________________________________________________________________________________

Volvo Penta D3-150 Engine

The Volvo Penta D3-150 is an in-line, 5-cylinder, 2.4-liter marine diesel engine engineered for high reliability, exceptional operating economy, and long-term durability. Manufactured between 2003 and 2022, this lightweight unit utilizes an advanced aluminum cylinder block and cylinder head design. Equipped with a Variable Geometry Turbocharger (VGT) and a piezo-electric common-rail injection system, the engine delivers robust low-end torque and responsive performance while complying with EU RCD Stage II and US EPA Tier 3 emissions standards. It is highly regarded for leisure repowering and marine inboard applications.

The cylinder head features a double overhead camshaft (DOHC) arrangement driving a 4-valve per cylinder technology. This setup incorporates hydraulic valve adjusters to automatically maintain proper clearance, eliminating the need for periodic mechanical manual adjustment. The engine geometry is defined by a cylinder bore diameter of 81.0 mm and a piston stroke length of 93.2 mm, operating across a total displacement of 2.4 liters.

Fuel delivery is managed via an electronically controlled Common Rail fuel injection system. The system features high-pressure piezo-electric injectors capable of multiple precise injection events per cycle. The engine control unit automatically compensates for variances, providing constant power output regardless of fuel quality or ambient fuel temperature within a range of 5C to 55C (41F to 131F). The primary fuel circuit includes a fine fuel filter integrated with a water separator and an active "water-in-fuel" sensor connected to the main helm alarm.

The engine uses a full-pressure lubrication network utilizing a plate-type oil cooler to stabilize operating oil temperatures under heavy marine loads. Maintenance is supported by an easily replaceable, insert-type full-flow oil filter. Additionally, the pistons are specifically oil-cooled via internal cooling jets to handle extreme thermal stress. The unit employs an integrated marine cooling system designed to manage engine and component temperatures. This setup incorporates a closed-loop configuration that interfaces with a plate oil cooler and a stainless steel exhaust elbow to prevent raw water contamination within core engine passages while ensuring optimal heat dissipation.

General Technical Data

Engine Specifications

Engine Model ............... Volvo Penta D3-150
Engine Type ............... 4-stroke inline 5-cylinder direct injection liquid-cooled diesel
Number of Cylinders ............... 5
Cylinder Arrangement ............... Inline vertical
Engine Bore, mm (in) ............... 81.0 (3.19)
Engine Stroke, mm (in) ............... 93.2 (3.67)
Displacement, L (cu.in) ............... 2.40 (146.4)
Rated Power at Crankshaft, kW (hp) ............... 110.0 (150.0)
Rated Propeller Shaft Power, kW (hp) ............... 106.0 (144.0)
Rated Engine Speed, rpm ............... 3000
Maximum Crankshaft Torque, Nm (lb-ft) ............... 330.0 (243.4)
Maximum Torque Engine Speed, rpm ............... 2000-2500
Idling Speed, rpm ............... 700-750
Maximum No-Load Speed, rpm ............... 3300-3400
Aspiration Type ............... Turbocharger (VGT) with charge air cooler
Compression Ratio ............... 16.5:1
Firing Order ............... 1-2-4-5-3
Direction of Rotation ............... Counter-clockwise facing the flywheel
Cylinder Block Material ............... Die-cast aluminum alloy
Cylinder Liner Type ............... Cast-in grey iron liners
Cylinder Head Material ............... Gravity-cast aluminum alloy
Number of Valves per Cylinder ............... 4
Total Number of Valves ............... 20
Camshaft Configuration ............... Double Overhead Camshafts (DOHC)
Camshaft Drive Mechanism ............... Toothed timing belt with automatic tensioner
Crankshaft Main Bearings ............... 6
Lubrication System ............... Full-pressure wet sump lubrication
Oil Pump Type ............... Crankshaft-driven internal gear pump
Oil Filter Type ............... Full-flow spin-on cartridge paper element
Oil Cooler Type ............... Integrated multi-plate seawater-cooled heat exchanger
Cooling System ............... Dual-circuit liquid cooling with freshwater loop
Freshwater Pump Type ............... Timing belt-driven centrifugal pump
Seawater Pump Type ............... Gear-driven flexible rubber impeller pump
Heat Exchanger Type ............... Tubular bundle type with expansion tank
Thermostat Type ............... Wax element bypass type thermostat
Emission Certification ............... EU RCD Stage II, US EPA Tier 3
Starting System ............... Electric Starter
Starter Motor Power, kW (hp) ............... 2.2 (2.95)
Electrical System, V ............... 12
Alternator Rating, A ............... 180

Fuel System

Fuel Injection System ............... High-pressure common rail electronic direct injection
Low-Pressure Feed Pump Type ............... Mechanical gear pump
Low-Pressure System Delivery Pressure, kPa (psi) ............... 400.0-550.0 (58.0-79.8)
High-Pressure Fuel Injection Pump Model ............... Bosch CP3 three-plunger pump
Maximum Common Rail Operational Pressure, bar (psi) ............... 1800.0 (26107.0)
Minimum Common Rail Pressure for Engine Start, bar (psi) ............... 120.0 (1740.0)
Fuel Injector Type ............... Piezo-electric actuated multi-hole needle injectors
Number of Injector Spray Orifices per Nozzle ............... 7
Fuel Injector Electronic Drive Voltage, V ............... 140
Fuel Filter Type ............... Single spin-on fine element with water separator sensor
Governor Type ............... Electronic Control Unit (ECU) regulated
Maximum Fuel Return Line Backpressure, kPa (psi) ............... 50.0 (7.25)
Maximum Fuel Feed Line Restriction, kPa (psi) ............... 20.0 (2.9)
Fuel Grade Specs ............... EN 590, ASTM D975 No.1-D, No.2-D Low Sulfur Diesel
Fuel Feed Line Inner Diameter, mm (in) ............... 8.0 (0.31)
Fuel Return Line Inner Diameter, mm (in) ............... 6.0 (0.24)
Fuel Pressure Control Valve Location ............... High-pressure pump inlet and fuel rail manifold

Dimensions and Weight

Overall Length without Transmission, mm (in) ............... 785 (30.9)
Overall Length with HS25AE Gearbox, mm (in) ............... 1015 (40.0)
Overall Length with HS45AE Gearbox, mm (in) ............... 1025 (40.3)
Overall Length with HS63IVE V-Drive, mm (in) ............... 940 (37.1)
Overall Width, mm (in) ............... 630 (24.9)
Overall Height, mm (in) ............... 695 (27.3)
Dry Weight without Gearbox or Fluids, kg (lbs) ............... 260 (573)
Dry Weight with HS25AE Hydraulic Transmission, kg (lbs) ............... 297 (655)
Dry Weight with HS45AE Hydraulic Transmission, kg (lbs) ............... 301 (665)
Dry Weight with HS63IVE V-Drive Transmission, kg (lbs) ............... 342 (755)
Wet Weight with Fluids and HS25AE Transmission, kg (lbs) ............... 314 (692)

Maintenance Data

Service Information

Oil Pressure at Low Idle, kPa (psi) ............... 150.0-200.0 (21.8-29.0)
Oil Pressure at Rated Speed, kPa (psi) ............... 400.0-550.0 (58.0-79.8)
Relief Valve Opening Pressure, kPa (psi) ............... 600.0 (87.0)
Cooling System Pressure Cap, kPa (psi) ............... 75.0 (10.9)
Thermostat Opening Initial Temperature, C (F) ............... 82.0 (179.6)
Thermostat Fully Open Temperature, C (F) ............... 92.0 (197.6)

Engine Oil and Coolant

Engine Oil Type .................. SAE 5W-30, SAE 10W-30, or 15W-40
API Service Classifications ......................... CH-4 or CI-4
Oil Sump Capacity (Minimum), L (qt) ............... 5.5 (5.8)
Oil Sump Capacity (Maximum), L (qt) ............... 6.5 (6.9)
Freshwater Circuit Capacity, L (qt) ............... 8.5 (9.0)
Engine Oil Capacity with Filters, L (qt) ............... 7.0 (7.4)

Service Intervals

Change oil and filter ............... Every 200 hours
Service air cleaner ............... Every 100 hours
Replace air cleaner ............... Every 400 hours
Replace fuel filter ............... Every 200 hours
Fuel system inspection ............... Every 1200 hours
Change coolant ............... Every 2000 hours
Compression test ............... Every 2000 hours
Replace drive belt ............... Every 400 hours
Replace impeller ............... Every 200 hours
Service heat exchanger ............... Every 800 hours

Service Specifications

Cylinder Bore Inner Diameter, mm (in) ............... 81.000-81.015 (3.1889-3.1895)
Cylinder Block Deck Face Flatness Distortion, mm (in) ............... 0.050 (0.0020)
Main Bearing Bore Inner Diameter, mm (in) ............... 69.000-69.019 (2.7165-2.7173)
Main Bearing Journal Diameter, mm (in) ............... 64.981-65.000 (2.5583-2.5590)
Main Bearing Journal Max Out of Round, mm (in) ............... 0.006 (0.0002)
Main Bearing Clearance, mm (in) ............... 0.024-0.062 (0.0009-0.0024)
Crankshaft Axial End Play, mm (in) ............... 0.080-0.190 (0.0031-0.0075)
Thrust Bearing Surface Width, mm (in) ............... 26.000-26.050 (1.0236-1.0256)
Crankpin Journal Diameter, mm (in) ............... 49.982-50.000 (1.9678-1.9685)
Connecting Rod Bearing Clearance, mm (in) ............... 0.020-0.056 (0.0008-0.0022)
Connecting Rod Big End Bore Inner Diameter, mm (in) ............... 53.000-53.015 (2.0866-2.0872)
Connecting Rod Small End Bushing Inner Diameter, mm (in) ............... 28.005-28.012 (1.1026-1.1028)
Connecting Rod Side Axial End Play, mm (in) ............... 0.150-0.300 (0.0059-0.0118)
Piston to Cylinder Bore Clearance, mm (in) ............... 0.050-0.085 (0.0020-0.0033)
Piston Pin Outer Diameter, mm (in) ............... 27.994-28.000 (1.1021-1.1024)
Piston Pin to Con Rod Bushing Clearance, mm (in) ............... 0.005-0.018 (0.0002-0.0007)
Piston Pin to Piston Pin Bore Clearance, mm (in) ............... 0.002-0.010 (0.0001-0.0004)
Top Ring Side Clearance, mm (in) ............... 0.050-0.090 (0.0020-0.0035)
Second Ring Side Clearance, mm (in) ............... 0.040-0.080 (0.0016-0.0031)
Oil Ring Side Clearance, mm (in) ............... 0.030-0.070 (0.0012-0.0028)
Top Ring End Gap, mm (in) ............... 0.250-0.400 (0.0098-0.0157)
Second Ring End Gap, mm (in) ............... 0.300-0.500 (0.0118-0.0197)
Oil Ring End Gap, mm (in) ............... 0.250-0.500 (0.0098-0.0197)
Cylinder Head Deck Surface Flatness Distortion, mm (in) ............... 0.030 (0.0012)
Inlet Valve Stem Outer Diameter, mm (in) ............... 5.965-5.980 (0.2348-0.2354)
Exhaust Valve Stem Outer Diameter, mm (in) ............... 5.950-5.965 (0.2343-0.2348)
Inlet Valve Guide Inner Diameter, mm (in) ............... 6.000-6.015 (0.2362-0.2368)
Exhaust Valve Guide Inner Diameter, mm (in) ............... 6.000-6.015 (0.2362-0.2368)
Inlet Valve Stem to Guide Clearance, mm (in) ............... 0.020-0.050 (0.0008-0.0020)
Exhaust Valve Stem to Guide Clearance, mm (in) ............... 0.035-0.065 (0.0014-0.0026)
Inlet Valve Face Angle, degrees ............... 45
Exhaust Valve Face Angle, degrees ............... 45
Inlet Valve Seat Angle, degrees ............... 45
Exhaust Valve Seat Angle, degrees ............... 45
Inlet Valve Head Diameter, mm (in) ............... 31.000 (1.2205)
Exhaust Valve Head Diameter, mm (in) ............... 27.000 (1.0630)
Valve Head Margin Thickness, mm (in) ............... 1.000 (0.0394)
Valve Spring Free Length, mm (in) ............... 43.500 (1.7126)
Camshaft Bore Inner Diameter, mm (in) ............... 28.000-28.021 (1.1023-1.1032)
Camshaft Journal Outer Diameter, mm (in) ............... 24.959-24.980 (0.9826-0.9835)
Camshaft Bearing Housing Clearance, mm (in) ............... 0.020-0.062 (0.0008-0.0024)
Camshaft Thrust End Play, mm (in) ............... 0.050-0.150 (0.0020-0.0059)
Inlet Cam Lobes Height, mm (in) ............... 36.500 (1.4370)
Exhaust Cam Lobes Height, mm (in) ............... 36.500 (1.4370)
Hydraulic Lifter Outer Diameter, mm (in) ............... 12.000 (0.4724)
Hydraulic Lifter Bore Inner Diameter, mm (in) ............... 12.015-12.030 (0.4730-0.4736)

Tightening Torques

Cylinder Head Screws (Step 1), Nm (lb-ft) ............... 20.0 (14.8)
Cylinder Head Screws (Step 2), Nm (lb-ft) ............... 40.0 (29.5)
Cylinder Head Screws (Step 3), degrees ............... 90 + 90
Cylinder Head Screws (Step 4), degrees ............... 90
Main Bearing Cap Screws (Step 1), Nm (lb-ft) ............... 30.0 (22.1)
Main Bearing Cap Screws (Step 2), deg ............... 90
Main Bearing Cap Bolts, Nm (lb-ft) ............... 24.0 (17.7)
Connecting Rod Big End Cap Bolts (Step 1), Nm (lb-ft) ............... 25.0 (18.4)
Connecting Rod Big End Cap Bolts (Step 2), deg ............... 90
Flywheel to Crankshaft Mounting Screws (Step 1), Nm (lb-ft) ............... 30.0 (22.1)
Flywheel to Crankshaft Mounting Screws (Step 2), deg ............... 90
Crankshaft Vibration Damper Pulley Bolt (Step 1), Nm (lb-ft) ............... 100.0 (73.8)
Crankshaft Vibration Damper Pulley Bolt (Step 2), deg ............... 90
Camshaft Timing Gear Wheel Center Screw, Nm (lb-ft) ............... 60.0 (44.3)
Timing Belt Automatic Tensioner Pulley Nut, Nm (lb-ft) ............... 28.0 (20.7)
Timing Belt Idler Deflection Roller Pulley Bolt, Nm (lb-ft) ............... 24.0 (17.7)
Valve Cover Assembly Upper Frame Screws, Nm (lb-ft) ............... 10.0 (7.4)
Engine Rear Oil Seal Plate Fasteners, Nm (lb-ft) ............... 10.0 (7.4)
Oil Pan Perimeter Screws, Nm (lb-ft) ............... 10.0 (7.4)
Oil Pan Sump Fluid Drain Plug Screw, Nm (lb-ft) ............... 35.0 (25.8)
Oil Pump Body Module Mounting Screws, Nm (lb-ft) ............... 10.0 (7.4)
Oil Pump Pressure Relief Valve Plug, Nm (lb-ft) ............... 40.0 (29.5)
Oil Pressure Monitoring Sensor Switch, Nm (lb-ft) ............... 20.0 (14.8)
Oil Temperature Measuring NTC Sensor, Nm (lb-ft) ............... 15.0 (11.1)
Freshwater Circulation Pump Body Module Fasteners, Nm (lb-ft) ............... 10.0 (7.4)
Thermostat Outer Cover Housing Screws, Nm (lb-ft) ............... 10.0 (7.4)
Heat Exchanger Shell Body Mounting Support Screws, Nm (lb-ft) ............... 24.0 (17.7)
Heat Exchanger Fluid Sump End Cover Cap Screws, Nm (lb-ft) ............... 8.0 (5.9)
Seawater Impeller Pump Drive Hub Mounting Nuts, Nm (lb-ft) ............... 24.0 (17.7)
Freshwater Coolant Sump Drain Valve Plug, Nm (lb-ft) ............... 30.0 (22.1)
Charge Air Cooler Core Mounting Bolts, Nm (lb-ft) ............... 24.0 (17.7)
High-Pressure Fuel Injection Pump Mounting Screws, Nm (lb-ft) ............... 24.0 (17.7)
High-Pressure Injection Pump Drive Pulley Nut, Nm (lb-ft) ............... 50.0 (36.9)
Fuel Rail Manifold Distribution Block Fasteners to Head, Nm (lb-ft) ............... 24.0 (17.7)
High-Pressure Injector Supply Line Nuts (Step 1), Nm (lb-ft) ............... 15.0 (11.1)
High-Pressure Injector Supply Line Nuts (Step 2), Nm (lb-ft) ............... 28.0 (20.7)
Fuel Injector Assembly Hold-down Clamp Nut, Nm (lb-ft) ............... 13.0 (9.6)
Fuel Injector Fuel Return Leak-off Line Banjo Bolt, Nm (lb-ft) ............... 10.0 (7.4)
Fuel Temperature Sensor NTC Module, Nm (lb-ft) ............... 15.0 (11.1)
Fuel Rail Manifold Linear Fuel Pressure Sensor, Nm (lb-ft) ............... 70.0 (51.6)
Fuel Rail Pressure Regulator Valve, Nm (lb-ft) ............... 80.0 (59.0)
Fuel Primary Filter Casing Base Bracket Support Bolts, Nm (lb-ft) ............... 24.0 (17.7)
Low-Pressure Supply Fuel Line Union Banjo Screw, Nm (lb-ft) ............... 15.0 (11.1)
Intake Manifold Mounting Screws, Nm (lb-ft) ............... 15.0 (11.1)
Exhaust Manifold Mounting Stud Copper Nuts (Step 1), Nm (lb-ft) ............... 12.0 (8.9)
Exhaust Manifold Mounting Stud Copper Nuts (Step 2), Nm (lb-ft) ............... 24.0 (17.7)
Turbocharger Unit Flange Mounting Nuts, Nm (lb-ft) ............... 24.0 (17.7)
Turbocharger Oil Feed Rigid Pipe Bolt to Block, Nm (lb-ft) ............... 25.0 (18.4)
Turbocharger Oil Feed Rigid Pipe Bolt to Turbo, Nm (lb-ft) ............... 18.0 (13.3)
Turbocharger Oil Return Tube Flange Allen Screws, Nm (lb-ft) ............... 10.0 (7.4)
Air Cleaner Housing Silencer Retaining Straps, Nm (lb-ft) ............... 8.0 (5.9)
Compressor Discharge Aluminum Elbow Screws, Nm (lb-ft) ............... 10.0 (7.4)
Crankcase Ventilation Separator Cover Box Screws, Nm (lb-ft) ............... 10.0 (7.4)
Exhaust Gas Recirculation Cooler Flange SMounting Bolts, Nm (lb-ft) ............... 24.0 (17.7)
Starter Motor Housing Mounting Flange Bolts, Nm (lb-ft) ............... 45.0 (33.2)
Starter Motor Rear End Frame Support Screw, Nm (lb-ft) ............... 24.0 (17.7)
Alternator Pivot Mounting Long Bolt, Nm (lb-ft) ............... 45.0 (33.2)
Alternator Tension Locking Adjuster Screw, Nm (lb-ft) ............... 24.0 (17.7)
Electronic Control Unit Module Isolation Mount Screws, Nm (lb-ft) ............... 8.0 (5.9)
Engine Glow Plug Pre-heater Modules, Nm (lb-ft) ............... 12.0 (8.9)

________________________________________________________________________________________

• Volvo Penta Engines Specs
  
• Volvo Penta D2-75F Specs
  
• Volvo Penta D3-130 Specs
  
• Volvo Penta D3-160 Specs
  
• Volvo Penta D4-300 Specs
  
• Volvo Penta D5A-TA Specs
  

______________________________________________________________________________________

________________________________________________________________________________________

_______________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________