H1C/D/E/H2A

Service Repair Manual

Copyright® 1998
Holset Engineering Co. Ltd. Part No. 3580700
All rights reserved Effect date 11.98
Foreword
This publication was written to assist field personnel with basic overhaul and rebuilding of the Holset H1C/D/E/H2A
turbocharger.
The specifications and rebuild information in this manual is based on information in effect at the time of printing. Holset
Service reserves the right to make any changes at any time without obligation. If differences are found between your
turbocharger and the information in this manual, contact your local approved dealer.
The latest technology and the highest quality standards are used in the manufacture of Holset Turbochargers. When
replacement parts are needed, we recommend using only genuine Holset parts.
 Table of Contents
Page 3

Table of Contents
Introduction
General Information .....................................................................................................................................................4
About the Manual.........................................................................................................................................................4
How to Use the Manual ...............................................................................................................................................4
Fault Finding Chart ......................................................................................................................................................5
Symbols .......................................................................................................................................................................6
Component Identification
Turbocharger Identification ........................................................................................................................................11
Components ..............................................................................................................................................................12
Exploded View ...........................................................................................................................................................13
Optional Components ................................................................................................................................................14
Component Disassembly and Assembly
Service Tools .............................................................................................................................................................15
Disassembly ..............................................................................................................................................................16
Cleaning.....................................................................................................................................................................21
Inspection ..................................................................................................................................................................21
Assembly ...................................................................................................................................................................23
Installation Data .........................................................................................................................................................30
Installation Checklist ..................................................................................................................................................31
General Information Introduction
Page 4

Introduction
General Information
A turbocharger is a mechanical device which uses the engine’s exhaust gases to force more air into the engine
cylinders. A turbocharger uses energy from the engine to help increase its overall efficiency. Hot exhaust gas energy is
used to turn a “shaft and wheel”. At the other end of the shaft is the “compressor impeller” (or compressor wheel),
which draws in air and forces it into the engine cylinders.
Supplying increased air mass flow to the engine provides improved engine performance, lower exhaust smoke density,
improved operating economy and altitude compensation, The turbocharger has proven to be one of the most beneficial
devices for improving engine performance. It performs its job very well, as long as it is properly cared for.

About the Manual

The procedures in this manual were developed to instruct in the correct overhaul of the Holset H1C/D/EH2A
turbocharger to provide for the optimum performance and minimum of maintenance operation.

How to Use the Manual

This manual is organised according to the steps needed to most easily and correctly overhaul the Holset
H1C/D/EH2Aturbocharger. In the unlikely event of turbocharger malfunction, please check the Fault Finding Chart to
identify potential causes, before attempting disassembly. To make sure of optimum performance, certain items must be
discarded during the disassembly operation and replaced with new for re-assembly. These items are indicated in the
disassembly section with the use of a * symbol. All items showing a * are available in a basic H1C/D/EH2A overhaul kit.
Contact your local agent for part number and availability.

Warning
This turbocharger may have been manufactured using the ‘core balance’ process and therefore MUST be check
balanced on rebuild.
A core balanced turbocharger will not have any co-relation marks on the thrust collar or oil slinger, and also may not
have co-relation marks on the end of the turbine shaft and impeller nose.
If you intend to overhaul/repair a core balanced turbocharger, and do not have access to a core balancing machine,
we recommend that you make your own rotor co-relation marks during disassembly ( see appropriate illustration in the
disassembly section) with an indelible-ink pen, so that these parts can be reassembled in the same relative positions.
Please refer to the balance data section of this manual for the balance limits to be used for either core balancing or
rotor balancing.
It is important to note that operating a turbocharger with a Rotor or Core balance level greater than the published limits
could cause turbocharger or engine failure. If you are in any doubt regarding the balancing process, please contact an
approved Holset distributor for assistance.
Introduction Fault Finding Chart
Page 5

Fault Finding Chart

Cyclic Sound from the Turbocharger

Oil Leak from Compressor Seal

Oil Leak from Turbine Seal

Poor Transient Response

High Oil Consumption

Black Exhaust Smoke

Blue Exhaust Smoke

Engine Lacks Power
Engine Running Hot

Turbocharger Noisy
Smoke
Dirty air cleaner
Clean or replace element according to manufacturer’s recommendations
Restricted compressor intake duct
Remove restriction or replace damaged parts as required
Restricted air duct from compressor to intake manifold
Remove restriction or replace damaged parts as required
Restricted intake manifold
Refer to engine manufacturer’s manual and remove restriction
Air leak in feed from air cleaner to compressor
Replace seals, gaskets or tighten fasteners as required
Air leak in feed from compressor to intake manifold
Replace seals, gaskets or tighten fasteners as required
Air leak between intake manifold and engine
Refer to engine manufacturer’s manual and replace gaskets or tighten fasteners as required
Foreign object in exhaust manifold (from engine)
Refer to engine manufacturer’s manual and remove obstruction
Restricted exhaust system
Remove restriction or replace damaged parts as required
Exhaust manifold cracked, gaskets blown or missing
Refer to engine manufacturer’s manual and replace gaskets or damaged parts as required
Gas leak at turbine inlet/exhaust manifold joint
Replace gasket or tighten fasteners as required
Gas leak in ducting after turbine outlet
Refer to engine manufacturer’s manual and repair leak
Restricted turbocharger oil drain line
Remove restriction or replace damaged parts as required
Restricted engine crankcase breather
Refer to engine manufacturer’s manual, clear restriction
Turbocharger bearing housing sludged or coked
Change engine oil and oil filter, overhaul or replace turbocharger as required
Fuel injection pump or fuel injectors incorrectly set
Refer to engine manufacturer’s manual and replace or adjust faulty components as required
Engine valve timing incorrect
Refer to engine manufacturer’s manual for correct settings and adjust as required
Worn engine piston rings or liners
Refer to engine manufacturer’s manual and repair as required
Burnt valves and/or pistons
Refer to engine manufacturer’s manual and repair as required
Excessive dirt build up on compressor wheel and/or diffuser vanes
Clean in accordance with details in the appropriate Holset publication
Turbocharger damaged
Find and correct cause of failure, repair or replace turbocharger as necessary
Failed diaphragm
Replace using correct actuator Service Kit
Siezed valve
Free valve/replace complete turbine housing sub-assembly
Leaking hose
Replace hose and clips
Wastegate mechanism set incorrectly
Contact approved agent for correct setting details
Symbols Introduction
Page 6
Symbols - English
The following group of symbols have been used in this manual to help communicate the intent of the instructions. When
one of the symbols appears, it conveys the meaning defined below.
WARNING - Serious personal injury or extensive property damage can result if the warning instructions are
not followed.
CAUTION - Minor personal injury can result or a part, an assembly or the engine can be damaged if the
caution instructions are not followed.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

Ensure that the BALANCE MARKS on the rotor assembly are in alignment

PERFORM an electrical MEASUREMENT.

Refer to another location in this manual or another publication for additional information.

Please wear protective clothing at all times.

Introduction Symbols
Page 7
Simbolos - Español
Los simbolos siguientes son usados en estes manual para clarificar el proceso de las instrucciones. Cuado aparece
uno de estos simbolos, su significado se espcifica en la parte inferior..
ADVERTENCIA - Serios daños personales o daño a la propiedad puede resultar si las instrucciones de
Advertencia no se consideran.
PRECAUCION - Daños menores pueden resultar, o de piezas del conjunto o el motor puede averiarse si las
instrucciones de Precaución no se siguen.

Indica un paso de REMOCION o DESMONTAJE.

Indica un paso de INSTALACION o MONTAJE.

Se requiere INSPECCION.

LIMPIESE la pieza o el montaje.

EJECUTESE una MEDICION mecánica o del tiempo.

LUBRIQUESE la pieza o el montaje.

Indica que se dará una LLAVE DE TUERCAS o el TAMAÑO DE HERRAMIENTA.

APRIETESE hasta un par torsor especifico.

Ceriórese de que están alineadas las MARCAS DE BALANCE en el rotor.

EJECUTESE una MEDICION eléctrica.

Para información adicional refiérase a otro emplazamiento de este manual o a otra publicación anterior.

Favor de siempre llevar ropa protectora.

Symbols Introduction
Page 8
Symbole - Deutsch
In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die Symbole
haben folgende Bedeutung:
WARNUNG - Wird die Warnung nicht beachtet, dann besteht erhöhte Unfall- und Beschädigungsgefahr
.
VORSICHT - Werden die Vorsichtsmassnahmen nicht beachtet, dann besteht Unfall- und
Beschädigungsgefahr.

AUSBAU bzw. ZERLEGEN.

EINBAU bzw. ZUSAMMENBAU.

INSRPEKTION erforderlich.

Teil oder Baugruppe REINIGEN.

DIMENSION - oder ZEITMESSUNG.

Teil oder Baugruppe ÖLEN.

WERKZEUGGRÖSSE wird angegeben.

ANZUG auf vorgeschriebenes Drehmoment erforderlich.

Sicherstellen, daß die AUSWUCHTMARKEN an der Rotor-Baugruppe richtig ausgerichtet sind.

Elektrische MESSUNG DURCHFÜRHREN.

Weitere Informationen an anderer Stelle bzw. in anderen Handbüchern.

Schutzkleidung muß immer getragen werden.

Introduction Symbols
Page 9
Symboles - Français
Les symboles suivants sont utilisés dans ce manuel pour aider à communiquer le but des instructions. Quand l’un de
ces symboles apparait, il évoque le sens défini ci-dessous:
AVERTISSEMENT - De graves lésions corporelles ou des dommages matérials considérables peuvent
suvenir si les instructions données sous les rubriques “Avertissement” ne sont pas suivies.
ATTENTION - De petites lésions corporelles peuvent survenir, ou bien une pièce, un ensemble ou le moteur
peuvent être endommagés si les instructions données sous les rubriques “Attention” ne sont pas suivies.

Indique une opération de DEPOSE.

Indique une opération de MONTAGE.

L’INSPECTION est nécessaire.

NETTOYER la pièce ou l’ensemble.

EFFECTUER une MESURE mécanique ou de temps.

GRAISSER la pièce ou l’ensemble.

Indique qu’une DIMENSION DE CLE ou D’OUTIL sera donnée.

SERRER à un couple spécifique.

S’assurer que les REPERES D’ÉQUILIBRAGE sur l’ensemble de rotor sont alignés.

EFFECTUER une MEASURE électrique.

Se reporter à un autre endroit dans ce manuel ou à une autre publication pour obtenir des information plus
complètes.
Il faut toujours mettre vêtements de protection.
Symbols Introduction
Page 10
Símbolos - Português
Os símbolos a seguir serão utilizados neste manual para facilitar a comunicação das instruções e seue significados
estão déscritos abaixo.
ATENÇÃO - Se as instruções não forem seguidas, hã possibilidade de ocorrer sérios danos pessoais e
materials.
CUIDADO - Danos aos componentes, ao conjunto ou ao motor, ou mesmo pequenos danos pessoais
podem ocorrer se as instruções não forem seguidas..

Indica um passe de DESMONTAGEM.

Indica um passo de MONTAGEM.

Requer INSPEÇÃO.

LIMPE a peça ou conjunto.

Requer MEDIÇÃO mecãnica ou de tempo.

LUBRIFIQUE a peça ou o conjunto.

Indica necessidade de APERTO.

TORQUEAR de acordo com o especificado.

Assegure-se de que as MARCAS DE BALANCEAMENTO do conjunto eixorotor estejam alinhadas.

Requer medição ELÉTRICA.

Procure em outra seção deste manual ou em publicação par obter informações adicionais

Por favor, sempre utilize EPI (Equipamento de Protecao Individual)

Component Identification Turbocharger Identification
Page 11

Component Identification
Turbocharger Identification
A dataplate is fitted to the compressor housing (8). The 35XXXXX
H01XXXX
information on this dataplate must be quoted for service and
parts support. H1C

H1C/D/E/H2A - Center Housing Rotating Assembly (C.H.R.A.)

2
Components - H1C/D/E/H2A Component Identification
Page 12
Components - H1C/D/E/H2A
Item No. Description Quantity
4 Bearing Housing 1
5 Turbine Housing 1
6 Assembly Turbine Wheel 1
7 Compressor Wheel 1
8 Compressor Housing 1
11 Journal Bearing 2
12 Thrust Bearing 1
13 Piston Ring Seal, Turbine 1
14 Diffuser 1
16 Piston Ring Seal, Compressor 1
29 V-band Clamp 1
31 Oil Slinger 1
32 O Ring Seal, Bearing Housing 1
33 Oil Baffle 1
36 Thrust Collar 1
38 Heat Shield 1
41 O Ring Seal, Compressor 1
51 Clamp Plate, Compressor Cover 3
54 Lockwasher, Compressor 6
56 Diffuser Screw 4
57 Bolt, Turbine Housing 6
58 Screw Thrust Bearing 3
59 Bolt Compressor Cover 6
61 Locknut, Compressor Wheel 1
62 V-band Locknut 1
64 Ring Retaining Bearing (Snap Ring) 4
88 Clamp Plate, Turbine Housing 2
Component Identification Exploded View - H1C/D/E/H2A
Page 13
Exploded View - H1C/D/E/H2A

16
59
41
54
78
51
31

29
62 32
8

14
61 *
61 * 7

38

11
4

11 64

56

58

64
36

12
33 88
57

5
13

* Alternative options
Optional Components Component Identification
Page 14
Watercooled Turbine Housing (5) (if fitted)
Certain engine manufacturers can specify a watercooled
turbine housing. These can have additional water feed
drain plug fittings. Special attention should be made to the
position of these fittings as they may be specific for each
5 application

Old Style Nut New Style Nut

3503562 3590306
Caution: Always use specified torque. Failure to do
so may result in turbocharger / engine failure.
New Compressor Wheel Locknut
Holset have introduced a new compressor wheel lock nut
which is to be fitted to all new H1C/E/D & H2A
turbochargers. If your turbo is fitted with the new nut, it
indicated that this turbocharger was built using the core
balance process at point of manufacture rather than the
traditional rotor balance process. The new nut will also
require a different torque process when rebuilding the turbo
after service.
Old Lock Nut Part Number 3503562
Torque value: 17Nm [150lb ins].
New Lock Nut Part Number 3590306
Torque value: 16Nm [142lb ins].
(or shaft stretch of .0006” - .0012”)

Always Check there are correlation marks between the

Shaft End and the Compressor Wheel before disassembly.
If no marks exist, make sure you make your own marks
before loosening the compressor wheel lock nut.

ALWAYS check balance the Rotor before rebuild.

Component Disassembly and Assembly Service Tools
Page 15

Component Disassembly and Assembly

Service Tools
The following special tools are recommended to perform procedures in this manual. The use of these tools is shown in
the appropriate procedure. These tools can be purchased from your local Authorised Repair Location.

Part No. Tool Description Tool Illustration

56664 Circlip Pliers

Dial Gauge
-0+
10 10

TYPE 20
20 20

30 30
MERCER

40 40
50

Torque Wrench

3503071 T20 Torx®

Disassembly Component Disassembly and Assembly
Page 16
Disassembly
Note: * Denotes a part which is included in the basic
overhaul kit.
Before disassembling the turbocharger, scribe the parts
listed below to help in alignment during assembly.
- compressor housing (8)
- turbine housing (5)
- bearing housing (4)

11mm
Secure the turbine housing (5) in a vice.
Loosen and remove the 6 bolts (59), 6 lockwashers (54)
and 3 clamp plates (51).
Loosen and remove V-band locknut (62) if fitted.

Caution: The compressor wheel blades can be easily

damaged when the compressor housing is removed
Gently remove the compressor cover (8) and V-band
clamp (29)
Also remove and discard O ring seal (41*) if fitted.

13mm
Loosen and remove the four bolts (57) and clamp plates
(88).
Component Disassembly and Assembly Disassembly
Page 17
Caution: The turbine blades can be easily damaged
when the turbine housing is removed.
Remove the C.H.R.A. from the turbine housing (5).

19mm
Caution: (See Page 14)
Locate the C.H.R.A. onto a 19mm socket clamped in the
jaws of a vice or a suitable fixture.
Caution: Always make sure the turbine wheel shaft
and the compressor wheel have alignment marks
before disassembly of the C.H.R.A
If no marks exist, scribe the shaft and compressor
wheel (as shown) before removing the compressor
wheel locknut.

13mm
Remove the compressor wheel lock nut (61*).
Note: Left hand thread

Remove the compressor wheel (7).

Disassembly Component Disassembly and Assembly
Page 18
Remove the remaining C.H.R.A. from the socket and gently
slide the shaft and wheel (6) from the bearing housing (4).

Caution: Care should be taken not to score the

assembly turbine wheel shaft.
Carefully remove and discard the piston ring seal (13*).

8mm
Remove the heat shield (38).
Loosen, remove and discard the 4 diffuser screws (56*).

Hold the diffuser (14) flat on a work bench and carefully

separate the bearing housing (4) from the diffuser (14).
Component Disassembly and Assembly Disassembly
Page 19
Remove the oil deflector (33).

Remove and discard rectangular ring seal (32*).

Remove the oil slinger (31).

Remove and discard the piston ring seal (16*).

T20 TORX®
Remove and discard the 3 flat head screws (58*).
Disassembly Component Disassembly and Assembly
Page 20
Remove and discard the thrust bearing (12*).

Remove the thrust collar (36).

Using circlip pliers, Part No. 56664, remove and discard the
two circlips (64*) and the journal bearing (11*) from the
compressor end.

Turn the bearing housing over and repeat the process.

Component Disassembly and Assembly Cleaning
Page 21

Cleaning
With the turbocharger completely dismantled for overhaul, soak all the components in a non-caustic metal cleaner to
loosen deposits. Bead blast the turbine housing if chemicals do not clean sufficiently.
On aluminium parts a bristle brush can be used. Never use a wire brush or metal scraper on any turbocharger
component. Ensure that all the parts are finally cleaned with an air jet, especially drilled passages and machined
apertures.Turbine Wheel: In the event of carbon build-up, it may be necessary so carefully blast the Piston Ring
Groove area of the turbine wheel using low grade shot medium.
Caution: Shot Blasting specific areas for long periods of time may effect component balance.
The surface adjacent to the turbine and compressor wheels on the stationary housings must be clean, smooth and free
from deposits.

Inspection
Caution: Do not attempt to straighten the turbine
shaft.
a) Place the shaft on a vee block, using a dial gauge (a)
rotate the turbine wheel and check for movement on 10
-0+

10

the dial gauge. Replace the assembly turbine wheel if it 20

TYPE 20
20

is bent. 30
MERCER
30

40 40

50

Shaft Bend
mm in
0.025 Max [0.001]

Major Components
Assembly Turbine Wheel (6)
b) Inspect the piston ring groove walls for wear.
(d)
Turbine Wheel Piston Ring Groove
mm in (b)
1.664 MIN [0.0665]
(d)
c) Inspect the bearing journals for excessive scratches
and wear. Minor light scratches may be tolerated.

(c)
Assembly Turbine Wheel Journals
mm in
10.972 MIN [0.432]

d) Inspect for cracked, bent or damaged blades but

DO NOT ATTEMPT TO STRAIGHTEN BLADES.

Turbine Housing (5)

Inspect the profile for damage caused by possible contact
with the rotor. Check all threads for damage. Inspect the
outer and internal walls for cracks or flaking caused by
overheating also check mounting flanges for signs of
distortion.
Replace with new if any of the above are visible.
Inspection Component Disassembly and Assembly
Page 22
Compressor Housing (8)
Inspect the profile for damage due to possible contact with
the rotor. Also check the retaining ring groove area is free
from deposits.
Replace with new if any damage is visible.

Bearing Housing (4)

Inspect the bore for wear or score marks on both the
bearing and piston ring area. Also check all tapped holes
are clean and free from dirt.
Replace with new if any damage is found.

Bearing Housing Bore

mm in
15.885 MAX [0.6254]

Compressor Wheel (7)

Inspect carefully for cracked, bent or damaged blades but
DO NOT ATTEMPT TO STRAIGHTEN BLADES.
Replace with new if any damage is found.

Minor Components
Oil Slinger (31)
Inspect and replace if the piston ring seal groove walls are
scored or damaged. Also check for signs of rubbing on the
flat surfaces.

Groove Width
mm in
1.664 MAX [0.0665]
Component Disassembly and Assembly Inspection
Page 23
Diffuser (43)
Inspect the seal bore, replace if scored or damaged.
Check tapped holes and rectangular seal groove for
damage.

Heat Shield (38)

Check and replace if the heat shield is distorted or if signs
of rubbing or cracking are visible.

Assembly
Caution: Circlips (64). Premature failure will result if
the circlips are fitted incorrectly.
Make sure that the circlips are always fitted with the
bevelled edge facing the journal bearing.

Caution: Balance marks (See Page 14)

Always make sure that the balance marks on the
rotor assembly are in alignment when rebuilding the
turbocharger.
Make sure that both compressor wheel and
assembly turbine wheel are individually check
balanced.

Rotor Balance Limits

Turbine End Compressor End
gmm (oz. ins.) gmm (oz. ins.)
1.5gmm 1.5gmm
(.002) (.002)
Assembly Component Disassembly and Assembly
Page 24
Place the bearing housing (4) on a bench with the turbine
end facing uppermost.
Fit the inner circlip (64) with the bevelled edge facing
upwards.

Lubricate the journal bearing (11) and install into position.

Fit the outer circlip (64) with the bevelled edge facing the
bearing.
Turn the bearing housing over and repeat the process.

Install the heat shield (38).

Component Disassembly and Assembly Assembly
Page 25
Install the new piston ring seal (13) to the assembly turbine
wheel (6).

Caution: Align the piston ring seal (13) so the gap is

positioned 180˚ from the oil drain hole. Gently press
down on the turbine wheel - a slight rotation of the
wheel will assist in properly locating the piston ring
seal.
Lubricate the shaft using clean engine oil.

Support the assembly turbine wheel (6) in a suitable fixture.

Caution: Align the balance mark on the thrust collar

with that on the shaft. (Old models only)
Install the thrust collar (36).
Assembly Component Disassembly and Assembly
Page 26
T20 TORX®
Using clean engine oil, lubricate the thrust bearing (12).
Install the thrust bearing.
Install the 3 flat head screws (58).
Using torque wrench part number 3503071 tighten to
required torque.
Torque value: 4.5 Nm [40 in-lbs].

Fit the new piston ring seal (16) to the oil slinger (31).

Using clean engine oil, lubricate the oil slinger (31) and
install into the diffuser (43).

Install the oil baffle (33) into the bearing housing (4).
Component Disassembly and Assembly Assembly
Page 27
Apply a small amount of engine oil to the diffuser (43) and
place the rectangular ring seal (32) into position.

Caution: Align the balance marks on the oil slinger

(31) with that on the shaft end.
Install the diffuser (43) into the bearing housing (4).
Take care not to trap the rectangular seal (32)

Caution: (See Page 14)

Align the balance marks and install the compressor wheel (7).

Caution: (See Page 14) Ensure that the balance

marks are aligned on the compressor wheel and the
shaft.
13mm
Note: Left hand thread.
Install the compressor wheel locknut (61) and tighten to the
torque value.
Old Lock Nut Part Number 3503562
Torque value: 17Nm [150lb ins].
New Lock Nut Part Number 3590306
Torque value: 16Nm [142lb ins].
(or shaft stretch of .0006” - .0012”)
Assembly Component Disassembly and Assembly
Page 28
Using the compressor cover (8) for support, install and
tighten the four diffuser screws (56)

Tighten to required torque.

Torque Value: 8.5 Nm [75 in-lbs].

Caution: Make sure the scribe marks are aligned.

Locate the C.H.R.A. into the turbine housing (5).

Caution: Make sure the scribe marks are aligned.

13mm
Install the two clamp plates (88) and tighten the four bolts
(57) to the torque value.
Torque Value: Locknut (62) - 8.5 Nm [75 in-lbs]
Bolts (57) - 20.3 Nm [180 in-lbs]

Secure the turbine housing and check the thrust clearance

20
10
-0+
10

TYPE 20
20
using a dial gauge.
30 30
MERCER

40 40
50

Thrust Clearance
mm in
0.038 MIN [.0015]
0.093 MAX [.0037]
Component Disassembly and Assembly Assembly
Page 29
Check the radial clearance using a dial gauge.

30

20

10
40

MERCER

-0+
50
Radial Clearance

TYPE 20
40

10
30

20
mm in
0.329 MIN [.013]
0.501 MAX [.020]

Caution: Make sure the scribe marks are aligned.

If applicable, lubricate and install the O ring seal (41).
Carefully install the compressor cover (8).
Install the two clamp plates (51) eight lockwashers (54) and
tighten the eight bolts (59) to the torque value.
Install the V-band clamp (29) and tighten the locknut (62) to
the torque value.
Torque Value: Locknut (62) - 8.5 Nm [75 in-lbs]
Bolts (57) - 20.3 Nm [180 in-lbs]
Installation Data Component Disassembly and Assembly
Page 30
Installation Data
1. Mount the turbocharger on the turbine inlet flange. All other connections must be flexible and heavy pipework
should be supported. Always pre-lube with clean engine oil.
2. Always position the bearing housing so that the oil drain is at the bottom and kept within 22˚ of the vertical centre
line when installed on the engine.
3. Oil should be filtered below 15/20 microns. The oil quality must be as specified by the engine manufacturer.
e.g. API - CD (MIL - L - 2104C). Improvement in life can be obtained by using super high performance diesel
(SPHD) oils, particularly where extended oil drain periods are used.
4. Oil pressure must show at the turbocharger oil inlet within 3 - 4 seconds of engine firing to prevent damage to
turbocharger bearing system from lack of lubrication.
5. The minimum oil pressure, when the engine is on load must be 210 kPa [2.0 kgf/cm2, 30 lbf/in2] and pressures up
to 415 kPa [4.0 kgf/cm2, 60 lb/in2] are satisfactory. Under idling conditions the pressure should not fall below 70 kPa
[0.7 kgf/cm2. 10lbf/in2].
6. The oil inlet pipe should be 9.5 mm [0.375 in.] bore minimum and the oil drain pipe should be 19 mm [0.75 in.] bore
minimum. The oil must drain downwards by gravity from the turbocharger into the engine under all operating
conditions.
7. Air cleaner pressure drop should not exceed 500 mm [20 in.] of water. Avoid damp/wet air conditions in filter as this
can dramatically increase pressure drop on a temporary basis.
8. The exhaust back pressure after the turbocharger should not exceed 500 mm [20 in.] of water. Consult Holset
where high restrictions are expected, particularly when exhaust brakes are to be used.
Component Disassembly and Assembly Installation Checklist
Page 31
Installation Checklist
1. Always understand why the original turbocharger needs replacing before fitting another unit.
2. Check the turbocharger dataplate to ensure the Part No. is correct for the engine/application.
3. Check the engine intake and exhaust systems are clean and without obstruction ie. free from oil, gasket pieces,
dust/dirt/carbon or foreign objects.
4. Replace the oil and air filters using those only recommended by the equipment manufacturer.
5. Change the engine oil using the type specified by the engine manufacturer. A minimum of CD oil is needed for the
turbocharger diesel engine.
6. Check that the turbocharger oil inlet and drain connections are clean and free from obstruction and will not leak
under pressure.
7. Mount the turbocharger on the exhaust flange and check that the turbine inlet gasket fits properly without
obstructing the gas passages.
8. Rotate the turbocharger central bearing housing (4) so that the oil inlet and drain are in the vertical position. Up to
22 Degrees from vertical is permitted.
9. Pour some clean engine oil into the turbocharger oil inlet hole and twist the turbocharger rotor assembly until clean
oil starts to flow out of the oil drain flange.
10. Rotate the compressor housing (8) into the correct position and assemble the air intake and boost outlet
connections. Check that the connections are well made and do not have a possibility of leaking under pressure.
11. Assemble the exhaust system to the turbine housing outlet (5). Check that the gasket/connection is well made and
will not leak in use.
12. Check the exhaust system is well supported and not causing excess loads on the turbocharger. Fit any
supports/brackets back in position.
13. Check all hose/pipe clamps/studs/nuts are correctly torqued.
14. Carefully assemble the turbocharger oil inlet pipe and check that the connection is clean, well made and will not
leak under pressure.
Do NOT use liquid gasket substances as any excess will enter the turbocharger oil system and obstruct oil flow
damaging the turbocharger bearing system in use.
15. Crank the engine WITHOUT firing (engine/fuel pump stop out) until engine oil flows out of the turbocharger drain flange.
16. Assemble the oil drain pipe and check that the connection is well made without obstruction.
17. Check that the engine fuel injection system is correctly regulated as per the manufacturers specifications.
18. Start the engine and leave ticking over at idle for approx. 1 minute so that the oil supply system is fully operational
including the new filter(s).
19. Accelerate the engine and check that there are no leaks/obstructions of the air/oil/gas under pressure.
20. Check that the hoses/connections do not deform under normal operation.
21. Before switching off the engine, leave it ticking over at idle for at least 1 minute to cool the turbine.