We also fit a set of BFGoodrich's...
We also fit a set of BFGoodrich's new E-load-range-rated 285/75R16 tires. Check back next month to see how.
Project 300 is Diesel Power's budget buildup. In two stages we were able to buy a diesel truck and get it running for $1,203. For this third stage we added a turbo. Ford Motor Company made this same decision back in 1994 when it offered ATS-turbocharged 7.3L International diesel pickups and vans. ATS claimed its turbo could double the vehicle's power to the rear wheels and increase fuel economy. Today's ATS kit is based on the original design. However, the turbo was changed from a Garrett to an Aurora 2000, which is said to have a stronger cartridge and a more advanced housing and wheel design. Another change is with the 3-inch exhaust system that is designed to drop exhaust gas temperatures 200 degrees and add 30 hp compared to the stock system.
Project 300's 6.9L International engine is so similar to the later 7.3Ls, the ATS kit bolts on easily to either version. These older indirect injection (IDI) engines had high compression ratios of 21.5:1, which is why the ATS turbo is only designed to produce a maximum of 7 to 8 psi of boost. The advantages of this combination are less turbo lag and peak torque is achieved from idle to 2,000 rpm. The cons include not taking full advantage of high turbo boost pressures, which along with electronic controlled injection, distinguishes the newer 7.3L Power Stroke from the older IDI diesels.
 Here are the major pieces,...  Here are the major pieces, which come in the ATS wastegated turbo kit:
1. Silicone reducer
2. Steel vent tube
3. Y collector
4. Driver-side valve cover
5. Downpipe
6. Crossover pipe
7. ATS wastegated Aurora 2000 turbo assembly
8. Pressure chamber
9. Heat shield
10. Oil drain casting
11. Inlet pipe |  We used parts cleaner and...  We used parts cleaner and then a pressure washer to thoroughly clean the engine. Then we disconnected the batteries. After placing these two pieces of cardboard in the engine bay, we were able to kneel comfortably while we worked. The stock air duct and cold-air intake work great with the ATS turbo kit. The new ATS filter housing uses Fram CA7403 or K&N 33-2088 square filter elements. |  The '83 to '92 model years...  The '83 to '92 model years required the relocation of the vacuum distribution block screwed to the top of the passenger-side firewall. We removed the two screws and used a 1/8-inch drill bit to reinstall the block 3 inches up and 3 inches to the left. We also went ahead and removed all the factory insulation. In the future we'll put some new aftermarket material in to absorb the heat and noise. While we were at it, we replaced the 11/32-inch vacuum brake hose going from the vacuum pump to the distribution block and finally to the brake booster. We made sure to use thick vacuum hose because thinwalled fuel line will collapse under the pressure. Our truck has a ZF five-speed, but if you have an automatic, it is necessary to switch the vacuum line from the driver side to the passenger side using the 1/2-inch cap screw. |