Summary of Contents for ATS Diesel Performance Aurora Plus - 5000
- Page 1 Installation Manual v1.2: Aurora Plus - 5000 Turbo Kit (2003-2007) 5.9L Dodge Please read all instructions before installation. Figure 1: Aurora Plus - 5000 Kit Contents...
- Page 2 Figure 2: Aurora Plus Hardware Kit Please make sure all of the components are in the Aurora Plus – 5000 Turbo kit before beginning installation. A complete corresponding list of parts and part numbers can be found on pages 17-19. Tools Required: 1.
- Page 3 Preparing the vehicle: 1. Set parking brake and block the wheels. 2. Disconnect batteries by removing both negative (-) terminals. Secure the negative (-) terminals away from batteries. 3. Remove the passenger side inner fender to make it easier to access the side of the engine (driver side shown).
- Page 4 control solenoid from the engine harness and remove it from the stock turbo. Install the harness jumper provided (Figure 2, #13) in the kit to prevent the computer from setting the check engine light. Harness Jumper Wastegate Control Solenoid 6. Remove the rubber grommet from the factory front air box and install it into the ATS air box mounting bracket.
- Page 5 Modifying the Factory Turbo: 1. The factory turbo cartridge must be clocked (rotated) in order to correctly mount the assembly in the new location. The oil drain must be at the bottom of the cartridge when the turbo is installed on the ATS manifold. To do this, the alignment pins inside on the cartridge flanges must be removed.
- Page 6 to remove the thread lock punch. Do not use a drill bit larger than .125”. Drill deep enough to allow the clevis to break the lock on the threaded rod. Do not drill completely through the rod. Drill Here 4. After the thread lock punch is drilled out. Remove the clevis and thread on the 5/16-24 lock nut supplied with the kit.
- Page 7 7. Remove the two 10mm studs using a set of vise-grip pliers. 8. Drill out the two threaded holes using a 7/16” drill bit. Remove all burrs after drilling. 9. The factory Wastegate hole measures .710” on the HX35 (03-04 trucks) turbine housing and .840”...
- Page 8 10. Reinstall the turbine housing and locate the oil feed fitting as shown in the picture below. Align the oil feed fitting with the letter “L” in the “Holset” name on the turbine housing. Oil Feed Fitting Alignment 11. Reinstall the compressor housing. Use the indexing marks applied in step 1 to correctly align the compressor housing with the turbine housing.
- Page 9 13. (03-04 Trucks only) Remove the brass 90° fitting and rubber hose from the front of the compressor housing. Install the 1/8NPT plug (Figure 2, #16) supplied in the kit. 14. Remove the oil feed fitting located on the top of the cartridge. Install the provided 12mm to JIC-4 fitting with one 12mm o-ring (Figure 2, #10).
- Page 10 16. Make sure the Wastegate control rod is aligned correctly as shown. The picture below shows the factory turbo ready to be used on the Aurora Plus system. Installing the Aurora Plus – 5000 Compound System 1. Remove the plug from the auxiliary oil drain port located on the side of the engine block just above the oil pan on the passenger side.
- Page 11 the best clearance for a wrench in this location. Install this nut first by holding the turbo just off and while turning the nut lower the turbo onto the studs. Install the three serrated flange hex nuts and use three more serrated washers.
- Page 12 9. Connect the factory oil drain tube to the Aurora 5000 using the gasket provided in the kit (Figure 1, #25) and the two 8mm x 20 bolts (Figure 2, #12). 10. Route the supplied long drain tube (Figure 1, #17) from the front oil drain port up to the factory turbo charger.
- Page 13 Oil Feed Lines (blue) Wastegate Line (red) Drain Tubes (green) Figure 3: Line and Drain Tube Routing 16. Connect the Wastegate actuator to the port on the Aurora 5000 compressor housing using the ¼” rubber line and two hose clamps (Figure 2, #15) supplied in the kit.
- Page 14 provided in the kit to make room for the turbo-to-intercooler charge pipe. Install the bracket by removing the alternator and bolts that secure it to the block. 21. Install the 2-bend silicone (Figure 1, #10) elbow onto the intercooler inlet. The A/C line that is connected to the A/C compressor and the condenser must be routed on the driver’s side of the 2-bend silicone elbow.
- Page 15 25. Route the radiator overflow line through the air box grommet and reconnect it to the radiator fill spout. 26. Install the air filter (Figure 1, #5) provided in the kit and secure it using a 4” clamp. 27. Install the IAT sensor into the side of the ATS air box using the 10-¾” sheet metal screws provided.
- Page 16 Bill of Materials Air Box Enclosure 206-030-2272 Silicone 180° Hose 202-040-2164 2.75” to 3.00” Reducer Boot 202-017-2272 3-Piece 24V Manifold 204-930-2218 a. (1) 1.625” x M10-1.5 stud installed b. (3) 2” x M10-1.5 stud installed ATS Air Filter w/ 4” Clamp 206-410-1000 4”...
- Page 17 a. ¼-28 Lock Nut 20. 4.2” V-band Clamp 134348 a. ¼-28 Lock Nut 21. 4.5” T-Bolt Clamp 94100-0450 22. (3) 3.5” T-Bolt Clamp 94100-0350 23. (1) 5.5” Worm Drive Hose Clamp SS-88 24. (3) 4.5” Worm Drive Hose Clamp ET-72 25.
- Page 18 11. Oil Feed Fitting (1/8NPT to JIC-4) 4FTX-S 12. (2) M8-1.25 x 20 Flange Bolts 13. Wastegate Solenoid Harness Jumper 202-010-2272 14. Map Sensor Voltage Cap (Boost Fooler) a. (3) section of heat shrink b. (3) non-insulated butt connector c. ring terminal 15.
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