Bf ES turbo build

[Pickle]

Hey everyone I'm new on here and I am currently planning on putting a ba xr6 turbo motor and t5 box into a 2007 falcon ES ( means euro sport apperntly) it currently runs a N/A grey top barra and a ZF six speed box... really I don't know where to start with it and Im unsure on a many things so any help would be awesome.

main thing I need help with first is a wiring loom diagram, also I already have the ba red top turbo engine and t5 gearbox, ba xr6 turbo ecu and loom .... would I also need to change tail shaft and diff gears? Anything else I'm gonna need to change ? Any help would be awesome people that way I can get this build on the road ???

[masda74]

 

It can be a tough crowed on here, but if you can stand up to the banter, you should be okay.

I can't help you with any of your questions as I have not been through the process before.

 

I am not sure if you have the workshop manuals for the ba and the bf, but I am sure that they may come in handy for you.

https://mega.co.nz/#F!loVQwT5D!a_eVD1oUflY1DMd1Gq_MRw

 

There is a thread for the FG workshop manual somewhere, but I can't find it now for some reason.

This is quite a significant project that you have taken on. I take it that you have not had much experience in a project like this?

I am hoping that someone like @k31th @Ralph Wiggum or @JETURBO will come along and give you a few pointers.

 

Enjoy and have fun.

[NathanB]

Hey everyone I'm new on here and I am currently planning on putting a ba xr6 turbo motor and t5 box into a 2007 falcon ES ( means euro sport apperntly) it currently runs a N/A grey top barra and a ZF six speed box... really I don't know where to start with it and Im unsure on a many things so any help would be awesome.
main thing I need help with first is a wiring loom diagram, also I already have the ba red top turbo engine and t5 gearbox, ba xr6 turbo ecu and loom .... would I also need to change tail shaft and diff gears? Anything else I'm gonna need to change ? Any help would be awesome people that way I can get this build on the road ???

What's the story behind this build?? First car on p's and now want a turbo or was a cheap purchase and want to slap it all together. Might be worth chatting to those mentioned above and seeing if there are any other mods that would be more easily done whilst motor and box are out to make it stronger long term?

But what sort of power are you chasing, just stock ATM I assume??

Would be great to see a build thread

[Pickle]

Story on the build is I've never seen a ES turbo before so I decided to build a sleeper ES to be different, I know it's going to be a challenge and a lot of work but I'm in no rush to finish just want it done right... the motor made 419rwhp in the old car with 1000cc injectors, surge tank, big intercooler, 8 psi actuator throttle Body relocation kit  and a tune... im hoping to make 350- 400rwhp on a safe tune when it's in the ES 

[NathanB]

That sounds mad. Build thread and photos would be amazing

[Pickle]

Will definitely be doing a build thread with photos, I just need some more info on what is actually involved in the conversion to be a quick reliable car and if There is anything that im missing that I'll have to change for the ba turbo motor to work correctly that's going in to bf ES mk2... I just don't want to walk into it blind and have all sorts of sh*t hit the fan by rushing it and not doing it properly  ... and the ES is still a perfectly driveable car ATM so I don't really want to take it off the road until I have everything I need ready and a bit more knowledge on doing the conversion??

[Ex chaser]

Is the manual gearbox out of the same car the engine came from? The t5 box won't last long with that sort of power without doing upgrades to it to make it reliable your better of bolting it to your zf box or get t56 box much better starting platforms both should get round the 280kw 300kw safish stock ( depends how hard u drive it).    So things u need to complete all computers ecu pcm etc possible wireing loom the xr6 na  has the turbo loom u would have to cheack if the es has the same new cradle with LSD diff, tail shaft exguast dump pipe intercooler, intercooler brackets piping etc new o2 sensor probly some things iv missed but wouldn't be much more its not like your turboing your na would be much more if u were, still would be easier possibly cheeper buy a xr6t and through a es body kit on and throw the motor in if you won't the power but each to there own. I was going to turbo my na a few years ago but pricing every thing wasn't worth it. Hope that helps a bit. O and welcome.             

[jrmr]

I swapped a BA turbo engine into my BA wagon. Both cars were auto which made it easier. I wanted to keep it easy for me in that I didnt want to take the car somewhere to get the PCM flashed to get it going. Its not exactly what you are doing but its just an example and might prompt you to think about some of the other issues you will come across.

 

I had to install a turbo engine bay loom (or N/A XR6 as previously mentioned) which has the plug for wastgate solenoid. This required removing the drivers side guard. The passenger side loom was just the additional third plug plus loom on the PCM for wastegate. I swapped in the PCM and BEM from the donor car. I also had to swap the dash loom as it has extra wiring for T/C light in the cluster, wiring for the auto headlight sensor and a few other things. This meant the whole dash came out. The wagon was only a 3 channel ABS sensor car so I had to swap the ABS module for the 4 channel one out of the turbo car. This also required a second brake line running from the front to back of the car. The rear brakes are normally on one circuit on the wagon and the turbo ABS module requires two lines. I used the existing airbag/restraint module. 

 

There is a program called Forscan that I used to delete the turbo keys from the PCM and BCM so I could use my wagon keys (wagon steering column). This process was relatively easy but I couldn't find much info on it before I started. Installing the turbo engine, turbo trans and intercooler etc was the easy bit. The only outstanding thing is that the car has a 3.23 ratio diff whereas the donor car had a 3.45. Speedo is not out as the speed is measured from the wheel ABS sensors. The only part I paid someone for was to make the rear section of the exhaust over the diff.

 

In your case, you have the pedal assembly to swap, clutch reservoir, wastegate solenoid, engine bay loom or just the wiring for the solenoid if you want to save a bit of time, tailshaft... The diff will be fine to get it mobile but as has been said it might not last too long. In saying that, my M78 wagon diff with an LSD has held up fine but its just a stock tune.

 

Your biggest hurdle will be because you are installing an earlier series engine into a later series car and I expect you will have to take it somewhere to sort the PCM out so it talks with the rest of your car and you can start it UNLESS you change everything so the PATS system is happy. If you are getting it tuned anyway they can probably sort that stuff out for you anyway. Will just need to get towed there.