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BA Falcon I6 FG Manifold Conversion 

 

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 Post subject: BA Falcon I6 FG Manifold Conversion
Posted: Thu Sep 13, 2018 7:43 pm 
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Hey guys,so as the title says,after cat & exhaust change it only made the inlet manifold leak much worse,so ordered some fg inlet manifold gasket kit and a new fg cold side heater pipe and used the fg manifold from the xg + K & N panel filter and got to work on making it all good,working well so far smooth low idle (compared to nearly 1500 rpm with the leaky ba bbm) very nice throttle response.

 

 

Attachments:
File comment: BA with FG inlet manifold.
IMG_20180913_58492.jpg
IMG_20180913_58492.jpg [ 46.48 KiB | Viewed 16 times ]

 

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Fri Sep 14, 2018 5:01 pm 
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Thought I'd take a vid of what it sounds like with the pacies/venom cat/middle delete pipe and rear redback sports muffler before I add a middle redback muffler,will do one after too.

https://youtu.be/_D5f3zqI9qA

 

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Tue Sep 18, 2018 6:41 pm 
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Hey guys,the ba engine has adapted well to the mods so far (the more I drive it the better it gets) although its not possible to get the full potential from what I've done so far without a tune-it does make me wonder how the engine would react to using the E-flex E85 set up as it is now.
Anyone got some input on the E-flex with similar mods?

 

 

Attachments:
File comment: Better engine bay shot.
IMG_20180918_27722.jpg
IMG_20180918_27722.jpg [ 65.57 KiB | Viewed 16 times ]

 

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XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Thu Sep 20, 2018 10:56 pm 
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That's very good mate. I doubt I will be doing anything similar any time soon as my BA eng is too old.

:)
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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Fri Sep 21, 2018 2:00 pm 
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Papa Smurf wrote:
That's very good mate. I doubt I will be doing anything similar any time soon as my BA eng is too old.

:)


Thanks Papa smurf,the fg manifold really unlocks the potential of the barra-really nice to drive now.
You mentioned before you were going to lower your BA,Im wanting to do the same but don't want to go to low-so I'm thinking maybe just lowering it to XR spec with some good shocks-any advice papa smurf?

Cheers Johnny.

 

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Mon Oct 29, 2018 5:52 pm 
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Hey guys,never got around to details of the conversion, as in parts needed and how to etc...

Parts list:
FG I6 manifold (try and get all the following at the same time)
FG fuel rail (complete with reg and quick connect hoses)
FG manifold bolts (BA-BF are too short)
Lower brackets and bolts.
FG front lift bracket (as you cannot use BA-BF)
FG manifold side brackets and bolts.
Fuel rail spacers I got from K&H Harris bolt shop 4-5mm thick.
5mm aluminium plate to make a plate between FG mani and BA TB
FG manifold gaskets (if needed)
FG TB gasket (if needed)
Tube of ultrablue silicone sealant

Will add more info soon...
Cheers Johnny.

 

 

Attachments:
File comment: New FG manifold gaskets (oring style)
IMG_20180819_55659.jpg
IMG_20180819_55659.jpg [ 84.62 KiB | Viewed 8 times ]
File comment: FGcold side heater pipe.
IMG_20180819_41968.jpg
IMG_20180819_41968.jpg [ 70.29 KiB | Viewed 5 times ]
IMG_20180819_38858.jpg
IMG_20180819_38858.jpg [ 84.74 KiB | Viewed 5 times ]

 

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Mon Oct 29, 2018 6:51 pm 
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So starting with removing the fuel pump relay and start the car till stall to relieve the fuel pressure in the rail,then remove the airbox,intake tube,disconnect all the injectors and TB,disconnect quick release fuel connections from rail hoses,remove TB and fuel rail,remove the whole thermostat housing from the head with top still attached,the aircon pump needs unding from engine without undoing the piping losing the gas-undo A/C bracket from engine to get the crank sensor wiring through,around this point you may need to jack the car up (place on stands/never ever get under any car with only the jack!)so you can get at the lower manifold bolts and brackets from underneath the car,the lower rear bracket will need you to loosen the starter motor bolts to pull the starter away from the engine to get the bottom back bolt out. (BA-BF mani bolts and brackets)

Will add more info soon.........
Cheers Johnny.

 

 

Attachments:
File comment: New gaskets in
IMG_20180819_58636-1.jpg
IMG_20180819_58636-1.jpg [ 76.62 KiB | Viewed 5 times ]
File comment: I had to remove the thermo housing from head before manifold would go in.
IMG_20180819_15599-1.jpg
IMG_20180819_15599-1.jpg [ 79.34 KiB | Viewed 4 times ]

 

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Mon Oct 29, 2018 8:41 pm 
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Okay once the BA-BF manifold is out you can remove the the cold side heater pipe,the FG heater pipe comes with a long and shorter pipe,undo the bolt retaining the small pipe and throw small pipe over left shoulder for luck,I had some stainless steel door hooks that I made into the heater pipe brackets as it mounts different from missing the small pipe and bracket,I made a stencil of the FG manifold flange to make the aluminum plate and work out where to drill the new holes in the BA throttle body.

 

 

Attachments:
File comment: Making the flange adapter.
IMG_20181029_291.jpg
IMG_20181029_291.jpg [ 53.38 KiB | Viewed 5 times ]
File comment: Aluminum plate to seal between the FG manifold and BA throttle body.
file-7.jpg
file-7.jpg [ 35.61 KiB | Viewed 5 times ]
File comment: The spacers to fit the FG rail with BA injectors.
file-9.jpg
file-9.jpg [ 27.89 KiB | Viewed 4 times ]
File comment: FG vs BA-BF cold side heater pipes.
IMG_20180819_16183.jpg
IMG_20180819_16183.jpg [ 62.4 KiB | Viewed 5 times ]

 

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XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Tue Oct 30, 2018 4:11 pm 
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Hey guys, will add as much info as I can about the conversion,but I thought a bit of background on the car may be relevant,so I bought the car awhile back cheap and running terrible,I knew it had a partially blocked cat and possibly a vacuum leak (was hoping minor leak),so did full exhaust 4495 pacemakers and venom cat & redback mufflers, also did full service cleaned the injectors/new plugs coils,car got worse,checked DTC's again and still had TB codes and engine shut down code-new symptom was after starting the car and letting it come down to idle (between 12 -1500 rpm) once you put it in gear it would go straight into engine shut down making the car almost undriveable,the only way to get it to go into gear without shutting down was to put it in gear whilst the rpm is dropping which the gearbox did not like at all-once in gear it drove okay,so after illiminating everything else including 2 different TB's,it was time to bite the bullet and do the manifold gasket-better yet If I have to take out the stupid BBM why not mod up and put the FG manifold in and while am at it upgrade all the radiator hoses and a K&N panel filter too.

Will add more info soon...........
Cheers Johnny.

 

 

Attachments:
File comment: DTC's.
IMG_20181030_48447.jpg
IMG_20181030_48447.jpg [ 71.68 KiB | Viewed 6 times ]
File comment: K&N,brakes stuff.
IMG_20181030_1690.jpg
IMG_20181030_1690.jpg [ 47.25 KiB | Viewed 7 times ]
File comment: Exhaust system.
IMG_20181030_42650.jpg
IMG_20181030_42650.jpg [ 71.3 KiB | Viewed 6 times ]

 

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XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

the-garage-f53/project-xg-fpv-dohc-barra-182-t128753-60.html

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Tue Oct 30, 2018 5:59 pm 
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Ride: EF-XR6/XG-6/XE-V8- project

Hey guys, just remember that I am doing this from memory so I may have to edit a couple of posts along the way,swap out the map sensor to BA in the FG manifold,nows the best time to remove the wiring conduit so the wires extend for injectors and TB wiring (which they will easily) then once you've done that you can put some of the conduit back on and tape up.The only one that needed its wires extended was the MAP sensor in which I cut the plug off the ute with as long wiring as I could and cut the plug off the BA loom fairly close to the plug-soldered the MAP plug off the ute on the BA loom thereby extending it by 4-5 inchs,BA heater pipes have like a cross over pipe between the hot and cold side heater pipes near where the heater pipes enter the cabin-FG cross's over on the cold side using the small pipe that was thrown over left shoulder for luck,so to replicate the BA cross over you just need to cut the end off the BA heater pipe that has the barb and pipe which you add back in the heater hose that enters the cab,will add pics to help with that.

Will add more info soon.........
Cheers Johnny.

 

 

Attachments:
File comment: Better shot of cross over pipe.
IMG_20181030_31881.jpg
IMG_20181030_31881.jpg [ 44.16 KiB | Viewed 4 times ]
File comment: MAP plug with extra wire and heat shrink.
IMG_20181030_34789.jpg
IMG_20181030_34789.jpg [ 81.43 KiB | Viewed 5 times ]
File comment: The peice to cut off BA heater pipe for cross over
IMG_20180819_16183-1.jpg
IMG_20180819_16183-1.jpg [ 12.23 KiB | Viewed 127 times ]
File comment: Heater pipe cross over.
IMG_20181030_32977.jpg
IMG_20181030_32977.jpg [ 56.49 KiB | Viewed 7 times ]

 

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XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Tue Oct 30, 2018 8:12 pm 
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Gallery: 16 images

Ride: EF-XR6/XG-6/XE-V8- project

Hey guys, been trying to show you the heater pipe brackets as they are rather important-they mount on outside of the bottom of the manifold with the FG manifold bolts around runner 2-3 and 4-5,you'll know when you're working it out, also pic of the BA oil dipstick shaped to fit with the front side bracket.

Will get better pics of brackets fitted etc tomorrow
Will add more info soon...........
Cheers Johnny.

 

 

Attachments:
File comment: BA dipstick-FG manifold.
IMG_20181030_4368.jpg
IMG_20181030_4368.jpg [ 54.55 KiB | Viewed 3 times ]
File comment: FG heater pipe brackets left.
XG radiator-EF thermo fan brackets right.

IMG_20181030_50863.jpg
IMG_20181030_50863.jpg [ 62.38 KiB | Viewed 5 times ]

 

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XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

the-garage-f53/project-xg-fpv-dohc-barra-182-t128753-60.html

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Tue Oct 30, 2018 10:26 pm 
Getting Side Ways
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Age: 65

Posts: 3539

Joined: 11th Jan 2009

Ride: BA Falcon XT

Location: Smithfield
NSW, Australia

Sorry it took so long for me to answer, sorry.

I have standard XR shocks and springs to add, new lwr front control arms, new upper inner bushes, ball joints. I also have the upgraded BF 322.mm and 328.mm calipers plus discs to add.
I have brand new rear arms and and also will be pulling out the cradle to change it's bushes. I have been waiting for the weather to be a little better. :)
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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Tue Oct 30, 2018 10:27 pm 
Getting Side Ways
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Age: 65

Posts: 3539

Joined: 11th Jan 2009

Ride: BA Falcon XT

Location: Smithfield
NSW, Australia

BTW Johnny, I so love all the work you have done and thanks for keeping us informed with the pics. :)
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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Wed Oct 31, 2018 4:06 pm 
Getting Side Ways
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Posts: 446

Joined: 16th May 2012

Gallery: 16 images

Ride: EF-XR6/XG-6/XE-V8- project

Hey guys,so once you sort out the wiring and heater pipes,you can put the TB and rail/injectors on before or after (easier to get to the manifold bolts with them out of the way though)you may notice my TB is upside down this is to make more room for the wiring to reach and has no negative effect on how it works,FG gasket on manifold side and Ultra Blue on the TB side do up finger tight let UB cure for 15 minutes and tighten,rail goes in with the spacers of course,loosely put the cold side pipe in before putting the manifold in to line up with the heater pipe brackets,then you can put the thermostat housing back on the head-I used the same metal gasket with a thin layer of Ultra Blue on either side 15/cure/tighten.

Hope this is all making some sort of sense

Will add more info soon...............
Cheers Johnny.

 

 

Attachments:
File comment: More vacuum lines and extended brake booster pipe.
IMG_20181031_25942.jpg
IMG_20181031_25942.jpg [ 65.47 KiB | Viewed 7 times ]
File comment: Closer look of vacuum lines etc....
IMG_20181031_35119.jpg
IMG_20181031_35119.jpg [ 78.37 KiB | Viewed 8 times ]
File comment: Front cold side heater pipe bracket.
IMG_20181031_46913.jpg
IMG_20181031_46913.jpg [ 39.52 KiB | Viewed 3 times ]
File comment: Upside down TB.
IMG_20181031_56213.jpg
IMG_20181031_56213.jpg [ 34.45 KiB | Viewed 3 times ]

 

_________________

XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

the-garage-f53/project-xg-fpv-dohc-barra-182-t128753-60.html

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 Post subject: Re: BA Falcon I6 FG Manifold Conversion
Posted: Wed Oct 31, 2018 6:27 pm 
Getting Side Ways
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Age: 45

Posts: 446

Joined: 16th May 2012

Gallery: 16 images

Ride: EF-XR6/XG-6/XE-V8- project

Papa Smurf wrote:
Sorry it took so long for me to answer, sorry.

I have standard XR shocks and springs to add, new lwr front control arms, new upper inner bushes, ball joints. I also have the upgraded BF 322.mm and 328.mm calipers plus discs to add.
I have brand new rear arms and and also will be pulling out the cradle to change it's bushes. I have been waiting for the weather to be a little better. :)


Hey Papa Smurf,I think I am going with XR springs and shocks too as I have BA-XR wheels now,roads are too s**t to go lower,I just had to do brakes-didn't think of going bigger though (maybe one day) did front slotted rotors/bendix pads,rear generic pads and all new braided brake hoses,would love to see whats involved in the brake upgrade though,thanks again for your comments mate.
Cheers Johnny.

 

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XG ute now powered with DOHC-BARRA 182/Tiger extractors/20% Underdrive and BA 4-SPEED + Tiptronic shifter

the-garage-f53/project-xg-fpv-dohc-barra-182-t128753-60.html

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