Approval Details

Valid E.O.

Validity

This Executive Order approved the specified parts on on November 14, 1986.
As of Monday, September 16th, 2019 this Executive Order has not been overturned or superceeded.

Approved Parts

Part NumberModelsModification
No. ATS 6.9L1983 through 1987 model year Ford Motor Company heavy-duty vehicles powered by a 6.9 liter Navistar International heavy-duty diesel engine.Modifications to the OEM emission-related parts due to the installation of the turbocharger kit include replacement of the air cleaner assembly and replacement of the OEM exhaust system with a 3" diameter exhaust system.

This Executive Order may be listed as:
  • C.A.R.B.E.O. D-171-1A
  • Executive Order 171-1A / D171-1A
  • ARB # D-171-1A
  • Executive Order No: D-171-1A
  • C.A.R.B. No. D-171-1A
  • Resolution D-171-1A
For Free CARB Executive Order Status verification, email an image of the device Executive Order label as well as the Year/Make/Model and Test Group # of the vehicle to [email protected]

Download: Executive Order D-171-1A PDF

D-171-1A Document:



            A—1




                               w rar
                               zis
ADVANCED TURBO SYSTEMS, INC.
          6.9 — 085
    PICKUP INSTALLATION
        PROCEDURE


      FUEL RETURN LINE
1983 & EARLY 84 MODELS ONLY.


 1. Disconnect both batteries at the negative terminals.
 2. Remove air cleaner and air cleaner canister.
 3. Remove rear engine lifting bracket and install new shorter cap screws provided {item #36). Reinstall
      bolits without the lifting bracket.
      NOTE: Do not install fuel return line retaining clamp, if clamp is present.

NOTE: Steps 4—6 only need to be followed if your vehicleis a 1983 or 1984 year model.
 4. Remove the fuel return line, which was previously held in position with the rear engine lifting bracket
      boit. Remove this line only from the passenger side near injector.

      Cut 4" out of the return line between the third and fourth injector on the right bank (passenger side}.
      Install the "T" fitting (item #33) supplied in the kit, Connect the fuel return line which was removed
      from the rear injector to this "T" fitting in such a manner the fuel line will lie on the intake manifold
      directly behind the air intake.
      Install fuel return cap (item #34) supplied in kit on the rear injector where the fuel return line was
      previously located.
      Remove transmission dipstick and dipstick tube. Cover hole in transmission where dipstick tube has
      been removed.                                                    (
      Vehicle with a sound insulating blanket covering the firewall, must cut and remove the passenger side
      half of the sound insulating blanket.
 9.   Remove oil pressure sending unit.

  .   Using a pry bar or a piece of 2" pipe, bend the lip of the firewall upward directly behind the turbo
      mount exhaust inlet. The center of this bend is 1%" to the passenger side of the original location of
      the oil pressure sending unit.                                                                        '
11. Install the steel adapter (item #31) where oil pressure sending unit has been removed behind the
    intake manifold. Tighten fitting so that the 4" female pipe thread faces the firewall to the driver‘s side.
12. Install the oil pressure sending unit in this female pipe thread. Reconnect oil pressure sending unit
      lead wire.
                                            z_i z_ _—_————gM




                                                                          ons


PARTS_ ORDERS
           St
TURBOCHARGEE


                             —     VJ d    vmAuvuUE   ri:   C


                              .    AIR FILTER ELEMENT
                              .    BAND CLAMP
                              .    SADDLE CLAMP
                              .    INDICATOR, AIR FILTER
                               .   O—RING, TURBO OIL DRAIN
                               .   O—RING, AIR FILTER
                               .   O—RING, PRESSURE CHAMBER IN
                              .    O—RING, PRESSURE CHAMBER 0
                              .    HEX NIPPLE, INDICATOR    >
                             .     TEE, TURBO OjL FEED
                              .    ELBOW, TURBO OIL FEED
                             .     TEE, FUEL RETURN
                              .    CAP, FUEL RETURN
                             .     PIPE PLUG
                             .     CAP SCREW, HEX HEAD (3)
                             .     CAP SCREW, HEX HEAD (2)
                             .     CAP SCREW, HEX HEAD (2)
                            .      CAP SCREW, SOCKET HEAD (2)
                            .      STVD, NC/NF (5)
                            _ STUD, NC (2)
                            .      STUD, NC/NF (2)
                            .      STUD, NC/NF (2)
                            .      NUT, HEX, NF (5)
                            .      NUT, HEX , NC (2)
                            .      LOCK WASHER (9)
                            .      LOCK NUT, HEX, (4)
                            .      SEAL WASHER
                            .      FLAT WASHER (2)
                                   %% 1983 AND EARLY 1984 MODEL ONLY.
                                   + WHEN BOOST GAUGE KIT, ITEM 21, is
                                     IT REPLACES PIPE PLUG, ITEM 35.
                                   % OPTIONAL


                                       6.9—085 TURBOSYS®
                                         PARTS ASSEMBL

                                     ADVANCED TuRBO syYSTEM:
                                    P.O. BOX 7547, 5919 SOUTH 35
                                             MURRAY, UTAH 84107
T FOR PRICE QuOTATION                     TELEPHONE (801) 263—09
HE _FOLLOWING
DESCRIPTION, AND ITEM No.


     18. Install turbo oit pressure line (item #15) onto the steel adapter (item #31) in such a manner that the
      >  "L" fitting connecting the oil line to the steel adapter faces the number three injector on the left bank
            {driver‘s side) when tightened.
       14. Remove the anti—depression valve from the rear of the intake manifold. Retain capscrews for latter
            use,

       15. Install rubberplug (item #16) in rear of intake manifold where anti—depression vavie was removed. Do
            not aver—tighten.
            NOTE: The hole must be clean and dry.
       16. install one %" x 1%" stud (item #40) in the upper rear threaded portion of the right bank (passenger
            side) cylinder head. Make sure stud is tightaned in head.

       17. Relocate the vacuum block on the firewall above the right bank (Passenger side) valve cover, Two
           new holes will need to be drilled. The location of this vacuum block should be two inches more to the
            passenger side and two inches higher than the original location.
       18. Relocate the power brake vacuum hose to the retaining hangers just below the hood in the center of
            the engine compartment. This moves the vacuum hose away from the turbine housing of the turbo.
       19. Vehicles with automatic transmissions, must move the transmission vacuum line from the passenger
           side to the driver‘s side of the transmission, using the top belthousing retaining bolt.
       20. Mount the stainless heat shield (item #9) to the back of the intake manifold using capscrews which
           were removed in step #14.
       NOTE: Steps 21—27 are done on a work bench.
       21. Assemble turbocharger (item #1) to turbo mount {item #2), using studs (item #40), turbo flange
            gasket(item #18), nuts (item #44), and lock washers (item #46) provided in Kit.
       22. Install O-ring seal (item #26) in oil drain assembly (item #14). Attach oil drain assembly to turbo using
           allen head cap screws (item $39).
       23. At this time, check to make sure the 4" pipe plug (item #35) or a manifold pressure adapter {item #21)
—~         is tightened into the pressure chamber (item #4).




                                                                                                    PARTS
                                                                                   TURBOCHARGER
                                                               o o ~ o a s un —



                                                                                   TURBO MOUNT CASTING
                                                                                   TURBINE EXHAUST CASTING
                                                                             .     PRESSURE CHAMBER
                                                                                   AIR FILTER BASE CASTING
                                                                                   AIR FILTER COVER CaASTING
                                                                                   FEED PIPE ASsSEMBLY
                                                                             .     FINAL EXHAUST PIPE
                                                                                   HEAT SHEILO
                                                                              .    SUPPORT BRACKET, TURBINE EXHA
                                                         0 5 6 No a s o n — 5
                                                                              z




                                                                              .    SUPPORT BRACKET, AIR FILTER
                                                                              .    DIPSTICK TUBE, AUTOMATIC TRANS
                                                                           m
                                                         M oo ow on en e e *k




                                                                               .   HOSE SUB—ASSEMBLY, CRANKCASE
                                                                               .   HOSE. SUB—~ASSEMBLY, TURBO OIL L
                                                                              .    HOSE, TURBO OIL FEED
                                                                              .    PLUG, INTAKE MANIFOLD
                                                                              .    GROMMET, CRANKCASE vENT
                                                                               .   GASKET, TURBO MOuNT
                                                                              .    SEAL RING, TURBO EXHAUST
                                                                              .    PYROMETER KIT
                                                    —%,4 21. BOOST GAUGE KIT —
                                                                   22.             AIR FILTER ELEMENT
                                                                   23.             BAND CLAMP
                                                                   24.             SADDLE CLAMP
                                                                   25.             INDICATOR, AIR FILTER
                                                                   26.             O—RING, TURBO OIL DRAIN
                                                                   27.             O—RING, AlR FILTER


 24. Lubricate the 2" 1.D. O—ring seal (item #28) and install O—ring seal in the pressure chamber (item #4).
     With O—ring seal lubricated, push pressure chamber over turbo discharge of turbo compressor housing.
 25. instail 90° adapter fitting (item #32) in the female pipe threaded portion of the turbo. When fitting is
       tight, the fitting should be facing the radiator.

 26. Install the pyrometer thermocouple adapter (item #20) in the 4—18 NPT threaded portion.
 27. At this time, the final exhaust brace {item #10) must be checked for proper alignment. Bolt the final
     exhaust brace (item #10) to the turbo mount (item #2) using capscrew and lock washer (item #38, 46).
     Without the piston ring seal (item #19) installed, install the final exhaust (item #3) into the turbo (item
     #1), holding the casting flat against the inside of the turbine housing. Rotate the final exhaust casting
     (item #3) towards the brace (item #10) that has been mounted to the turbo mount (item #2). If the two
     holes do not line up exactly, the brace hole must be elongated so that a proper alignment is obtained.
       After proper alignment is obtained, remove the final exhaust casting {item #3).. Do not remove the
       brace (item #10) from the turbo mount (item #2).
 28. Install the large O—ring seal (item #29) over the intake manifold where the air cleaner gasket was
     located. Be sure the O—ring seal is well lubricated.
 29. With steps 21—27 completed on a work bench, install the assembly on the engine using the one stud
       {item #40) and two capscrews (item #37), lock washer (item #46) and nut {item #44).
 30. Install the base of the oil drain line in the grommet where the anti—depression vaive was removed. Be
     sure that the fuel return line is forward (toward radiator) of the oil drain line.
 31. Secure pressure chamber (item #4) with the O—ring washer (item #48) and capscrew {item #36).
 32. Route the ofl supply line {item #15), so that the throttle cable, cruise control cable, and plastic wire
       assembly are under the oil supply line. This helps keep the cables and wire assembly away from the
       turbine housing of the turbo.
 33. Route the oil supply line to the driver‘s side of the oil drain line. Now route the line between the turbo
     and the pressure chamber. Connect the straight end of the oil supply line to the fitting onto the fitting
     in the turbo and tighten securely.
       CAUTION: if this oil line is not routed correctly, serious damage will result to the turbocharger!
 34. Remove the entire exhaust system.
 35. With the exhaust system removed, cut the exhaust approximately 1%" to the rear of the stock "Y"
       assembly. The rear portion of the stock "Y" assembly must be rounded. This is most easily done by
       using a tubing expander and a hammer. If you don‘t have a tubing expander, you can use a solid piece
       of stock that is approximately 2%4" to 2—3/16" in diameter and a hammer.
 36. Using a file, clean and remove any burrs from the inside and outside of the stock "Y" assembly.
 87. Reinstall the stock "Y" assembly, but do not tighten.
 38 Instail feed pipe assembly (item #7). Slide the exhaust flange of the feed pipe assembly over studs
       {item #41) and use flat washers {item #49) and nuts (item #45), only hand tighten at this time. Stide
       the expanded portion of the feed pipe assembly over the rounded stock "Y" assembly. Make sure that
       the expanded portion of the feed pipe comes all the way onto the stock "Y" assembly.
 39. Tighten exhaust flange to turbo mount securely.
 40. Install exhaust clamp (item #24) over expanded portion of feed pipe assembly and tighten securely.
 41. Tighten stock "Y" assembly to exhaust manifolds securely.
 42. install piston ring seal {item #19}) in final exhaust casting {item #3). Install final exhaust assembly
     using a %" x %" cap screw (item #38) and lock washer (item #46).
 43. Install exhaust down pipe (item #8) by using the 3" band clamp {item #23) as shown in the parts
       assembly.
       NOTE: On four wheel drive models it is necessary to remove the transmission crossmember brace to
       mstall the down pipe.
 44.   Vehictes with automatic transmission should now install the optional dipstick tube {item #12). Use the
       same O—ring from the original dipstick tube. Lubricate the O—ring. Secure the new dipstick tube by
       using the rear valve cover bolt.
 45. Remove the left bank (driver‘s side} valve cover, being eareful not to harm the valve.cover gasket.
 46. Using a %" hole saw, puta hole in the rear most round flat portion of the vaive cover and install the
       grommet (item #17) in this hole. Lubricate the inside of the grommet.
— 47. Reinstall valve cover in engine and tighten boits.
       CAUTION: Do not over—tighten bolts.
 48. Instali pyrometer lead wire and thermocouple into thermocoupte adapter in turbo mount casting.
  49. Install air cleaner brace bracket (item #11) in the front of intake manifold using long 5/16" studs (item
      #42) and hex lock nut (item #47). Instail bracket with long portion of angle running from the intake
        toward the radiator. Level bracket and tighten securely.
  50. Install crankcase vent assembly {item #13) in air cleaner base casting {item #5). Do not over—tighten.
  51. Install short 5/16" studs (item #43) in air cleaner base casting (item #5).
  52. Install air cleaner restriction indicator (item #25) in air cleaner base casting (item #5) in using %4" NPT
       coupler (item #30).
  53. Lubricate O—ring seal (item #27) and install in air cleaner base casting (item #5). With O—ring seal
       lubricated, push air cleaner base casting assembly over turbo inlet and locate air cleaner base against >
       angle bracket. Secure air cleaner base assembly to angle bracket using two 5/16" hex lock nuts
        Mie oc db n


      #42) and hex lock nut (item #47). Instail bracket with long portion of angle Funni“ng'(rom—%he ‘\n-\;\—ké
      toward the radiator, Level bracket and tighten securely.
50. Install crankcase vent assembly {item #13) in air cleaner base casting (item #5). Do not over—tighten.
51. Install short 5/16" studs (item #43) in air cleaner base casting (item #5).
52. Install air cleaner restriction indicator {item #25) in air cleaner base casting (item #5) in using 4" NPT
       coupler (item #30).                             ‘
53.    Lubricate O—ring seal (item #27) and install in air cleaner base casting {item #5). With O—ring seal
       lubricated, push air cleaner base casting assembly over turbo inlet and locate air cleaner base against
       angle bracket. Secure air cleaner base assembly to angle bracket using two 5/16" hex lock nuts
       (item #47).
54. Install crankcase vent fitting into lubricated vaive cover grommet.
55. Install air cleaner element(item #22) in air cleaner cover casting (item #6). Secure air cleaner cover
       to air cleaner base by first centering the cover length—wise and the latching the over center latches.
       NOTE: A small amount of grease should be used on the underside of the air cleaner element gasket
       surface.

56.    Reconnect both battery cables.
57. Install 3" mandrel bend exhaust system with 3" diameter straight through muffier.
58. To realize the benefit from turbocharging your diesel engine, the injection pump maximum fuel
    delivery should be increased. This should be done at this time. For instructions as to increase the
    injection pump‘s maximum fuel delivery, read INJECTION PUMP SETTING PROCEDURE.
59. Start engine and check for any exhaust leaks, air leaks or oll leaks.
       CAUTION: NEVER REY THE ENGINE UNTIL OIL PRESSURE IS OBTAINED!




                             INJECTION PUMP FUEL SETTING
                                      PROCEDURE
To realize the benefit from turbocharging your diesel engine, the injection pump maximum fuel delivery
should be increased. This is done by removing the timing cover on the passenger side of the injection
pump. Remove the top capscrew of the timing cover by using a 4" wrench. Loosen the bottom capscrew
and let the timing cover plate rotate to the bottom with the rubber gasket. Now rotate the engine using a
15/16" socket and ratchet on the alternator belt pulley nut until the allen head leaf spring screw is
centered in the opening. Using a 5/32" allen wrench, turn the allen head screw inward {clockwise) 4" of a
turn. The injection pump output will determine maximum exhaust temperature.
CAUTION: Never exceed 1150 degrees exhaust temperature.



                                            MAINTENANCE
1. GIVE YOUR ENGINE A GOOD WARM—UP PERIOD BEFORE YOU WORK YOUR ENGINE HARD.
2. GIVE YOUR ENGINE ACOOQL—DOOWN PERIOD AFTER WORKING THE ENGINE. LET IT COOL TO AT
   LEAST 300 DEGREES FAHRENHEIT.
3. CHANGE OIL AT INTERVALS OF NOT MORE THAN 2,500 MILES. CHANGE OIL FILTER WiTH                                   1
   EACK OHL CHANGE,
                                                                                                                  &
4. KEEP AIR FILTER ELEMENTS CLEAN. WHEN THE ELEMENT GETS DIRTY, CHANGE IT! A DIRTY                                g.
      AIR CLEANER ELEMENT WILL CAUSE EXCESSIVE EXHAUST TEMPERATURE AND EXCESSIVE
      OIL CONSUMPTION.
5. KEEP FUEL FILTERS CLEAN. DRAIN WATER FROM FUEL REGULARLY. CLEAN DIESEL FUEL
   WILL ASSURE LONG TROUBLE—FREE INJECTION PUMP AND INJECTOR LIFE.
6. NEVER REY YOUR ENGINE UNTIL Oil PRESSURE IS OBTAINED!
7. NEVER SHUT OFF YOUR ENGINE AFTER WORKING IT HARD WITHOUT GIVING YOUR ENGINE A
   COOL—DOWN PERIOD!



Document Created: 2005-09-01 12:43:53
Document Modified: 2005-09-01 12:43:53

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