencer
Courtenay Sport Stage 2
Exclusive Courtenay Sport Stage 2 Software Upgrade, 76mm (3") FULL Stainless Steel Sports Exhaust System (turbo downpipe pre-cat removal, Hi Flow Motorsport cat, Cat Back 2 Silencer 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 325-340 lb ft torque
£1785 Fitted including Rolling Road Set Up
£1675 1 Silencer
For Astra VXR Nürburgring and cars already fitted with a full sports exhaust system. £565 Fitted including Rolling Road Set Up
Courtenay Sport Stage 3
Exclusive Courtenay Sport Stage 3 Software Upgrade, 76mm (3") FULL Stainless Steel 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 CTS Actuator to replace VXR actuator, Software customising whilst on our rolling road optimising fuelling, full boost and ignition maps, Full Power and Torque Graph Print Outs.
Increases 50 - 55 bhp

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

Approx 330-345 lb ft torque
£3040 Fitted including Rolling Road Set Up
£2930 1 silencer
For Astra VXR Nürburgring and cars already fitted with a full sports exhaust system. £1820 Fitted including Rolling Road Set Up
Courtenay Sport Stage 3'+'
Exclusive Courtenay Sport Stage 3+ Software Upgrade, 76mm (3") FULL Stainless Steel 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, K06 Hybrid Turbo, Turbo Gaskets, Studs and Nuts, oil and filter change, 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
additional power and torque over Stage 3

Approx 340+ lb ft torque
£4275 Fitted including Rolling Road Set Up
£4165 1 silencer
For Astra VXR Nürburgring and cars already fitted with a full sports exhaust system. £3240 Fitted including Rolling Road Set Up
Courtenay Sport Stage 4
Exclusive Courtenay Sport Stage 4 Software Upgrade, 76mm (3") FULL Stainless Steel 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, K06 Hybrid Turbo, Turbo Gaskets, Studs and Nuts, oil and filter change, 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: Steel rods required for maximum power gains for safety and strength - from £1650 fitted (+ mapping costs)
Increase 90 - 95 bhp

e.g. 240 becomes 330-335bhp
Max 320bhp on 70mm Exhaust
£4965 Fitted including Rolling Road Set Up
£4855 1 silencer
For Astra VXR cars already fitted with a full 76mm sports exhaust system.
Note: 76mm exhaust recommended for Stage 4
£3950 Fitted including Rolling Road Set Up
Note: 1 silencer 76mm exhaust systems are available with our tuning packages.
Further Stages under development.

Switchable Power via Sport Button
Our remaps make use of the Sport Mode button to offers two levels of driveability, if required. 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.
Non Switchable option also available.

*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 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 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 99 RON, or a similar Super Unleaded fuel, on all remapped vehicles for optimum performance.

Power and Torque Graphs

Example Power and Torque Graphs for Stages 1, 2, 3, 3'+' and 4.
Garrett Upgrades.
Garrett Upgrades, V Band Cast Manifold, Tubular and Cast Manifolds, High Flow Inlet Manifold, Engine Building, Pistons, Steel Rods.

Astra H 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 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 Astra 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

Astra H 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: from £1063 Fitted. Price includes warranty, turbocharger, gaskets, oil and filter change using fully synthetic oil

Uprated Actuator and Stainless Steel Bracket for Stage 3 Cars: £189 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, uprated seals including a step gap oil seal without compromising the bearing housing wall thickness and cut back exhaust wheel. The K06 option also 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

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

Astra H VXR Uprated Water Radiator

All Aluminium high performance water radiator for improved cooling. Developed and tested on a 300+ bhp car.

Uprated core section - 54% thicker than the standard unit

All alloy construction - therefore end tanks will not crack or fail/leak like the standard plastic ones

Direct replacement - utilises all standard fittings and OE fan

Easy fitment - Will fit with aftermarket or standard intercooler

Price - £538.80 £498 inc VAT
Exhaust Systems.

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

High Flow Plenum


High Flow Plenum

Astra VXR Kit

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 hose(s).

As used in the 2011 Dubai 24 Hour Race.

The plenum can be supplied on its own with stud and nut kit, or with the required silicone hoses. For more information and images >>>> Click Here <<<<

High Flow Plenum £89.50 including VAT.
Kit including Hose for Astra VXR £122.50 including VAT.

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 separately for subsequent re-oiling after cleaning.

As used in the 2011 Dubai 24 Hour Race.

Price £34.95  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. 

Further plug upgrades also available.

FREE fitting as part of a stage upgrade.

Uprated Actuator and Bracket

We have a range of uprated actuators for Astra H VXR suitable for standard power to 350bhp 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
Details of Direct Replacement Brake Discs and Pads, Upgrade Discs and Pads and Big Brake Kits - 4 Pot, 6 Pot and 8 Pot Kits.
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, Engine Mounts and Polyurethane Bushes.
Clutch Options and Lightweight Flywheels

Details of Clutches, Lightweight and Dual Mass Flywheels.
Turbo and Water Hose Kits
Details of our silicone turbo and water hose kits which are available for Astra VXR, including the direct route hose kit and CDTi airbox.
Alloy Bottom Pulleys

Direct Route Airbox Fitting Kit and CDTi Airbox.


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

Power Fold Mirror Kit

Power Fold Mirrors Details of our OE Power Fold Mirror Kit

OPC Plug Cover

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

Alloy Map Sensor Pipe

Alloy Map Sensor Pipe. Direct replacement for the OE black plastic item.... £34.95

Stainless Steel Heatshield

Stainless Steel Heatshield .... £34.95 Fitting available

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