Installed My rebuilt and lightly modified Holset turbo. WOW!

[bigceltic]

I have a question about intercoolers. My research has led me to believe that unless you are making major HP, an intercooler upgrade is not worth it - except for towing applications (or at least this is what I believe the preponderance of comments say). Given upgrades to the turbo, manifold, and air horn, BBi Stage 1s, as well as use of UDC, is a good intercooler (I like the BD) a worthwhile upgrade (maybe not 'worthwhile" given the cost, but rather effective or beneficial)? My main application/reason would be to further lower EGTs when towing - esp through the CO mountains. I would especially like to get John's (AH64ID) opinion.

George

PS - Yes, I know this is not a "modded turbo" question - but it is related to the upgraded turbo so I posted it here rather than start a new thread.

 

[promisedland]

This may be of interest...https://www.dropbox.com/s/cwfjcqxfuq2cdvw/High%20Tech%20Turbos%20Airflow%20For%20Tow%20Cummins%20Package.pdf?dl=0

 

[bigceltic]

This may be of interest...https://www.dropbox.com/s/cwfjcqxfuq2cdvw/High%20Tech%20Turbos%20Airflow%20For%20Tow%20Cummins%20Package.pdf?dl=0

That is a good article. Thanks Matthew!

 

[rckymtn]

So today I started removing the Turbo, it's really kicking my butt. I have everything unhooked except the 4 nuts on the Turbo flange. I was so frustrated I started to remove the manifold. I then stopped after watching a couple youtube vids and sprayed the bolts down with kroil to let it sit over night before I broke a wrench or destroyed the nuts. The Turbo is shot it looks like it went to war some mini ball bearings and the fins are all cracked and chipped. The big kicker is that I decided to drain the oil and do an oil change while I was at this project. As I pulled the dip stick my heart almost stopped there was barely any oil on the dipstick. After I cracked the drain plug only about a 1/2 gallon of oil came out. The day I drove home the oil gauge was in the middle like normal I had no idea there is no low oil sensor in the Cummins engine. I also found oil in the intercooler hose and am not sure now if I need to pull the intercooler and replace it also? I didn't know a trashed Turbo could eat so much oil!!! Anyway any info or input is much appreciated.

 

[Bob4x4]

I prefer to remove the exhaust manifold with the turbo attatched and reinstall as an assembly too,especially with a larger than stock turbo.If there is oil in the cooler the safe thing to do is remove it and clean. If the compressor wheel is pitted or warn looking I would be concerned with your air filtation

 

[rckymtn]

I am using the PSM cold air kit on a stock air box and the tall WIX filters when I pulled off the the hose connected to the Turbo I found a little very fine sand in the Turbo pipe. I don't know how it could have gotten in there unless the air box did not seal on the air filter correctly all the hoses were tight.

 

[AH64ID]

I have gone back and forth over intercoolers. I generally don't see much more than +30-35°F over ambient at the intake manifold so IMHO there isn't going to be a lot of EGT reduction with an intercooler on stock, or close to, CFM. But someone should try it and report back

 

[boonhauler]

I just went through a turbo modification. I had Turbo Re-Source do a 'Stage I' modification. Being that my truck had a plastic intercooler I changed that out as well. I had a Mishimoto installed. Along with the turbo upgrade I had a new exhaust manifold (steed speed) installed as well.

After running the truck for some 400 miles I can report much lower EGT's now. The truck cools down much faster as well. I've seen a bump in boost as well. I use to have the white haze smoke (thinking I needed new Injectors) under hard acceleration but that's gone now.

All-n-all I see this as a very positive upgrade and would recommend it to all. Turbo Re-Source was great to work with!

 

[promisedland]

Good deal!

 

[rckymtn]

I just got a my turbo back from Turbo Re-Source and also purchased the stage 1 really nice work, I have a 2005 5.9 I am about to order a steed speed manifold. Did you guys use a T4 flange with the Stage 1 turbo?

 

[dieseldanhowes]

I just got a my turbo back from Turbo Re-Source and also purchased the stage 1 really nice work, I have a 2005 5.9 I am about to order a steed speed manifold. Did you guys use a T4 flange with the Stage 1 turbo?

I stayed with the T3 flange. I did not want to have an adapter plate, and have any changes to the Pac-Brake/exhaust alignment.

Also, for those who might be interested in my results with the HE351CW Stage 2 turbo I purchased from Turbo Re-source, sorry for the wait. I wanted to get some data before I reported back. Right now just waiting to log some back pressure readings. What I can say is, there has been a very positive improvement!! I agree 100% with other members statements that this turbo modification is how these 3rd Gen 5.9's should have left the factory. I do not hesitate to say this should have been my first modification to this truck, well worth the investment, and highly recommended to everyone. I cannot vouch for other shop's modified turbo's, but I am very impressed with the work from Tom at Turbo Re-Source, and will do business there again if needed.
I will be back to post the back pressure/EGT results soon. Besides the instant boost response, and obviously more power/torque, my tailpipe tip and rear bumper are much cleaner (less soot) which tells me I am burning much more of the fuel!

 

[Motorhead]

I just got a my turbo back from Turbo Re-Source and also purchased the stage 1 really nice work, I have a 2005 5.9 I am about to order a steed speed manifold. Did you guys use a T4 flange with the Stage 1 turbo?

Stay with the T-3.... Don't try to make a great thing better by changing up what works. I say this to you with no malice... I have been driving my truck more lately and the instant boost is fantastic. Very little smoke to none at all.

 

[rckymtn]

So I called a local shop that is a steed speed dealer here in Colorado. He was steering me away from the steed speed. He is telling me that with my truck (FASS 95, smarty jr, cold air and stage 1 turbo re-source factory injectors) that the steed speed is made to well and would be a waste of money and that I would not notice anything from the steed speed. He is telling me I should go with a PDI or ATS 2-piece cast iron manifold. If I order the manifold on the web, the steed speed is $630 vs $520 for the PDI the guy here was thinking that the steed speed was $800+. $110 doesn't really matter to me and was still leaning on getting the steed speed. Any thoughts appreciated.

 

[bigceltic]

Stay with the T-3.... Don't try to make a great better by changing up what works. I say this to you with no malice... I have been driving my truck more lately and the instant boost is fantastic. Very little smoke to none at all.

I stayed with the T-3 as well.

 

[bigceltic]

So I called a local shop that is a steed speed dealer here in Colorado. He was steering me away from the steed speed. He is telling me that with my truck (FASS 95, smarty jr, cold air and stage 1 turbo re-source factory injectors) that the steed speed is made to well and would be a waste of money and that I would not notice anything from the steed speed. He is telling me I should go with a PDI or ATS 2-piece cast iron manifold. If I order the manifold on the web, the steed speed is $630 vs $520 for the PDI the guy here was thinking that the steed speed was $800+. $110 doesn't really matter to me and was still leaning on getting the steed speed. Any thoughts appreciated.

Wow. The Steed Speed has come down in price! I paid $825 for mine. That is a heck of a deal.

 

[dieseldanhowes]

After logging some miles with the Turbo Re-Source Stage 2 Turbo and manifold up-grade, I can offer the following results taken with a very accurate Fluke digital meter for Exhaust Back PSI, and Edge CTS Exhaust Pyrometer for EGT's and boost PSI in very similar driving conditions, (no load & flat road) using throttle input to maintain 65 MPH. The EGT probe was very close to the same position (within an inch) in both the stock and Steed Speed manifolds.

Engine running at idle back pressure:
Stock turbo and manifold - 5 PSI exhaust back pressure
Modified turbo and Steed Speed 3rd gen manifold - 2-3 PSI exhaust back pressure

Readings with factory Exhaust manifold and turbo at 65 MPH:
4 PSI boost
13 PSI exhaust Back pressure
EGT's were 650*F +- *10

Readings with modified turbo and Steed Speed 3rd gen manifold:
2 PSI boost
9.5 PSI exhaust back pressure
EGT's were 515*F +- 10*

I can not speak to MPG improvement at this point, since it has been difficult to drive conservatively!!!! this modification really woke this truck up, and right in the RPM range I drive it most (1500-2300 RPM's) the torque increase is very evident, EGT's are down across the board, the exhaust haze when towing has all but gone.

Overall, I am very happy with this investment, Tom at Turbo Re-Source has a great product for this application, and I recommend it to everyone who has a 2003-2007 5.9.

Thank you to everyone who has posted their results in the past on this and similar topics, it surely helped me from doing the trial and error method!!

 

[Motorhead]

Nice report and nice results. I agree with your comment about Tom and the TurboResource crew.

 

[promisedland]

Thanks for reporting! We need #ers like this. Glad you like it.