HC5A

HC5A/HX80/82/83/85
turbochargers HT4B/4C/80
Service Repair Manual
Ref. JV/PF Effect Date: 10:01
Copyright® 2001 Part No. 4029600 Rev. 00

Holset Engineering Co. Ltd. Effect date 10.01
All rights reserved
HC5A/HX80/82/83/85/HT4B/4C/80 Service Repair Manual Foreword
Foreword
This publication was written to assist with installation, maintenance and overhaul of the Holset HC5A/HX80/
82/83/85/HT4B/4C/HT80 turbochargers. It is not a warranty of any kind expressed or implied.
The specifications and procedures in this manual are based on information in effect at the time of publication.
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 Holset approved agent.
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.
HC5A/HX80/82/83/85/HT4B/4C/80 Service Repair Manual Table of Contents
Table of Contents
1: Introduction
About the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1
How to Use the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1
How to Order Holset Original Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:1
Description and Operation of Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2
Introduction to Turbocharger Matching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2
Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:3
Installation Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:4
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:5
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:6
2: Component Identification
Turbocharger Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:1
Dataplate and CHRA (Core) of Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . 2:1
Installation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:2
Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:4
Component List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:8
Purchasable Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:9
3: Troubleshooting and Diagnosis

Fault Finding Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:1
4: Component Testing and Replacement

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:1
On Engine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:2
Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:5
Turbine and Compressor Housings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:6
Cleaning of Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:12
5: Turbocharger Service and Overhaul

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:2
Component Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:7
Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:9
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:14
6: Service Data Sheets

HX Range Service Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6:1
HC5A/HX80/82/83/85/HT4B/4C/80 Service Repair Manual Introduction
About the Manual

The procedures in this manual were developed to instruct in the correct overhaul of the Holset HC5A/HX80/
82/83/85/HT4B/4C/80 turbochargers for optimum performance and minimum maintenance operation.
How to Use the Manual

The manual is split into sections designed to provide service information in a logical sequence. The manual
contains links to help the user navigate between relevant sections. Users who are unfamilier with navigating in
PDF documents are refered to Navigating in PDF documents in the Adobe® Acrobat® Reader™ help file.
Contents is an interactive page with links to all the sections. It can be accessed from any page
in the manual by clicking this icon.
Section 1 defines the layout of the manual, introduces the reader to the operation of the turbocharger
and presents important installation guidelines.
Sections 2, 3 and 4 concentrate on Turbocharger Component Identification, Troubleshooting and

Diagnosis, Component Testing and Replacement.
Section 5 identifies the Service and Overhaul procedures to be followed in the unlikley event of a
major turbocharger malfunction.
Section 6 quantifies build data to ensure the turbocharger will continue to operate to Holset Service
standard on completion of overhaul.
Manual sections 1 to 5 where applicable, appear as a self extracting compressed file which is organised
according to the steps needed to most easily and correctly maintain the operation of the turbocharger. Users
are required to download this file to hard disk. Section 6 has its own file identity and resides at
www.holset.co.uk. so that Holset can update the Service Data as changes occur. The links between manual
and service data are active only when the user is connected to the Internet.
Chapter 6 has an expiry date to encourage users to discard outdated saved or printed versions and always
access the latest information available at www.holset.co.uk.
When using the manual on-line this icon will link to Holset’s website to help find your nearest agent
for advice and how to order Holset original parts.
How to Order Holset Original Parts

To make sure of optimum performance, certain items must be discarded during disassembly and replaced with
*
new for re-assembly. These items are indicated in the Service and Overhaul section with the use of a symbol.
All items showing a *are available in a basic overhaul kit.
To get the correct parts for your turbocharger, refer to the ‘component identification’ section of this manual to
help you find the following information:
1) Refer to the exploded view and component list to define the major components to be replaced.
2) Refer to the turbocharger’s dataplate which will be found on the compressor cover or wastegate
actuator to define the identifying information about your turbocharger build standard.
3) Contact your local Holset agent with componant identification nos. and dataplate assembly no., serial
no. and turbocharger type.
4) With this information, your local agent can provide you with the optimum kit of parts for re-assembling
your turbocharger for continued long life operation.
1:1
Description and Operation of Turbocharger

General Information
A turbocharger is a mechanical device which uses the engine’s exhaust gases to force more air into the engine
cylinders. Hot exhaust gas energy is used to turn a turbine wheel and shaft. 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.
Introduction to Turbocharger Matching

The need for optimised matching over the engine speed range
A standard turbocharger can be perfectly matched to only one particular engine condition, eg maximum torque
speed or maximum load speed. At this engine speed, the turbocharger supplies the optimum mass of air to
give the required air/fuel ratio. At other speeds the air/fuel ratio cannot be held at the optimum hence fuel
consumption and emission levels worsen.
Engine emission legislations have forced manufacturers to improve their engine efficiencies, particularly at low
speeds where low air/fuel ratios cause high smoke levels.
The Holset turbocharger is carefully matched to meet the required engine characteristics during application
engineering. It is important that this match is maintained by using only Holset original turbine and compressor
parts.
The importance of correctly servicing the turbocharger

A turbocharger requires accurate assembly at point of manufacture. It is very important to adhere to setting
limits when servicing the turbocharger, as failure to do so could result in turbocharger or engine failure.
Effects of wrong match

Possible consequences if turbocharger boost pressure is too low:-
• Engine runs fuel rich • Fuel consumption increase
• Exhaust temperature increase • Smoke levels increase
• Hydrocarbon levels increase • Risks of failing emissions tests
• High cylinder temperature risks
damage to engine pistons
Possible consequences if turbocharger boost pressure is too high:-

• Engine runs fuel weak (lean) • Nitrous oxide levels increase
• Excessive boost overspeeds • Turbocharger bearing failure and
turbocharger wheel fatigue problems
• Increased cylinder pressure risks damage • Intercooler load increases causing engine
to engine head gasket, pistons and valves to overheat, risking piston damage
1:2
Notes, Cautions and Warnings

Notes, Cautions and Warnings are used in this manual to emphasise important or critical instructions.
Note
Information which is essential to highlight.
Caution
Maintanence or Service procedures which if not strictly followed, will result in damage or destruction of the
turbocharger.
Warning
Maintanence or Service procedures which if not correctly followed will result in personal injury or loss of life.
Note
Holset turbochargers can be remanufactured using recovered parts. Where it is necessary to dispose of
components or whole turbochargers, an environmentally responsible process such as recycling should be
used, with due regard to local laws.
Note
Holset Service receives many turbocharger returns that are no fault found. Before assuming the turbocharger
is not performing to specification always refer to the engine diagnostic system and the troubleshooting
diagnostic procedures of this manual.
Warning
Turbocharger surface temperature during operation can achieve 700°C (1300°F). The HC5A/HX80/82/83/85/
HT4B/4C/80 turbochargers weigh up to 60 kg (132 lb) and turbine housing weight is greater than
20 kg (45 lb).
Caution
This turbocharger has been manufactured using piece part and rotor balance processes and MUST be check
balanced on rebuild.
If you intend to overhaul/repair a rotor balanced turbocharger, ensure that all the rotor parts have co-relation
marks prior to disassembly so that they can be reassembled in the same relative positions.
Balance limits for turbocharger rebuild are shown on Holset’s Service Data Sheet. with the exception of HX83
which requires a unique balancing process available through an approved Holset agent.
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 agent for assistance.
Warning
Some parts are manufactured in Viton that requires special treatment in the case of repair and service after
fire.
1:3
Installation Data
1. Holset Service receives many turbocharger returns that are no fault found. Before assuming the
turbocharger is not performing to specification always refer to the engine diagnostic system and the fault
finding chart of this manual to make all the recommended health checks.
2. It is important that intake and exhaust systems are fitted in accordance with the recommendations of
the Equipment and Engine manufacturers. Limiting mass inertia loading is critical to turbocharger wholelife
operation. Maximum engine vibration input must not exceed 10g.
3. The air filter must remove particles greater than 5µm at an efficiency of 95% and be of sufficient capacity
to match the air consumption of the engine. Recommended filters should always be used with a pressure
drop indicator. Intake systems must be capable of withstanding depressions up to 6.9 kPa (1.0 lbf/in2).
4. Hose and clip connections of intake manifold systems must be capable of withstanding the turbocharger
pressure ratio. V band clamps are preferred and must be used above 3:1 pressure ratio.
5. Exhaust systems must be capable of operating at exhaust back pressures of up to 10 kPa (1.5 lbf/in2).
This limit is increased to 13.4 kPa (2.0 lbf/in2) if a catalytic converter is fitted. Exhaust brake applications
are permitted to impose 450 kPa (65.3 lbf/in2) back pressure.
6. Oil should be filtered to 10µm with efficiency of 60% TWA (Time Weighted Average) /20 µm with efficiency
of 85% TWA. Efficiency assessed using ISO Standard 4572/SAE J 1858.
7. The oil quality must be as specified by the engine manufacturer and will be a minimum API SE - CD
(MIL - L - 2104C) specification. Improved life can be obtained by using super high performance diesel
(SHPD) oils, particularly in industrial applications which use extended oil drain periods.
8. Normal oil temperature is 95+/-5°C (203+/-9° F). It should not exceed 120°C (248° F) under any operating
condition.
9. Any pre-lube oil must be clean and meet the minimum CD classification.
10. The orientation of turbine housing, bearing housing and compressor cover is fixed according to
application. During installation, do not attempt to rotate these components. Inclined turbocharger
installation is not recommended. If an installed angle is necessary, oil inlet centreline must be +/- 10
degrees from vertical and rotor centreline +/- 5 degrees from horizontal.
11. Holset permits oil return pipes to decline at an overall angle of not less than 30 degrees below horizontal.
All turbocharger applications require a pipe of internal diameter greater than 25 mm which has integrated
connectors. To ensure oil returns into the engine under all operating conditions, the return connection
into the engine sump must not be submerged and the outlet flange of the turbocharger must be 50 mm
above the maximum oil level of the engine sump pan. Crankcase pressure should be limited ideally to 0.8
kPa (0.12 lbf/in2) but 1.4 kPa (0.20 lbf/in2) can be accepted by reference to Holset.
12. Oil pressure of 150 kPa (20 lbf/in2) must show at the oil inlet within 3 - 4 seconds of engine firing to
prevent damage to turbocharger bearing system. A flexible supply pipe is recommended. Recommended
oil pressure at full load/ rated speed is 300 kPa (44 lbf/in2) although 600 kPa (88 lbf/in2) is permitted
during cold start up. Under idling conditions pressure should not fall below 70 kPa (10 lbf/in2).
14. Recommended oil flows for the turbochargers are 3.5 litre/min at idle and 5 - 6 litre/min above maximum
torque speed.
15. Do not use liquid gasket substances or thread sealant as any excess can enter the turbocharger oil
system to obstruct flow.
16. Recommended coolant flows for the turbochargers are 6 litre/min at idle and 13 - 19 litre/min above
maximum torque speed.
Note:
100 kPa = 1 bar (14.5037 lbf/in2 =psi).
1:4
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 exhaust, intake and aftercooler systems are clean and without obstruction i.e. free from
oil, gasket pieces, dust/dirt/carbon or foreign objects.
4. Replace the oil and air filters using replacement parts specified by the equipment manufacturer.
5. Change the engine oil using the type specified by the engine manufacturer.
6. Check that the turbocharger oil inlet and drain pipes and connectors are clean, free from obstruction and
will not leak under pressure.
7. Check that the coolant pipes of water cooled bearing housing applications and connectors are clean, free
from obstruction and will not leak under pressure.
8. To pre-lube the turbocharger bearings, pour some clean engine oil into the oil inlet and rotate the
turbocharger rotor assembly by hand.
9. Check that the exhaust manifold flange is flat and undamaged. Mount the turbocharger on the flange and
check that the turbine inlet gasket fits properly without obstructing the gas passages.
10. Assemble the air intake and boost outlet connections. Check that the connections are well made and will
not leak in use.
11. Check the exhaust system is fitted using the original mounting arrangement provided by the equipment
manufacturer. Always re-fit any supports/brackets back in position to ensure the system is correctly
supported.
12. Assemble the exhaust system to the turbine housing outlet. Check that the gasket/connection is well made
and will not leak in use.
13. Assemble any coolant pipes and check that the connections are well made, without obstruction and will
not leak in use.
14. Assemble the turbocharger oil inlet pipe and check that the connection is clean, well made and will not
leak in use.
15. Check all clamps and fasteners are correctly tightened to the torque recommended by the equipment
manufacturer.
16. Make any ECU checks recommended by the engine manufacturer.
17. Crank the engine WITHOUT firing until engine oil flows out of the turbocharger drain flange.
18. Assemble the oil drain pipe and check that the connection is well made, without obstruction and will not
leak in use.
19. Start the engine and run at idle speed for approximately 1 minute so that the oil supply system is fully
operational.
20. Accelerate the engine and check that there are no leaks/obstructions of air/oil/coolant/gas under pressure.
21. Check that no hose or connection deforms under normal operation.
22. Before switching off the engine, leave it running at idle speed for at least 1 minute to cool the turbine.
1:5
Symbols
Symbole - Deutsch
In diesem Handbuch werden die folgenden Symbole verwendet, die wesentliche Funktionen hervorheben. Die
Symbole haben folgende Bedeutung:
WARNUNG - Unterhaltungs und Wartungsverfahren müssen genau befolgt werden, da ein
Nichtbeachten zu Personenschäden oder tödlichen Verletzungen führt.
ACHTUNG - Falls Unterhaltungs und Wartungsverfahren nicht genau beachtet werden, kann der
Turbolader dadurch beschädigt oder zerstört werden.
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.
Deutet an, daß Teile schwer sein können.

KG
Website-Verzeichnis mit Ihrem nächsten Holset-Händler.
Gehe zu Inhalt
1:6
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.
Indicates components may be heavy.

KG
Website access to find your nearest Holset Agent.
Go to contents
1:7
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 – Procedimientos de Mantenimiento o Servicio que al no seguirse resultarán en
daños personales o pérdida de vida.
ATENCION – Procedimientos de Mantenimiento o Servicio que al no seguirse al pie de la letra,
resultarán en el daño o la destrucción del turbosobrealimentador.
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 mec·nica o del tiempo.
LUBRIQUESE la pieza o el montaje.
Indica que se dar· una LLAVE DE TUERCAS o el TAMA—O DE HERRAMIENTA.
APRIETESE hasta un par torsor especifico.
Ceriórese de que est·n 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.
KG
Indica que los componentes pueden ser pesados.
Acceso a Sitio Web para localizar su agente Holset más cercano.
Ir a la tabla de materias
1:8
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:
ATTENTION DANGER - Procédures de maintenance ou d’entretien qui, si elles ne pas observées
correctement, auront pour résultat des lésions corporelles ou un décès.
MISE EN GARDE - Procédures de maintenance ou d’entretien qui, si elles ne sont pas observées
strictement, auront pour résultat de causer des dégâts au turbocompresseur ou de conduire à sa
destruction.
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 repères 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.
KG Indique que les composants peuvent être lourds.
Accès au site Web pour trouver l’agent Holset le plus proche.
Aller au sommaire
1:9
Símbolos - Português
Os símbolos a seguir serão utilizados neste manual para facilitar a comunicação das instruções e seue
significados estão déscritos abaixo.
ATENÇÃO - Os procedimentos de Manutenção ou Serviços que não forem seguidos correctamente
resultarão em ferimentos pessoais ou riscos de vida.
AVISO - Os procedimentos de Manutenção ou Serviço que não forem rigorosamente seguidos
resultarão em danos ou destruição do carregador turbo.
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)
Indica que os componentes podem estar pesados.

KG
Visite o Website para encontrar o seu Agente Holset mais perto.
Vá para Conteúdo
1:10
HC5A/HX80/82/83/85/HT4B/4C/80 Service Repair Manual Component Identification
Turbocharger Identification
Dataplate
XXXXXXX
PYYMMXXXXX
Note
Dataplates will be fitted to the compressor housing
(8). The information from the dataplate must be
quoted for service and parts support.
Center Housing Rotating Assembly (CHRA) (2)
2:1
Installation Options
Type A
Type B
Type C
2:2
Installation Options
Type D
Type E HT4B/HT4C/HT80
2:3
Exploded View - HC5A/HX80/82/85

14
7
29
62
60
61
11
56 114
4
8
57 50
64
11
92 36 64
12
33 53
64
64
31
16 92
146
32
27
6
13 5
71
38
Cast iron
Note
Cast iron and Stainless steel heat shield options are not interchangeable.
Exploded views represent a generic build standard. Parts may be added or subtracted in specific applications.
2:4
Exploded View - HX83 HPRC

(High Presure Ratio Compressor) unique components
29
62
Note
Compressor housing, wheel, diffuser and V-band are manufactured utilising special materials.
2:5
Exploded View - HT4B/HT80 unique components
38 61
12
28
62
5
6
13
71
Note
HT4B/HT4C/HT80 rotate in the opposite direction to HC/HX type turbochargers. Do not mix the turbine or
compressor wheels of HC/HX and HT turbochargers. Exploded views represent a generic build standard.
Parts may be added or subtracted in specific applications.
2:6
Exploded View - Optional Parts
34
22
71
Note
2:7
Component List - HC5A/HX80/82/83/85/HT4B/4C/80

Item No. Description Quantity
1 Repair Kit CHRA (Core)* 1
2 CHRA (Core) 1
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 Split Ring Seal, Turbine* 1/2
14 Diffuser 1
16 Split Ring Seal, Compressor* 1
22 Retaining Ring, Inlet Baffle 0/1
27 O-Ring Seal 0/1
28 V-band Clamp, Turbine 0/1
29 V-band Clamp, Compressor 1
31 Oil Slinger 1
32 O-Ring Seal, Bearing Housing* 1
33 Oil Baffle* 1
34 Inlet Baffle 0/1
36 Thrust Collar 1
38 Heat Shield 1
50 Lockplate, Turbine Housing* 4
53 Gasket, Oil Outlet* 1
56 Screw, Diffuser 4
57 Bolt, Turbine Housing* 8
60 Plain Washer 4
61 Locknut, Compressor Wheel 1
62 Locknut, V-band* 2
64 Retaining Ring, Bearing* 4
71 Gasket, Turbine Housing 1
92 Roll Pin 2
103 Blanking Plug 0/2
105 Connector Male, Water 0/2
114 O-Ring Seal, Oil Inlet 1
115 O-Ring Seal, Water 0/4
146 Shim 1
Note
Exploded views may not contain all listed components.
2:8
Purchaseable Service Tools

Service Tools
The following special tools can be purchased from your local Authorised Repair Location. The use of these
tools is recommended and where necessary they are shown in the appropriate service procedure.
Part No. Tool Description Tool Illustration
3575186 Circlip Pliers
4027202 Wastegate Air Feed Adapter
4027203 Wastegate Air Feed Adapter
4027204 E-Clip Tool
Caution
All Service and Maintenance settings are shown in Holset’s Service Data Sheet. It is essential that these
settings are used. Common tools found in mechanic’s tool box not included.
2:9
HC5A/HX80/82/83/85/HT4B/4C/80 Service Repair Manual Troubleshooting and Diagnosis
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 Running Hot
Engine Lacks Power
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
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
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
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
3:1
HC5A/HX80/82/83/85/HT4B/4C/80 Service Repair Manual Component Testing and Replacement
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.
Torque Wrench
Dial Gauge and Dial Gauge Adaptor -0+

10 10
TYPE 20
20 20
30 30
MERCER
40 40
50
Caution
4:1
On Engine Checks
Oil Leakage
Oil Adapter M16 x 1.5 or 9/16 18 UNF 28 tpi
Warning
The oil inlet is pressurised and no service action
should be taken with the engine running.
Replacement gaskets, seals and adapters should be

fitted without sealant as this can contaminate the oil.
Torque tighten adapter to value shown in
Service Data Sheet.
It is important to avoid kinked pipes during servicing
and subsequent operation.
Oil Flanges M10 x 1.5 or 3/8-16 UNC 28 tpi
Warning
Outlet oil is hot and no service action should be taken
with the engine running.
Replacement gaskets and flange fasteners should be

fitted without sealant as this can contaminate the oil.
Torque tighten fasteners to value specified by engine
manufacturer.
All outlet pipes should be free flowing without kinks and
sharp bends and decline at an overall angle not less
than 30° below the horizontal.
Warning
Turbochargers and installation parts are heavy. KG
Always use safe lifting methods.
Closed crankcase ventilation systems have a tendency

to deposit oil in the compressor housing. Where
practical remove intake system pipework every 2000
hours to check housing, compressor wheel and inlet
baffle condition.
Always refer to Cleaning of Housings to clean

housing. Rotor components can be cleaned using a non
metallic bristle brush.
Warning
Always wear safety glasses during cleaning.
Warning
HX83 titanium compressor wheel edges are sharp.
Handle with care.
4:2
Gas Leakage
Turbine housing flange leakage will cause soot
formation on the flange. Check exhaust manifold to
flange gasket seal ensuring fastener torque meets
engine manufacturer’s recommendation.
Check flange for cracks.
Check Marmon and half Marmon connections (turbine
outlet to exhaust system) for fretting damage. Where
turbine housing damage is visible refer to
Turbine and Compressor Housings for disassembly
and reassembly instructions.
Warning
Turbochargers and installation parts are heavy.
KG
Coolant Leakage
Coolant Adapter M18 x 1.5 and 3/4 UNC 28 tpi
Repair by replacement of coolant inlet and outlet
fittings. Where housing threads are damaged replace
turbocharger. Torque tighten adapters to value specified
by engine manufacturerer.
Caution
Do not use sealant as this may affect performance of
o-ring seals.
Visual Checks
Check for cracked, bent or damaged compressor wheel
blades.
KG
Warning
Handle with care.
Where practical, check for cracked, bent or damaged

turbine wheel blades.
KG
Caution
Never attempt to straighten blades.
4:3
With intake system disconnected from compressor

housing, it may be possible to check visually for excess
bearing axial and radial clearances.
If in doubt, the turbocharger must be removed from KG
engine to check bearing clearance against
recommended values shown in Service Data Sheet.
Warning
Warning
Handle with care.
4:4
Bearing Clearance
Secure the turbine housing and check the axial
clearance using a dial gauge.
Ensure clearance is within MIN/MAX values shown on
Service Data Sheet. KG
If axial clearance does not meet specification refer to
turbocharger Service and Overhaul to strip and rebuild
the CHRA (core).
Warning
Warning
Handle with care.
Check the radial movement at compressor impeller KG

nose using a dial gauge.
Ensure movement is within MIN/MAX TIR (Total
Indicator Reading) values shown on
Service Data Sheet.
If radial movement does not meet specification refer to
turbocharger Service and Overhaul to strip and rebuild
the CHRA (core).
4:5
Turbine and Compressor Housings

Turbine Housing
Place turbine outlet on a clean flat surface. Mark turbine
housing, bearing housing and V-band clamp, turbine
(where fitted). This action assists in the re-assembly KG
process defining correct component orientation.
Warning
Turbine housings and CHRA assemblies are heavy.
V-band Option HT4B/HT4C/HT80

1/4 UNF 28 tpi (7/16 in)
Loosen locknut, V-band clamp (62) and discard.
KG
Lockplate Option HC5A/HX80/82/83/85

M8 x 1.25 (13 mm)
Secure turbine housing flange in vice. Use a hammer KG
and chisel to knock lockplate tabs away from turbine
housing bolts. Loosen remove and discard the 8 bolts
(57) and 4 lockplates, (50).
Caution
Take care not to shear the clamp plate bolts.
Seized bolts may be freed by spraying with penetrating

oil and soaking for twenty minutes or a period of time
recommended by the oil manufacturer.
Check bearing housing and compressor housing

assembly rotates freely in turbine housing. If not, gently
tap turbine housing with soft hammer. When assembly
comes loose, safely lift it out of turbine housing KG
engagement.
Caution
Turbine blades can be damaged easily when the
turbine housing is removed.
4:6
Warning
Always use safe lifting methods. KG
Caution
Where a crack will cause leakage to atmosphere the
turbine housing must be replaced.
Cracking of the internal wall at the entry to the turbine

wheel (tongue) is an acceptable service condition and
the turbine housing may be re-used.
Always clean the turbine housing before re-assembly
paying particular attention to surfaces close to the
turbine wheel and the bearing housing location.
Refer to Cleaning of Housings for details.
KG
Caution
Turbine housings can exhibit cracking when subject to
excessive thermal and mechanical loads.
Cracking of the turbine housing inlet flange and inlet

duct generally requires turbine housing replacement.
Acceptance and rejection guidelines are shown in these
illustrations. If an exhaust gasket is available, always
ensure that any cracks lie within its sealing area.
Check turbine housing inlet flange flatness is within
0.1 mm (0.004 in) before retaining component for re-
use.
KG
Flange Fasteners - Clearance Holes
Check fastener hole diameter is not more than 1.5 mm
larger than the max. thread diameter of the fastener.
To replace turbine housing secure housing in a vice.

Position V-band clamp (where fitted) over the bearing
housing.
Apply anti seize compound to bearing housing bore
location of the turbine housing.
Safely slide bearing and compressor housing assembly
KG
into turbine housing. Use ink alignment mark to locate
housing assembly in correct orientation with the turbine
housing.
Caution
The turbine blades can be easily damaged when
installing in the turbine housing.
4:7
Warning
Turbine housings and CHRA assemblies are heavy. KG

1/4 UNF 28 tpi (7/16 in)
Place V-band clamp in correct orientation and torque
tighten new locknut (62) to value specified in
Service Data Sheet.
Lockplate Option HC5A/HX80/82/83/85

M8 x 1.25 (13 mm)
KG
Secure turbine housing flange in vice.
Install the four new lockplates (50) and torque tighten
the eight bolts, turbine housing (57) to value specified in
Service Data Sheet.
Depending on housing orientation, some lockplate bolts
may have restricted access. In these cases, use a
suitable torque wrench adapter attached to a specially
calibrated torque wrench.
Use a hammer and drift to knock lockplate tabs into

position against the turbine housing bolts.
Warning KG

Handle with care.
4:8
Compressor Housing
Place compressor inlet on a clean flat surface. Mark
compressor housing, bearing housing and V-band
clamp to record correct orientation. This action assists KG
in housing orientation during re-assembly.
Warning
CHRA assemblies are heavy. Always use safe lifting
methods.
M8 (11 mm) HX83 only

1/4 UNF (7/16 in) KG
Secure the turbine housing (5) in a vice.

Loosen and remove the compressor housing V-band
locknut (62).
Warning
Handle with care.
KG
Use a soft hammer to gently tap the compressor
housing off the bearing housing.
Remove V-band clamp and retain.
Caution
Compressor blades can be damaged easily when the
compressor housing is removed.
Inspect internal profile of compressor housing for

scoring damage due to possible contact with
compressor wheel. Move to Cleaning of Housings
if deposits remain.
Replace with new if profile damage is visible.
To clean compressor housings fitted with an inlet baffle
move to Inlet Baffle Option.
4:9
Inlet Baffle Option HX82/83

A B
To clean compressor housings fitted with an inlet baffle
it is necessary to remove baffle.
Inlet baffle (A) is the old type; inlet baffle (B) is the new
type. Baffle (B) has been improved and no longer
incorporates the four stepped areas. This gives the new
baffle increased service life.
Caution
Always fit the new type of baffle (B) on re-assembly.
Warning
Always wear safety glasses when removing or C D
refitting retaining rings.
Using a flat screw driver, carefully apply force in the

area shown (C) as the retaining ring starts to move,
force the screwdriver under the ring as shown in (D).
Caution
When removing the inlet baffle retaining ring, be
careful not to damage the compressor wheel with the
screw driver. Use a rag or rubber bung to protect the
wheel.
Warning
Always wear safety glasses when removing or
Push the screwdriver in an anti-clockwise (counter-
clockwise) direction to force the retaining ring out of the
groove. Remove the retaining ring.
Remove the inlet baffle.
Warning
Following cleaning of the compressor housing, locate a
new type of inlet baffle onto the location ledge of the
compressor housing inlet.
4:10
Warning
Hold one end of the retaining ring in position in its
compressor cover groove. Press the remainder of the
retaining ring into position using free hand.
Use a flat screw driver to make sure the retaining ring is
correctly seated in the compressor cover groove.
Warning
Place the turbine and bearing housing assembly on a
clean surface. To refit compressor housing, loosely fit V-
KG
band clamp. Carefully locate the compressor housing
over the compressor wheel.
Caution
The compressor wheel blades can be easily damaged
when the compressor housing is installed.
Warning
Handle with care.

1/4 UNF 28 tpi (7/16 in)
Place V-band clamp in position and torque tighten new
locknut (62) to value specified in Service Data Sheet.
Ensure rotor assembly freely rotates.
Warning
Turbochargers and installation parts are heavy. KG
Warning
Handle with care.
4:11
Cleaning of Housings
Warning
Turbine housings are heavy. Always use safe lifting
methods. KG
Visually inspect the parts to detect signs of burning and

other conditions in order to obtain as much information
as possible before washing.
Caution
Housing surfaces adjacent to turbine and compressor
wheels must be clean, smooth and free from deposits.
Warning
KG
Soak the housings in a non-corrosive low flash point
metal cleaner to loosen deposits.
Dry the components using compressed air.
Warning
Always wear safety glasses during cleaning. KG
Scale like deposits, if any, must be removed by using a

non metallic bristle brush. After removing the deposits ,
re-wash and dry the components.
KG
Warning
4:12
Warning
methods. KG
It is permissible to bead blast turbine and cast iron

compressor housings if chemical and brush cleaning is
not effective.
Warning
Warning
Do not bead blast Aluminium and Cast Iron
components together.
Caution
Prevent the bead spray impinging directly on clamp
plate and turbine flange threads by masking or
plugging
After removing the deposits, re-wash and dry the
components.
4:13
HC5A/HX80/82/83/85/HT4B/4C/80 Service Repair Manual Turbocharger Service and Overhaul
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.
Torque Wrench
Dial Gauge and Dial Gauge Adaptor -0+

10 10
TYPE 20
20 20
30 30
MERCER
40 40
50
Caution
5:1
Disassembly
Note
Before disassembly, check for turbine and compressor
blade damage. Measure bearing radial movement and
axial clearance to ensure the CHRA (core) is within KG
the MIN/MAX values shown on Service Data Sheet.
Warning
Turbochargers and CHRA assemblies are heavy.
Warning
HX83 cores with titanium compressor wheels must not
be disassembled. Refer to Holset approved agent for
overhaul and repair.
Locate the CHRA (2) on to a 29 mm 6 point socket
located in a suitable fixture.
Caution
Always make sure the assembly, turbine wheel and
compressor wheel have alignment marks before
disassembly of the CHRA.
If no marks exist scribe the shaft and compressor wheel
before removing the compressor wheel lock nut. The
washing process may remove indelible ink so a file
mark on the shaft and scribe line on the compressor
wheel nose is recommended.
HC5A/HX80/85 v HT4B/HT4C/HT80 Wheels

M10 (17 mm)
Note
HC5A/HX80/85 - Left hand thread.
HT4B/HT80 - Right hand thread.
Remove the locknut, compressor wheel (61).
Caution HC5A/HX80/82/85 HT4B/HT4C/HT80

Do not mix the turbine or compressor wheels of
HC/HX and HT series of turbochargers
Remove compressor wheel (7).
Warning
5:2
Warning
methods. KG
Remove remaining CHRA from fixture and gently slide

bearing housing (4) off the assembly, turbine wheel (6).
It is permissible to tap the protruding turbine shaft
gently with a soft hammer if the split ring seal/s are
stuck in their bore.
Carefully remove split ring seal, turbine (13)

discard.
* and
Warning
Always wear safety glasses when removing sealing
rings.
Caution
Care should be taken not to score the turbine wheel
shaft assembly.
Note
HT4B/HT4C/HT80 turbochargers are fitted with twin
split ring seals
Remove heat shield (38)
KG
Warning
8 mm x 1.25 (13 mm)

KG
Secure the bearing housing in a vice using soft jaws.
Remove and discard the four diffuser patch screws
(56 )
* and the four diffuser washers (60).
Note
Diffuser patch screws may be tight. Apply a small HC5A/HX80/82/85 HX83
amount of penetrating oil to help free. HT4B/HT80
5:3
Warning
methods. KG
Carefully remove the diffuser (17).
Remove the oil slinger (31).
Carefully remove and discard the piston ring seal

*
(16) .
Warning
Always wear safety glasses when removing sealing
rings.
Remove and discard the oil baffle (33) *.

Where core is fitted with water cooled bearing housing,
*
it is necessary to remove o-ring seal (27) at this
stage.
5:4
Remove the shim (146) * and discard.
Remove the thrust bearing (12) * and discard.
Remove the thrust collar (36) and remove and discard

*
the o-ring seal (32) .
Warning
Always wear safety glasses when removing retaining
rings.
Using circlip pliers, Part No. 56664, remove and discard
*
the two circlips (64) and the journal bearing (11)
from the compressor end.
*
5:5
Warning
Always wear safety glasses when removing retaining
rings.
Turn the bearing housing over and repeat the process

of bearing removal at turbine end.
Inlet Baffle Option HX82/83

Where specified by the engine manufacturer, certain
turbochargers can have a pressed steel baffle fitted into
the inlet section.
This item is not serviceable and if damaged, must be
replaced, as the geometry of the part is critical to the
performance of the baffle.
To clean compressor housings always remove inlet
baffle.
Refer to Turbine and Compressor Housings for
removal instructions.
Warning
5:6
Component Cleaning
Warning
methods. KG
Visually inspect all parts to detect signs of burning and
other fault conditions in order to obtain as much
information as possible before washing.
Soak the components in a non-corrosive low flash point

metal cleaner to loosen deposits.
Warning KG
Dry the components using compressed air.

Protect the sliding surfaces of the cleaned parts against
corrosion by applying clean engine oil.
KG
Warning
M6 x 1.25
Scale like deposits, if any, must be removed by using a
non metallic bristle brush. After loosening the deposits
with the brush, wash and dry components as above. KG
Warning
5:7
Warning
methods. KG
Flange M10 x 1.5 - Clamp Plate M8 x 1.25
Warning
Do not bead blast Aluminium and Cast Iron
components together.
It is permissible to bead blast turbine and cast iron
compressor housings if chemical and brush cleaning is
not effective.
Caution
Housing surfaces adjacent to turbine and compressor
wheels must be clean, smooth and free from deposits.
Always protect threads during bead blasting and
clean with the specified thread tap after blasting.
Warning
Caution
Do not bead blast Aluminium compressor housing as
this may damage critical surfaces.
Oil fittings M16 x 1.5 - M10 x 1.5

Coolant fittings M18 x 1.5
It is important that the oil chamber of the bearing
housing is free of carbon before re-building. If heavy
deposits persist after repeat washing replace bearing
housing (4).
Caution
Do not bead blast the bearing housing as this may
damage critical bearing surfaces.
It is permissible to bead blast steel rotating parts.
Caution
Blasting specific areas for long periods of time may
affect component balance. Protect thread of turbine
wheel assembly.
Caution
Always clean components with compressed air after
blasting.
5:8
Inspection and Testing

Major Components
Assembly Turbine Wheel 10
-0+
10
TYPE 20
Place assembly, turbine wheel (6) on a vee block.

20 20
Position a dial gauge on the turned surface of the shaft 30
40
MERCER
40
30
at the threaded end. Check dial gauge reading. Where 50
shaft bend is greater than the recommended maximum

of 0.015 mm (0.0006 in) replace the assembly.
Caution
Do not attempt to straighten the turbine shaft.
*
Inspect split ring seal, turbine (13) groove walls for
wear. If groove width exceeds recommended maximum
of 1.70 mm (0.067 in) replace assembly.
If the wear step on the ring face exceeds 0.102 mm
(0.004 in) replace split ring seal, turbine.
If the free gap of the ring is less than 2.0 mm (0.08 in)
replace split ring seal, turbine.
Note
HT4B/HT4C/HT80 turbochargers have twin rings of
the same dimensions as the single ring variants.
Inspect the bearing journals for excessive scratches

and wear. Where scratching is excessive or where
either journal diameter is less than the recommended
minimum of 15.97 mm (0.629 in) replace the assembly.
Inspect for cracked, bent or damaged blades.
Caution
Never attempt to straighten blades.
Replace with new if any damage found.
5:9
Compressor Wheel
Inspect compressor wheel (7), for cracked, bent or
damaged blades.
Caution
Do not attempt to straighten blades.
Replace with new if any damage found.
Caution
Compressor Housing
Inspect internal profile of compressor housing (8), for
scoring damage due to possible contact with
compressor wheel.
Return to Component Cleaning if deposits remain.
Replace with new if profile damage is visible.
Caution
Cast Iron and aluminium compressor housings are
used. Always ensure correct replacement part is
fitted.
Turbine Housing
Inspect the turbine housing (5) profile for damage
caused by possible contact with the rotor. Inspect the
outer and internal walls for cracks or flaking caused by
overheating. KG
Check turbine housing inlet flange flatness is within
0.1 mm (0.004 in). Check fastener hole diameter is not
more than 1.5 mm larger than the max. thread diameter
of the fastener.
Replace with new if any of the above features are non
compliant.
Air and Liquid Cooled Bearing Housings

Oil Flanges M10 x 1.5 and 3/8-16 UNC 28 tpi
Oil Adapter M16 x 1.5 or 9/16 18 UNF 28 tpi
Inspect journal bearing bores for wear and score marks.
Replace bearing housing (4) if a bore diameter exceeds
a maximum of 28.02 mm (1.103 in) or when bore
scratching is severe.
Ensure groove locations for retaining rings, bearing (64)
are free from deposits and do not exceed width of
1.45 mm (0.057 in)
Check that the oil cavity is free from carbon and any
entrained debris that may be the result of a failure.
Ensure all oil port threads are clean then check with the
appropriate thread guage.
5:10
Liquid Cooled Bearing Housing

Coolant Adapter M18 x 1.5 and 3/4 UNC 28 tp
Ensure all coolant port threads are clean then check
with the appropriate thread gauge.
Caution
Bearing housing lockplate interface can corrode in
high temperature operation. Bearing housings
showing corrosion damage must be replaced.
Diffuser
Inspect diffuser (14) seal bore. Replace if scored or
damaged.
Small Components
Oil Slinger
Inspect and replace oil slinger (31) if the piston ring
groove walls are scored or damaged or if groove width
exceeds a maximum of 1.70 mm (0.067 in).
Check for signs of rubbing and scoring on the thrust
surface and replace where damage is severe.
If the ring faces show any signs of wear replace the
*
split ring seal/seals, compressor (16) .
If the free gap of the ring is less than 2.0 mm (0.08 in)
*
replace the split ring seal, compressor (16) .
Heat Shield
Check and replace if the heat shield (38) is distorted or
if signs of rubbing or cracking are visible.
Caution
Cast iron and stainless steel heat shields are not
interchangeable.
5:11
Cast Iron Heat Shield
Caution
interchangeable.
Cast Iron Heat Shield (with webs) 28.6mm

Heat Shield 28.5mm Bearing Housing
Stainless Steel Heat Shield
Caution
interchangeable.
Note
All liquid cooled bearing housings are fitted with
stainless steel heat shields.
Stainless Steel Heat Shield (without webs) 27.3mm

Heat Shield 27.2mm Bearing Housing
5:12
Thrust Collar
Check and replace if thrust collar (36) is scored on
thrust face or if any cracks are visible.
Compressor Inlet Baffle Option

Check baffle for debris entrainment damage. Always fit
new type inlet baffle on reassembly.
Refer to Turbine and Compressor Housings for
re-fitting instructions.
Warning
5:13
Reassembly
Rotor Balance
Caution
This turbocharger will have been manufactured using
the separately piece part balanced compressor wheel
and assembly, turbine wheel. Rotor balance MUST
always be checked on re-build.
A turbocharger should always have co-relation marks

on the end of the turbine shaft and impeller nose if it
has been disassembled according to the process
defined in Disassembly. The thrust collar and oil
slinger will not have co-relation marks.
Components that should be included in rotor balance

are:
• Turbine wheel and shaft
• Thrust collar
• Oil slinger
• Compressor wheel
• Nut
Balance is achieved by relative rotation of components
as indicated by the balance machine output.
The balance process requires a purpose built rig and Balance Flow Chart
compliance with the rig procedure. Load

Component
Rotate At
Balancing Speed
Re-load
Component
Hold
Steady Speed
Caution
Measure Out
Only use genuine Holset compressor wheels and Of Balance
assembly turbine wheels which are individually check Halt Clean
balanced for long life and quiet operation. Rotation Component
Display Balance Take Corrective

Data Action
Rotor balance limits appear in the Service Data Sheet. Corrective

Unload NO YES Unload
Component Action Required? Component
Caution
HX83 cores with titanium compressor wheels must
be core balanced using specialist equipment. Refer to
Holset approved agent for overhaul and repair.
On achieving balance, parts should be permanently

marked for subsequent re-alignment during reassembly.
5:14
Turbocharger Reassembly
Warning
Always wear safety glasses when refitting retaining
rings.
Caution
Make sure the circlips are always fitted with the
bevelled edge facing the journal bearing. Premature
failure may result from incorrect fitting.
Place bearing housing compressor mating face on a

clean surface.
Fit inner turbine end retaining ring, bearing (64)
circlip pliers Part No. 56664.
* using
Lubricate journal bearing (11)
and install.
* with clean engine oil
Fit outer retaining ring (64)

the bearing.
* with bevelled edge facing
Turn bearing housing over and repeat retaining ring
* *
(64) and journal bearing (11) installation process at
compressor end.
Install heat shield (38).
Caution
Ensure cast iron or pressed steel heat shields are
matched with correct bearing housings.
5:15
Warning
Always wear safety glasses when refitting sealing
rings.
Using expander pliers, install new split ring seal/seals,

*
turbine (13) to assembly turbine wheel.
Note
HT4B/HT4C/HT80 turbochargers have twin rings.
Caution
Align single split ring seal so that gap is positioned
180 degrees from oil drain flange. Align twin split ring
seals so the gaps are positioned 180 degrees apart.
Lubricate shaft with clean engine oil and insert into

journal bearings. Positively locate split ring seal/seals
*
(13) into position and ensure assembly, turbine wheel
rotates freely. Gently press down on turbine wheel.
A slight rotation of the wheel will assist in properly
locating the split ring seals.
Support the assembly turbine wheel (6) in a suitable

fixture.
Use clean pliers to pull two roll pins (92) out 3mm
(0.01 in) approximately. Roll pin end contact with
diffuser (14) ensures thrust bearing (12) and shim (146)
are properly located.
Caution
Do not use excessive force on the pliers as the roll
pins can collapse. If the roll pins collapse they must
be replaced.
Caution
Align balance mark on thrust collar with that on shaft.
Install thrust collar (36).
5:16
Using clean engine oil, lubricate thrust bearing (12) *.

Install thrust bearing.
Install a new shim (146) so that the letter “T” is facing
away from the thrust bearing.
Install oil baffle (33) *.
Lubricate and install o-ring seal, compressor (32) *.

Install o-ring seal (27) to liquid cooled bearing housings
at this stage.
Fit the new split ring seal, compressor (16)

slinger (31).
* to oil
Warning
Always wear safety glasses when refitting sealing
rings.
5:17
Using clean engine oil, lubricate slinger (31) and install

into diffuser (14).
Caution
Align balance marks on oil slinger with that on shaft
end.
Install diffuser (14) onto bearing housing (4).
8 mm x 1.25 (13 mm)

Install four new diffuser washers (60) and four new
screws, diffuser (56).
Tighten the diffuser screws in a diagonal pattern to the
value specified in the Service Data Sheet.
Note
Torque the diffuser screws twice in sequence to
ensure that all four are tightened equally.
Caution
Do not rotate the assembly as this can misalign
balanced components.
Align balance marks and install compressor wheel (7).
Caution
HX83 cores with titanium compressor wheels must
be core balanced using specialist equipment. Refer to
Holset approved agent for overhaul and repair.
5:18
Brush thread and clamp face of locknut, compressor

wheel (61) with an anti-seize compound to avoid loss of
alignment during torque tightening.
Caution
The impeller nut must be installed with the flat side
towards the compressor wheel.
HC5A/HX80/85 v HT4B/HT4C/HT80 Wheels

M10 (17 mm)
HC5A/HX80/85 HT4B/HT4C/HT80
Install the locknut, compressor wheel (61) and tighten
to the torque value specified in the
Service Data Sheet.
Caution
Do not mix the turbine or compressor wheels of
HC/HX and HT series of turbochargers
Note
HC5A/HX80/85 - Left hand thread.
HT4B/HT4C/HT80 - Right hand thread.
Place turbine housing (5) on a clean surface. Place V-

band clamp loosely into position on the turbine housing.
Safely slide CHRA (2) assembly into the turbine
housing.
KG
Warning
Caution
The turbine wheel blades can be easily damaged
when the CHRA is installed.
Lock Plate Option HC5A/HX80/82/83/85

M8 x 1.25 (13 mm)
Secure turbine housing flange in vice.
Locate the CHRA into the turbine housing (5).
*
Install four lock plates, turbine housing (50) , fit eight
*
new bolt, turbine housing (57) and tighten to the
value specified in the Service Data Sheet.
Depending on housing orientation, some clamp plate
bolts may have restricted access. In these cases, use a
suitable torque wrench adapter attached to a specially
calibrated torque wrench.
5:19

M6 (10 mm) 1/4UNF 28tpi (7/16 in)
Place V-band clamp, turbine (28) in position and torque
*
tighten new locknut, V-band (62) to value specified in
Service Data Sheet.
Check compressor end radial movement using a dial -0+
gauge. Ensure clearance lies within MIN/MAX TIR (Total

10 10
TYPE 20
20 20
30 30

MERCER
40 40
50
Service Data Sheet.

KG
Warning
Handle with care.
Warning
HX80 turbochargers and installation parts are heavy.
Check compressor end radial movement using a dial

gauge. Ensure clearance lies within MIN/MAX TIR (Total
30
20
10
40
Service Data Sheet.

MERCER
-0+
50
TYPE 20
KG
40
10
30
20
Use a hammer and drift to knock lockplate tabs into

position against the turbine housing bolts.
Warning KG
HX80 turbochargers and installation parts are heavy.
Warning
Handle with care.
5:20
Warning
KG
Place the turbine and bearing housing, assembly on
clean surface. To refit compressor housing loosely fit V-
band clamp, compressor (29). Carefully locate the
compressor housing (8) over the compressor wheel.
Caution
The compressor wheel blades can be easily damaged
when the CHRA is installed.

1/4 UNF 28 tpi (7/16 in)
Place V-band clamp, compressor (29) in position and
KG
*
torque tighten locknut, V-band (62) to value specified
in Service Data Sheet.
Warning
HX83 titanium compressor wheel edges are sharp. KG
Handle with care.
5:21

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HC5A/HX80/82/83/85

Ref. JV/PF Effect Date: 10:01

Copyright® 2001 Part No. 4029600 Rev. 00

3: Troubleshooting and Diagnosis

4: Component Testing and Replacement

5: Turbocharger Service and Overhaul

6: Service Data Sheets

About the Manual

How to Use the Manual

Sections 2, 3 and 4 concentrate on Turbocharger Component Identification, Troubleshooting and

How to Order Holset Original Parts

Description and Operation of Turbocharger

Introduction to Turbocharger Matching

The importance of correctly servicing the turbocharger

Effects of wrong match

Possible consequences if turbocharger boost pressure is too high:-

Notes, Cautions and Warnings

AUSBAU bzw. ZERLEGEN.

EINBAU bzw. ZUSAMMENBAU.

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.

Deutet an, daß Teile schwer sein können.

Website-Verzeichnis mit Ihrem nächsten Holset-Händler.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

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.

PERFORM an electrical MEASUREMENT.

Please wear protective clothing at all times.

Indicates components may be heavy.

Website access to find your nearest Holset Agent.

Indica un paso de REMOCION o DESMONTAJE.

Indica un paso de INSTALACION o MONTAJE.

LIMPIESE la pieza o el montaje.

Ejecutese una MEDICION mec·nica o del tiempo.

LUBRIQUESE la pieza o el montaje.

Indica que se dar· una LLAVE DE TUERCAS o el TAMA—O DE HERRAMIENTA.

APRIETESE hasta un par torsor especifico.

Ceriórese de que est·n alineadas las marcas de balance en el rotor.

EJECUTESE una MEDICION eléctrica.

Favor de siempre llevar ropa protectora.

Acceso a Sitio Web para localizar su agente Holset más cercano.

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.

EFFECTUER une MEASURE électrique.