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Convert AU to Low-Restriction BA Induction Tube - Part 1 

 

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 Post subject: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Sun Jan 30, 2011 4:04 pm 
Getting Side Ways
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Ride: EF XR6 Wagon, AU2 XR6 VCT

Power: 148 rwkw

Location: Auckland
New Zealand

I was concerned about the obvious restriction in the induction of my AU2 XR6 VCT, so went about fixing it. The objective was to significantly improve breathing, while retaining a factory look. I have taken pics along the way to document it, in case anyone else wants to try it. Prices are in NZ$, so will be less in AU$ - sometimes a lot less.

The inspiration for this mod was an article by Julian Edgar in Autospeed (http://www.autospeed.co.nz/cms/A_107828/article.html) which I used to successfully modify my EF XR6 airbox exit.

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For a start, the paper filter element was replaced by a Simota panel filter ($46).

The next thing to go was the standard skinny snorkel. I replaced it with a factory XR8 (BA or AU) or XR6T snorkel, which is significantly larger, but a straight bolt-in ($85).
Test
Attachment:
PC240001b.JPG


The factory AU induction tube is very restrictive, with four sharp bends and a very small (50mm/2") airbox exit.
Attachment:
P1290001b.JPG


The BA tube ($60) has a larger and more constant cross-section, with a smooth continuous curve. And it bolts straight into the AU, using the same locating points on the intake manifold. The attachment point on the shock mounting bolt is not used and can be removed.
Attachment:
P1290009b.JPG


This leaves a gap between the induction tube and the airbox, so a length of pipe needs to be inserted to bridge the gap. The airbox exit is ridiculously small, so needs to be replaced. We can kill two birds with one stone by simply removing the airbox exit (4 bolts) and replacing it with a length of 3" PVC drain pipe ($15 for 1.5 metre length).

The pipe I used was 76mm inside diam and 80mm outside. 80mm happens to be EXACTLY the size of both the hole in the airbox and the inside of the induction flex tube so is a tight friction fit at both ends. It can be used without clamps or sealant and without modifying the airbox in any way.

This gives a feel for the difference in size of the standard tube and the 3" pipe:
Attachment:
P1290003b.JPG


Here is the new pipe beside the standard airbox exit, from the inlet side:
Attachment:
P1290004b.JPG


To be continued....

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_________________

95 EF XR6 wagon, 17" FTRs, DBA, QFM, KYB/Koni, SS Ind, BA ind, MLS, milled, Franklin RH24B cam, Coby headers, no cat, Tickford 2.5", 2900rpm stall, J3 chip
01 AU XR6 VCT, Tickford body kit/alloys, Momo wheel/shifter, leather, QFM, SS Ind, BA ind, 3" airbox exit, Coby headers, no cat

Last edited by efxr6wagon on Sun Jan 30, 2011 5:41 pm, edited 1 time in total.

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 Post subject: Convert AU to Low-Restriction BA Induction Tube - Part 2
Posted: Sun Jan 30, 2011 4:19 pm 
Getting Side Ways
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Posts: 719

Joined: 1st Apr 2005

Gallery: 4 images

Ride: EF XR6 Wagon, AU2 XR6 VCT

Power: 148 rwkw

Location: Auckland
New Zealand

This is the view from the outlet side:
Attachment:
P1290005b.JPG


Here is the size of the hole in the airbox with the exit piece removed:
Attachment:
P1290012b.JPG


You have probably noticed that the pipe has a slight bell-mouth at the airbox end. This was acheived easily with a heatgun and used a funnel as a former. The length of pipe required to bridge the gap and provide a bell-mouth was about 18cm. It was then wet-sanded, cleaned and painted with satin black to closely match the factory finish.
Attachment:
P1290010b.JPG


When the paint was dry, the pipe was inserted from inside the airbox - a bit of a tight fit, but airtight without sealant:
Attachment:
P1290018b.JPG


The end of the pipe slips snugly into the induction flex tube. The clamp is not necessary, but I put it on anyway for added security and a factory look.
Attachment:
P1290019b.JPG


To be continued...

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_________________

95 EF XR6 wagon, 17" FTRs, DBA, QFM, KYB/Koni, SS Ind, BA ind, MLS, milled, Franklin RH24B cam, Coby headers, no cat, Tickford 2.5", 2900rpm stall, J3 chip
01 AU XR6 VCT, Tickford body kit/alloys, Momo wheel/shifter, leather, QFM, SS Ind, BA ind, 3" airbox exit, Coby headers, no cat

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 Post subject: Convert AU to Low-Restriction BA Induction Tube - Part 3
Posted: Sun Jan 30, 2011 4:39 pm 
Getting Side Ways
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Posts: 719

Joined: 1st Apr 2005

Gallery: 4 images

Ride: EF XR6 Wagon, AU2 XR6 VCT

Power: 148 rwkw

Location: Auckland
New Zealand

The only issue left to sort was the oil breather tube. On the AU, it attaches to the induction tube from the back. But on the BA it attaches at the front, so the existing AU breather tube is far too short. I fixed that for the time being with about 30cm of heater hose ($5), joined to the existing breather tube with a short piece of 15mm pipe I had laying around. I will replace it with proper breather tube during the week when I can find a source for it.

Here are pics of the finished job:
Attachment:
P1290022b.JPG

Attachment:
P1290024b.JPG

Attachment:
P1290025b.JPG

Attachment:
P1290026b.JPG


I also had an aluminium "scoop" left over from the SS Inductions Big Mouth kit on my EF and attached it behind the grill to direct air into the snorkel.

So, for a very reasonable cost, I have significantly improved the breathing on the intake side, yet you wouldn't pick it as modded unless you knew what to look for. The former bottleneck of the airbox exit now flows more than twice as much. There is no noticeable increase in induction noise. But there is a noticeable increase in performance. The car feels lighter, as it requires less throttle for the same acceleration. And it continues to pull hard higher into the revs before running out of puff.

Next upgrade: exhaust :twisted:

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95 EF XR6 wagon, 17" FTRs, DBA, QFM, KYB/Koni, SS Ind, BA ind, MLS, milled, Franklin RH24B cam, Coby headers, no cat, Tickford 2.5", 2900rpm stall, J3 chip
01 AU XR6 VCT, Tickford body kit/alloys, Momo wheel/shifter, leather, QFM, SS Ind, BA ind, 3" airbox exit, Coby headers, no cat

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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Sun Jan 30, 2011 4:48 pm 
Getting Side Ways
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Ride: GREEN ED XR6

Power: 249 rwkw

Location: CENTRAL WEST QLD
QLD, Australia

Well Done, cant wait to see if it improved you fuel econ? But a easy cheap way to upgrade your intake most people can do this, with minimal outlay and tools.

 

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AU2 engine with Hoppers head/cam performance package & spool rods / CP pistons ,Snort 1200 plenum, T56 Manual & Billet short shifter, Front & Rear Slotted rotors, Pedders lowered suspension, LSD and tuned with EMS stinger 4424 347rwkw THE ED XR6 IS BOOSTED

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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Sun Jan 30, 2011 5:12 pm 
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Ride: Falcon

Location: adelaide
SA, Australia

s**t ,i wished you put this up yesterday,i did this with my futura yesterday,this would have been helpful, i had to drill a hole in mine for the gas inlet which meant i had to buy another inlet as i buggered up the first ......but easy as ,worth doing , great write up.
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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Sun Jan 30, 2011 5:40 pm 
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I did this about 8 months ago and got a piece of pipe to make it fit into the air box. I used an EA PCV hose, a piece of plastic conduit and the original AU hose, joined together and voila. :)
Attachment:
DSCF3100.JPG
Attachment:
DSCF3102.JPG

Attachment:
DSCF3104.JPG
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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Sun Jan 30, 2011 5:44 pm 
Getting Side Ways
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Posts: 719

Joined: 1st Apr 2005

Gallery: 4 images

Ride: EF XR6 Wagon, AU2 XR6 VCT

Power: 148 rwkw

Location: Auckland
New Zealand

That looks very tidy. I think I'll copy that. Thanks.

 

_________________

95 EF XR6 wagon, 17" FTRs, DBA, QFM, KYB/Koni, SS Ind, BA ind, MLS, milled, Franklin RH24B cam, Coby headers, no cat, Tickford 2.5", 2900rpm stall, J3 chip
01 AU XR6 VCT, Tickford body kit/alloys, Momo wheel/shifter, leather, QFM, SS Ind, BA ind, 3" airbox exit, Coby headers, no cat

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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Sun Jan 30, 2011 8:07 pm 
Getting Side Ways
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i bought the BA intake, and there was no way it looked like it was going to fit properly. The AU pipe coming from the airbox outlet has a sharp bend to the right & upwards to clear the aircon hose.

I couldnt see anyway to run a pipe striaght out of the airbox with fouling on the aircon hose, and gave up on the idea. I have took out the guts on the airbox outlet to a 3" opening

however on my EF, it worked beautifully
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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Sun Jan 30, 2011 8:46 pm 
Getting Side Ways
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Posts: 719

Joined: 1st Apr 2005

Gallery: 4 images

Ride: EF XR6 Wagon, AU2 XR6 VCT

Power: 148 rwkw

Location: Auckland
New Zealand

In mine, the aircon hose was very close, but not in the way at all. I guess there must be variations on the routing of the aircon hoses among the AUs. But I can't think why an AU2 Ghia would be any different from my AU2 XR6 - they have identical VCT engines. Would climate control change hose placement?

 

_________________

95 EF XR6 wagon, 17" FTRs, DBA, QFM, KYB/Koni, SS Ind, BA ind, MLS, milled, Franklin RH24B cam, Coby headers, no cat, Tickford 2.5", 2900rpm stall, J3 chip
01 AU XR6 VCT, Tickford body kit/alloys, Momo wheel/shifter, leather, QFM, SS Ind, BA ind, 3" airbox exit, Coby headers, no cat

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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Thu Mar 17, 2011 3:47 pm 
Getting Side Ways
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Age: 30

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Ride: 97 EL XR6

Power: 162 rwkw

Location: liverpool
NSW, Australia

that air con line can be 'manipulated'

 

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07 BF MKII XR6T
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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Sun Nov 06, 2011 9:29 pm 
Oompa Loompa
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Age: 23

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Joined: 31st May 2011

Ride: Falcon Forte AU II

Location: Bellingen
NSW, Australia

Wow this is fantastic. thanks!
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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Tue Jul 31, 2012 9:20 pm 
Oompa Loompa
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Joined: 4th Jan 2010

Ride: AU 1 Futura,Previous-EA 2 S Pac

Location: North West Slopes & Plains
NSW, Australia

Thanks for the write up efxr6wagon, i just completed this mod & it works very nicely. I also saw the autospeed article & in conjunction with your well written thread i had no worries finishing the job.
Keep up the good work! :D

cheers,Maka

 

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Maka- Damn all those beer binges in my youth! Oh crap, what was that?- I forgot! Dont laugh-I bet you're the same!

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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Tue Jul 31, 2012 9:53 pm 
Getting Side Ways
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Posts: 719

Joined: 1st Apr 2005

Gallery: 4 images

Ride: EF XR6 Wagon, AU2 XR6 VCT

Power: 148 rwkw

Location: Auckland
New Zealand

Cool! I'm lazy, so like an easy upgrade. I've since replaced the snorkel with the one with the Tickford wings (same size) - the wings must be good for another 5kw at least :lol: Glad the write-up helped.

 

_________________

95 EF XR6 wagon, 17" FTRs, DBA, QFM, KYB/Koni, SS Ind, BA ind, MLS, milled, Franklin RH24B cam, Coby headers, no cat, Tickford 2.5", 2900rpm stall, J3 chip
01 AU XR6 VCT, Tickford body kit/alloys, Momo wheel/shifter, leather, QFM, SS Ind, BA ind, 3" airbox exit, Coby headers, no cat

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 Post subject: Re: Convert AU to Low-Restriction BA Induction Tube - Part 1
Posted: Tue Jul 31, 2012 10:05 pm 
Technical Contributor
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Age: 24

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Ride: ED Falcon

Power: 110 rwkw

Location: Leeton
NSW, Australia

Just fitted mine on the weekend... In my build linked in my sig... Just posted pics tonight...

I capped the breather on the BA tube and fitted an EF throttle body and hose to the rear of the rocker cover... Also an EF lid which has the internal trumpet and a larger hole than the AU one...

Cheers,
Tim

 

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93 Red ED 5spd Manual Build Thread

Performance: Complete AUII VCT Wiring & Power Train, Pacey Headers, 2.5" Exhaust, Exedy Clutch, DBA Rotors
Visuals: FG XR Wheel, XR Front, 17's, BA 5 Spd Shifter, BA Ghia Window Switches, NL Cluster
Tunes: 8" Pioneer Sub, JBL Speakers, Clarion Double DIN Headunit

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