ATS aurora plus 4000 compound turbo

[MChrist]

After waiting a month for my setup to arrive, I installed it the same day. I ordered this system because I didn't want the huge power that other systems can generate, and seems more financially "responsible" to spend $3100 and be done, compared to $5000 and then have to pony up for second CP3, head studs, injectors, different intake horn... (I have the composite CFM+). Seems like an additional $5000... so $10,000 out the door vs. $3100 and no exhaust modifications, VERY quick spool-up and PLENTY power. Now for the bad news... The install SUCKED!!! I am by no means retarded, and I had a second guy helping me, and it took 12 hours with no breaks and no interruptions!!(5 pm straight through to 5am). Whoever wrote the instructions needs a smack, because many things were not mentioned, directions weren't in proper order,and the 3 piece exhaust manifold was pressed together too far by 3/8"!!

After fighting with it for an hour, out came the die grinder with carbide bit!! Ten minutes later, it was perfect. I will say that every part was there, but not labeled,so you had to figure out which bolt was to be used for which application yourself.

If the instructions were laid out better and more thorough, and the manifold was aligned properly, this would have been an 8 hour install for the first time. If I did this again, maybe 6 hours.

Now for the part you are all waiting for... how does it feel/sound?? I'm breaking in the turbo for the next few days, but so far I notice a DISTINCT whistle from the intake. . verrry nice... and the exhaust sound lost its deep, low moan. Almost sounds stock, which I prefer, especially while towing. Haven't towed yet, but I'm sure the exhaust will lose it's slight drone. After all, the exhaust pulses are being broken up by two turbos now. . :-laf

I'll report back after I have more results/info for you. And my Smarty Jr is on Economy mode (40 hp) during break-in.

 

[Tinman]

How much power is this set up supposed to support?

 

[MChrist]

I don't know of any dynos locally that can test my truck, but I'll keep looking. According to ATS, I think they say this setup can support 550 ish. We'll see. So far, I'm satisfied with the "around town" driveability, quick response, nice turbo whistle, and quieter exhaust. I floored it for about 5 seconds starting at 50 mph and my egts never went above 950!! Before the switch,they would have been 1050-1100. My overhead is giving me higher mpg, but we all know how that goes...

 

[SSalzer]

Is that the setup where you use your stock turbo?

 

[Tinman]

It does use the stocker. I kinda wish I had gone this route now. But you still have that teeny tiny 9cm2 turbine on the stocker. That can be over come if set up properly and drive pressure never exceeds boost. But still.

 

[MChrist]

Tinman is correct. Tiny 9 square cm exhaust turbine on original turbo, ( maybe 2 inches across) which was chosen to help stock motor build boost quickly, but a detriment to big top-end power. Second turbo seems to address that, because power seems to climb more steeply than before, while still having near instant boost! Again, I realize that NOT using the stock turbo will give me more power, but I don't need it. I just want the extra oomph with quick boost response. And it's just plain cool thinking I have "twins" under the hood. It was my birthday present to myself!Oo.

 

[Tinman]

I decided to keep in simple and use a moderate sized BB turbo and make the engine breath really well. So I did about everything else but twins; cam, IC, intake horn, exhaust man. I really like the Garrett BB turbo. Spools super quick and seems to cool well. I haven't been on the dyno but it can handle the smarty on 9 (empty) without problems. I have to admit, I keep thinking of a twin set up. Or maybe Big Hoss intake with a ported and polished head with my current set up.

 

[MChrist]

Well, today I decided that the turbo was broken in enough, so I turned the Smarty Jr. to the perf setting (100 hp), engaged 4WD, set my Edge Insight monitor to record 0-60. With foot on brake, boost built up and let 'er loose! Once the monitor told me I had reached 60 mph, I quickly checked the time to see a 0-60 time of 5. 45... . exactly the same as before the second turbo!!!!! O. K. , so what's up??? I've noticed that my boost is 37, and before I had 38.
I'm pretty sure I saw in the installation sheet that the wastegate should be adjusted to reach 42-44, so I may monkey with that a little. I also noticed that even at full boost for 10 seconds, my EGT never got over 1050. I'll report back in a few days with further 0-60's.

 

[SShafranko]

Keep posting! I'm curious about your results. I am looking for a set up which utilizes the factory turbo also. I just started loking at kits and the one you have is one of them. Please keep updating i'm curious about your findings. You have already helped me a lot by posting about the directions. That turns me off big time.

 

[MChrist]

SShafranco, I'll call ATS tomorrow and see what's up and what I should expect. If they tell me I need new injectors, I'll be a little peeved, since they told me I wouldn't need any, and it will work great with my Smarty Jr! The only difference I can think of between the stock turbo and the compound plus 4000, is that I had Smarty on "default" timing on first, then timing #4 for the runs with the twins... I'll do a few runs on "default" tomorrow and re-post my findings. (I would think timing #4 should be more powerful, but maybe not with twins???)

 

[MChrist]

I called ATS this AM to find out why I wasn't making any more power than before, and they said I need more fuel. Seems the Smarty Jr doesn't add enough even at 100 hp! I then called Bob and he agreed, so he is sending a Smarty CR and giving me fair $ for returning the Smarty Jr. Should be here Wednesday, I'll keep everyone posted.

 

[Tinman]

You'll like the smarty and will have plenty of fuel. Try the tnt sw also. If you haven't done it, consider getting the pod unit. It gives a tremedous amount of adjustablitly.

 

[MChrist]

Tinman, thanks for the info. I believe that is what Bob is sending out. He said S06 POD... does anybody make some kind of mount to put the Smarty so it isn't dangling by a cord on the floor? Velcro'd to dash?

 

[osiris]

have you got your smarty yet? i am interested to hear how this setup works for you... I am thinking about going with the stocker 5k kit... .

 

[MChrist]

Smarty came Thursday night, installed immediately, went for a ride, and noticed a difference on the SW#7, which is 130 hp, w/timing. It's raining heavily, so no 0-60's, but oddly, I tripped a CEL with a turbo overboost code... Wastegate setting on Smarty is "off", boost on my Insight Monitor still only reads 37 psi... I'm just waiting for Bob to call back to help me w/why I'm getting a turbo overboost code. Sat and Sun is supposed to stop raining, so I'll have more info soon. Based on seat of pants dyno, it seems like way more that 37 psi. Come to think of it, the digital display sticks at exactly 37. 2 and doesn't move from there while the CEL comes on... maybe a sensor. Maybe I'll try a mechanical gauge off the CFM+ intake horn.

So far, WAY peppier, maybe 60 hp over the 100 hp setting on the Smarty Jr. Possibly because more fuel is lighting the big turbo??

 

[SShafranko]

Smary should boost you to 45lbs without a problem. I also have an insight monitor which i am pulling out this week and replacing with more gauges. My insight will not go past 23lbs and i know im boosting 42. Weird. My insight is always gliching out. I don't like it at all. Keep updating. Heres some picks of my Smarty mount.

 

[SShafranko]

https://www.turbodieselregister.com/forums/5-9l-engine-transmissions-2003-2007/215530-new-me-smarty-thoughts.html



There are more picks of the mount here.

 

[MChrist]

OK, I have an update, and things are looking up! Once Smarty Jr got replaced with Smarty, I put it on SW7, ( 130 hp w/timing) and I started tripping a Check Engine Light (turbo overboost). I decided to install the Boost Fooler that came with the ATS kit, and haven't tripped a code yet. Now it seems my Edge Insight monitor doesn't read past 23 or so... Originally, ATS said that I didn't have to install the fooler, since Smarty has one, but it turns out I did have to. Not difficult to do, so no big deal.

As you can see by my monitor's 0-60 clock, the truck is scooting now! When I was on Smarty Jr perf setting (100 hp), my 0-60s were always 5. 4-5. 5, with one turbo or two. So obviously, the extra fuel really lit the second turbo, because it takes way more than just 30 hp to drop my times by 7/10ths! Until I install an analog boost gauge, I won't know how much boost I have.

 

[SShafranko]

My insight won't go past 23 either. I wonder why? You should probably find a dyno and tune everything nicely for piece of mind.

 

[SShafranko]

Are you doing the 0-60 test in 4 wheel drive?