Thorney Motor Sport Zafira VXR

The standard Zafira VXR already has an excellent power level but as with all manufacturer supplied cars it is a design of compromise, what we do is develop the power with more of an eye on absolute performance without sacrificing longevity or reliability. All of our performance upgrades are covered by our three year/60,000 mile warranty which matches that of your standard Vauxhall warranty, whatever goes wrong with your car will be covered (conditions apply obviously).

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Thorney Motorsport Zafira VXR Power Pack 1 | only £399
Engine ECU Remap+30BHP&+35ft/lb

The standard power delivery of the Zafira VXR is a little severe, its not the level of power that causes torque steer but how the power is delivered. Being a racing team we specialise in creating power delivery which is smooth and controllable as well as a lot higher!  With a Power Pack 1 ECU upgrade we create a power delivery which pulls from idle all the way to the red line, the delivery is smooth but punchy at the same time and really is a revelation over the standard car. As well as this the fuel economy is typically improved by 10% so you really can have your cake and eat it.

Your car is expertly inspected and thoroughly checked to make sure all is perfect utilising the full Vauxhall approved diagnostic equipment (what would you expect form a full Vauxhall authorised Masterfit operation as we are) and the car thoroughly checked and run on our state of the art dyno equipment. We then read and check your cars standard ECU, copy it and install the new upgraded ECU software directly into the cars ECU via the diagnostic port (this can also be done using the Bluefin unit). We then run your car again on the dyno making any necessary adjustment to the ECU and software to optimise the power delivery. Full dyno charts are provided showing before and after power and torque both measured at the wheels and the flywheel.

Power delivery is controlled by the useage of the sport button, in standard mode we smooth out the power delivery and add a little more power but give maximum fuel economy, think of it as a ‘poodling about' mode, but when you press the Sport button then the full fury of the map is let loose, still controllable, still smooth and silky to drive but with an extra 30bhp and 35lb of torque the car is literally transformed. If you're not happy we refund you, simple as that (subject to conditions of course). After a while you'll notice an improvement in fuel economy as well - bargain.

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Thorney Motorsport Zafira VXR Power Pack 2 | only £1850
Engine ECU Remap and Exhaust+45BHP&+55ft/lb

Turbo charged cars are all about airflow and heat, you want to move the air through the engine as quickly as possible and keep the temperature of the air used in combustion as low as possible, sadly turbo chargers are prone to heating up the air (exhaust gases are used which are hot) so whilst power gains are good the resulting increase in air temperature is bad. By adding a free-er breathing exhaust onto the Zafira VXR the air is moved through the process faster which also has the effect of sucking heat from the engine as well. The standard exhaust is pretty good but with a 400 cell catalytic converter and a 200 cell precat exhaust gases are relatively restricted and power is capped as a result

By adding an exhaust system with a genuine race catalytic converter, replacing the precat with a straight through pipe and adding a performance rear silencer the gains in performance are immediately noticeable. Only a genuine motorsport cat should be used, there are plenty of 100 cell cats available but these will eventually cause the engine management system to see a degradation in emissions and fail an MOT, true motorsport cats are fully MOT compliant and are responsible for most of the power gains. The addition of a proper race exhaust allows us to increase the boost on the ECU map without compromising reliability so we get a lot more power as a result.

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Thorney Motorsport Zafira VXR Power Pack 3 | Only £2950
Engine ECU Remap, Front Mount Intercooler and Exhaust 295+BHP&+55ft/lb
You'll notice a common theme throughout the Zafira VXR tuning and that is one of heat, the car is very susceptable to it so its always a limiting factor on how to upgrade it. For this reason the fitting of a larger, more efficient intercooler is a crucial step towards obtaining larger amounts of power. Basically speaking an engine is a controlled explosion; mix air with fuel and ignite it - bang, the cooler the air is the more oxygen it can hold and the greater the explosion = more power. With turbo charged engines the intake air gets hot very quickly which subsequently reduces the power, you feel this effect every day, in the cold air in the morning the car actually has more power compared to a drive home in the afternoon where the air temperature is hotter.

To combat this problem we worked directly with Pace Products in developing a pair of larger front mounted intercoolers. These intercoolers are unique in that the actual cores have been custom designed for the Zafira VXR to maximise air volume and flow through the system, note we don't say how many litres they hold - that measure is pointless, what is crucial is how fast the air moves through the system along with the volume of air. By fitting one of our larger intercoolers it allows us to advance the map to the next stage by running more boost and resulting in a lot more power and even more torque. We now directly recommend the use of the new 3" bore race exhaust with stage 3 upgrades and above, such are the extra gains offered by the system, however the standard Millteks work very well as well as the Remus. Self fitting is quite simple but does require the front of the car to be removed and replaced. The kits come complete with all the extra pipe work, silicone hoses nothing else is required.