General description
1. The turbo generator is installed on models with DE, NC and 1T engines and is located on the exhaust manifold. Lubrication is provided by an oil feed pipe coming from the oil filter mounting bracket. The oil returns to the sump through a return pipe that connects to the cylinder block wall. The turbogenerator block has a built-in relief valve and an actuator vacuum diaphragm which is used to control the boost pressure.
2. The internal components of the turbogenerator rotate at a very high speed and are also extremely sensitive to contamination; small particles of dirt entering the turbine can cause great damage.
Warning: Thoroughly clean the area around all oil line couplers before disconnecting them to prevent dirt from entering the system. Store removed components in an airtight container to prevent contamination. Cover the air intake passages of the turbogenerator to prevent dirt from entering and use only tight fittings for cleaning (lint-free) fabrics. Do not start the engine with the turbogenerator intake duct disconnected; when the engine speed is increased, boost may suddenly turn on and there is a risk of foreign particles being sucked into the system.
Withdrawal
Note: The following procedure describes the removal of the turbogenerator leaving the exhaust manifold in place, however this method requires the use of special wrenches to access the inner mounting nuts. An alternative method is to remove the manifold together with the turbogenerator and then separate the block as described in Chapter 4.
3. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands.
4. Remove the lower protective plate from under the engine compartment.
5. Turn off nuts, and disconnect the taking-away exhaust pipe from a final collector. Support the exhaust pipe on the axle support and remove the gasket (see illustrations).
6. Unscrew the union nut, and disconnect the oil supply pipe from the turbogenerator (see illustration).
7. If necessary, remove the bolts and separate the oil feed tube from the top of the oil filter bracket. Remove gasket (see illustration).
8. Loosen the clamp and disconnect the air supply hose from the turbogenerator (see illustration).
9. Unscrew the bolts and disconnect the oil outlet pipe from the turbogenerator and crankcase (see illustrations). Remove gaskets or O-rings where present.
10. Disconnect the vacuum tube from the turbogenerator boost pressure control valve (see illustrations).
11. Unscrew the mounting nuts, and remove the turbogenerator down from the exhaust manifold. Discard the nuts, use new ones when reassembling.
12. Clean the contact surfaces of the turbogenerator and exhaust manifold.
13. Position the turbogenerator on the manifold, then apply a small amount of high temperature grease to the threads of the thru-struts. Install and gradually tighten the mounting nuts with a tightening torque specified specifications.
14. Connect the vacuum tubes.
15. Install the oil drain pipe with new gaskets or o-rings, and tighten the bolts to the specified torque specifications.
16. Connect the air supply hose, and clamp the bracket.
17. Before installing the oil feed pipe, inject oil into the opening on the turbogenerator. This must be done in order to provide the turbine with lubrication at the first start.
18. Install the oil feed tube and tighten the union nut.
19. Connect the outlet pipe to the manifold, along with a new gasket, and tighten the nuts with the tightening torque specified specifications.
20. Install the bottom skid plate, then lower the vehicle to the ground.
21. When starting the engine for the first time, it is important to let it idle for a few minutes until the oil pressure stabilizes.
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