HX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 1 of 16 Bolt, Compressor Housing (Item 59) Locknut, V-Band Compressor (Item 29) Air Tapping - Male Union (item 105) = Donot work an a unningtuboctarger or engine. Turocharges can be hazardous when not sad ae pected by tho ranufocue. To prevent domege and peony: ‘ovaj use te turbocharger pat number spect Sythe engine manure. Ue ry nse epee byte egne + Domotec botor checking sutac temperatures, De net meaty the turbocharger ina Way. + Dsaseombie and assem usrg the engine ‘manolachrersintuctons exon approved opr prt For scent sate ono roche Turbo Model Nm (Ib. in) Nm (Ib. in) Nm (Ib. in) ‘tomes a HX20W NA NA NA WA HX25/25W/27W NA NA NA NA HX30 (68mm wheel) NA NA NA NA HX30 (72mm whee!) NA NA NA NA HX32 NA NA NA WA HX35 NA NA NA NA HXx40 NA NA NA WA HX50 (2mm wheel) 8.5 (75) NA NA WA HIX50 (108 / 112 mm whee) 8.5 (75) NA NA A HX55/52 NA 85 (75) NA 85 (75) HX60/HT60 NA 8575) NA A HX80/85 NA 85(75) 85 (75) NA HT80 NA 85 (75) NA NA HX82 NA 85 (75) 12 (106) NA HX83 NA NA 12 (106) NA HY30W NA NA NA NA HY35W (Dcx Myo1) NA NA NA WA HY35W (ocx Moanuvo4.s) NA NA NA NAHX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 2 of 16 Locknut, Compressor Locknut, Compressor Screw, Diffuser Wheel (Item 61) ‘Wheel (item 61) (tem 58) Turbo Model Nm (Ib. in) Nm (Ib. in) oo cane HXx20W. T1A5 (147225 @2) see note NA NA HYX25/25W/27W 11:29,05)T2:49 (4) see nate 9 NA NA HX30 (68mm whee!) 15 (133) 14 (124) NA HX30 (72mm wheel) 45 (133) 44 (124) NA HX32 15 (133) a 14 (124) NA HX35 45 (133) 14 (124) NA HX40 15 (133) 14 (124) NIA HX50 (98mm wheel) 17 (150) N/A NA HIX50 (108 / 112 mm whee) 17 (150) NA NA HX58/52 17 (150) NA NA HX60/HT6O 40.7 (960) NA NA HX80/85, 45.2 (400) NA 24.9 (220) HT80 45.2 (400) N/A 24.9 (220) HX82 45.2 (400) see note 19 ‘45.2 (400) see note 21 24.9 (220) HXx83 NA NA NA HY30W NA 14 (124) NA HY35W (pcx myo1) NA 14 (124) NA HY35W (ocx mvosnavos.5) NA 14 (124) NAHX & HY Service Data Sheets HX & HY Service Data Sheet 3 of 16 Expiry Date: 06:2013 Bolt, Turbine Locknut, V-Band Turbine (Item 28) Housing (Item 57) Turbo Model Nm (Ib. in) Nm (Ib. In) HX20W NA 9.4-H-0.5 (80 4/- 4) (Bee note 13) NA HYX25/25W/27W NA 8.34/05 (74-444) (Se nate 12) NA HX30 (68mm wheel) NA 8.5 (75) N/A HX30 (72mm wheel) NA 85 (75) NA HX32 NA 85 (75) NA HX35 26 (230) NA NA HXx40 26 (290) NA NA HXX50 (oamm whee!) 81.6 (280) see note 6 NA NA X50 (108/112 mm whee) 31.6 (280) see note 6 NA NA HX55/52 81.6 (280) see note 6 see note 18 see note 18 HX60/HT60 NA 8.5 (75) - see note 14 11.3 (100) - see note 14 HX80/85, 20.3 (180) NA NA HT80 20.3 (180) NIA NIA Hx82 20.3 (180) NA NA HX83 20.3 (180) NIA NA HY30W NA 85 (75) NA HY35W (pcx myo1) NA 8.5 (75) N/A HY35W (ocx myosmvos.5) NA 85 (75) NIAHX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 4 of 16 Bolt, Cover Plate Bolt, Exhaust Adapter Locknut, Heatshield, {item 67) (item 67) External (item 108) Turbo Model Nm (Ib. in) Nm (Ib. in) HX20W NVA NA NA HX25/25W/27W NA NIA NA HX30 (68mm wheel) NA NA NA HX30 (72mm whee!) NA NIA NA HX32 NA 25 (220) N/A HX35 NA 25 (220) NA HX40 NVA 25 (220) NA HX50 (8mm whee!) 8.5 (75) 30.7 (270) NA X50 (108 / 112 mm whee) 85 (75) 307 (270) NA HX55/52 8.5 (75) 30.7 (270) 4.1 (10) HX60/HT60 8.5 (75) NA NIA HX80/85 NA NIA NA HT80 NA NA NA HX82 NA NIA NA HX83 NA NA NA HY30W NA 25 (220) NA HY35W (0¢x Myo) NA 25 (220) NA HY35W (ocx mvosnavos.s) NA 25 (220) NAHX & HY Service Data Sheets HX & HY Service Data Sheet Stud nut, Exhaust connector {item no 98/108) 5 of 16 Radial Movement amr) Expiry Date: 06:2013 Axial Clearance Turbo Model Nm (Ib.in) HX20W NA HX25/25W/27W NA HX30 (68mm wheel) NA HX30 (72mm whee!) NA HX32 NA HX35 NA HX40 NA HX50 (98mm wheel) 25 (220) HX50 (108 / 112 mm wheel) 25 (220) HX55/52 NA HX60/HT60 NA HX80/85 NA HT80 NA HX82 NA HX83 NA HY30W NA HY35W (pcx Myo1) NA HY35W (ocx Myoamavo4.s) NA (0.394 - 0.602 0.016 - 0.024) 0.894 - 0,602 (0.016 - 0.024) (0.390 - 0506 (0.013 - 0.020) (0.890 - 0.508 (0.013 - 0.020) (0.390 - 0506 (0.013 - 0.020) 0.890 - 0.508 (0.013 - 0.020) (0390 - 0506 (0.013 - 0.020) 0.981 - 0610 (0.015 - 0.024) 0.981 - 0.610 (0.015 - 0.024) 0.406 - 0.610 (0.016 - 0.024) 0.406 + 0.584 (0.016 - 0.028) 0.254 - 0.787 (0.010- 0.031) (0.264 - 0787 (0.010- 0.031) 0.254 - 0.787 (0.010- 0.031) (0.264 - 0.787 (0.010- 0.031) 0.856 - 0.559 (0.014 - 0.022) (0.326 - 0506 (0.013 - 0.020) 0.826 - 0.508 (0.013 - 0.020) mm (in) (0.027 - 0.073 (0.001 - 0.008) 2.010 - 0.076 (0.0004 - 0.003) (0.025 - 0.427 (0.004 - 0.008) 0.025 - 0.127 (0.001 - 0.005) (01025 - 0.427 (0,001 - 0.005) (0.025 + 0.127 (0.001 - 0.005) (0.025 - 0.427 (0.001 - 0.008) 0.025 - 0.127 (0.001 - 0.005) (0.026 - 0.127 (0.004 - 0.008) 0.025 + 0.127 (0.001 - 0.005) (0051 - 0.182 (0.002 - 0.006) 0.025 - 0.152 (0.001 - 0.006) (01.026 - 0.462 (0.001 - 0.006) (0.025 - 0.12 (0.001 - 0.006) (0.025 - 0.182 (0.001 - 0.006) 0.025 + 0.127 (0.001 - 0.005) (0.025 - 0.427 (0.004 - 0.008) (0.025 + 0.127 (0.001 = 0.005) ‘Always refer to Service Notes before using this service datHX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 6 of 16 Rotor Balance (see note 15) Turbo Model g. mm (oz. In) g- mm (oz. In) Turbine End Compressor End HX20W NA NA HX25/25W/27W NA NA HX30 (68mm wheel) 4.1 (0.0015) 4.1 (0.0015) HX30 (72mm whee!) 1.4 (0.0019) 1.4 (0.0019) HX32 1.4 (0.0019) 1.4 (0.0019) HX35 1.4 (0.0019) 1.4 (0.0019) HX40 4.4 (0.0019) 1.4 (0.0019) HX50 (98mm whee!) 2.2 (0.003) 4.4 (0.006) X50 (108 / 112 mm whee) 2.2 (0.008) 4.4 (0.006) HX55/52 2.2 (0.008) 4.4 (0.006) HX60/HT60 4.4 (0.006) 4.4 (0.006) HX80/85 7.2 (0.010) 7.2 (0.010) HT80 7.2 (0.010) 123 (0.017) HXB2 7.2 (0.010) 12.3 (0.017) HX83 NA NA HY30W 1.1 (0.0015) 1.1 (0.0015) HY35W (Dcx myo) 4.1 (0.0015) 4.1 (0.0015) HY35W (ocx myos/yo4.s) 1.4 (0.0015) 1.4 (0.0015)HX & HY Service Data Sheets HX & HY Service Data Sheet 7 of 16 Core Balance at 4000 rev/min Turbo Model g. mm (oz. in) HX20W NA HX25/25W/27W NA HX30 (68mm wheel) 0.75 (0.0010) HX30 (72mm whee!) 0.9 (0.0012) HX32 1.4 (0.0019) HX35 1.5 (0.0020) HXx40 1.5 (0.0020) HX50 (8mm whee!) 2.2 (0.0030) X50 (108/112 mm whee) 2.7 (0.0037) see note 20 HX55/52 2.2 (0.0080) HX60/HT60 4.4 (0.0060) HX80/85 7.2 (0.010) HT80 5.8 (0.0080) HX82 7.2 (0.010) HX83 NA HY30W 0.9 (0.0012) HY35W (Dcx yo) 1.4 (0.0019) HY35W (0cx Myoa;Mvo4.5) 1.25 (0.0017) g.mm (oz. in) NA NVA 4.0 (0.0014) 41.25 (0.0017) 1.4 (0.0019) 1.8 (0.0025) 4.8 (0.0025) 4.4 (0.0060) 5.3 (0.0073) see note 20 4.4 (0.0060) 7.2 (0.010) 12.3 (0.017) 5.8 (0.0080) 12.3 (0.017) N/A 1.25 (0.0017) 1.4 (0.0019) 1.25 (0.0017) Expiry Date: 06:2013HX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 8 of 16 Vibration Level ‘on VSR rig cuna Z Acclrometor ©, L pe Letepeng ——~"| Suspension Turbo Model gforce peak g-force peak {x speeds up to 100,000 rev! At speeds between ‘min 100,000 and 190,000 rewmin HX20W 11g see note 11 2g see note 11 HX25/25W/27W 11g see note 11 2g see note 11 HX30 (68mm whee!) NA N/A HX30 (72mm whee!) NA NA HX32 NA NIA HX35 NA NA HX40 NA NA HX50 (8mm whee!) NA NA HX50 (108 / 112 mm wheel) NA N/A HX55/52 NA NA HX60/HT60 NA NA HX80/85 NA NA HT80 NA N/A HX82 NA NA HX83 NA N/A HY30W NA NA HY35W (pcx Myo1) NA N/A HY35W (ocx Myoanivo4.s) NA LNAHX & HY Service Data Sheets HX & HY Service Data Sheet 9 of 16 Vibration Level ‘on VSR rig CPM pecslrorier 3) be Stereos] Turbo Model g-force peak g-force peak apo betwen 3500 and st pond ot ‘sam oa 104908 ron HX20W NA NA HX25/25W/27W NA NA X30 (68mm whee!) 2g see note 17 3.5g see note 17 HX30 (72mm wheel) 2g see note 17 3.59 see note 17 HX32, 2.g see note 17 3.5 g see note 17 HX35 2g see note 17 35 see note 17 HXx40 2 see note 17 3.59 see note 17 HX50 (98mm wheel) NA N/A HX50 (108 / 112 mm wheel) NA NA HX55/52 NA NA HX60/HT60 NA NA HX80/85, NA NIA HT80 NA NA HX82 NA NA HX83 NA NA HY3OW NA N/A HY35W (0¢x Myo) 2g see note 17 359 see note 17 HY35W (ocx myosmyos.s) 2.9 see note 17 N/A Expiry Date: 06:2013HX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 10 of 16 Vibration Level ‘on VSR rig G4. tot Stason 5 Turbo Model g-force peak g-force peak [At opeed ot At epeed of 110,000 rewmin 120,000 revimin HX20W NA NA HX25/25W/27W NA NA HX30 (68mm whee!) NA NIA HX30 (72mm whee!) NA NA HX32 NA N/A HX35 NA NA HX40 NA NA HX50 (8mm wheel) NA NA HX50 (108 / 112 mm wheel) NA N/A HX55/52 NA NA HX60/HT60 NA N/A HX80/85 NA NA HT80 NA N/A HX82 NA NA HX83 NA N/A HY30W NA NA HY35W (pcx Myo1) NA NA HY35W (ocx Myoamvo4.s) 2.7 g see note 17 29g see note 17HX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 11 of 16 ‘Turbine Housing Water Fittings Bearing Housing Straight Thread, Taper Thread, Water Fitting, (item101/102/103) (item 104) Turbo Model Nm (Ib. in) Nm (Ib. In) Nm (Ib. in) HX20W NA NA NA HYX25/25W/27W NA NA NA HX30 (68mm whee) NA NA NA HX30 (72mm whee) NA NA NA HX32 NA NA NA HX35 67.8 (600) NA 40 (954) x40 67.8 (600) NA 40 (354) HXX50 (oemm whee!) 67.8 (600) NA NA HIX50 (108 / 112 mm whee), 67.8 (600) NA WA HX58/52 67.8 (600) NA NA HX60/HT6O NA NA NA HX80/85, 748 (660) 678 (600) NA HT80 NA NA NA HX82 NA NA NA HXx83 NA NA NA HY30W NA NA NA HY35W (ocx my01) NA NA WA HY35W (ocx mvoamvo4.5) NA NA NAHX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 12 of 16 Adapter, Oil Adapter, Oi Infet (Item 113) Drain (Item 116) oa | © Turbo Model Nm (Ib. in) Nm (Ib. In) HX20W 24 (212) NA HX25/25W/27W 24 212) NA HX30 (68mm whee!) 35 (310) NA HX30 (72mm whee!) 35 (810) NA HX32 98 (810) NA HX35 95 (810) NA HX40 40 (954) azn» HX50 (8mm wheel) 40 (954) NA HX50 (108 / 112 mm wheel) 40 (354) NA HX55/52 NA NA HX60/HT60 NA NA HX80/85 NA NA HT80 NA NA HX82 NA NA HX83 NA NA HY30W 35 (310) NA HY35W (D¢x Myo) 35 (310) NA HY35W (ocx mvosmvos.s) 35 810) NAHX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 13 of 16 Temperature Sensor/ Speed Sensor lanl tem (tom 138/103) oa Turbo Model ‘Nm (Ib. in) ‘Nm (Ib. in) HX20W NA NA HYX25/25W/27W NA NA HX30 (68mm wheel) NA NK HX30 (72mm whee!) NA NA Hx32 NA NA HX35 17 (150) NA HXx40 17 (150) NA HX50 (98mm wheel) NA NA X50 (108 / 112 mm wheel) NA NA HX55/52 NA NA HX60/HT6O NA NA HX80/85 NA NA HT80 NA NA HX82 NA 12 (106) HX83 NA 12(106) HY30W NA NA HY35W (ocx myo1) 7150) NA HY35W (ocx Mvoamvo4.s) 17 (180) NAHX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 14 of 16 Nut, Wastegate Screw, Westegate Screw, Wastegate ‘Actuator (Item 83) Actuator (Item 108) Brace Bracket (item 139/142) cS Turbo Model Nm (Ib. in) Nm (Ib. In) Nm (Ib. in) HX20W NA 196 4/1 (173-49) NA HX25/25W/27W NA 196 41 (173 4/-9) NA HX30 (68mm wheel) 85 (75) NA 25 (220) HX30 (72mm whee!) 85 (75) NA 25 (220) HX32 8.5 (75) NA 25 (220) HX35 8575) 19.6 (178) 25 (220) HX40 85 (75) 19.6 (173) 25 (220) HX50 (8mm whee!) Nw 85 (75) 25 (220) HX50 (108 / 112 mm wheel) NA 8.6 (75) 25 (220) HX55/52 8575) NA 25 (220) HX60/HT60 a5 (75) NVA 25 (220) HX80/85 NA NA NA HT80 NA NIA NA HX82 NA NA NA HXx83 NA NA NA HY30W 85:75) NA NA HY35W (pcx Myo1) 8.5 (75) NIA NA HY35W (ocx Myoamavo4.s) 85 (75) NA NAHX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 15 of 16 Jam Nut, Wastegate Screw, Wastegate Hose Clip ‘Actuator (Item 128) Valve Body (Item 79) (item 75) Ss | Turbo Model Nm (Ib. in) Nm (Ib. In) Nm (Ib. In) HX20W. 6.9 4+ 1.9 (61 +17) NA NA HX25/25W/27W 6.9 +/- 1.9 (61 + 17) NA NA HX30 (65mm whee!) 85 (75) NA NA HX30 (72mm whee) 85 (75) NA NA HX32 8575) NA NA ‘HX35 85 (75) NA NA X40 8575) NA NA X50 (98mm wheel) 8.5 (75) 30 (267) NAL X50 (109/112 mm wheet) 85 (75) 901267) NA HX55/52 85 (75) 30 (267) 17 (15) HX60/HT60 85 (75) NA NA HX80/85 NA NA NA ‘HT80 NA NA NA HX82 NA NA NA X83 NA NA NA HYSOW 8575) NA NA HY35W (pcx mvo1) 85 75) NA NA HY35W (ocx mvoapavos.5) 85 (75) NA NAHX & HY Service Data Sheets Expiry Date: 06:2013 HX & HY Service Data Sheet 16 of 16 Service Data Sheet Notes 1. The ist of turbocharger models represents the majority of current specications. it your model does not appear inthe Service Data Shoes, please reer to your nearest ditibutr for guidance 2, Service Datais sourced from Engineering Specifications and Drawings. AA permissible Service Alowances are included in his data sot 44. Where nominal torque is quoted alway aim to achieve ths mid-point value during turbocharger assembly processes. Toavoid inefecive cam loading r plastic deformation of components through under or over ightening respectively, nominal torque Trust be appid using a calibrated toque wrench wth not lass than ++ 1 Nr (= 10 Ibn) capaity. For ow torque jit, use {equipment that can achieve the epected claton accuracy. Never use breakaway torque tb check clamping eflency a this can vary up to 40% from nominal 5. Some madels have optional specifications (e.g. turbine housing bots or V-band arrangements). Both are shown for raterenoe. 6. European OEM's and Holset Atermarke's orque tightening concession of 31.6 Nm (280 Ibn) now adopted in Engineering Specticatons. 7. For the latest Service Data Shoots and Bulletin Board information refer io wweholstatermarket oom. 8. Wastogato versions of H series turbochargers aro pre-fxed wih a "W. Refer to your nearest distributor for wastogato instalation instructions. 8. HX20125/27 compressor wheel nut (61) Is tightened in 2 stages. Always use @ new nut. Apply Molycote to nut or shat thread. “Torque tT, loosen and retarque to T2 10. Not applicable 11. Robuit CHRA must be core balanced using highspeed vibration soring rig (VSF). 12, Allfastoners must be visually clean and be lubricated with ght ol prior o torque tightening except where the Service FRepair Manval instructs tothe contrary Excoptions are: + HXBOWIX25/25W/27W Compressor Wheel Locknut, (61) V-Band Locknut, (28) - apply malycote. “Al other V-Band Locknut (28) (29) and Wastegale Vale Body Screw (79) «fit dy. + All fasioners treated with a thread locking patch - ft cry and within 5 minutes of insertion. Use stow tightening food rato to prevent activation of locking patch prior ofl thread engagement. 18, Refer to HX20W and HX25/25W/27W Service Repair Manuals fr tightening procedure. 14. \éband Part no. 3539458 (1.3 Nm) superceded Part no. 3504959 (8.5 Nm) fram October 2002. Check part number to ensure correct torque seting is used during reassembly 15. Use cate balance process when facilis are avaiable. 16. Use VSR process i aces are avaiable. 17. VSR passfal limits are rig pectic and advisory. Refer to repairer to warantcurabiliy, nose and vibration o repair. 18, Part no, 3596763 (11.3 Nm) superceded Part no. 2536399 (8.5Nm) from January 2006. Torque setting is now dependent on ‘band and nut part numbers. Check part numbers to ensure corec torque setting Is used during reassembly 7 7e0609 | with captivenut | 105 19. HX82 Turbocharger Assembly 4044033 is tightened to 80 Nm (708 lb. in). Other specifications which feature a stanloss steak hexagon nut may be torqued to this figure only with Product Engineering agreement 20. Some HXS0 and derivative turbochargers are fited wit titanium compressor wheels. Alvays check wheel diameter and use appropriate core balanoe specification. 24, HX83 A181 and HX82 B151A Turbochargers fted with impellers of 138 mm or greater back face diameter will bo fited with a b-hexagon locknut, Before fiting impeller, ghtly oll shaft shoulder, add thrust colar and rotate to spread ol, assemble ol singer. Degrease impeller and bi-nex nut before fiting clean and cry. Position impeller 135 degrees from balance mark and allow it to rotate as torque is applied. Ensure impeller rotational postion is within +/- 45 deg of balanced positon when ‘pected torque is achieved. Otherwise slacken nut, readjust impeller postion and re-torque to achieve specitied impeller rotational postion. ‘Always refer to Service Notes before using this service data,