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Volvo Penta D4-300 Engine

The Volvo Penta D4-300 is a heavy-duty, in-line 4-cylinder marine diesel engine engineered for high-performance and commercial propulsion profiles. Developed using modern marine diesel technology, it utilizes a rigid cast-iron cylinder block and head configuration incorporating an integrated ladder frame. This design optimizes structural rigidity to lower running noise and structural vibrations drastically. Combined with integrated balancing shafts and tuned engine mounts, it ensures excellent onboard comfort. The power plant delivers high marine torque across low and high operational RPM windows, allowing for rapid vessel planing and consistent load-carrying capacity regardless of sea state. Engine logic and fuel mapping are entirely governed via Volvo Penta’s Electronic Vessel Control (EVC) system to balance low-emission compliance with crisp throttle responses.

Valve Configuration: Double Overhead Camshafts (DOHC). Valves: 4 valves per cylinder (16 valves total), driven directly to optimize gas exchange efficiency. Service Elements: Replaceable valve seats and valve guides. Rear-end gear transmission drive train ensures precise timing synchronization under extreme structural loads. Bore: 103 mm (4.06 in). Stroke: 110 mm (4.33 in). Displacement: 3.7 liters (224 cubic inches). Compression Ratio: 17.5:1 base ratio.

Lubrication System: Full-pressure lubrication circuit powered by an engine-driven pump. Filtration Layout: Features a multi-stage oil filtration design using easily replaceable, separate full-flow and bypass-flow oil filters. Piston Cooling: Thermal management utilizes integrated oil-cooled pistons, fed via oil jets, matching a configuration of two compression rings and a dedicated oil scraper ring. Oil Cooling: Seawater-cooled tubular oil heat exchanger integrated into the main engine cooling bracket. Includes a modern closed-circuit crankcase oil separator to filter venting gases directly back into the air inlet.

Cooling System: Thermostatically regulated closed-loop freshwater cooling system. It encompasses the cylinder block, cylinder head, and the integrated freshwater-cooled turbocharger housing. Secondary Circuit: Seawater circuit driven by an easily accessible, rubber-impeller raw water pump. Heat Exchanger: Heavy-duty tubular heat exchanger equipped with a separate, high-volume composite expansion tank. The cooling system comes factory-prepared with external ports to supply hot water outlets for onboard cabin heating loops. Equipped with an integrated safety loss-of-seawater alarm system.

Fuel System: High-pressure Common Rail Fuel Injection system operating up to 2000 bar pressure. Injection Control: Piezoelectric injectors managed precisely by the electronic engine control unit (ECU). This allows multiple injection phases per combustion stroke to maximize thermal efficiency and operating economy. Aspiration Support: Forced induction via a freshwater-cooled turbocharger coupled with a high-capacity sea-water-cooled aftercooler (charge air cooler). System Filtration: High-efficiency fuel fine-filter matched with an external primary fuel-water separator vessel featuring an integrated water-in-fuel electronic alarm sensor.

General Technical Data

Engine Specifications

Engine Model ............... Volvo Penta D4-300
Engine Type ............... 4-stroke inline 4-cylinder direct injection liquid-cooled marine diesel
Number of Cylinders ............... 4
Cylinder Arrangement ............... In-line vertical
Engine Bore, in (mm) ............... 4.05 (103.0)
Engine Stroke, in (mm) ............... 4.33 (110.0)
Displacement, cu.in (L) ............... 224 (3.67)
Rated Engine Power, hp (kW) ............... 300 (221) at 3500 rpm
Propeller Shaft Power, hp (kW) ............... 288 (212) at 3500 rpm
Rated Engine Speed ............... 3500 rpm
Peak Torque ............... 703 Nm (518.5 lb-ft) at 2000-2500 rpm
Low Idle Speed ............... 700-750 rpm
High Idle Speed ............... 3700 rpm
Aspiration Type ............... Turbocharged with aftercooler
Operating Speed Range ............... 1500-3500 rpm
Compression Ratio ............... 17.5:1
Firing Order ............... 1-3-4-2
Cylinder Block Material ............... Cast iron alloy
Cylinder Head Material ............... Cast iron alloy
Cylinder Liners Type ............... Integrated non-replaceable parent bore design
Ladder Frame Component ............... Cast iron integrated ladder frame structure
Balance Shafts Mechanism ............... Twin gear-driven counter-rotating balance shafts
Camshaft Arrangement ............... Double overhead camshafts (DOHC)
Number of Valves Per Cylinder ............... 4
Total Number of Valves ............... 16
Valve Lash Adjustment ............... Hydraulic automatic lash adjusters
Crankshaft Bearings Number ............... 5 main bearings
Crankshaft Rotation Direction ............... Clockwise from front end view
Engine Cooling Layout ............... Freshwater heat exchanger system
Oil Filter Type ............... Full-flow spin-on cartridge and bypass spin-on cartridge
Oil Cooler Type ............... Tubular seawater-cooled integrated heat exchanger
Air Filter Type ............... Dry disposable element pleated paper material
Charge Air Cooler System ............... Seawater cooled multi-pass core framework
Emission Certification ............... IMO NOx, EU RCD Stage II, US EPA Tier 3
Electrical System ............... 12V
Alternator Capacity ............... 115A

Fuel System

Injection System Architecture ............... High-pressure common rail direct injection
Maximum Common Rail Pressure ............... 2000 bar (29007 psi)
Fuel Feed Pump Type ............... Mechanical gear-driven transfer pump
Fuel Feed Pump Supply Pressure ............... 450-550 kPa (65.3-79.8 psi)
High Pressure Pump Drive ............... Gear-driven from rear-end timing train
High Pressure Injection Pump ............... Radial piston high-pressure common rail pump
Fuel Injectors Actuation ............... Solenoid-operated electronic injectors
Fuel Filter Primary Assembly ............... Water separator filter with water-in-fuel sensor
Fuel Filter Secondary Assembly ............... Fine spin-on secondary element filter
Fuel Injection Electronic Control ............... EVC Electronic Vessel Control management
Maximum Fuel Inlet Temperature ............... 50 C (122 F)
Recommended Fuel Grade ............... EN 590 ultra-low sulfur diesel, ASTM D975 No. 2-D
Specific Fuel Consumption Rate ............... 224 g/kWh (0.368 lb/hph)
Fuel Delivery Pressure Regulator ............... Electronic rail pressure control valve MPROP
Fuel Leakage Return Temperature ............... 65 C (149 F) under continuous operation

Dimensions and Weight

Overall Length (Bobtail Only) ............... 915 mm (36.0 in)
Overall Width (Bobtail Only) ............... 780 mm (30.6 in)
Overall Height (Bobtail Only) ............... 795 mm (31.3 in)
Overall Length with DPH Drive ............... 1230 mm (48.5 in)
Overall Height with DPH Drive ............... 975 mm (38.3 in)
Dry Weight (Bobtail Only) ............... 480 kg (1058 lbs)
Dry Weight with DPH Duoprop Drive ............... 663 kg (1462 lbs)
Dry Weight with HS63AE Reverse Gear ............... 559 kg (1232 lbs)
Dry Weight with HS63IVE V-Drive Gear ............... 585 kg (1290 lbs)

Maintenance Data

Service Information

Oil Pressure at Low Idle ............... 125 kPa (18.1 psi)
Oil Pressure at Rated Speed ............... 440 kPa (63.8 psi)
Oil Pressure Valve Opening ............... 550 kPa (79.8 psi)
Thermostat Start Opening Temperature ............... 82 C (180 F)
Thermostat Fully Open Temperature ............... 92 C (198 F)

Engine Oil and Coolant

Engine Oil Type .................. SAE 5W-40, SAE 10W-40, or 15W-40
API Service Classifications ......................... CH-4 or CI-4
Engine Oil Capacity with Filters ............... 12.5 L (13.2 qt)
Engine Oil Capacity without Filters ............... 11.0 L (11.6 qt)
Engine Oil Capacity (Minimum) ............... 9.0 L (9.5 qt)
Engine Oil Sump Max Capacity ............... 11.5 L (12.2 qt)
Cooling Freshwater Capacity ............... 30 L (7.9 gal)

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 Liner Inside Diameter ............... 103.000-103.015 mm (4.0551-4.0557 in)
Cylinder Liner Maximum Out-of-Round ............... 0.015 mm (0.0006 in) internal deviation
Cylinder Liner Maximum Taper ............... 0.020 mm (0.0008 in) height axis deviation
Cylinder Upper Block Deck Flatness ............... 0.050 mm (0.0020 in) surface check limit
Main Bearing Bore Inside Diameter ............... 90.000-90.022 mm (3.5433-3.5442 in)
Main Bearing Journal Outer Diameter ............... 84.985-85.000 mm (3.3459-3.3465 in)
Main Bearing Clearance ............... 0.042-0.090 mm (0.0017-0.0035 in)
Connecting Rod Journal Outer Diameter ............... 67.985-68.000 mm (2.6766-2.6772 in)
Connecting Rod Clearance ............... 0.038-0.082 mm (0.0015-0.0032 in)
Crankshaft Thrust End Play ............... 0.090-0.260 mm (0.0035-0.0102 in)
Main Bearing Shell Thickness ............... 2.470-2.480 mm (0.0972-0.0976 in)
Connecting Rod Bearing Shell Thickness ............... 1.965-1.975 mm (0.0774-0.0778 in)
Piston Skirt Outer Diameter ............... 102.880-102.900 mm (4.0504-4.0512 in)
Piston to Cylinder Liner Clearance ............... 0.100-0.135 mm (0.0039-0.0053 in)
Piston Pin Bore Inside Diameter ............... 40.005-40.012 mm (1.5750-1.5753 in)
Piston Pin Outer Diameter ............... 39.993-40.000 mm (1.5745-1.5748 in)
Piston Pin to Piston Pin Bore Clearance ............... 0.005-0.019 mm (0.0002-0.0007 in)
Top Ring End Gap ............... 0.300-0.450 mm (0.0118-0.0177 in)
Second Ring End Gap ............... 0.400-0.600 mm (0.0157-0.0236 in)
Oil Ring End Gap ............... 0.250-0.500 mm (0.0098-0.0197 in)
Top Ring Groove Side Clearance ............... 0.090-0.130 mm (0.0035-0.0051 in)
Second Ring Groove Side Clearance ............... 0.050-0.090 mm (0.0020-0.0035 in)
Oil Ring Groove Side Clearance ............... 0.030-0.070 mm (0.0012-0.0028 in)
Cylinder Head Deck Bottom Surface Distortion ............... 0.050 mm (0.0020 in)
Intake Valve Stem Outer Diameter ............... 6.965-6.980 mm (0.2742-0.2748 in)
Exhaust Valve Stem Outer Diameter ............... 6.945-6.960 mm (0.2734-0.2740 in)
Intake Valve Guide Inner Diameter ............... 7.000-7.015 mm (0.2756-0.2762 in)
Exhaust Valve Guide Inner Diameter ............... 7.000-7.015 mm (0.2756-0.2762 in)
Intake Valve Stem to Guide Clearance ............... 0.020-0.050 mm (0.0008-0.0020 in)
Exhaust Valve Stem to Guide Clearance ............... 0.040-0.070 mm (0.0016-0.0028 in)
Intake Valve Head Thickness ............... 1.20 mm (0.0472 in)
Exhaust Valve Head Thickness ............... 1.00 mm (0.0394 in)
Valve Seat Angle ............... 45 degrees
Valve Face Angle ............... 44.5 degrees
Camshaft Journal Outer Diameter ............... 34.000-34.025 mm (1.3386-1.3396 in)
Camshaft Housing Bore Inside Diameter ............... 37.000-37.025 mm (1.4567-1.4577 in)
Camshaft Bearing Bore Inner Diameter ............... 34.060-34.085 mm (1.3409-1.3419 in)
Camshaft Journal Clearance ............... 0.035-0.085 mm (0.0014-0.0033 in)
Camshaft Thrust Axial End Play ............... 0.050-0.150 mm (0.0020-0.0059 in)
Intake Cam Lobe Height ............... 48.250 mm (1.8996 in)
Exhaust Cam Lobe Height ............... 47.850 mm (1.8839 in)

Tightening Torques

Cylinder Head Bolts (Step 1) ............... 50 Nm (36.9 lb-ft)
Cylinder Head Bolts (Step 2) ............... 100 Nm (73.8 lb-ft)
Cylinder Head Bolts (Step 3) ............... 150 Nm (110.6 lb-ft)
Main Bearing Cap Bolts (Step 1) ............... 65 Nm (47.9 lb-ft)
Main Bearing Cap Bolts (Step 2) ............... 130 Nm (95.9 lb-ft)
Connecting Rod Cap Bolts (Step 1) ............... 35 Nm (25.8 lb-ft)
Connecting Rod Cap Bolts (Step 2) ............... 65 Nm (47.9 lb-ft)
Flywheel Retaining Bolts (Step 1) ............... 50 Nm (36.9 lb-ft)
Flywheel Retaining Bolts (Step 2) ............... 100 Nm (73.8 lb-ft)
Crankshaft Vibration Damper Pulley Bolt ............... 220 Nm (162.3 lb-ft)
Flywheel Housing Fixing Screws ............... 85 Nm (62.7 lb-ft)
Ladder Frame To Lower BlockScrews ............... 48 Nm (35.4 lb-ft)
Main Bearing Cap Cross Bolts ............... 35 Nm (25.8 lb-ft)
Common Rail Delivery Pipe Coupling Nuts ............... 30 Nm (22.1 lb-ft)
Fuel Injector Hold-Down Clamp Bridge Bolts ............... 24 Nm (17.7 lb-ft)
Oil Pan Bottom Drain Sump Plug ............... 45 Nm (33.2 lb-ft)
Oil Pan Flange Mounting Fasteners ............... 24 Nm (17.7 lb-ft)
Oil Pressure Regulator Spring Plug ............... 50 Nm (36.9 lb-ft)
Oil Cooler Core External Cover Fasteners ............... 24 Nm (17.7 lb-ft)
High Pressure Fuel Pump Drive Gear Nut ............... 85 Nm (62.7 lb-ft)
Common Rail High Pressure Pump Screws ............... 24 Nm (17.7 lb-ft)
Fuel Feed Transfer Low Pressure Pump Union ............... 22 Nm (16.2 lb-ft)
Oil Sump Pickup Tube Foot Bracket ............... 10 Nm (7.4 lb-ft)
Camshaft Drive Timing Gear Face Hub Bolt ............... 65 Nm (47.9 lb-ft)
Camshaft Journal Bearing Cap Mount Screws ............... 24 Nm (17.7 lb-ft)
Valve Camshaft Cover Outer Shell Screws ............... 10 Nm (7.4 lb-ft)
Freshwater Thermostat Housing Base Fasteners ............... 24 Nm (17.7 lb-ft)
Seawater Water Pump Mounting Screws ............... 24 Nm (17.7 lb-ft)
Turbocharger Exhaust Turbine Housing Flange Nuts ............... 48 Nm (35.4 lb-ft)
Exhaust Manifold Assembly To Block Screws ............... 48 Nm (35.4 lb-ft)
Alternator Charging Frame Pivot Bracket Bolts ............... 48 Nm (35.4 lb-ft)
Starter Motor Unit Flange Mounting Screws ............... 48 Nm (35.4 lb-ft)
Serpentine Poly-V Belt Tensioner Lock Nut ............... 50 Nm (36.9 lb-ft)
Intake Manifold Air Distribution Base Fasteners ............... 24 Nm (17.7 lb-ft)
Charge Air Cooling Inner Tube Screws ............... 10 Nm (7.4 lb-ft)
Crankcase Breather Centrifugal Separator Screws ............... 10 Nm (7.4 lb-ft)

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• Volvo Penta Engines Specs
  
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• Volvo Penta D3-150 Specs
  
• Volvo Penta D3-160 Specs
  
• Volvo Penta D5A-TA Specs
  

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