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Volvo Penta D6-480 Engine

The Volvo Penta D6-480 is an in-line 6-cylinder, 5.5-liter marine diesel engine designed for high-performance inboard shaft and waterjet propulsion applications. Developed by Volvo Penta, this power plant utilizes heavy-duty cast-iron construction for both the cylinder block and head to ensure excellent structural rigidity and long-term durability. The engine is engineered around an advanced Electronic Vessel Control (EVC) architecture, integrating electronic shift and throttle operations with real-time engine management. Performance is optimized via dual-stage aspiration, utilizing both a mechanical supercharger (compressor) for immediate low-end torque and a turbocharger with a charge air cooler for high-rpm efficiency. It complies with stringent marine emissions regulations, including US EPA Tier 3 and IMO NOx Tier II standards.

The crankshaft power rating is 353 kW (480 hp) achieved at a maximum rated speed of 3700 rpm. The valvetrain features a double overhead camshaft (DOHC) design activating 4 valves per cylinder (24 valves total). This configuration allows for optimized gas exchange, low pumping losses, and precise vertical alignment of the centrally located fuel injectors. The engine has a cylinder bore of 103 mm (4.06 in.) and a piston stroke of 110 mm (4.33 in.). The total engine displacement is 5.50 liters (335.6 cubic inches), operating with a static compression ratio of 17.5:1.

Fuel distribution is managed through an electronically controlled common-rail high-pressure direct injection system. Fuel is pressurized by a dedicated high-pressure injection pump and delivered to a shared fuel rail that feeds individual solenoidal injectors. The injection timing, duration, and pressure are dynamically adjusted by the Electronic Vessel Control engine management system. The fuel delivery network relies on a primary fuel filter and an external water-separating pre-filter, utilizing a manual priming hand pump for system bleeding during service. The system is fully rated for operation with standard marine diesel or Hydrotreated Vegetable Oil (HVO) alternative fuels.

A pressure-fed lubrication system supplies oil through an internal gear-driven oil pump. The system contains a multi-stage filtration assembly featuring separate, replaceable full-flow and bypass oil filters. Standard provisions include integrated oil level and temperature sensors along with a specialized crankcase oil separator to filter blow-by gases. The engine uses a closed-loop, freshwater-cooled pressurized sealed system paired with an external seawater circuit through a heat exchanger or keel cooling configuration. Seawater flow is generated by a gear-driven raw water pump equipped with a flexible rubber impeller. Additionally, a dedicated charge air cooler reduces intake air temperatures post-compression to maximize air density.

General Technical Data

Engine Specifications

Engine Model ............... Volvo Penta D6-480
Engine Type ............... 4-stroke inline 6-cylinder direct injection liquid-cooled 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) ............... 336 (5.5)
Rated Engine Power, hp (kW) ............... 480 (353) at crankshaft
Rated Engine Speed, rpm ............... 3700
Peak Torque ............... 1050 Nm (774 lb-ft) at 2000-2500 rpm
Idle Speed ............... 600-650 rpm
Aspiration Type ............... Turbocharged and supercharged with charge air cooler
Operating Speed ............... 3700 rpm
Compression Ratio ............... 17.5:1
Firing Order ............... 1-5-3-6-2-4
Camshaft Configuration ............... Double overhead camshafts
Valves Per Cylinder ............... 4
Crankcase Ventilation ............... Closed system with replaceable separator
Combustion Principle ............... Direct injection common rail technology
Direction of Rotation ............... Counter-clockwise looking at flywheel
Cylinder Block Type ............... Cast iron
Cylinder Head Type ............... Cast iron
Lubrication System ............... Full-pressure lubrication with oil cooler
Oil Pump Type ............... Gear-driven
Oil Filter Type ............... Replaceable full-flow and bypass spin-on filters
Cooling System ............... Thermostatically regulated freshwater cooling with seawater heat exchanger
Water Pump Type ............... Belt-driven centrifugal freshwater pump and seawater impeller pump
Air Cleaner Type ............... Dry type with replaceable insert
Emission Certification ............... IMO NOx Tier II, US EPA Tier 3, EU RCD Stage II
Starting System ............... Electric Starter
Electrical System ............... 12V or 24V
Alternator Capacity, A ............... 150A for 12V or 80A for 24V installations

Fuel System

Injection Pump Type ............... Bosch CP3.3 High-Pressure Rail Pump
System Operating Pressure, psi (bar) ............... 29000 (2000) maximum
Minimum Starting Rail Pressure, psi (MPa) ............... 2900 (20.0)
Fuel Feed Pump Type ............... Gear-driven mechanical lift pump
Fuel Filter Type ............... Primary water separator plus fine spin-on secondary filter
Governor Type ............... Electronic management via EVC system
Fuel Type Compatibility ............... Ultra-low sulfur marine diesel or HVO renewable fuel
Maximum Fuel Return Temperature, deg F (deg C) ............... 140 (60)
Fuel Delivery Control ............... Solenoid actuator electronic controllers
Injector Type ............... Centrally positioned multi-hole electro-hydraulic injectors
Fuel System Line Type ............... Double-walled high-pressure steel pipes
Maximum Fuel Lift Pump Suction, in Hg (kPa) ............... 4.5 (15.0)
Fuel Consumption at Max Output, gal/hr (L/hr) ............... 24.3 (92.0)
Fuel Consumption at 3000 rpm, gal/hr (L/hr) ............... 14.5 (55.0)
Fuel Consumption at 2500 rpm, gal/hr (L/hr) ............... 9.2 (35.0)
Fuel Feed Line Diameter, in (mm) ............... 0.39 (10.0)
Fuel Return Line Diameter, in (mm) ............... 0.31 (8.0)

Dimensions and Weight

Overall Length (Bobtail), in (mm) ............... 40.7 (1035)
Length with HS85A Gearbox, in (mm) ............... 49.8 (1265)
Overall Width, in (mm) ............... 33.5 (850)
Overall Height, in (mm) ............... 31.3 (795)
Dry Weight (Bobtail), lbs (kg) ............... 1378 (625)
Dry Weight with HS85A Gearbox, lbs (kg) ............... 1543 (700)

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 D6-440 Specs
  

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