ATS recently released a new compound turbo setup that is capable of almost doubling the power output of your Cummins-powered truck. It is called the Aurora Plus and will fit on any 5.9 common rail engine sold in the '03-'07 heavy duty Ram 2500 and 3500 pickups. Not only can it support almost 600 hp in the right configuration but it also is the most economical compound setup they offer. Furthermore, it is a complete bolt-on kit and everything needed to make your truck run on two turbos is included and can be installed using conventional hand tools.
Intrigued (of course), we went to the ATS facility in Arvada, Colorado, to watch as this kit was installed on a customer's truck. While we were there, we took the chance to wander around ATS's manufacturing and service areas. We were impressed to see that the ATS crew designs, manufactures and can install all of their parts in this one building. Interestingly, many of the trucks in the service bays were average-looking work trucks. Obviously, people who depend on their trucks for everyday work and transportation trust the ATS reputation for a combination of reliability and performance. About the Aurora Plus SystemThe Aurora Plus System uses the stock Holset turbo in conjunction with an ATS Aurora 4000 or 5000 turbo. Reusing the stock turbo is key to keeping the price of the kit as low as possible. Turbos are expensive and you can save about $1,500 by reusing the factory turbo (compared to a compound kit that requires two new turbos).
The stock turbo is responsible for the initial boost and therefore the factory drivability is maintained. The problem with the stock turbo though is that it is only effective in the lower rpm ranges and cannot deal with the airflow developed on the top end. If you currently drive one of these trucks you know this from experience by the power band of the engine. Around 1,500 rpm you can feel the boost really kick in and then the power feels about the same until you reach redline. Imagine if that feeling of the turbo building boost was extended much further into the higher rpm ranges.
That is exactly what the second turbo in the Aurora Plus system is responsible for. After the original turbo builds the initial boost the ATS turbo kicks in and continues to add more boost. According to ATS, the Aurora Plus with the Aurora 4000 turbo will develop 38-44psi boost and with the Aurora 5000 turbo will develop 48-52psi boost. Compare these numbers to the stock turbo's capability of about 25-28psi and you can start to understand how much more power will be available. Couple this extra airflow with more fuel from a programmer and or larger fuel injectors and you will realize the 423-593 rear-wheel horsepower potential of your new setup.
Another benefit of the Aurora Plus system is its emissions-friendly characteristics. Because of the increased volume of air produced, the particulate content (black smoke) and NO2 in the exhaust is reduced compared to the stock turbo. How often do you hear of performance modifications that will improve your vehicle's emissions?
 This one building houses some...  This one building houses some of the most knowledgeable diesel specialists in the industry. Inside, ATS designs, manufactures, and installs almost all of its products. We are lucky enough to have our correspondent live nearby in Denver, Colorado, and we stopped in to check out their latest development: the Aurora Plus compound turbo system. |  This is the ATS Aurora 4000...  This is the ATS Aurora 4000 turbo. It is the smaller of the two turbo options offered with the Aurora Plus kit. The beauty of this turbo though is that you don't have to worry about using aftermarket head studs which can be costly. That being said it still can provide enough airflow to produce 532 hp, which is a 63-percent increase over stock. |  The first step in the installation...  The first step in the installation is to remove the factory exhaust manifold, turbo, and airbox. A nice feature of the Cummins motor is its inline configuration that yields plenty of space in the engine compartment to access all these parts. At this stage the stock parts have been removed and the original turbo was being prepared to be reinstalled in its new arrangement. |
 We mocked up the kit to give...  We mocked up the kit to give you a clearer idea how the new exhaust manifold, stock turbo, exhaust elbow, and ATS turbo fit together. The exhaust first flows through the stock turbo for good response, and then down to the larger turbo for continued boost. Once initial boost builds, the wastegate in the stock turbo opens and relieves exhaust pressure by passing more air straight to the larger turbo. In a configuration like this the stress on each individual turbo is lessened since they share the work. |  Once installed, the new ATS...  Once installed, the new ATS turbo will be about where the original turbo used to be. This is very nice since the stock exhaust, seen behind the new turbo, will bolt right up. In fact, almost everything in this kit is bolt-on besides a few modifications to the stock turbocharger that are very basic. |  The exhaust manifold and twin...  The exhaust manifold and twin turbochargers have been installed. All that is left is the ATS air filter, which will go in the lower left, and the boost tubes that run between the turbos and then to the intercooler. It is important to note that you will need a special boost tube that ATS can supply if you have an aftermarket intercooler with a larger inlet. |
 This lucky truck was the recipient...  This lucky truck was the recipient of one of the first Aurora Plus kits. As you can see it is not a highly-modified race or off-road truck. The owner also had an ATS-built automatic transmission put in while it was in the shop as well, as that's the one link that might not hold up to the power the ATS twin turbocharger setup will put out. Combine the tranny with the turbos and this truck should run strong and reliably for many years to come. ATS warranties its turbos for 150,000 miles or three years, and its transmissions for 500,000 miles or five years. |  Here is where the ATS products...  Here is where the ATS products first take shape. In-house designers make 3-D models on a computer that later become the parts ATS manufactures and sells. It is not very common these days to find a business that does all this itself without outsourcing any work. Operating this way gives ATS complete control and results in nothing but high quality parts. |  Check out this unique turbo...  Check out this unique turbo configuration that was bolted to the end of a table in the ATS turbo assembly room. That is three turbos attached to a Cummins exhaust manifold. There is two smaller turbos in parallel with one huge turbo in series. Sorry, this is not part of their production line but ATS is capable of building custom setups ... if you have the money. |
 This is an employee's truck...  This is an employee's truck in the ATS service bay. We have been focusing on Cummins performance in this article but rest assured ATS has parts for all you Ford and Chevy fans as well. This truck is running a 7.3 Powerstroke with an Aurora 5000 turbo capable of 637 hp and has been used to compete in sled pulls and drag racing. |  The dyno results pretty much...  The dyno results pretty much speak for themselves. These graphs show the power of the stock setup (dashed lines), Aurora Plus 4000 kit (red lines) and the Aurora Plus 5000 kit (blue lines). Usually, when this much power is possible, drivability and reliability are sacrificed but this is not the case here. Either the 4000 or 5000 Aurora Plus systems are equally suitable for driving around town, towing heavy loads or racing the 1/4-mile. If you are looking for the best combination of value, power, and drivability, give ATS a call and inquire about its Aurora Plus kits. |  |