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Dillz

Modding Your Fg Xr6 Turbo

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FG XR6 Turbo - First Round Mods: 290-330rwkw range

"The internal combustion engine is an engine in which the combustionof a fuel(normally a fossil fuel) occurs with an oxidizer (usually air) in a combustion chamber" –wikipedia

Now the Golden Rule is: The more fuel and air you can safely force into an engine the more power you will make.

The key word here is "safely" and although there is risk involved in taking any engine above stock power there are nurmerous ways to minimise this risk. Having said that, below you will find details on the most common way to get your FG XR6 Turbo to around 290-330rwkw and beyond.

*Note this is just a guide, feel free to do your own research.

Modifying your 08-11 FG XR6 Turbo to

290-330RWKW Approx

CPU

When modifying your XR6 Turbo the first thing you will need is a Flash Tuner. This is the device that is used to "tweak" the cars factory cpu in order to updrgrade performance. These can range from $500 to $1000, one of the main Flash tuners used at the moment is the X3 Flash tuner seen below

rsz_x3-sct_flash_tuner_lg.jpg

*Please note the X1Flash tuner is now obsolete and should be avoided.

Injectors

The factory injectors are one of the first limiting factors on the FG 's being good for only around 250rwkw max, these will need to be upgraded pretty much straight away not only to increase power but also as a safety precaution to prevent the engine from leaning out due to lack of fuel supply.

Two common brands are the Siemens 60lb injectors and the Bosch 968's both around the $350 mark and good for around 350rwkw's.

rsz_accel_injectors2.jpg

Valve Springs

Although valve springs arn't really a performance modification as such they are an important safety measure when trying to make more power.

The FG XR6 Turbos have acquired the upgraded HD valve springs from the F6 engines so they should be ok at this level, SHOULD being the operative word. But again these are really just cheap insurance rather then another unnecessary cost so if you got the funds it would be worth upgrading to some stronger Atomic or Nizpro springs.And for around $400 it's allot cheaper then a new engine.

xr6-accessories--1.jpg

Fuel Pump

Ok back to performance mods and back to the golden rule. To make more power you need higher volumes of fuel pumped into your engine which means a bigger fuel pump. Quite simple really. The FG fuel pumps should be ok at this leavel, Most tuners agreeing that they can flow enough fuel to max out the stock turbo. But if you want to upgrade the WALBRO GSS series seems to be one of the most common used and is around the $130 mark.

rsz_maa-4261fi_w.jpg

Ported Wastegate and Bigger Flapper

The stock FG turbo is good for around 320rwkw before it runs out of puff. Porting the waste gate and installing a bigger flapper might not be necessary but will bring boost need down and help your turbo spool quicker so you might want to ask your tuner what they think before going ahead.This should cost you around $600 change over not including installation.

rsz_ud_turbo_ct26_4.jpg

Actuator

The actuator is used to control boost levels produced by the turbo and to prevent over boosting. You should base the size of your actuator on how much boost you wish to run.

rsz_actuator2.jpg

High Flow Cat

The FG exhaust has been designed pretty well and is almost able to flow enough to make your 320rwkw's, the only thing limiting it's potential is the factor catalytic converter. Replacing this with a high flow 100cpi (cells per square inch) will free up the exhaust and has been proven enough to make290-330rwkw's(Obviously a full exhaust would be better but that's later on)

100CellCat.jpg

Inter-cooler Piping

The FG intercooler piping is of a much better design then the old B series layout however there is a down side, it's been commonly known to pop or crack once boost level is raised even slightly. Unfortunately this means you pretty much need to replace it straight away with stronger alloy piping, last thing you want is a hose to blow after giving it a bootfull in the middle of nowhere leaving you stranded.

Currently there are a few companys making this alloy kit as a direct replacement of the factory pipes, Herrod, Coolerworks and Plazmaman to name a few. Should cost between $400-$600 for a kit.

Replacementalloypipe.jpg

Full Inter-Cooler Kit

The factory intercooler may be able to make 290-330rwkw but it will be at it's limit and starting to suffer from heat soak after multiple dyno runs or lots 'spirited driving', loosing power and efficiency. If your happy to splash a little more cash at this stage it would be a good idea to upgrade to a bigger intercooler and piping kit. These can range from $1500 (entry level) up to $3000+ (full high flow race level). There are some quality kit manufactures for the FG XR6 Turbo including Process West, Rapid Systems, Plazmaman, HDI and PWR.

fgfrontmountsmall5.jpg

With the all the Red mods completed you should be able to have your car tuned to around the 290-310rwkw mark, with the blue mods completed too you should safely make the 310-330 mark or maybe even a bit more.

Good Luck

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To try and make it a bit easier for new members to find out a bit about modding their new FG XR6 Turbo's I decided to make a bit of a "how to" thread based on the easiest and most common way people have been reaching certain power levels in there FG Turbos. (To be honest it's been a work in progress for the last 12 months or so...)

Now IMO I would class this as probably the easiest/cheapest/safest way to get into the 290-330 range, obviously there is a million ways to do it but I think this way will appeal to the most people, as we progress I can add more info on higher power levels or different routes if need be.

If anyone disagrees with what I've put or if I've forgotten something please feel free let us know, all feedback is welcome.

Cheers,

Dillz

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Maybe add "tuning" to your write up and an explanation of why it's necessary.

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And that replacing the cat needs a retune at the same time.

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Great work Dillz, nice write up.

Benny.

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Nice work buddy! Very helpful.

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Great write up Dillz. Can add the Cat restriction ring removal in the euro 4 models, and maybe turbo side intake?

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Cheers Guys

I'll add a bit more detail in the CPU part about tuning, I just don't want to make it too complicated right off the bat with other little things atm.

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Just read it and that is good info and should clear things up for new members, there are a few spelling and grammar errors which is bound to happen when writing all that. Nice work fella.

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Yeah I never dun good at the engish...

Also got a B series one underway that I'll post up when it's done, B series doesn't seem to be as straight forward and obvious as the FG.

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Good work Dillon :buttrock:

some good feedback from the lads :spoton:

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Good wright up dillz, it's good how you also added some price's in there so guys have a idea what it cost's. :clap:

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:spoton: Would have saved me a long time of searching and asking questions, when I was looking to mod.. Good work mate.

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Good work mate.

Of note, Atomic valve springs installed cost around a grand. Unless you want to remove the head, your mechanic will need access to the special tool that atomic have made.

The factory F6 injectors are a better option than deka's on FG's - most tuners will agree.

You will need un upgraded intercooler to make 300rwkw with safety.

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Great write up dillz, good for any new members to feast their eyes on to get an idea on what to do and what to roughly expect price wise. Good stuff!

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Very helpful writeup! Thankyou!

I would be interested to see also whether there is an FG maintenance guide - With some things simmilar to the BA solenoid maintenance routine.

Jake.

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Thanks Dillz, that's just what I need.

Can I ask though, I pick up my brand newie towards the middle of September, how long or km's do you recommend before starting mod work?

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Depends if you care about your warranty or not, I'd probably at least wait till after the first service but people have done it straight from the factory in the past. Up to you.

Love the avi by the way buttrock.gif

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Yeah I've loved that eye since I first saw it.

I'll wait some, suppose save the cash and make sure there are no bugs, thanks.

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I have everything you have in this. 12 PSI tune. Process west stage 3.1 intercooler kit. I'm pushing 313KW. But the guy told me its a super safe tune.

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And sounds like it is.

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You reckon I could get more but still be pretty safe ?

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Nice write up mate brought my xr6 turbo ute about a year ago and now its time to start modding and now im pointed in the right direction with this. Thanks

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No worries mate, glad it helped.

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Yeh great work dillz I'm just about to purchase an fg xr6t myself and I'll be doin the mods within the first month of owning her, my question is I know I have to do every mod you have explained but how do I go chasing the 380rwkw do I need to do internals do u think..Also does anyone have a ruff estimate on what they spent just to get their fg's to the 320kw mark.. Sorry for all the questions guys I'm a newbie on this site cheers.

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