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Volvo Penta D3-160 Engine

The Volvo Penta D3-160 is an ultra-modern, high-performance marine diesel engine based on the successful inline 5-cylinder automotive block developed by Volvo Cars. Designed specifically as a "sport diesel," it utilizes an all-aluminum base design with highly efficient marinization. The engine is engineered around Volvo Penta's Electronic Vessel Control (EVC) CAN-bus platform. This architecture enables the engine, controls, and instruments to seamlessly communicate for real-time digital management and diagnostics. Typically paired with the Aquamatic Duoprop DP-S sterndrive, it offers rapid acceleration, high torque at low RPMs, and exceptionally low exhaust and noise emissions. It is highly regarded as a reliable power unit for sport boats, sailboats, and twin installations in light sport cruisers up to 30 feet.

The cylinder head incorporates a four-valve-per-cylinder technology (20 valves total) driven by double overhead camshafts (DOHC). This system employs dual intake manifolds situated on opposing sides of the cylinder head to optimize the dynamic mixing of fuel and air, resulting in highly efficient combustion gas exchange. The design is rounded out by replaceable valve seats to facilitate cylinder head overhauls. The engine features a total swept displacement of 2.4 liters (2,370 cc) across its 5-cylinder inline configuration. The structural layout is defined by a cylinder bore of 81.0 mm (3.19 in) and a piston stroke of 93.2 mm (3.67 in).

Fuel System: Fuel distribution is governed by an electronically controlled common rail direct injection system operating at pressures up to 1600 bar. The delivery circuit consists of a dual-stage arrangement with a low-pressure lift pump feeding a high-pressure common rail injection pump. Pressurized diesel enters a shared rail manifold and is metered precisely into the cylinders through electronically controlled solenoid or piezo-electric injectors. The system includes a fine-element fuel filter coupled with a built-in water separator to guarantee fuel purity. A Variable Geometry Turbocharger (VGT) complements the fuel delivery by adjusting electronic vanes to match exhaust velocity, ensuring smokeless acceleration from low engine speeds.

Lubrication is managed via a pressure-fed system driven by an internal gear pump located at the front edge of a six-bearing crankshaft. The circuit includes a full-flow oil filter with an easily replaceable insert element to minimize maintenance footprint. Thermal regulation of the engine oil is sustained by an integrated plate-type oil cooler. Crankcase gases are scrubbed through a closed ventilation assembly using a cyclone-type oil separator before recycling into the air inlet.

The thermal management network utilizes a thermostatically regulated freshwater (coolant) circuit. Primary circulation is sustained via a toothed-belt-driven water pump, which routes coolant through a tubular heat exchanger assembly outfitted with a separate, high-volume expansion tank. The sea-water (raw water) circuit utilizes an easily accessible rubber impeller pump to draw raw water from the drive pick-up, running it through the heat exchanger and intercooler before discharging via a stainless steel exhaust elbow.

General Technical Data

Engine Specifications

Engine Model ............... Volvo Penta D3-160
Engine Type ............... 4-stroke inline 5-cylinder direct injection liquid-cooled marine diesel
Number of Cylinders ............... 5
Cylinder Arrangement ............... In-line
Engine Bore, in (mm) ............... 3.19 (81.0)
Engine Stroke, in (mm) ............... 3.67 (93.2)
Displacement, cu.in (L) ............... 146.4 (2.40)
Rated Engine Power, hp (kW) ............... 163 (120)
Rated Engine Speed, rpm ............... 4000
Peak Torque ............... 251 lb-ft (340 Nm) at 1750 rpm
Idle Speed ............... 700-750 rpm
Aspiration Type ............... Variable Geometry Turbocharger with Aftercooler
Compression Ratio ............... 17.3:1
Firing Order ............... 1-2-4-5-3
Cylinder Block Type ............... Die-cast aluminum alloy with grey iron liners
Cylinder Head Type ............... Aluminum alloy with double overhead camshafts
Lubrication System ............... Full-pressure lubrication system with plate oil cooler
Oil Pump Type ............... Internal gear pump chain-driven from crankshaft
Oil Filter Type ............... Replaceable full-flow cartridge spin-on element
Cooling System ............... Fresh water closed loop cooling with heat exchanger
Water Pump Type ............... Toothed-belt driven centrifugal circulation pump
Sea Water Pump Type ............... Rubber impeller engine-driven raw water pump
Air Cleaner Type ............... Washable silencer housing with integrated air filter
Emission Certification ............... EU RCD, US EPA Tier 2, IMO NOx compliant
Starting System ............... Electric starter motor with solenoid engagement
Electrical System, V ............... 12
Alternator Capacity, A ............... 140

Fuel System

Fuel Injection Type ............... High pressure common rail direct injection
Injection Pump Manufacturer ............... Bosch high pressure radial piston pump
Maximum Rail Pressure, psi (bar) ............... 23200 (1600)
Fuel Feed Pump Type ............... Mechanical gear-driven low pressure transfer pump
Injector Type ............... Solenoid operated multi-hole electronic fuel injectors
Number of Injectors ............... 5
Governor Type ............... Electronic Vessel Control engine management
Fuel Pre-Filter Type ............... Spin-on water separator filter element
Main Fuel Filter Type ............... Fine micron element spin-on filter housing
Fuel Return System ............... Closed circuit overflow to fuel tank cooler line
Fuel Grade Compatibility ............... Ultra low sulfur marine diesel grade fuels
Fuel System Delivery Line Pressure, psi (bar) ............... 43.5-72.5 (3.0-5.0)
Fuel Return Line Max Backpressure, psi (bar) ............... 14.5 (1.0)
High Pressure Line Material ............... Thick-walled seamless double-sheathed steel tubing
Electronic Control Unit Type ............... Volvo Penta Electronic Vessel Control unit
Fuel Injection Control ............... Time-controlled pulse width modulated solenoid signal
Fuel Delivery Volume Control ............... Electronic fuel suction control valve on high pressure pump
Fuel Pressure Sensor Type ............... Piezo-resistive pressure strain gauge sensor
Diagnostic System Compatibility ............... Volvo Penta VODIA diagnostic tool interface

Dimensions and Weight

Overall Length with Gearbox, in (mm) ............... 43.4 (1100)
Overall Width, in (mm) ............... 25.1 (640)
Overall Height, in (mm) ............... 29.8 (755)
Dry Weight (Engine Only), lbs (kg) ............... 474 (215)
Dry Weight with Aquamatic DPS Drive, lbs (kg) ............... 727 (330)
Dry Weight with HS45A Reverse Gear, lbs (kg) ............... 584 (265)

Maintenance Data

Service Information

Standard Engine Oil Pressure, psi (bar) ............... 43.5-72.5 (3.0-5.0)
Minimum Oil Pressure at Idle, psi (bar) ............... 14.5 (1.0)
Coolant Pressure Cap Rating, psi (bar) ............... 10.1 (0.7)
Maximum Oil Temperature, F (C) ............... 248 (120)
Coolant Temperature Range, F (C) ............... 167-194 (75-90)
Thermostat Opening Start Temperature, F (C) ............... 172 (78)
Thermostat Fully Open Temperature, F (C) ............... 194 (90)

Engine Oil and Coolant

Engine Oil Type .................. SAE 5W-30, SAE 10W-30, or 15W-40
API Service Classifications ......................... CH-4 or CI-4
Engine Oil Capacity with Filter, qt (L) ............... 7.2 (6.8)
Coolant System Capacity, gal (L) ............... 2.1 (8.0)

Service Intervals

Change oil and filter ............... Every 200 hours
Service air cleaner ............... Every 100 hours
Replace air cleaner ............... Every 200 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 Inside Diameter, in (mm) ............... 3.1890-3.1894 (81.000-81.010)
Cylinder Bore Maximum Out of Round, in (mm) ............... 0.0004 (0.010)
Cylinder Bore Maximum Taper, in (mm) ............... 0.0004 (0.010)
Cylinder Head Deck Flatness Distortion, in (mm) ............... 0.0020 (0.050)
Cylinder Block Deck Flatness Distortion, in (mm) ............... 0.0020 (0.050)
Crankshaft Main Journal Diameter, in (mm) ............... 2.5591-2.5596 (65.000-65.013)
Crankshaft Main Journal Clearance, in (mm) ............... 0.0012-0.0028 (0.030-0.070)
Crankshaft Rod Journal Diameter, in (mm) ............... 1.9685-1.9691 (50.000-50.015)
Crankpin Journal Clearance, in (mm) ............... 0.0012-0.0028 (0.030-0.070)
Crankshaft End Play, in (mm) ............... 0.0031-0.0075 (0.080-0.190)
Piston Skirt Outer Diameter, in (mm) ............... 0.394 (10.0)
Piston to Cylinder Wall Clearance, in (mm) ............... 0.0016-0.0024 (0.040-0.060)
Piston Pin Bore Inside Diameter, in (mm) ............... 1.1024-1.1026 (28.000-28.005)
Piston Pin Outer Diameter, in (mm) ............... 1.1021-1.1023 (27.993-27.998)
Piston Pin to Small End Bushing Clearance, in (mm) ............... 0.0006-0.0012 (0.015-0.030)
Top Ring Groove Side Clearance, in (mm) ............... 0.0024-0.0047 (0.060-0.120)
Second Ring Groove Side Clearance, in (mm) ............... 0.0016-0.0031 (0.040-0.080)
Oil Ring Groove Side Clearance, in (mm) ............... 0.0008-0.0024 (0.020-0.060)
Top Ring End Gap, in (mm) ............... 0.0079-0.0157 (0.200-0.400)
Second Ring End Gap, in (mm) ............... 0.0118-0.0217 (0.300-0.550)
Oil Ring End Gap, in (mm) ............... 0.0098-0.0197 (0.250-0.500)
Intake Valve Stem Outside Diameter, in (mm) ............... 0.2354-0.2360 (5.980-5.995)
Exhaust Valve Stem Outside Diameter, in (mm) ............... 0.2346-0.2352 (5.960-5.975)
Valve Guide Inside Diameter, in (mm) ............... 0.2362-0.2370 (6.000-6.020)
Intake Valve Stem to Guide Clearance, in (mm) ............... 0.0008-0.0016 (0.020-0.040)
Exhaust Valve Stem to Guide Clearance, in (mm) ............... 0.0016-0.0024 (0.040-0.060)
Valve Spring Free Length, in (mm) ............... 1.772 (45.00)
Camshaft Journal Diameter, in (mm) ............... 1.2205-1.2211 (31.000-31.015)
Camshaft Journal Bearings Clearance, in (mm) ............... 0.0016-0.0031 (0.040-0.080)
Camshaft End Play, in (mm) ............... 0.0020-0.0059 (0.050-0.150)
Cam Lobe Height (Exhaust), in (mm) ............... 1.4882 (37.800)
Cam Lobe Height (Intake), in (mm) ............... 1.4882 (37.800)

Tightening Torques

Cylinder Head Screws (1-Step) ............... 15 lb-ft (20 Nm)
Cylinder Head Screws (2-Step) ............... 30 lb-ft (40 Nm) then plus 90 deg angle
Main Bearing Cap Bolts (1-Step) ............... 22 lb-ft (30 Nm)
Main Bearing Cap Bolts (2-Step) ............... 44 lb-ft (60 Nm) then plus 90 deg angle
Connecting Rod Cap Bolts (1-Step) ............... 15 lb-ft (20 Nm)
Connecting Rod Cap Bolts (2-Step) ............... 26 lb-ft (35 Nm) then plus 90 deg angle
Flywheel Fasteners ............... 22 lb-ft (30 Nm) then plus 90 deg angle
Vibration Damper Crankshaft Bolt ............... 74 lb-ft (100 Nm) then plus 90 deg angle
Camshaft Bearing Cap Fasteners ............... 13 lb-ft (17 Nm)
Camshaft Gear Center Bolt ............... 44 lb-ft (60 Nm) then plus 90 deg angle
Valve Cover Mounting Fasteners ............... 7.4 lb-ft (10 Nm)
Oil Sump Mounting Bolts ............... 11 lb-ft (15 Nm)
Oil Drain Plug ............... 26 lb-ft (35 Nm)
Oil Pump Assembly Fasteners ............... 11 lb-ft (15 Nm)
Oil Cooler Bracket Assembly Fasteners ............... 18 lb-ft (25 Nm)
Water Pump Assembly Fasteners ............... 11 lb-ft (15 Nm)
Thermostat Housing Assembly Fasteners ............... 11 lb-ft (15 Nm)
Intake Manifold Assembly Fasteners ............... 18 lb-ft (25 Nm)
Exhaust Manifold Assembly Fasteners ............... 22 lb-ft (30 Nm)
Turbocharger Housing Mounting Nuts ............... 22 lb-ft (30 Nm)
High Pressure Fuel Pump Center Nut ............... 37 lb-ft (50 Nm)
Common Rail Mounting Bolts ............... 18 lb-ft (25 Nm)
Fuel Injector Clamp Fasteners ............... 10 lb-ft (13 Nm) then plus 110 deg angle
High Pressure Fuel Line Unions ............... 21 lb-ft (28 Nm)
Fuel Filter Housing Fasteners ............... 18 lb-ft (25 Nm)
Starter Motor Mounting Bolts ............... 33 lb-ft (45 Nm)
Alternator Assembly Mounting Bolts ............... 33 lb-ft (45 Nm)
Alternator Pivot Slider Link Bolt ............... 18 lb-ft (25 Nm)
Engine Mount Isolation Bracket Fasteners ............... 37 lb-ft (50 Nm)
Flywheel Housing Core Bolts ............... 33 lb-ft (45 Nm)
Glow Plug Assembly Fasteners ............... 9.0 lb-ft (12 Nm)
Crankcase Ventilation Valve Screws ............... 7.4 lb-ft (10 Nm)
Timing Belt Cover Screws ............... 7.4 lb-ft (10 Nm)
Timing Belt Tensioner Pulley Nut ............... 18 lb-ft (25 Nm)
Timing Belt Idler Pulley Bolt ............... 18 lb-ft (25 Nm)
Sea Water Pump Bracket Fasteners ............... 18 lb-ft (25 Nm)
Oil Pressure Sensor ............... 15 lb-ft (20 Nm)
Coolant Temperature Sensor ............... 15 lb-ft (20 Nm)
Camshaft Position Sensor ............... 7.4 lb-ft (10 Nm)
Crankshaft Position Sensor ............... 7.4 lb-ft (10 Nm)
Intake Air Temperature Pressure Sensor ............... 7.4 lb-ft (10 Nm)

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• Volvo Penta Engines Specs
  
• Volvo Penta D2-75F Specs
  
• Volvo Penta D3-130 Specs
  
• Volvo Penta D3-150 Specs
  
• Volvo Penta D4-300 Specs
  
• Volvo Penta D5A-TA Specs
  

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