3801449 Volvo.Penta Turbocharger

Lubrication System
Oil Flow In The Engine
From oil manifold (14) in one side of the cylinder block, oil is sent to the oil manifold in the other side through drilled passages in the cylinder block that connect main bearings (11) and the camshaft bearings at (7). Oil goes through drilled holes in the crankshaft to give lubrication to the connecting rod bearings. A small amount of oil is sent through tubes (8) to make the pistons cooler. Oil goes through grooves in the bores for the front and rear camshaft bearings and then into passages (6) that connect the valve lifter bores. These passages give oil under pressure for the lubrication of the valve lifters.Oil is sent through passages (2), on front and rear, to the rocker arm shafts (5) on both cylinder heads. Holes in the rocker arm shafts let the oil give lubrication to the valve system components in the cylinder head.Oil passage (3) is plugged. The transmission oil pump bearing is lubricated by an external oil line that connects from the right side of the cylinder block to the flywheel housing.Idler gear bore (10) gets oil from a passage in the cylinder block and in the shaft for the idler gear installed on the front of the cylinder block.The fuel injection pump and governor gets oil from passage (4) in the cylinder block. There is a small gear pump between the injection pump housing and the governor. This pump sends oil under pressure for the hydraulic operation of the hydra-mechanical governor. The automatic timing advance unit gets oil from the injection pump housing, through the camshaft for the fuel injection pumps.There is a bypass valve in the oil pump. This bypass valve controls the maximum pressure of the oil from the oil pump. The oil pump can put more oil into the system than is needed. When there is more oil than needed, the oil pressure goes up and the bypass valve will open. This allows the oil that is not needed to go back to the inlet oil passage of the oil pump.After the lubricating oil has done its work, it goes back to the engine oil pan.
OIL FLOW IN THE ENGINE
1. Bore for balancer shaft. 2. To rocker arm shaft. 3. Passage is plugged. 4. To fuel injection pump housing. 5. Rocker arm shaft. 6. To valve lifters. 7. Bore for camshaft. 8. Piston cooling tubes. 9. To timing gear housing. 10. Bore for idler gear shaft. 11. Main bearings. 12. To turbocharger. 13. From oil filters. 14. Oil manifold.Oil Flow Through The Oil Filter And Oil Cooler
With the engine warm (normal operation), oil comes from oil pan (12) through a suction bell to oil pump (11). The oil pump sends warm oil to oil cooler (13) and then to oil filters (15).From the oil filters, oil is sent to the oil manifold in the cylinder block and to the oil sypply line for the turbocharger (16). Oil from the turbocharger goes back through an oil return line to the oil pan (12).With the engine cold (starting conditions), bypass valves (10 and 14) give immediate lubrication to all components when cold oil with high viscosity causes a restriction to the oil flow through oil cooler (13) and oil filters (15). The oil pump then sends the cold oil through bypass valve (14) for the oil filter to the oil manifold in the cylinder block and to the supply line for the turbocharger. Oil from turbocharger (16) goes back through the oil return line to oil pan (12).
FLOW OF OIL (ENGINE WARM)
1. Bore for balancer shaft. 2. To rocker arm shaft. 3. Passage is plugged. 4. To fuel injection pump housing. 5. Rocker arm shaft. 6. To valve lifters. 7. Bore for camshaft. 8. Piston cooling tubes. 9. To timing gear housing. 10. Bypass valve for oil cooler. 11. Oil pump. 12. Oil pan. 13. Oil cooler. 14. Bypass valve for oil filters. 15. Oil filters. 16. Turbocharger.When the pressure difference in the bypass valves decreases, the bypass valves close. Now there is a normal oil flow through the oil cooler and oil filter. Filter bypass valve is open only a few seconds and closes before the oil gets warm.The bypass valves will also open (with engine warm) when there is a restriction in the oil cooler or oil filter. This action does not let an oil cooler or oil filter with a restriction prevent the lubrication of the engine.
FLOW OF OIL (ENGINE COLD)
1. Bore for balancer shaft. 2. To rocker arm shaft. 3. Passage is plugged. 4. To fuel injection pump housing. 5. Rocker arm shaft. 6. To valve lifters. 7. Bore for camshaft. 8. Piston cooling tubes. 9. To timing gear housing. 10. Bypass valve for oil cooler. 11. Oil pump. 12. Oil pan. 13. Oil cooler. 14. Bypass valve for oil filters. 15. Oil filters. 16. Turbocharger.Cooling System
Radiator Cooled System
When the temperature regulators are fully closed (engine cold), no coolant goes through outlets (4) to the radiator. All the coolant flows directly to water pump (12) through both radiator bypass lines (14).When the temperature regulators are fully open (engine warm), a small amount of coolant goes through two radiator bypass lines (14). Most of the coolant flows through the core of radiator (6).Water pump (12) takes the coolant from radiator bypass lines (14) and water pump inlet (13) and forces it through inlet bonnets (10 and 11). Part of the coolant will flow through engine oil cooler (8), and part will flow through transmission oil cooler (9). From outlet bonnet (7), the coolant will flow into the cylinder block and then to both cylinder heads.Coolant inlet line (1) supplies coolant to the turbocharger housing to cool the bearings. Coolant outlet line (3) returns the coolant to the radiator.
RADIATOR COOLED SYSTEM SCHEMATIC
1. Coolant inlet line. 2. Turbocharger. 3. Coolant outlet line. 4. Outlet from temperature regulator housing to radiator top (one on each side at front of engine). 5. Temperature regulator housing (both