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Volvo Penta D6-440 Engine

The Volvo Penta D6-440 is an in-line 6-cylinder, 5.5-liter marine diesel engine engineered for high-performance pleasure craft and commercial high-speed planing applications. It utilizes a heavy-duty block design with a ladder frame to handle extreme load conditions. The engine combines a high-pressure common-rail fuel injection system with dual-stage forced induction (a mechanical supercharger/compressor for low-end torque paired with a turbocharger and charge air cooler for top-end power). Managed by Volvo Penta’s Electronic Vessel Control (EVC) system, the D6-440 delivers massive marine torque, low noise, minimal vibrations, and full compliance with major global emissions frameworks like US EPA Tier 3 and EU RCD Stage II.

Cylinder Block and Valve Configuration: In-line 6-cylinder, 4-stroke diesel. Valve Architecture: 4 valves per cylinder (24 valves total) driven by a dual overhead camshaft (DOHC) arrangement, ensuring precise gas exchange and volumetric efficiency. Compression Ratio: 17.5:1. Crankshaft Power: 324 kW (440 hp) at a rated engine speed of 3700 RPM. Bore: 103 mm (4.06 inches). Stroke: 110 mm (4.33 inches). Total Displacement: 5.50 liters (335.6 cubic inches).

Fuel System: Common-rail high-pressure direct fuel injection system. System Pressure: Monitored via an integrated rail pressure sensor with an active operational envelope scaling from 0-180 MPa (0-26100 psi). Fuel Delivery and Management: Fuel is drawn through a primary water-separating pre-filter and fine secondary engine filters by a high-pressure pump. Injection timing, quantity, and multi-pulse strategies are dynamically controlled via the Electronic Control Unit (ECU) utilizing high-voltage solenoid injectors that operate up to 80V. Compatible with standard marine diesel and Hydrotreated Vegetable Oil (HVO) renewable fuels.

Lubrication System: Forced pressure lubrication system featuring a seawater-cooled engine oil cooler. Operating Pressures: 125 kPa (18.1 psi) minimum at low idle (600-650 RPM); 440 kPa (63.8 psi) under standard operating RPM ranges. Cooling System: Pressurized, sealed freshwater cooling circuit (closed loop) regulated by a thermostat, working alongside a raw/seawater heat exchanger circuit. Components: Integrated expansion tank, heat exchanger core, raw water pump with flexible impeller, and a sacrificial zinc anode protection array.

General Technical Data

Engine Specifications

Engine Model ............... Volvo Penta D6-440
Engine Type ............... 4-stroke inline 6-cylinder direct injection liquid-cooled marine diesel
Number of Cylinders ............... 6
Cylinder Arrangement ............... In-line
Engine Bore, in (mm) ............... 4.06 (103.0)
Engine Stroke, in (mm) ............... 4.33 (110.0)
Displacement, cu.in (L) ............... 335.6 (5.50)
Crankshaft Power, hp (kW) ............... 440 (324)
Propeller Shaft Power, hp (kW) ............... 423 (311)
Rated Engine Speed, rpm ............... 3700
Peak Torque ............... 1050 Nm (774 lb-ft) at 2000-2500 rpm
Low Idle Speed ............... 600 rpm
Aspiration Type ............... Turbocharged, charge air cooler, mechanical supercharger
Compression Ratio ............... 17.5:1
Firing Order ............... 1-5-3-6-2-4
Cylinder Block Type ............... Cast iron short block
Cylinder Head Type ............... Cast iron mono-block four-valve system
Camshaft Configuration ............... Double overhead camshafts DOHC
Lubrication System ............... Full-pressure circulation with integrated oil cooler
Oil Pump Type ............... Gear-driven displacement pump
Oil Filter Type ............... Multi-stage full-flow spin-on with bypass filtration
Cooling System ............... Fresh water heat exchanger closed circuit with sea water raw circuit
Water Pump Type ............... Centrifugal fresh water pump and rubber impeller raw water pump
Air Cleaner Type ............... Replaceable dry element cartridge with silencer housing
Emission Certification ............... IMO NOx Tier II, EU RCD Stage II, US EPA Tier 3, BSO II
Starting System ............... Two-pole electric starter motor
Electrical System ............... 12V or 24V
Alternator Capacity ............... 115A or 80A
Starter Motor Power, hp (kW) ............... 4.8 (3.6) or 6.7 (5.0)

Fuel System

Fuel Injection Type ............... High-pressure common-rail system electronic injection control
High Pressure Pump ............... Bosch CP3.3 radial piston engine driven mechanical assembly
Maximum Rail Pressure, psi (bar) ............... 23206 (1600)
Pressure Regulation ............... Magnetic proportional valve MPROP actuator system
Fuel Feed Pump Type ............... Mechanical gear-driven supply unit integrated to high pressure pump
Fuel Injector Type ............... Solenoid-actuated multi-hole vertical centrally mounted electro-injectors
Electronic Controller ............... Volvo Penta Electronic Vessel Control EVC marine management unit
Fuel Filter Type ............... Primary water separating pre-filter with secondary fine spin-on filter element
Fuel Grade Compatibility ............... Ultra-low sulfur marine diesel oil, HVO synthetic paraffinic fuels
Fuel Supply Pipe Diameter, in (mm) ............... 0.39 (10.0)
Fuel Return Pipe Diameter, in (mm) ............... 0.31 (8.0)
Maximum Fuel Inlet Suction, in Hg (kPa) ............... 5.9 (20.0)
Maximum Fuel Return Backpressure, psi (bar) ............... 2.9 (0.20)
Fuel Cooler Configuration ............... Sea water cooled tube heat exchanger integrated on return path
Injection Timing Control ............... Dynamic electronic mapping variable across thermal load ranges
Post-injection Capability ............... Available for emission thermal optimization under part load cycles
Diagnostic Protocol ............... J1939 CAN-bus telemetry interface monitored via EVC system

Dimensions and Weight

Overall Length, in (mm) ............... 53.7 (1365)
Overall Width, in (mm) ............... 32.8 (835)
Overall Height, in (mm) ............... 33.4 (850)
Dry Weight (Bobtail), lbs (kg) ............... 1378 (625)
Dry Weight with Aquamatic DPI, lbs (kg) ............... 1742 (790)
Dry Weight with HS85IV Marine Gear, lbs (kg) ............... 1653 (750)

Maintenance Data

Service Information

Oil Pressure at Normal Idle, psi (kPa) ............... 18.1 (125)
Oil Pressure at 3500 rpm, psi (kPa) ............... 63.8 (440)
Oil Pressure at Low Idle, psi (kPa) ............... 11.6 (80)
Oil Pressure Relief Valve, psi (kPa) ............... 101.5 (700)
Cooling System Cap Pressure Rating, psi (kPa) ............... 10.9 (75)
Maximum Engine Oil Temperature, F (C) ............... 257 (125)
Thermostat Start To Open Temperature, F (C) ............... 180 (82)
Thermostat Fully Open Temperature, F (C) ............... 198 (92)

Engine Oil and Coolant

Engine Oil Type .................. SAE 5W-30, SAE 10W-30, or SAE 15W-40
API Service Classifications ......................... CH-4 or CI-4
Engine Oil Capacity with Filters, US qt (L) ............... 21.1 (20.0)
Engine Oil Capacity (Low Level), US qt (L) ............... 16.9 (16.0)
Coolant Capacity Closed Circuit, US gal (L) ............... 4.2 (16.0)
Compressor Oil Capacity, US qt (L) ............... 0.11 (0.1)
HS80AE Reverse Gear Oil Capacity, US qt (L) ............... 5.8 (5.5)
HS80IVE V-Drive Oil Capacity, US qt (L) ............... 7.4 (7.0)
DPH Duoprop Drive Oil Capacity, US qt (L) ............... 5.5 (5.2)

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 1000 hours
Compression test ............... Every 2000 hours
Replace drive belt ............... Every 400 hours
Replace impeller ............... Every 200 hours
Service heat exchanger ............... Every 400 hours

Service Specifications

Cylinder Bore Inner Diameter, in (mm) ............... 4.0551-4.0559 (103.000-103.020)
Cylinder Bore Maximum Wear Limit, in (mm) ............... 4.0591 (103.100)
Cylinder Bore Ovality Maximum, in (mm) ............... 0.0008 (0.020)
Cylinder Bore Taper Maximum, in (mm) ............... 0.0008 (0.020)
Main Bearing Journal Diameter, in (mm) ............... 3.3461-3.3468 (84.992-85.012)
Main Bearing Clearance, in (mm) ............... 0.0015-0.0035 (0.040-0.090)
Connecting Rod Bearing Journal Diameter, in (mm) ............... 2.5587-2.5594 (64.992-65.010)
Connecting Rod Bearing Clearance, in (mm) ............... 0.0015-0.0033 (0.038-0.084)
Crankshaft Axial End Play, in (mm) ............... 0.0031-0.0118 (0.080-0.300)
Thrust Bearing Journal Width, in (mm) ............... 1.4567-1.4583 (37.000-37.040)
Connecting Rod Total Side Play, in (mm) ............... 0.0059-0.0138 (0.150-0.350)
Piston Skirt Outside Diameter, in (mm) ............... 4.0511-4.0523 (102.900-102.930)
Piston to Cylinder Bore Clearance, in (mm) ............... 0.0027-0.0047 (0.070-0.120)
Piston Pin Diameter, in (mm) ............... 1.5746-1.5748 (39.994-40.000)
Piston Pin to Con Rod Bushing Clearance, in (mm) ............... 0.0006-0.0014 (0.015-0.035)
Top Ring Groove Side Clearance, in (mm) ............... 0.0024-0.0043 (0.060-0.110)
Second Ring Groove Side Clearance, in (mm) ............... 0.0019-0.0037 (0.050-0.095)
Oil Ring Groove Side Clearance, in (mm) ............... 0.0011-0.0029 (0.030-0.075)
Top Ring End Gap, in (mm) ............... 0.0118-0.0197 (0.300-0.500)
Second Ring End Gap, in (mm) ............... 0.0197-0.0295 (0.500-0.750)
Oil Ring End Gap, in (mm) ............... 0.0098-0.0197 (0.250-0.500)
Cylinder Head Flatness Distortion, in (mm) ............... 0.0039 (0.10)
Cylinder Block Deck Flatness, in (mm) ............... 0.0020 (0.05)
Intake Valve Stem Outside Diameter, in (mm) ............... 0.2736-0.2742 (6.950-6.965)
Exhaust Valve Stem Outside Diameter, in (mm) ............... 0.2724-0.2732 (6.920-6.940)
Intake Valve Guide Inside Diameter, in (mm) ............... 0.2756-0.2764 (7.000-7.020)
Exhaust Valve Guide Inside Diameter, in (mm) ............... 0.2756-0.2764 (7.000-7.020)
Intake Valve Stem to Guide Clearance, in (mm) ............... 0.0014-0.0027 (0.035-0.070)
Exhaust Valve Stem to Guide Clearance, in (mm) ............... 0.0024-0.0039 (0.060-0.100)
Intake Valve Head Depth, in (mm) ............... 0.0276-0.0394 (0.700-1.000)
Exhaust Valve Head Depth, in (mm) ............... 0.0276-0.0394 (0.700-1.000)
Valve Seat Angle ............... 45 degrees
Valve Face Angle ............... 44.5 degrees
Camshaft Journal Diameter, in (mm) ............... 1.9681-1.9693 (49.990-50.020)
Camshaft Bearing Clearance, in (mm) ............... 0.0019-0.0039 (0.050-0.100)
Cam Lobe Height (Intake), in (mm) ............... 0.3346 (8.50)
Cam Lobe Height (Exhaust), in (mm) ............... 0.3543 (9.00)
Camshaft Axial End Play, in (mm) ............... 0.0039-0.0098 (0.100-0.250)

Tightening Torques

Cylinder Head Bolts (1-Stage), lb-ft (Nm) ............... 36.9 (50.0)
Cylinder Head Bolts (2-Stage), lb-ft (Nm) ............... 73.8 (100.0)
Cylinder Head Bolts (3-Stage), lb-ft (Nm) ............... 110.6 (150.0)
Main Bearing Cap Bolts (1-Stage), lb-ft (Nm) ............... 44.3 (60.0)
Main Bearing Cap Bolts (2-Stage), lb-ft (Nm) ............... 95.9 (130.0)
Connecting Rod Cap Bolts (1-Stage), lb-ft (Nm) ............... 22.1 (30.0)
Connecting Rod Cap Bolts (2-Stage), lb-ft (Nm) ............... 47.9 (65.0)
Flywheel Fixing Bolts (1-Stage), lb-ft (Nm) ............... 36.9 (50.0)
Flywheel Fixing Bolts (2-Stage), lb-ft (Nm) ............... 73.8 (100.0)
Vibration Damper Crankshaft Pulley Bolts, lb-ft (Nm) ............... 62.7 (85.0)
Camshaft Gear Center Retaining Bolt, lb-ft (Nm) ............... 55.3 (75.0)
Camshaft Bearing Cap, lb-ft (Nm) ............... 17.7 (24.0)
Crankcase Oil Pan Mounting Bolts, lb-ft (Nm) ............... 17.7 (24.0)
Oil Pan Drain Plug, lb-ft (Nm) ............... 33.2 (45.0)
Valve Rocker Arm Shaft Support Bolts, lb-ft (Nm) ............... 22.1 (30.0)
Engine Valve Cover Top Screws, lb-ft (Nm) ............... 8.1 (11.0)
Exhaust Manifold Flange Nuts, lb-ft (Nm) ............... 35.4 (48.0)
Turbocharger Mounting Flange Nut, lb-ft (Nm) ............... 35.4 (48.0)
Common Rail High Pressure Fuel Line Nuts, lb-ft (Nm) ............... 20.7 (28.0)
Fuel Injector Clamping Bracket Fasteners, lb-ft (Nm) ............... 15.5 (21.0)
High Pressure Fuel Pump Drive Gear Bolt, lb-ft (Nm) ............... 66.4 (90.0)
Fuel Injector Feed Pipe Connection Joints, lb-ft (Nm) ............... 19.9 (27.0)
Alternator Bracket Base Pivot Bolts, lb-ft (Nm) ............... 35.4 (48.0)
Starter Motor Frame Mounting Fasteners, lb-ft (Nm) ............... 35.4 (48.0)
Seawater Pump Housing Screws, lb-ft (Nm) ............... 15.5 (21.0)
Oil Cooler Housing Core Clamping Screws, lb-ft (Nm) ............... 17.7 (24.0)
Freshwater Thermostat Housing Cover Bolts, lb-ft (Nm) ............... 17.7 (24.0)
Flywheel Housing to Engine Block (M12), lb-ft (Nm) ............... 62.7 (85.0)
Flywheel Housing to Engine Block (M10), lb-ft (Nm) ............... 35.4 (48.0)
Crankcase Breather Element Cover Screws, lb-ft (Nm) ............... 8.1 (11.0)
Supercharger Compressor Sump Drain Plug, lb-ft (Nm) ............... 14.8 (20.0)
Supercharger Assembly Main Bracket Bolts, lb-ft (Nm) ............... 35.4 (48.0)
Intake Manifold Air Inlet Plenum Bolts, lb-ft (Nm) ............... 17.7 (24.0)
Glow Plug Cylindrical Heating Elements, lb-ft (Nm) ............... 11.1 (15.0)
Oil Pump Internal Delivery Pipe Flange, lb-ft (Nm) ............... 8.1 (11.0)
Piston Oil Cooling Jet Nozzle Bolt, lb-ft (Nm) ............... 11.1 (15.0)
Timing Gear Case Backplate M8 Bolts, lb-ft (Nm) ............... 17.7 (24.0)
Timing Gear Case Outer Cover M6 Screws, lb-ft (Nm) ............... 7.4 (10.0)
Engine Oil Filter Bypass Valve Assembly, lb-ft (Nm) ............... 25.8 (35.0)
Coolant Heat Exchanger Drain Cock Valve, lb-ft (Nm) ............... 18.4 (25.0)
Raw Water Sacrificial Anode Brass Plug, lb-ft (Nm) ............... 22.1 (30.0)
Engine Support Foot Marine Mount Bolts, lb-ft (Nm) ............... 103.3 (140.0)
Exhaust Riser Discharge Elbow Band Clamp, lb-ft (Nm) ............... 8.9 (12.0)
Engine Control Unit Heat Sink Bolts, lb-ft (Nm) ............... 6.6 (9.0)
Rail Pressure Sensor Threaded Interface, lb-ft (Nm) ............... 51.6 (70.0)
Fuel Temperature Sensor Brass Housing, lb-ft (Nm) ............... 14.8 (20.0)
Coolant Temperature Sensor Element, lb-ft (Nm) ............... 16.2 (22.0)
Manifold Boost Air Pressure Sensor Bolt, lb-ft (Nm) ............... 6.6 (9.0)
Lube Oil Pressure Sensor, lb-ft (Nm) ............... 22.1 (30.0)
Crankshaft Position Sensor Pickup Bracket, lb-ft (Nm) ............... 7.4 (10.0)
Camshaft Position Reference Indicator Bolt, lb-ft (Nm) ............... 7.4 (10.0)
Water In Fuel Contamination Bottom Sensor, lb-ft (Nm) ............... 2.2 (3.0)
Sea Water Circuit Impeller End Cover Screws, lb-ft (Nm) ............... 4.4 (6.0)
Air Intake Silencer Filter Housing Clamps, lb-ft (Nm) ............... 5.2 (7.0)
Compressor Drive Electromagnetic Clutch Bolt, lb-ft (Nm) ............... 44.3 (60.0)

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• Volvo Penta Engines Specs
  
• Volvo Penta D6-310 Specs
  
• Volvo Penta D6-350 Specs
  
• Volvo Penta D6-370 Specs
  
• Volvo Penta D6-380 Specs
  
• Volvo Penta D6-400 Specs
  
• Volvo Penta D6-480 Specs
  

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