HX35/40 - wright-here.net

1 Copyright 1998 Holset Engineering Co. rights reservedPart No. 3580800 Effect date Repair ManualturbochargersFor updates of this manual please visit publication was written to assist field personnel with basic overhaul and rebuilding of the Holset HX30/35 specifications and rebuild information in this manual is based on information in effect at the time of printing. HolsetService reserves the right to make any changes at any time without obligation. If differences are found between yourturbocharger and the information in this manual, contact your local approved latest technology and the highest quality standards are used in the manufacture of Holset Turbochargers.

2 Whenreplacement parts are needed, we recommend using only genuine Holset of ContentsIntroductionGeneral Information ..4 About the to Use the Manual ..4 Fault Finding Chart ..5 Symbols ..6 Component IdentificationTurbocharger Identification ..11 Components ..12 Exploded View ..13 Optional Components ..14 Component Disassembly and AssemblyService Tools ..15 Disassembly ..21 Assembly ..23 Installation Data ..30 Installation Checklist ..31 Table of ContentsPage 3 IntroductionGeneral InformationA turbocharger is a mechanical device which uses the engine s exhaust gases to force more air into the enginecylinders.

3 A turbocharger uses energy from the engine to help increase its overall efficiency. Hot exhaust gas energy isused 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 increased air mass flow to the engine provides improved engine performance, lower exhaust smoke density,improved operating economy, altitude compensation, and noise reduction. The turbocharger has proven to be one of themost beneficial devices for improving engine performance.

4 It performs its job very well, as long as it is properly cared the ManualThe procedures in this manual were developed to instruct in the correct overhaul of the Holset HX35/40 turbocharger toprovide for the optimum performance and minimum of maintenance to Use the ManualThis manual is organised according to the steps needed to most easily and correctly overhaul the Holset hx35 /40turbocharger. In the unlikely event of turbocharger malfunction, please check the Fault Finding Chart to identify potentialcauses, before attempting disassembly.

5 To make sure of optimum performance, certain items must be discarded duringthe disassembly operation and replaced with new for re-assembly. These items are indicated in the disassembly sectionwith the use of a * symbol. All items showing a * are available in a basic HX35/40 overhaul kit. Contact your local agentfor part number and turbocharger may have been manufactured using the core balance process and therefore MUST be checkbalanced on core balanced turbocharger will not have any co-relation marks on the thrust collar or oil slinger, and also may nothave co-relation marks on the end of the turbine shaft and impeller you intend to overhaul/repair a core balanced turbocharger, and do not have access to a core balancing machine.

6 We recommend that you make your own rotor co-relation marks during disassembly ( see appropriate illustration in thedisassembly section) with an indelible-ink pen, so that these parts can be reassembled in the same relative refer to the balance data section of this manual for the balance limits to be used for either core balancing orrotor is important to note that operating a turbocharger with a Rotor or Core balance level greater than the published limitscould cause turbocharger or engine failure. If you are in any doubt regarding the balancing process.

7 Please contact anapproved Holset distributor for InformationPage 4 IntroductionFault Finding Chart Engine Lacks Power Black Exhaust Smoke Blue Exhaust Smoke High Oil Consumption Turbocharger NoisyEngine Running HotPoor Transient ResponseSmokeCyclic Sound from the Turbocharger Oil Leak from Compressor Seal Oil Leak from Turbine SealDirty air cleanerClean or replace element according to manufacturer s recommendationsRestricted compressor intake ductRemove restriction or replace damaged parts as requiredRestricted air duct from compressor to intake manifoldRemove restriction or replace damaged parts as requiredRestricted intake manifoldRefer to engine manufacturer s manual and remove restrictionAir leak in feed from air cleaner to compressorReplace seals, gaskets or tighten fasteners as requiredAir leak in feed from compressor to intake manifoldReplace seals.

8 Gaskets or tighten fasteners as requiredAir leak between intake manifold and engineRefer to engine manufacturer s manual and replace gaskets or tighten fasteners as requiredForeign object in exhaust manifold (from engine)Refer to engine manufacturer s manual and remove obstructionRestricted exhaust systemRemove restriction or replace damaged parts as requiredExhaust manifold cracked, gaskets blown or missingRefer to engine manufacturer s manual and replace gaskets or damaged parts as requiredGas leak at turbine inlet/exhaust manifold jointReplace gasket or tighten fasteners as requiredGas leak in ducting after turbine outletRefer to engine manufacturer s manual and repair leakRestricted turbocharger oil drain lineRemove restriction or replace damaged parts as requiredRestricted engine crankcase breatherRefer to engine manufacturer s manual.

9 Clear restrictionTurbocharger bearing housing sludged or cokedChange engine oil and oil filter, overhaul or replace turbocharger as requiredFuel injection pump or fuel injectors incorrectly setRefer to engine manufacturer s manual and replace or adjust faulty components as requiredEngine valve timing incorrectRefer to engine manufacturer s manual for correct settings and adjust as requiredWorn engine piston rings or linersRefer to engine manufacturer s manual and repair as requiredBurnt valves and/or pistonsRefer to engine manufacturer s manual and repair as requiredExcessive dirt build up on compressor wheel

10 And/or diffuser vanesClean in accordance with details in the appropriate Holset publicationTurbocharger damagedFind and correct cause of failure, repair or replace turbocharger as necessaryFailed diaphragmReplace using correct actuator Service KitSiezed valveFree valve/replace complete turbine housing sub-assemblyLeaking hoseReplace hose and clipsWastegate mechanism set incorrectlyContact approved agent for correct setting detailsFault Finding ChartPage 5 IntroductionSymbols - EnglishThe following group of symbols have been used in this manual to help communicate the intent of the instructions.