Holset HE531V/HE551V - Cummins Turbo Technologies

Holset HE531V/HE551V - Cummins Turbo Technologies
Holset HE531V/HE551V
Service Repair Manual
Copyright 2007, Cummins Turbo Technologies Ltd. All rights reserved.
VGT, Command Valve and Super MWE are trade marks of Cummins Turbo Technologies Ltd.
Holset and the Holset Logo are registered trade marks of Cummins Turbo Technologies Ltd.
Cummins and the Cummins logo are registered trade marks of Cummins Inc.
HE531V/HE551V Service Repair Manual
Foreword
Foreword
This publication was written to assist with installation, maintenance and overhaul. It is not a warranty of any
kind express or implied.
The specifications and procedures in this manual are based on information in effect at the time of publication.
Cummins Turbo Technologies 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 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.
HE531V/HE551V 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 T urbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:2
Introduction to Variable Geometry Turbochargers . . . . . . . . . . . . . . . . . . . . . . 1:2
Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:4
Installation Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:6
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1:8
2: Component Identification
Turbocharger Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:1
Dataplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:1
Installation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:2
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2:4
Component List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
3: Troubleshooting and Diagnosis
Fault Finding Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3:1
4: Component Testing and Replacement
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:1
On Engine Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:3
Safe Lifting Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:8
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:9
Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:11
VG Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4:16
5: Turbocharger Service and Overhaul
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:1
Preliminary Health Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Bearing Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
Turbine and Compressor Housings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Core Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:18
VG Turbine Actuating Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5:33
6: Service Data Sheets
VG Range Service Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6:1
HE531V/HE551V Service Repair Manual
Introduction
About the Manual
The procedures in this manual were developed to instruct in the correct overhaul of the designated
turbocharger 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 the specified
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.holsetaftermarket.com so that Service Data can be updated 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.holsetaftermarket.com.
When using the manual on-line this icon will link to the 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 housing or actuator to
define the identifying information about your turbocharger build standard.
3) Contact your local agent with component 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.
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HE531V/HE551V Service Repair Manual
Introduction
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 Variable Geometry Turbochargers (VGT™)
The need for Variable Geometry
The turbocharger on your vehicle’s engine is of a very advanced type, which varies the effective size of its
turbine in response to the driver’s demands. Under all conditions of driving, the turbine is electronically
controlled to change the amount of air supplied to the engine, to ensure maximum performance, lowest fuel
consumption and minimum exhaust emission levels.
When rapid vehicle acceleration is required, the turbocharger will produce air for the engine more quickly than
a conventional unit, thus eliminating turbocharger lag and giving improved vehicle drivability. As the engine and
turbocharger run in, and eventually start to wear, the combination of the variable turbine and its associated
electronic control, will change its characteristic to keep to the original performance and emission levels over a
wide range of ambient temperatures and altitude.
The importance of correctly installing a Variable Geometry Turbocharger (VGT™)
The bearing housing of your turbocharger contains an internal water-cooled jacket. The purpose of this is to
reduce the operating temperature of the housing, to improve the operating environment of the speed sensor
and reduce the high soak temperatures produced when the engine is switched off after being heavily loaded.
The addition of water cooling has meant that there are two extra pipe connections to the turbocharger, to bring
water to the housing and to take it away. It is important to observe the correct installation of these pipes, so
that the circulation of the water is in the correct direction, or the effectiveness of the cooling system will be lost
and severe damage may result.
The Importance of Correct Operation of a Variable Geometry Turbocharger (VGT™)
A variable geometry turbocharger is controlled by the engine control module to optimise engine air fuel ratio for
performance and emissions. A malfunction may cause a mismatch between air and fuel supply which could
lead to progressive engine damage. It is important that any operating symptom which indicates incorrect
turbocharger operation is dealt with immediately by taking the unit safely out of service.
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HE531V/HE551V Service Repair Manual
Introduction
The advantages of a Variable Geometry Turbocharging (VGT™) system
You may already have experience of the effect of a Wastegate turbocharger on the performance of your
vehicle. As the name suggests a Wastegate turbocharger allows exhaust gas to by-pass the turbine wheel.
This by-passed gas contains energy which is lost to the turbine wheel.
The advantage of Variable Geometry over a Wastegate system is that all the exhaust gas flows through the
turbine wheel to increase net turbine power output. In addition, turbine power can be set to provide just
sufficient energy to drive the compressor at the desired boost level wherever the engine is operating. Speed
and pressure sensors feedback information to the Engine Control Unit to provide the necessary control.
Pneumatic
Control
Cylinder
Control Air
Exhaust Gas
Speed
Sensor
Fixed
Shroud
Plate
Air Inlet
Turbine
Compressor
Boost Air
Outlet
Operating
Yoke
Push Rods and Bushes
Sliding Nozzle Ring
and Vanes
The Holset Variable Geometry Turbocharging (VGT™) system works by controlling the width of a nozzle
guiding the gas flow into the turbine wheel. Control is achieved using an air supply from the vehicle’s auxiliary
air reservoir. The Engine Control Unit modulates the supply pressure to the turbocharger pneumatic actuator
which acts on a rod and yoke system to slide the nozzle ring and blades relative to the fixed shroud plate. This
movement varies the area through which exhaust gas enters the turbine wheel blades.
Pneumatic
Actuator
Control Air
Pressure
Sensor
(Optional)
Air Tank
Engine Speed
Throttle Demand
Inlet Manifold
Pressure & Temperature
Exhaust Manifold Pressure
Fuel Injection Pump Information
Ambient Pressure
Shut off
Valve
Control
Valve
Electrical
Control Line
Engine Control Unit (ECU)
Contains pre-set data on
airflow requirements for
any fuel quantity injected
at any engine speed,
with built-in safety
features for excessive
boost, smoke or
turbocharger speed.
Exhaust Outlet Pressure
Turbocharger Speed
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HE531V/HE551V Service Repair Manual
Introduction
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
Maintenance or Service procedures which if not strictly followed, will result in damage or destruction of the
turbocharger.
Warning
Maintenance or Service procedures which if not correctly followed will result in personal injury or loss of life.
Warning
'The designated turbochargers weigh up to 28 kg (61.7 lb).
When lifting the turbocharger manually always get assistance to avoid back strain or dropping the unit and
consequential injury.
External parts include electrical wiring and connectors which are sensitive to handling. VTi models are fitted
with titanium compressor wheels which have sharp edges and should be handled with care.
Warning
Some parts are manufactured in fluoroelastomers (eg Viton) or similar that require special treatment in the case
of repair and service after fire.
Warning
Turbocharger surface temperature during operation can achieve 700°C (1300°F).
Caution
Orientation of the turbine housing of a variable geometry turbocharger is factory set. Any attempt to
re-orientate the housing can cause severe damage to the VG mechanism and may void warranty.
Caution
This variable geometry turbocharger has been factory balanced using the core balance process.
Service overhaul/repair must be carried out by an approved agent to ensure the variable geometry system is
correctly rebuilt. It is important to note that operating a turbocharger with rotor or core balance level
greater than design limits could cause turbocharger or engine failure.
Caution
In the event of a suspected variable geometry turbocharger malfunction, symptoms which may include low
power and black smoke, it is important to avoid potential progressive engine damage. The vehicle should be
taken out of service and towed to an appropriate repair facility as soon as this can be accomplished without
sacrificing the safety of the operator and/or passengers.
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HE531V/HE551V Service Repair Manual
Introduction
Notes, Cautions and Warnings
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
Many turbochargers are returned 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.
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HE531V/HE551V Service Repair Manual
Introduction
Installation Data
1.
Many turbochargers are returned 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. It is important not to overload the turbocharger by external
attachments or forces.
3.
The air filter must remove particles greater than 5 µm 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 tightened to the values specified by the Equipment and Engine
manufacturers to withstand depressions up to 6.3 kPa (0.91 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 system connections must be tightened to the values specified by the Equipment and Engine
manufacturers to be capable of operating at exhaust back pressures of up to 10 kPa (1.5 lbf/in2).
Subject to an extensive review and formal approval, this limit may be increased to 25 kPa
(3.6 lbf/in2) if a catalytic convertor is fitted. Exhaust brake applications are permitted to operate at a
continuously rated pressure up to 450 kPa (65.3 lbf/in2) Experience exists running at instantaneous
pressures up to 700 kPa (101.5 lbf/in2) but any application operating above 450 kPa (65.3 lbf/in2) must be
referred for approval.
6.
Oil should be filtered to 10 µm with efficiency of 60% TWA (Time Weighted Average) /20 µm with
efficiency of 85% TWA. Efficiency assessed using ISO Standard 4572/SAE J 1858. Always use filters
recommended by the engine manufacturer.
7.
The oil quality must be as specified by the engine manufacturer and will be a minimum API - CD (MIL L - 2104C) specification. Improvement in life can be obtained by using super high performance diesel
(SHPD) oils, particularly where extended oil drain periods are used.
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 and bearing housing of a VG turbocharger is fixed. During installation,
do not attempt to rotate these components, as it may affect the operation of the VG actuating mechanism
and may void any warranty.
11. Oil drain pipes are permitted to decline at an overall angle of not less than 30 degrees below horizontal.
These turbochargers require a drain pipe of 19 mm internal diameter minimum which has integrated
connectors. To ensure oil drains into the engine under all operating conditions the return connection into
the engine sump must not be submerged.
12. Crankcase pressure should be limited to 0.8 kPa (0.12 lbf/in2). Pressure above this level should be
referred for further evaluation. Closed crankcase ventilation (CCV) systems are known to
operate at elevated pressure and all applications must be referred for approval.
13. Oil pressure must show at the turbocharger oil inlet within 3 - 4 seconds of engine firing to prevent
damage to turbocharger bearing system. A flexible supply pipe is recommended.
14. The minimum oil pressure when the engine is on load must be 210 kPa (30 lbf/in2). Normal maximum
operating pressure is 400 kPa (58 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).
15. Recommended oil flow ranges for these turbochargers are 2 - 3 litre/min at idle and 3.5 - 4.5 litre/min at
maximum engine speed.
16. Recommended coolant flows for these turbochargers are 3 litre/min at idle and 14 litre/min at maximum
engine speed. Coolant hose design must permit flow to increase progressively with engine speed.
17. Do not use liquid gasket substances or thread sealant as any excess can enter the turbocharger oil and
coolant systems to obstruct flow.
Note:
100 kPa = 1 bar (14.5037 lbf/in2 = psi).
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HE531V/HE551V Service Repair Manual
Introduction
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. Before re-installing flexible pipes always ensure any burnt-on lacquer or other
adhered material is removed from internal bores. If in doubt, always fit new pipes.
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 the electrical connections between VG sensors and engine control unit (ECU). Check the electrical
connection between control valve and ECU.
17. Check the air connection between the vehicle auxiliary tank and control valve.
18. Connect the air pipe from the control valve to the actuator ensuring the pipe bore is clean and dry before
fitment.
19. Make any ECU checks recommended by the engine manufacturer.
20. Crank the engine WITHOUT firing until engine oil flows out of the turbocharger drain flange.
21. Assemble the oil drain pipe and check that the connection is well made, without obstruction and will not
leak in use.
22. Start the engine and run at idle speed for approximately 1 minute so that the oil supply system is fully
operational.
23. Accelerate the engine and check that there are no leaks/obstructions of air/oil/coolant/gas under pressure.
24. Check that no hose or connection deforms under normal operation.
25. Before switching off the engine, leave it running at idle speed for at least 1 minute to cool the turbine.
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HE531V/HE551V Service Repair Manual
Introduction
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.
KG
Deutet an, daß Teile schwer sein können.
Website-Verzeichnis mit Ihrem nächsten Händler.
Gehe zu Inhalt
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HE531V/HE551V Service Repair Manual
Introduction
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.
KG
Indicates components may be heavy.
Website access to find your nearest Agent.
Go to contents
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HE531V/HE551V Service Repair Manual
Introduction
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 más cercano.
Ir a la tabla de materias
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HE531V/HE551V Service Repair Manual
Introduction
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 le plus proche.
Aller au sommaire
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HE531V/HE551V Service Repair Manual
Introduction
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)
KG
Indica que os componentes podem estar pesados.
Visite o Website para encontrar o seu Agente mais perto.
Vá para Conteúdo
1:11
HE531V/HE551V Service Repair Manual
Component Identificatio
Turbocharger Identification
Dataplate
Note
The dataplate will be fitted to the compressor housing (8).
The information from the dataplate must be quoted for
service and parts support.
XXXXXXX
XYYMMXXXXX
HE551V
HE551V
2:1
HE531V/HE551V Service Repair Manual
Component Identificatio
Installation Options
Type A
Type B
Type C
2:2
HE531V/HE551V Service Repair Manual
Component Identificatio
Installation Options
Type D
Type E
2:3
HE531V/HE551V Service Repair Manual
Component Identificatio
Exploded View - Original Equipment
120
112
27
105
115
75
81
75
92
126
106
114
115
77
120
129
113
117
105
116
Note
Exploded views represent a generic build standard. Parts may be added or subtracted in specific applications.
2:3
HE531V/HE551V Service Repair Manual
Component Identificatio
Exploded View - Rebuild Standard
8
22
172
41
34
172
29
61
7
62
56 14
60
11
2
27
120
33
1216 27
31
3611
64
8575
106
11
7
126
4
611
186 11
77
3
157 180 11
178
181
62
105
11
5
2
11
64
162
13 6
11
5
105
28
5
Note
Exploded views represent a generic build standard. Parts may be added or subtracted in specific applications.
2:5
HE531V/HE551V Service Repair Manual
Component Identificatio
Control Valves
Dcon Control Valve
125
Icon Control Valve
125
Note
Exploded views represent a generic build standard. Parts may be added or subtracted in specific applications.
2:6
HE531V/HE551V Service Repair Manual
Component Identificatio
Component List
Item No.
Description
1
Repair Kit CHRA (core)* comprising:
Quantity
1
11
Journal Bearing*
2
12
Thrust Bearing*
1
13
Split Ring Seal, Turbine*
2
16
Split Ring Seal, Compressor*
1
27
O-Ring Seal *
1
41
O-Ring Seal, Compressor *
1
56
Screw, Diffuser*
3
60
Plain Washer*
3
62
Lock nut, V Band*
2
64
Retaining Ring, Bearing*
4
31
Oil Slinger
1
33
Oil Baffle
1
36
Thrust Collar
1
2
CHRA (Core)
1
5
Turbine Housing
1
8
Compressor Housing
1
14
Diffuser
1
Housing fitting components:
28
V-band Clamp, Turbine
1
62
Lock nut, V Band
1
29
V-band Clamp, Compressor
1
62
Lock nut, V Band
1
41
O-Ring seal, Compressor
1
34
Inlet Baffle
1
22
Retaining Ring, Inlet Baffle
1
180
Retaining Ring, Shroud Plate
1
181
Shroud Plate
1
162
Nozzle ring seal
1
Note
Exploded views may not contain all listed components.
2:7
HE531V/HE551V Service Repair Manual
Component Identificatio
Component List
Item No.
Description
123
VG Bearing Housing Seals & Adapter Kit comprising:
Quantity
1
113
Adapter, Oil Inlet*
1
114
O-Ring Seal, Oil Inlet*
1
105
Connector Male, Water*
2
115
O-Ring Seal, Water*
2
116
Adapter, Oil Drain*
1
117
O-Ring Seal, Oil Outlet*
1
Actuator fitting components:
81
Hose
1
186
Split Ring Seal, Actuator Lever
2
121
VG Actuator Kit* comprising:
1
126
VG Actuator*
1
122
VG Actuator Fittings Kit* comprising:
1
172
Grease Pack*
1
106
Screw, Actuator*
2
75
Hose Clip*
2
90
Seal Washer*
2
27
O Ring*
1
120
Screw, Cover Plate*
1
157
Cover Plate*
1
173
Installation Sheet*
1
124
Speed Sensor Kit* comprising:
1
112
Speed Sensor*
1
120
Cap Head Screw*
1
27
O-Ring Seal*
1
125
Control Valve
1
Note
Exploded views may not contain all listed components.
2:8
HE531V/HE551V Service Repair Manual
Troubleshooting and Diagnosis
Oil Leak from Turbine Seal
Oil Leak from Compressor Seal
Cyclic Sound from the Turbocharger
Turbocharger Noisy
High Oil Consumption
Blue Exhaust Smoke
Black Exhaust Smoke
Engine Lacks Power
Smoke
Poor Transient Response
Engine Running Hot
Fault Finding Chart - All Applications
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
Contact your local approved dealer
Turbocharger damaged
Find and correct cause of failure, or replace turbocharger as necessary
3:1
HE531V/HE551V Service Repair Manual
Troubleshooting and Diagnosis
Oil leak
Coolant leak
Reduced braking
Poor acceleration
Turbocharger noisy
Low power at low engine speed
Engine does not run smoothly
Intermittent low power
Intermittent engine braking
Engine Overheats
Engine Lacks Power
Fault Finding Chart - Variable Geometry
Actuator rod not moving
Check for air leaks and change clips and hoses as appropriate. If actuator works with
separate air supply, check control valve. If no actuator movement confirmed, replace
actuator. If no movement with new actuator replace turbocharger.
VG mechanism partially jammed
Refer to Engine Control Unit (ECU) diagnostics for posible fault code data. Check for air
leaks and change clips and hoses as appropriate. If air system OK, check actuator
movement. If full and free movement not confirmed, replace actuator. If partial movement
with new actuator replace turbocharger.
Actuator loose or damaged
Refer to ECU diagnostics for possible fault code data. Check for damage to actuator
bracket and fasteners. If mechanical installation is OK, check actuator movement. If full
and free movement not confirmed, replace actuator. If partial movement with new actuator
replace turbocharger
Actuator air feed lines or connectors leaking
Check for air leaks and change clamps and hoses as appropriate. If actuator air system
OK, refer to general turbocharger fault finding chart.
No speed signal
Check sensor connections. If pin resistance measurement is incorrect replace sensor.
Where sensor may have been overheated check ECU diagnostic fault codes and if
necessary replace sensor.
Intermittent or noisy speed signal
Check sensor with multimeter. If either resistance measurement is incorrect replace
sensor. Where sensor may have been overheated check ECU diagnostic fault codes and
if necessary replace sensor.
No control valve drive signal
To ensure drive signal is being received from ECU check control valve operation. If either
0 V or battery voltage condition is incorrect replace control valve and refer to engine
manual.
Intermittent control valve drive signal
Refer to ECU diagnostics for possible fault code data. Check control valve connection to
ECU. If control valve condition at either 0 V or vehicle battery voltage is incorrect or if
intermittent fault persists replace control valve whilst referring to engine manual.
No boost pressure signal (P2)
If the ECU diagnoses a boost pressure signal error refer to engine manual.
No air inlet temperature signal (T2)
If the ECU diagnoses an air inlet temperature signal error refer to engine manual.
Incorrect actuator pressure
If the VG system has an actuator pressure sensor which reads an incorrect actuator
pressure signal the fault is likely to be with the shut-off valve, control valve or pressure
sensor itself. Refer to engine manual for repair and replacement instructions for shut-off
valve and pressure sensor test and replacement. Check and replace control valve whilst
referring to engine manual.
Incorrect control valve supply pressure
Likely causes are malfunctions of shut-off valve or control valve. Refer to engine manual
for repair and replacement instructions for shut-off valve. Check and replace control valve
whilst referring to engine manual.
Control valve sticking
Check actuator pressure if sensor fitted. If control valve sticking is likely cause, spray light
penetrating oil into control valve inlet. Allow to lubricate the valve mechanical parts.
Conduct pressure check. If either 0 V or battery voltage condition is incorrect change
valve whilst referring to engine manual.
3:2
HE531V/HE551V Service Repair Manual
Troubleshooting and Diagnosis
Oil leak
Coolant leak
Reduced braking
Poor acceleration
Turbocharger noisy
Low power at low engine speed
Engine does not run smoothly
Intermittent low power
Intermittent engine braking
Engine Overheats
Engine Lacks Power
Fault Finding Chart - Variable Geometry Continued
Coolant flow restricted
Check coolant pipework and connections for damage. Replace damaged bearing housing
fittings using only Holset recommended parts. Refer to engine manual for flow data and
service instructions for all other connections and pipework.
Coolant pipework or connectors leaking
Check coolant pipework and connectors for leakage. Tighten connections and if leak
persists, replace failed connectors or pipes using Holset recommended parts.
Oil feed and return lines or adaptors leaking
Check oil feed and return pipes and adaptors for leakage. Check O-ring seals and replace
if necessary. Tighten adaptors and if leak persists, replace failed adaptors or pipes using
Holset recommended parts.
Oil leakage from speed sensor
Check O-ring seal and replace if necessary. Refit sensor and if leak persists replace
speed sensor.
Bearing housing damaged
If O-ring or connector replacement does not resolve an oil leak, the bearing housing
tappings may be damaged requiring replacement of the turbocharger. Where water
connector replacement does not resolve a water leak, the bearing housing tappings may
be damaged requiring replacement of the turbocharger.
3:3
HE531V/HE551V 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.
Part No.
Tool Description
Tool Illustration
Torque Wrench
(Refer to Service Data Sheet for required torque ranges)
Regulated Air Supply
Steel Rule
13 mm Diameter Clean Rubber Plug
0-10 bar Pressure Gauge
Allen Key (6mm)
Caution
All Service and Maintenance settings are shown in Service Data Sheet at www.holsetaftermarket.com. It
is essential that these settings are used. Common tools found in mechanic’s tool box not included.
4:1
HE531V/HE551V 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. These tools can be purchased from your local Authorised Repair Location.
Part No.
Tool Description
Tool Illustration
Vehicle Battery Supply
Multi-meter
Caution
All Service and Maintenance settings are shown in Service Data Sheet at www.holsetaftermarket.com. It
is essential that these settings are used. Common tools found in mechanic’s tool box not included.
4:2
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
On Engine Checks
Variable geometry turbochargers have potential oil, gas, coolant and air leak paths. They are fitted with
a sensor and an actuator which contain sensitive components. When checking and correcting leaks it
is essential that good practice and the correct tools are used to avoid damaging the turbocharger .
Oil Leakage
M14 (19 mm A/F)
Warning
Always wear safety glasses.
Replacement seals and adapters should be fitted
without sealant as this can contaminate the oil. Torque
tighten adaptor to value shown in Service Data Sheet.
It is important to avoid kinked or worn pipes during
servicing and operation.
M22 (36 mm A/F)
Warning
Inlet oil is pressurized and outlet oil is hot. Never take
service action with engine running. Protect face and
hands from hot fluid leakage.
Replacement seals and adapters should be fitted
without sealant as this can contaminate the oil. Torque
tighten adapter to value shown in Service Data Sheet.
All outlet pipes should be free flowing without kinks and
sharp bends and decline at overall angle not less than
30 degrees below the horizontal.
M6 (8 mm A/F)
Speed sensor is sealed with o-ring and fastened using
set screw. Always use new set screw with patch sealant
feature provided in Holset Service Kit when re-fitting
sensor. Torque tighten sensor to value shown in
Service Data Sheet.
Caution
Do not use sealant when fitting speed sensor as this
may contaminate oil and bearings.
Caution
If leak occurs at lever change turbocharger.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
KG
4:3
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Coolant Leakage
M16 (22 mm A/F)
Warning
Always wear safety glasses.
Repair by replacement of fitting. Where housing threads
are damaged replace turbocharger. Torque tighten
adapter to value shown in Service Data Sheet.
Warning
Water connections may be hot and pressurized.
Never take service action with engine running.
Protect face and hands from hot fluid leakage.
Caution
Do not use sealant as this may affect performance of
o-ring seals.
Warning
KG
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Gas Leakage
M6 (8 mm A/F)
Speed sensor is sealed with o-ring and fastened using
set screw. Always use new set screw with patch sealant
feature provided in Holset Service Kit when re-fitting
sensor. Torque tighten sensor to value shown in
Service Data Sheet.
Caution
Do not use sealant when fitting speed sensor as this
may contaminate oil and bearings.
Turbine housing flange leakage will cause soot
formation on flange. Check exhaust manifold to flange
seal ensuring fastener torque meets engine
manufacturer’s recommendation.
4:4
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Warning
Always wear safety glasses.
Caution
Turbine housings can exhibit cracking when subject to
excessive thermal and mechanical loads.
Cracking of inlet duct requires turbocharger
replacement.
KG
Check flange for cracks and ensure flatness is within
0.1 mm (0.004 in).
Acceptance and rejection guidelines are shown in this
illustration. If exhaust gasket is available, always
ensure that any cracks lie within its sealing area.
Check fastener hole diameter is not more than 1.5 mm
larger than max. thread diameter of fastener.
M12 x 1.75
Check flange threaded holes with thread gauge.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Air Leakage
Caution
Visual checks and audible checks for air leaks may be
completed safely with a running engine. Alternatively,
apply an external air source.
Check for air leaks at the end plates and air hose to
actuator air inlet fitting.
Check for air leak at the base of the actuator housing.
Caution
If the actuator leaks air, however little, it must be
replaced. Using a damaged actuator will result in
inferior performance of turbocharger and engine.
4:5
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Visual Checks
Caution
To avoid damage to variable geometry control
mechanism always refer to
Turbine and Compressor Housings before
attempting to remove turbine housing.
Visual check for damaged or bent blades only.
Caution
Never attempt to straighten blades.
Caution
To avoid damage to impeller, always refer to
Turbine and Compressor Housings before
attempting to remove compressor housing.
Visual check for damaged and fouling of impeller
blades only.
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
engine to check Bearing Clearance against
recommended values shown in Service Data Sheet.
Warning
Titanium compressor wheel edges are sharp. Handle
with care.
Warning
Always wear safety glasses.
Always refer to Compressor Housing Cleaning to
clean housing. Rotor components can be cleaned using
a non metallic bristle brush.
4:6
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
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
engine to check Bearing Clearance against
recommended values shown in Service Data Sheet.
Warning
KG
Titanium compressor wheel edges are sharp. Handle
with care.
4:7
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Safe Lifting Methods
The designated turbochargers weigh up to 28 kg (62 lb) and include sensors, electrical wiring and
connectors which are sensitive to handling.
Always use a mechanical lifting method or seek assistance.
Mechanical Handling
Warning
KG
This turbocharger is not fitted with lifting eye.
Always seek assistance when lifting.
Always support the weight of turbocharger during
removal and refitting using a sling and mechanical hoist
system of correct load rating.
Manual Handling
When no lifting eye is fitted always seek assistance to
support weight of turbocharger.
KG
Warning
Turbochargers are heavy. Always use two-man safe
manual lifting method when removing or refitting.
4:8
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Speed Sensor
Disconnect sensor at its electrical connector. Using
multi-meter, check resistance between connector pins
1 and 2 is 880+/- 50 ohms with sensor at 20°C. Check
pins 1 to 3 and 2 to 3 have very high ((min 1 MOhm)
resistance.
1
2
3
Where road spray, dirt and fluid ingress has caused
fouling or corrosion of speed sensor fastener apply
penetrating oil in accordance with manufacturer’s
instructions.
Warning
Always wear safety glasses.
M6 (8 mm A/F)
Using socket wrench and ratchet, loosen and remove
cap head screw, speed sensor.
Caution
Breaking sealed fastener joint may require significant
torque. It is essential that socket spanner is properly
engaged on fastener to avoid inadvertent damage to
speed sensor cable and connector resulting from
spanner slip.
Extract speed sensor ensuring that o-ring seal is
removed with sensor. This is conveniently achieved by
tilting sensor as it exits recessed bore.
Place speed sensor on clean surface to avoid collection
of metal particles.
4:9
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Warning
Always wear safety glasses.
Caution
Removal of speed sensor leaves open access to
bearing housing. It is essential that no dirt or fluids
enter bearing housing cavity during speed sensor
replacement.
Insert clean rubber plug.
Speed Sensor Replacement
Remove clean rubber plug.
Prior to inserting speed sensor ensure it is clean and
unable to collect metal particles as it is inserted.
Ensure the o-ring seal is in position on the sensor body.
M6 (8 mm A/F)
Use new cap head screw with patch sealant feature
provided in service kit to fasten speed sensor flange to
bearing housing.
Torque tighten set screw to the value specified in
Service Data Sheet.
Caution
It is recommended NOT to re-use original fastener.
Where original fastener must be used, it is important
threads are clean and thread locking compound is
applied. Fastener torque must be applied within time
specified by thread lock manufacturer.
4:10
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Dcon Control Valve
Control valve is remote from turbocharger. It is
connected pneumatically to VG actuator and electrically
to engine control module (ECM).
24 V - Control Valve
Valve controls pressure applied to actuator in response
to signals sent from ECM. Where ECM signals control
valve error, check wiring harness is good. If error
persists check contol valve operation.
To check electrically, disconnect control valve at its
electrical connector. Use multi-meter to check
resistance between pins 1 and 2. Resistance for 24 Volt
control valve should be 24.5 +/- 0.5 Ohm at 20°C.
If engine diagnostics indicate problem with valve it must
be serviced by replacement as it contains no
serviceable parts.
12 V - Control Valve
To check electrically, disconnect control valve at its
electrical connector. Use multi-meter to check
resistance between pins 1 and 2. Resistance for 12 Volt
control valve should be 6.5 +/- 0.5 Ohm at 20°C.
Contact your approved agent for parts and availability.
Control Valve Removal & Replacement
Fixing and position of control valve is dependent on
engine application. Process of replacement will be
included in engine manual.
Pressure Guage
The Dcon valve can be cleaned when installed using
pressure wash or steam cleaning equipment.
Warning
Always wear safety glasses.
Control Valve
12 V or 24 V
Warning
Care must be taken when breaking pneumatic
connections as these may be pressurised.
Air Supply
Battery
12 V or 24 V
Depending on vehicle system.
Polarity not important
Caution
Always ensure valve is non-operational but connected
pneumatically and electrically during cleaning.
Caution
Where it is necessary to break the inlet, outlet and
capsule pressure sensor pneumatic connections, it is
essential that open pipes and connectors are
protected from dirt and fluid entry using clean rubber
plugs.
4:11
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Icon Control Valve
Valve Air and Electric Connections
Do not disconnect icon valve electrically or
pneumatically at this stage.
Icon valve has three pneumatic ports:
Port 1
Air supply port: M12 x 1.5
Port 2
Pulse Width Modulated (PWM) actuator
supply port: M12 x 1.5
Port 3
Exhaust port with shroud plate
1
2
12
11
10
9
8
3
7
There are three active pins in connector:
Pin 7
Supply voltage (9 to 32 Volt DC)
Pin 9
PWM input signal
Pin 12
Ground voltage (0 Volt)
Pneumatic
Actuator
Valve Functions
Control Air
Pressure
Sensor
(Optional)
Icon valve pneumatic system is not fitted with shut off
valve.
When Icon valve is activated electrically in key-on
engine start condition, it exhausts over PWM duty cycle
activated by Engine Electronic Control Module (ECM).
With key-off engine stopped, valve isolates air supply
and will not exhaust
Air Tank
Engine Speed
Control
Valve
Electrical
Control Line
Engine Control Module (ECM)
Throttle Demand
Inlet Manifold
Pressure & Temperature
Exhaust Manifold Pressure
Fuel Injection Pump Information
Ambient Pressure & Temperature
Contains pre-set data on
airflow requirements for
any fuel quantity injected
at any engine speed,
with built-in safety
features for excessive
boost, smoke or
turbocharger speed.
Exhaust Outlet Pressure
Turbocharger Speed
Warning
Always wear safety glasses.
Warning
Visual checks and audible checks for valve exhaust
air and air leaks may be completed safely with
running engine.
Caution
Icon valve has small but constant air bleed during
engine operation including operation at low idle
condition. To maintain system pressure, air
compressor and dryer will cycle.
All Icon valves have same physical dimensions and
features. It is very important to quote Customer/Part
Number and Date Code when re-ordering valve to
ensure replacement valve is preset to specified
performance characteristic.
Caution
Always check part number and date code of Icon
valve. Incorrect valve will affect engine performance.
Customer/Part Number
Date Code
4:12
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Valve Cleaning
Icon valve can be cleaned when installed using
pressure wash or steam cleaning equipment.
Warning
Always wear safety glasses.
Caution
Always ensure valve is non-operational (key-off)
but connected pneumatically and electrically during
cleaning.
Normal Installed Operation
OFF
ON
Icon valve is fitted with shrouded exhaust port. In any
key-on engine operating condition port will be active
and whistling/hissing sound will be heard. This
represents normal valve operation. In key-off engine
stopped condition there will be no exhaust air whistle.
Warning
OFF
ON
Visual checks and audible checks for valve exhaust
air and air leaks may be completed safely with a
running engine.
External Leakage
M12 x 1.5 (17 mm A/F)
In key-on engine operating condition, check for leakage
at inlet and outlet hose connections. Identify leaking
joint and move to key-off condition.
Warning
Care must be taken when breaking pneumatic
connections. These may be pressurised. Always
ensure engine key-switch is in off position and use
safety glasses and face protection during
disassembly.
Slacken failed joint and re-tighten adapter or hose
connection to torque specified by engine manufacturer.
Where leakage persists replace adapters or hoses in
accordance with Valve Removal and Refitting.
Warning
If an o-ring seal has been subject to fire, always wear
neoprene gloves when handling.
Caution
When breaking inlet or outlet pneumatic connections,
it is essential that open pipes and connections are
protected from dirt and fluid entry using clean rubber
plugs. Never apply thread tape during re-assembly of
adapters or hoses to avoid debris ingress.
4:13
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Internal Leakage
OFF
ON
If troubleshooting indicates control valve is jammed
open or valve spring is damaged or broken, it is
possible to check using forward leakage test.
Insert 0 to 1500 kPa (0 to 200 lbf/in2) pressure gauge
into actuator supply hose (Port 2). Apply system
pressure in range 700 to 1300 kPa (100 to 190 lbf/in2)
to valve inlet (Port 1) in the key off/ valve closed
position and check there is no pressure registered on
gauge.
If pressure registers, replace valve in accordance with
Valve Removal and Refitting.
Disconnect air supply and actuator supply hoses (Ports
1 and 2) and insert 0 to 1500 kPa (0 to 200 lbf/in2)
pressure gauges. Apply system pressure in range 700
to 1300 kPa (100 to 190 lbf/in2) to valve inlet (Port 1) in
key on/ valve actuated open position. Pressure
difference across valve must not exceed 200 kPa (29
lbf/in2 ).
If maximum pressure difference is exceeded, replace
valve in accordance with Valve Removal and Refitting.
Battery
12 V or 24 V
Depending on vehicle system.
Polarity not important
OFF
ON
If troubleshooting indicates abnormal engine
performance, it is possible that dirt or debris is
adversely affecting Icon valve performance.
Air Supply
Battery
12 V or 24 V
Depending on vehicle system.
Polarity not important
Warning
Always wear safety glasses.
Warning
Care must be taken when breaking pneumatic
connections. These may be pressurised.
Warning
If an o-ring seal has been subject to fire, always wear
neoprene gloves when handling.
Caution
When breaking inlet or outlet pneumatic connections,
it is essential that open pipes and connections are
protected from dirt and fluid entry using clean rubber
plugs. Never apply thread tape during re-assembly of
adapters or hoses to avoid debris ingress.
4:14
HE531V/HE551V Service Repair Manual
Valve Current Draw
Component Testing and Replacement
12
11
10
9
8
7
Valve current draw can be checked by inserting
ammeter in supply to valve (pin 7) and applying 12 Volt
DC from pin 7 to ground (Pin 12). Current draw must
not exceed 1.5 Amp at 20°C.
Where current draw exceeds this value, replace valve
in accordance with Valve Removal and Refitting below.
Warning
Always wear safety glasses.
Valve Removal and Refitting
To remove and replace valve always refer to engine
manufacturer’s instructions.
Removing Valve
Warning
Care must be taken when breaking pneumatic
connections as these may be pressurized. Always
ensure engine keyswitch is in off position.
Caution
Where it is necessary to break inlet or outlet
pneumatic connections, it is essential that open pipes
and connections are protected from dirt and fluid entry
using clean rubber plugs.
Never apply thread tape during re-assembly of
adapters or hoses to avoid debris ingress.
Refitting Valve
Caution
Always check part number and date code of Icon
valve. Incorrect valve will affect engine performance.
REMOVE
QUITAR
Caution
New valves are fitted with a protective adhesive
label over pressure sensor breather. For correct
valve function, adhesive label must be removed after
fitting/valve painting.
4:15
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
VG Actuator
Warning
Always wear safety glasses.
Caution
Actuator movement and leak checks should be carried
out on engine. If turbocharger removal is necessary it
may require:
• Drainage of water system
• Disassembly of oil circuit
• Disconnection of speed sensor
KG
Warning
Pneumatic connections may be pressurised. Always
ensure engine keyswitch is in off-position before
taking service action and use face protection.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
If hose is still connected to air inlet fitting, use small
screwdriver to remove hose clip.
Remove hose.
Caution
During VG actuator checks and replacement it is
necessary to break pneumatic connection
between control valve and actuator. It is essential that
open pipe is protected from dirt and fluid entry.
Warning
Ensure hose is securely fastened to air inlet fitting
using appropriate hose clip and clamp load.
Warning
Avoid touching the VG mechanism as finger injury
may result from sudden movement of the assembly
when air is supplied.
Connect and secure hose from regulated air supply to
actuator air inlet fitting.
Caution
Ensure regulated air supply is dry and filtered to avoid
damage to actuator piston and o-ring seals.
4:16
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Warning
Always wear safety glasses.
Warning
Ensure hose is securely fastened to air inlet fitting
using appropriate hose clip and clamp load.
Progressively apply 450 kPa (65 lbf/in2) from regulated
supply and ensure actuator rod moves lever.
If there is no movement or if movement is not smooth,
remove turbocharger.
KG
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Control regulated air supply between 0 and 300 kPa
(43.5 lbf/in2) and measure actuator rod stroke which
should be in range specified in Service Data Sheet.
Warning
Avoid touching VG mechanism as finger injury
may result from sudden movement of assembly
when air is supplied.
If actuator travel is not within permissible range remove
by reference to VG Actuator Removal and Checks.
Warning
Actuator internal parts are not serviceable items. Do
not disassemble as release of in-built separating
forces may cause personal injury.
Whilst air pressure is still applied at 300 kPa
(43.5 lbf/in2), check actuator for leaks. Use soapy water
and small brush. Small bubbles will appear if actuator is
leaking. If actuator is leaking, it must be removed and
replaced. Contact your local approved agent for details.
Caution
If actuator leaks air, however little, it must be
replaced. Using damaged actuator will result in
inferior performance of turbocharger and engine.
4:17
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
VG Actuator Removal and Checks
Warning
Always wear safety glasses.
Where actuator movement is outside range or where
actuator air leaks have been discovered it is necessary
to remove actuator to continue with fault diagnosis. If
possible these procedures should be carried out on
engine.
If removal of turbocharger is necessary it may require:
• Drainage of water system
• Disassembly of oil circuit
• Disconnection of sensors
KG
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Warning
Pneumatic connections may be pressurised. Always
ensure engine keyswitch is in off-position before
taking service action and use face protection.
Where road spray, dirt and fluid ingress has caused
fouling or corrosion of the actuator integrated bracket
fasteners apply penetrating oil in accordance with the
manufacturer’s instructions.
M8 (13 mm A/F) (10 mm A/F)
Loosen 2 actuator screws.
Connect clean dry regulated air supply to air inlet fitting
and apply 200 kPa (29 lbf/in2) to release actuator preload between bracket and crank journal.
4:18
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Warning
Always wear safety glasses.
Warning
Rod may retract quickly when freed from crank
journal. Avoid touching the VG assembly until rod is at
rest and there is no risk of finger injury.
M8 (8 mm A/F) (10 mm A/F)
KG
Remove grease nipple and cover plate.
Remove end link retaining ring. Slide the actuator rod
off crank journal.
Remove actuator scews and discard. Remove actuator.
If loaded section of crank journal is worn by more than
0.013 mm (0.005 in) replace turbocharger.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Warning
Ensure hose is securely fastened to air inlet fitting
using appropriate hose clip and clamp load.
Connect and secure the hose from a regulated air
supply to the actuator air inlet fitting.
Control regulated air supply to 0 and 300 kPa (43.5
lbf/in2) and confirm actuator travel is smooth and within
permissible range shown in Service Data Sheet.
Caution
Detached actuator stroke is greater than stroke when
attached to VG mechanism. Ensure correct range is
read from Service Data Sheet.
If actuator travel is not smooth nor within permissible
range shown in Service Data Sheet replace actuator.
Warning
Actuator is not a serviceable item. Do not
disassemble actuator as release of in-built
separating forces may cause personal injury.
KG
4:19
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
If actuator travel is within permissible range shown in
Service Data Sheet use light force to check linear
travel of VG crank pin.
If crank pin does not travel smoothly within permissible
range shown in Service Data Sheet replace
turbocharger.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
KG
4:20
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
VG Actuator Replacement/Refit
Service Actuator Kit (121)
Connect clean dry regulated air supply to actuator air
inlet fitting and apply 200 kPa (29 lbf/in2) to release
actuator pre-load.
Warning
Always wear safety glasses.
Warning
Ensure hose is securely fastened to air inlet fitting
using appropriate hose clip and clamp load.
Warning
Avoid touching VG assembly until it is clear that
actuator rod is at rest and there is no risk of finger
injury.
Clean crank journal with lint free cloth and noncorrosive metal cleaner or plastic scouring pad. Apply
grease from pack (172)* to crank journal and actuator
end link bore.
Push plain plastic washer (90)* on to crank journal.
Locate against crank lever face. Ensure split ring seals,
which are fit for life item, are in position. Slide actuator
end link on to crank journal and ease actuator mounting
flange into place on bearing housing roll pin location.
Insert two new patch treated actuator screws (106)* to
locate actuator to bearing housing.
M8 (10 mm A/F)
Torque tighten screws to value specified in
Service Data Sheet.
Caution
It is recommended NOT to re-use original actuator
screws. Where original fasteners must be used, it is
important that threads are clean and thread
locking compound is applied. Fastener torque must
be applied within time specified by thread lock
manufacturer.
4:21
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Warning
Always wear safety glasses.
M8 (10 mm A/F)
Fit plain plastic washer (90)* on to crank journal,
followed by o-ring seal (27)*. Ensure washer and
o-ring engage against end link bush. Fit new cover
plate (157)* and hand tighten new cap head screw
(120)*
Carefully tighten screw until cover plate is in metal
contact with end link face. Torque tighten to value
specified in Service Data Sheet.
Caution
Length of cap head screw is controlled. Always use
screw from service kit.
Apply Kluberpaste 46 MR 401 grease through end link
grease nipple
Note
This proprietary grease is HIGHLY RECOMMENDED
due to its lubrication and temperature capabilities. If
not available, a high quality Lithium ''LM'' grease may
be used.
4:22
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
Original Actuator
M8 (10 mm A/F)
Warning
Always wear safety glasses.
Ensure split ring seals, which are fit for life item, are in
position. Slide actuator end link on to crank journal and
ease integrated bracket onto roll pin (92)* in bearing
housing.
Insert two new dry actuator screws (106)* with patch
sealant feature.
Refit end link retaining ring (77)*.
Fit cover plate (129)* and grease nipple (178)* so that
the cupped edge wraps round actuator end link. Torque
tighten grease nipple to value specified in
Service Data Sheet.
Caution
It is recommended NOT to re-use the original actuator
screws. Where original fasteners must be used, it is
important that the threads are clean and thread
locking compound is applied. Fastener torque must
be applied within the time specified by the thread lock
manufacturer.
M8 (10 mm A/F)
Torque tighten actuator screws to value specified in
Service Data Sheet.
Apply Kluberpaste 46 MR 401 grease through crank
journal grease nipple.
Note
This proprietary grease is HIGHLY RECOMMENDED
due to its lubrication and temperature capabilities. If
not available, a high quality Lithium ''LM'' grease may
be used.
4:23
HE531V/HE551V Service Repair Manual
Component Testing and Replacement
VG Actuator Replacement Check
Warning
Always wear safety glasses.
Following installation it is necessary to check that
actuator moves through its complete stroke.
Ensure hose from dry regulated air supply is still
properly attached and secured to the actuator air inlet
fitting.
Warning
Avoid touching VG assembly until it is clear that
actuator rod is at rest and there is no risk of finger
injury.
Warning
Ensure hose is securely fastened to air inlet fitting
using appropriate hose clip and clamp load.
Progressively apply 0 to 450 kPa (65 lbf/in2) to actuator
until actuator is moving freely over its whole stroke.
Caution
Where progressive motion cannot be achieved it is
probable that element of variable geometry
mechanism internal to turbocharger is damaged.
In this case replace turbocharger.
Warning
KG
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Control regulated air supply to 0 and 300 kPa (43.5
lbf/in2). Using underside of actuator as reference
measuring point, check actuator stroke is within
permissible range shown in Service Data Sheet..
Remove air supply.
4:24
HE531V/HE551V 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.
Part No.
Tool Description
Tool Illustration
Torque Wrench
(Refer to Service Data Sheet for required torque ranges)
Regulated Air Supply
Steel Rule
0-10 bar (0 to 1000 KPa) Pressure Gauge
Dial Gauge and Dial Gauge Adapter
-0+
10
10
TYPE 20
20
20
30
30
MERCER
40
40
50
Allen Key (6 mm)
Diffuser Puller
Caution
All Service and Maintenance settings are shown in Service Data Sheet at www.holsetaftermarket.com. It
is essential that these settings are used. Common tools found in mechanic’s tool box not included.
5:1
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
The following special tools are recommended to perform procedures in this manual. The use of these tools is
shown in the appropriate procedure.
Part No.
J50968
Tool Description
Tool Illustration
V-band Spreader
VG Turbine Actuating Assembly (Not possible without remanufacturing facilities)
J90037
J90260
Drill Jig (Drawings Only)
J90290
J90291
Shroud Plate Retaining Ring Removal Tool (Drawings Only)
Caution
All Service and Maintenance settings are shown in Service Data Sheet at www.holsetaftermarket.com. It
is essential that these settings are used. Common tools found in mechanic’s tool box not included.
5:2
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Preliminary Health Checks
Caution
Many turbochargers are removed from engines before
engine, turbocharger and vehicle systems have been
health checked. Always conduct engine turbocharger
system fault diagnosis before commencing
turbocharger service and overhaul.
Always refer to Engine Control Module (ECM)
diagnostic data and Holset’s Turbocharger Diagnostic
Charts to identify the cause of any fault and to help
select the most economical repair.
Always check control valve functions by reference to
either Dcon Valve or Icon Valve.
Pressure Guage
Control Valve
12 V or 24 V
Air Supply
Battery
12 V or 24 V
Depending on vehicle system.
Polarity not important
Always check speed sensor functions by reference to
Speed Sensor Check and Replacement.
Always check VG actuator and VG mechanism by
reference to VG Actuator Checks and Replacement.
5:3
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Bearing Clearance
Warning
-0+
10
10
Titanium compressor wheel edges are sharp. Handle
with care.
TYPE 20
20
20
30
30
MERCER
40
40
50
Caution
Always check bearing clearances before commencing
turbocharger service and overhaul.
Secure turbine housing and check thrust clearance
using dial gauge.
Ensure clearance is within MIN and MAX values shown
on Service Data Sheet.
If axial clearance does not meet specification refer to
Bearing System Replacement.
Check radial movement at compressor impeller nose
using dial gauge.
Ensure movement is within MIN and MAX TIR (Total
Indicator Reading) values shown on Service Data
Sheet.
If radial movement does not meet specification refer to
Bearing System Replacement.
Warning
KG
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
5:4
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Turbine and Compressor Housings
Compressor Housing
Compressor Housing Removal
Warning
Always wear safety glasses.
Place turbine housing on clean flat surface. Mark
compressor housing, bearing housing, v-band clamp
and v-band nut position to record correct orientation.
This action assists in housing and v-band orientation
during re-assembly.
KG
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
1/4 UNF 28 tpi (7/16 in A/F)
Loosen and remove v-band locknut and discard.
Spread v-band and slide on to bearing housing.
Use soft hammer to gently tap compressor housing off
bearing housing.
Caution
Compressor blades can be damaged when
compressor housing is removed
5:5
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Warning
Always wear safety glasses.
Remove compressor o-ring seal and discard. Remove
v-band clamp.
Warning
If o-ring has been subject to fire, always use neoprene
gloves when handling.
Caution
Always fit new seal on re-assembly.
Pen marker lines may be removed by cleaning
processes. Once the housing is removed strike or score
all pen marks on housings and v-band.
5:6
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Inlet Baffle Removal and Replacement
To clean compressor housings fitted with inlet baffle it is
necessary to remove baffle.
Warning
Always wear safety glasses.
Caution
When removing inlet baffle retaining ring, be
careful not to damage compressor wheel with
screw driver. Use rag or rubber bung to protect
wheel.
A
B
Using flat screw driver, carefully apply force in area
shown (A) as retaining ring starts to move, force
screwdriver under ring as shown in (B).
Push screwdriver in anti-clockwise (counter-clockwise)
direction to force retaining ring out of groove.
Remove retaining ring.
Remove inlet baffle.
Refer to Compressor Housing Cleaning.
Following cleaning of compressor housing, locate inlet
baffle onto location ledge of compressor housing inlet.
5:7
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Hold one end of retaining ring in position in compressor
housing groove. Press remainder of retaining ring into
position using free hand.
Use flat screw driver to make sure retaining ring is
correctly seated in compressor housing groove.
Refer to Compressor Housing Re-assembly.
Warning
Always wear safety glasses.
5:8
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Compressor Housing Cleaning
Warning
Always wear safety glasses.
Caution
Housing surfaces adjacent to compressor wheel
must be clean smooth and free from deposits.
Inspect internal profile of housing for scoring damage
due to possible contact with compressor wheel.
Visually inspect housing in order to obtain as much
information as possible before washing.
Soak housing in non-corrosive low flash point metal
cleaner to loosen deposits.
Dry component using compressed air.
Remove scale-like and carbon deposits, if any, using
non-metallic bristle brush. After removing deposits rewash and dry components.
Caution
Do not bead blast Aluminium components.
5:9
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Compressor Housing Re-assembly
Warning
Always wear safety glasses.
Place turbine end assembly on clean surface. Ensure
diffuser to o-ring mating face is clean. Lubricate new
o-ring seal (41) with clean engine oil and install.
Loosely fit v-band clamp.
Align v-band and bearing housing and locate
compressor housing over compressor wheel. Refer to
marks on housings and v-band, made during
disassembly, to ensure correct v-band, v-band nut and
housing orientation.
Caution
Avoid compressor wheel damaged.
1/4 UNF 28 tpi (7/16 in A/F)
Place v-band clamp in position and torque tighten new
dry locknut (62)* to value specified in the Service Data
Sheet.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
KG
5:10
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Turbine housing
Turbine Housing Removal
Mark turbine housing, bearing housing, v-band clamp
and v-band nut position to record correct orientation.
This action assists in housing and v-band orientation
during re-assembly.
Warning
Always wear safety glasses.
KG
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Caution
Always complete engine turbocharger system
Preliminary Health Checks before commencing
turbine housing removal.
1/4 UNF (7/16 in A/F).
To avoid v-band nut thread seizure, apply penetrating
oil in accordance with manufacturer’s instructions.
Remove v-band lock nut.
Spread v-band and slide on to bearing housing,
Caution
V-band will move small distance only.
Caution
Always remove actuator before commencing
VG Core Assembly Cleaning.
Refer to VG Actuator Removal when removing
actuator.
5:11
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Warning
Always wear safety glasses.
To separate turbine housing and bearing housing, use a
soft metal hammer on two opposing areas of turbine
housing at 180 degrees.
Caution
Do not apply hammer to turbine housing flange.
Caution
Avoid significant housing separation at one side. This
may damage the turbine wheel or VG nozzle vanes.
Pen marker lines may be removed by cleaning
processes. Once the housing is removed strike or score
pen marks on housings and v-band.
Remove turbine housing to expose shroud plate and
nozzle ring and guide vane assembly. Cracking of
housing inlet duct requires turbocharger replacement.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Caution
Turbine housings can exhibit cracking when subject to
excessive thermal and mechanical loads.
KG
Shroud plate renewal is not possible without
remanufacturing facilities. If shroud plate is damaged
refer to VG Turbine Actuating Assembly.
Refer to Turbine Housing Cleaning with Shroud
Plate and VG Core Assembly Cleaning for guidance
before attempting to clean turbine housing and shroud
plate assembly or exposed areas of bearing housing
assembly.
5:12
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Turbine Housing Cleaning with Shroud Plate
Warning
Always wear safety glasses.
Heavy carbon build-up on faces shown must be
removed. Cleaning process must not contaminate
turbine housing and shroud plate assembly with loose
particles. If in doubt, refer to your nearest agent.
Caution
Refer to Gas Leakage for acceptable housing flange
conditions.
Caution
Turbine housings can exhibit cracking when subject to
excessive thermal and mechanical loads. Cracking of
inlet duct requires turbocharger replacement.
Caution
Small cracks may be visible running from the slots in
shroud plate to inner diameter. This is acceptable
and will have no detrimental affect on turbocharger
performance.
KG
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Caution
Abrasive cleaning processes may affect shroud plate
operation causing failure of variable geometry
mechanism. If in doubt replace shroud plate.
Place large lint free rag over shroud plate and push
edges into turbine volute to block debris from abrasive
cleaning process entering vane guide slots or volute.
Carefully clean three turbine housing joint faces shown
with scraper.
Sanding band/abrasive cloth grade: P180 can be used
as non-preferred alternative. Power tools can be used
carefully but ensure only corroded material is removed
from each face.
Caution
Removal of base metal by excessive abrasive
cleaning will destroy component geometry and scrap
the turbocharger.
KG
5:13
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Warning
Always wear safety glasses.
After abrasive cleaning remove rag containing cleaning
debris.
Use compressed air to blow any remaining debris out of
component.
Caution
Always protect vane slots in shroud plate against
debris ingress.
Check cleaned surfaces for pitting. Non pitted and
pitted surfaces are shown as qualitative guide only.
Caution
If any of three critical surfaces is pitted STOP
procedure and replace turbocharger.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
KG
5:14
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Pre-assembly Check
Before reassembly of turbine housing refer to
Core Assembly for bearing housing cleaning and
inspection.
Refer to VG Actuator Replacement/Refit for
information on fitting actuator.
Caution
Quote dataplate information for service and parts
support.
Warning
Always wear safety glasses.
Connect clean dry air supply to actuator air inlet fitting.
Warning
Ensure hose is securely fastened to air inlet fitting
using appropriate hose clip and clamp load.
Warning
Avoid touching VG mechanism as finger injury
may result from sudden movement of assembly
when air is supplied.
Repeat application of 450 kPa (65 lbf/in2) pressure from
regulated air supply to ensure actuator rod and VG
mechanism move freely over whole stroke.
Verify actuator stroke lies within range specified in
Service Data Sheet. Note actuator stroke.
Caution
If travel is not within permissible range or movement
is not smooth, STOP procedure and replace
turbocharger.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
KG
5:15
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Turbine Housing Re-assembly
Warning
Always wear safety glasses.
Stand the turbocharger on compressor inlet face. Fit
nozzle ring seal (162). Loosely assemble new v-band,
turbine (28).
Caution
Always rebuild with new v-band without integral heat
shield. Refer to turbocharger data plate when
ordering parts.
Caution
Replacement v-band clamp does not have integral
heat shield. To prevent actuator overheating, always
ensure turbocharger is fitted with actuator with integral
heat shield.
Apply 450 kPa (65 lbf/in2) to extend nozzle ring and
vanes to fully closed position.
Apply a thin layer of engine oil to nozzle ring seal,
turbine housing and core assembly joint faces.
Ensure nozzle ring seal is seated correctly.
5:16
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Warning
Always wear safety glasses.
Caution
Where turbine housing inlet duct is cracked or flange
condition does not meet rebuild standard defined in
Gas Leakage replace turbocharger.
Align turbine housing, bearing housing, v-band and vband nut according to marks made during disassembly.
Lower the turbine housing on to bearing housing
assembly. Take care not to damage turbine wheel and
nozzle ring vanes when aligning with shroud plate.
Caution
Never force turbine housing into position as this will
damage nozzle ring assembly.
Ensure there is no gap between the turbine and bearing
housing joint surfaces.
Caution
Quote dataplate information for service and parts
support.
Position new v-band (28)* over the joint using v-band
spreader.
1/4 UNF (7/16 in A/F).
Fit new v-band nut ( 62)* without grease or oil and
torque tighten to value specified in Service Data Sheet.
Turbine Housing Post-assembly Check
Repeat actuator rod movement check defined in
VG Actuator Replacement Check.
Ensure actuator travel is within permissible range
shown in Service Data Sheet and cross checks with
value measured at pre-assembly stage.
Remove air supply.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
KG
5:17
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Core Assembly
Cleaning and Inspection
Warning
Always wear safety glasses.
Check turbine wheel and VG nozzle vanes for signs of
damage. For example, bent blades, missing blade
sections, and scoring.
Caution
KG
If damage is found, STOP procedure and replace
turbocharger.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
Connect clean dry regulated air supply to actuator air
inlet fitting and apply 450 kPa (65 lbf/in2) maximum.
Warning
Avoid touching VG mechanism as finger injury
may result from sudden movement of assembly
when air is supplied.
Check nozzle ring and vane assembly travel is within
specification. This can be verified by checking actuator
stroke lies within range specified in
Service Data Sheet.
Caution
If actuator travel is not within range or if movement is
not smooth, STOP procedure and replace turbocharger.
KG
Block off all openings to prevent debris from cleaning
processes entering turbocharger.
5:18
HE531V/HE551V Service Repair Manual
Caution
Always clean bearing housing surfaces with nozzle
ring seal fitted and nozzle ring in fully closed position.
Turbocharger Service and Overhaul
Nozzle Ring
Nozzle Ring Seals
Caution
Removal of base metal by excessive abrasive
cleaning will destroy component geometry and scrap
turbocharger.
Caution
When cleaning surface next to nozzle ring, DO NOT
remove material from nozzle ring side wall.
Warning
Always wear safety glasses.
Protect all apertures with lint free rag.
Caution
Do not use power tools.
Carefully clean three bearing housing joint faces shown
with scraper. Abrasive cloth grade: P180 can be used
as non-preferred alternative.
Clean away all debris with lint free cloth.
Use clean compressed air to blow residual debris from
cleaned bearing housing surfaces.
Direct air through holes in nozzle assembly to remove
loose carbon behind nozzle.
Remove nozzle ring seal.
Remove actuator air supply.
5:19
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Check that cleaned bearing housing faces are not
pitted. Non pitted and pitted surfaces are shown as
qualitative guide only.
Caution
If any of three critical surfaces is pitted STOP
procedure and replace turbocharger.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
KG
5:20
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Bearing System Replacement
Warning
Always wear safety glasses.
Refer to Compressor Housing, Turbine Housing,
VG Actuator and Speed Sensor for removal
instructions.
Locate the CHRA (2) on to a 19 mm 12 point socket
located in a suitable fixture.
Caution
Ensure turbine wheel shaft and compressor wheel
have alignment marks before disassembly.
If no marks exist scribe shaft and compressor wheel
before removing compressor wheel lock nut. File
mark on shaft and scribe line on compressor wheel
nose.
M8 L.H. (13mm A/F)
Remove locknut, compressor wheel (61).
Note
Left hand thread.
Remove compressor wheel (7).
Remove remaining CHRA from fixture. Rotate assembly
and slide assembly turbine wheel (6) off bearing
housing assembly.
It is permissible to tap protruding turbine shaft
gently with a soft hammer to free dual split ring seals
stuck in bore.
5:21
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Carefully remove split ring seals, turbine (13)* and
discard.
Warning
Always wear safety glasses.
Caution
Care should be taken not to score turbine wheel
shaft assembly.
Locate bearing housing assembly in suitable fixture or
vice using soft jaws.
Mark diffuser and bearing housing for re-assembly.
Caution
Ensure nozzle ring and vanes are protected from
damage.
Pen marker lines may be removed by cleaning
processes. Once the diffuser is removed score pen
marks on diffuser and housing.
8 mm x 1.25 (6 mm Allen Key)
Remove and discard three diffuser patch screws (56)*
and washers (20)*.
Note
Diffuser patch screws may be tight. Apply small
amount of penetrating oil to help free.
Use soft hammer to loosen diffuser.
5:22
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Warning
Always wear safety glasses.
Use puller to remove diffuser (14).
Remove and discard diffuser o-ring seal (27)*.
Remove thrust collar (36) from diffuser.
Remove and discard piston ring seal (16)*.
Remove oil baffle (33).
5:23
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Warning
Always wear safety glasses.
Caution
Ensure nozzle ring and vanes are protected from
damage.
Remove thrust bearing (12)* and discard.
Remove oil slinger (31).
Using suitable circlip pliers, remove and discard two
bearing retaining rings (64)* and journal bearing (11)*
from compressor end.
Remove o-ring seal, compressor (41)* and discard.
Caution
Never slacken yoke pinch bolt as this will destroy VG
turbine setting
Rotate bearing housing assembly and place on clean
work surface.
Caution
Ensure nozzle ring and vanes are protected from
damage.
5:24
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Warning
Always wear safety glasses.
Caution
Ensure nozzle ring and vanes are protected from
damage.
Remove two bearing retaining rings (64)* and journal
bearing (11)* and discard.
5:25
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Component Cleaning
Warning
Always wear safety glasses.
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 components in non-corrosive low flash point
metal cleaner to loosen deposits.
Dry components using compressed air.
Protect sliding surfaces of cleaned parts against
corrosion by applying clean engine oil.
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 re-wash components after blasting. Dry with
compressed air.
5:26
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Inspection and Testing
Major Components
Assembly Turbine Wheel
-0+
10
10
TYPE 20
Place assembly, turbine wheel (6) on vee block.
Position dial gauge on turned surface of shaft at
threaded end. Check dial gauge reading. Where shaft
bend is greater than recommended maximum of 0.025
mm (0.001 in) replace assembly.
20
20
30
30
MERCER
40
40
50
Caution
Do not attempt to straighten turbine shaft.
Inspect split ring seal, turbine (13)* groove walls for
wear. If groove width exceeds recommended maximum
replace turbocharger.
Dual ring seal 3.30 mm (0.130 in)
If wear step on the ring face exceeds 0.102 mm
(0.004 in) replace split ring seal, turbine (13)*.
If free gap of the ring is less than 2.0 mm (0.08 in)
replace split ring seal, turbine (13)*.
Inspect bearing journals for excessive scratches and
wear.Where scratching is excessive or where either
journal diameter is less than the recommended
minimum of 12.19 mm (0.48 in) replace turbocharger.
Inspect for cracked, bent or damaged blades.
Caution
Never attempt to straighten blades.
Replace with new if any damage found.
5:27
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Compressor Wheel
Inspect compressor wheel (7), for cracked, bent or
damaged blades.
Caution
Do not attempt to straighten turbine shaft.
Replace with new if any damage found.
Small Components
Oil Slinger
Inspect and replace oil slinger (31) if piston ring groove
walls are scored or damaged or if groove width
exceeds maximum of 1.68 mm (0.066 in).
Check for signs of rubbing and scoring on thrust
surface and replace where damage is severe.
If ring faces show any signs of wear replace split ring
seal, compressor (16)*.
If free gap of ring is less than 2.0 mm (0.08 in) replace
split ring seal, compressor (16)*.
Thrust Collar
Check and replace if thrust collar (36) is scored on
thrust face or if any cracks are visible.
5:28
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Reassembly
Balance
Caution
This turbocharger was manufactured using ‘separately
piece part balanced’ process. Core or rotor balance
balance MUST always be checked on re-build.
Caution
Only use genuine Holset compressor wheel and
turbine wheel assemblies which are individually check
balanced for long life and quiet operation.
Turbocharger should always have co-relation marks on
end of turbine shaft and impeller nose if it has been
disassembled according to defined process. Thrust
collar and oil slinger will not have co-relation marks.
Rotor Balance
Components that should be included in rotor balance
are turbine wheel and shaft, thrust collar, oil slinger,
compressor wheel and Nut.
Rotor balance limits appear in Service Data Sheet. On
achieving balance, parts should be permanently marked
for subsequent re-alignment during reassembly.
Core Balance
Balance Planes
On completion of core build some turbochargers require
core balance. Core balance process requires purpose
built rig and compliance with rig procedure.
Where applicable, core balance limits appear in
Service Data Sheet.
Caution
Always make sure balance marks on rotor assembly
are in alignment when rebuilding turbocharger.
5:29
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Turbocharger Reassembly
Warning
Always wear safety glasses.
Caution
Make sure retaining rings are always fitted with
bevelled edge facing the journal bearing. Premature
failure may result from incorrect fitting.
Using suitable circlip pliers, insert two new turbine end
bearing retaining rings (64)* and journal bearing (11)*
Rotate bearing housing assembly and place on a clean
work surface.
Insert two retaining rings (64)* and journal bearing (11)*.
Caution
Never slacken yoke pinch bolt as this will destroy VG
turbine setting.
Caution
Ensure nozzle ring and vanes are protected from
damage.
Rotate bearing housing assembly and place on a clean
work surface.
Set split ring seal gaps at 180 deg and insert turbine
wheel and shaft.
Locate the turbine wheel on to 19 mm 12 point socket
located in suitable fixture.
Insert oil slinger (31).
5:30
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Warning
Always wear safety glasses.
Caution
Never slacken yoke pinch bolt as this will destroy
VG turbine setting.
Locate new thrust bearing (12)* on roll pins.
Locate oil baffle (33) on roll pins.
Fit new piston ring seal (16)* to thrust collar (36).
Insert thrust collar into diffuser (14).
Insert new diffuser o-ring seal (27)*.
5:31
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Warning
Always wear safety glasses.
Ensure score marks applied on disassembly are free
from burrs or raised edges.
Using marks, align diffuser screw holes with threaded
holes in bearing housing.
Using hand pressure, carefully insert diffuser into
bearing housing assembly.
8 mm x 1.25 (6 mm Allen Key)
Insert three new diffuser screws (56)* and washers (20)*.
Torque tighten to value specified in Service Data Sheet.
Fit compressor wheel (7) and compressor wheel nut
(61).
M8 L.H. (13mm)
Torque tighten compressor nut to value specified in
Service Data Sheet.
Some turbochargers require core balancing. Check
Service Data Sheet for core balance limits, if
applicable.
Refer to Compressor Housing Re-assembly and
Turbine Housing Re-assembly to complete
turbocharger re-build.
Warning
Turbochargers are heavy. Always refer to
Safe Lifting Methods before removing or refitting.
KG
5:32
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
VG Turbine Actuating Assembly
Shroud Plate Removal and Re-assembly
Double Bevel Ring Design
Warning
Always wear safety glasses.
Retaining ring has double bevel cross-section at outer
diameter which engages with bevel feature of ring
groove in turbine housing. Ring assembly creates
friction fit between shroud plate and turbine housing to
minimise potential for shroud plate rotation and axial
movement.
Warning
Removal of shroud plate with double bevel ring profile
requires turning fixtures and special tooling. Always
refer to Holset for safe removal and remanufacture.
Caution
Any attempt to remove shroud plate may damage
turbine housing requiring turbocharger replacement.
Caution
Do not attempt to rotate this assembly by hand.
5:33
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Turbine Housing Cleaning without Shroud Plate
Warning
Always wear safety glasses.
Caution
Housing surfaces adjacent to turbine wheel must
be clean smooth and free from deposits.
Visually inspect housing in order to obtain as much
information as possible before washing.
If in doubt, return turbocharger for remanufacture.
Caution
Check turbine housing inlet duct is not cracked and
flange condition meets rebuild standard defined in
Gas Leakage. If housing does not meet rebuild
standard ALWAYS replace turbine housing.
Soak housing in non-corrosive low flash point metal
cleaner to loosen deposits.
Dry components using compressed air.
Remove scale-like deposits, if any, using non-metallic
bristle brush. After removing deposits re-wash and dry
components.
It is permissible to bead blast turbine housing if
chemical and brush cleaning is not effective.
Caution
Prevent bead spray impinging directly on turbine
flange threads or housing joint faces by masking or
plugging.
After removing deposits re-wash and dry housing.
5:34
HE531V/HE551V Service Repair Manual
Turbocharger Service and Overhaul
Shroud plate re-assembly
Warning
Always wear safety glasses.
Where it has been necessary to remove shroud plate
from turbine housing, locate new retaining ring (180) in
shroud plate groove.
Caution
Parallel section and double bevelled section shroud
plate ring designs are not interchangeable. Always
select ring type compatible with turbine housing ring
groove detail.
Holding shroud plate push retaining ring ends into
shroud plate groove.
Insert exposed ring section into tubine housing groove.
Press remainder of retaining ring into position using
thumb pressure.
When correctly installed retaining ring will click into
position.
Check axial clearance of parallel section ring options is
within allowable range of 0.1 mm (0.004 in) and shroud
plate is free to rotate in turbine housing.
Double bevelled ring creates a friction fit between
shroud plate and turbine housing to minimise potential
for rotation and axial movement.
Caution
Do not attempt to rotate double bevel ring assembly
by hand.
5:35
Holset HE531V/HE551V
Service Repair Manual
Cummins Turbo Technologies Ltd.
Aftermarket Division
Croset Avenue
Huddersfield
West Yorkshire
HD1 6SE
www.holsetaftermarket.com
Copyright 2007, Cummins Turbo Technologies Ltd. All rights reserved.
VGT, Command Valve and Super MWE are trade marks of Cummins Turbo Technologies Ltd.
Holset and the Holset Logo are registered trade marks of Cummins Turbo Technologies Ltd.
Cummins and the Cummins logo are registered trade marks of Cummins Inc.
Part No. 4029640 Rev. 00 Ref. JV/KD Effect date 05.06
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