Volvo Penta D3-160 Specifications
| Engine Model: Volvo Penta D3-160 |
| Engine Type: 4-cycle inline 4-cylinder direct injection liquid-cooled diesel |
| Total Displacement: 146 cu.in (2.4 L) |
| Rated Engine Power: 155-160 Hp (115-118 kW) at 3500 rpm |
| Aspiration Type: Twin-turbocharged and aftercooled |
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The Volvo Penta D3-160 is a compact,
lightweight, and high-performance marine diesel engine. Constructed with
a composite block and an aluminum alloy cylinder head, this power unit
offers an advantageous power-to-weight ratio for its class. Utilizing
common rail fuel injection and twin turbochargers, it delivers
responsive power and high torque across a broad engine speed range.
Designed for recreational marine applications, the D3-160 combines
modern diesel technology with electronic control systems to provide
efficient, smooth, and quiet operation. This engine is suited for
installation in planing pleasure craft where performance and space
savings are critical factors.
Engine Model: Volvo Penta D3-160.
Engine Type: Four-stroke, direct injection, twin-turbocharged and
aftercooled diesel engine.
Number of Cylinders: 5, in-line.
Bore: 81.0 mm (3.19 inches).
Stroke: 93.0 mm (3.66 inches).
Displacement: 2.4 liters (146 cubic inches).
Compression Ratio: 17.3:1.
Aspiration: Sequential twin-turbocharging with charge air cooling
(aftercooled).
Rated Power: 160 Hp (118 kW) at 3500 RPM at crankshaft. Propeller shaft
output approximates 155 Hp (115 kW). Maximum Torque: 400 Nm at 1500-2750
RPM. (295 lb-ft).
Maximum Engine Speed: 3750 RPM.
Firing Order: 1-2-4-5-3.
Rotation (flywheel end): Clockwise (standard).
Governor Type: Electronic, integrated within the Engine Control Unit
(ECU).
Emissions Compliance: Meets EU Recreational Craft Directive (RCD) and US
EPA Tier 3 recreational marine standards.
The cylinder block is an innovative composite construction. It consists
of a deep-skirt aluminum alloy lower section that forms the crankcase,
combined with a cast iron upper section that houses the cylinder bores.
This design reduces overall weight while maintaining the durability and
wear resistance of iron at the cylinder interface.
The block incorporates four main bearing supports with rigid bearing
caps. Main bearing caps are secured with two vertical bolts each. The
aluminum crankcase section includes cast-in cooling passages and oil
galleries. The block assembly is engineered for high structural rigidity
and effective noise damping.
The cylinder head is a single-piece aluminum alloy casting. This
lightweight construction promotes efficient heat dissipation. The head
design is a direct injection, four-valve configuration with two intake
and two exhaust valves per cylinder. Valve seats are manufactured from
hardened material and are press-fitted into the aluminum.
Valve guides are replaceable. Valve actuation is via roller finger
followers driven by dual overhead camshafts (DOHC). The camshafts are
chain-driven from the crankshaft. This valvetrain design allows for
precise valve control and supports high engine speeds with low friction.
The fuel system is a high-pressure common rail direct injection (CRDi)
system. A single, engine-driven high-pressure pump supplies fuel to a
common rail. The rail maintains a constant, electronically controlled
high pressure, supplying fuel to solenoid-operated injectors at each
cylinder.
The Volvo Penta Engine Control Unit (ECU) manages injection pressure,
timing, and duration, enabling multiple precise injection events per
combustion cycle. This system optimizes power, fuel economy, and reduces
noise and emissions. The fuel supply circuit includes a pre-filter with
a water separator, a hand priming pump, and a main fuel filter.
The lubrication system is a wet-sump, pressure-fed design. A
trochoid-type oil pump, located in the oil pan and driven by the
crankshaft, draws oil through a pickup strainer. Oil is forced through a
full-flow, replaceable spin-on oil filter. An oil cooler, integrated
into the engine's cooling circuit, regulates oil temperature.
Pressurized oil is supplied to the crankshaft main and connecting rod
bearings, the dual overhead camshafts, the turbocharger bearings, and
the high-pressure fuel pump. The engine oil capacity, including filter,
is 6.8 liters (1.80 U.S. gallons). Lubricant must meet Volvo Penta VDS-4
or equivalent ACEA E7, API CJ-4 specifications.
The engine employs a dedicated freshwater (closed-circuit) cooling
system with a heat exchanger. A single, belt-driven centrifugal pump
circulates a coolant mixture (ethylene glycol and water) through the
engine block, cylinder head, oil cooler, and aftercooler. Heat is
transferred to a plate-type heat exchanger.
A separate raw seawater circuit, powered by an electric or engine-driven
impeller pump, flows through the heat exchanger, absorbing heat before
discharge. The system is regulated by a thermostatic valve that
maintains optimal engine operating temperature. A seawater-cooled
aftercooler lowers the temperature of the compressed intake air.
Starting System: A 12-volt electrical system with a high-torque starter
motor. Charging System: A 12-volt, 115-ampere marine alternator with
multi-stage regulation. Air Intake System: Includes an air filter and
ducting to the sequential twin-turbochargers. The system uses a small
turbo for low-speed response and a larger turbo for high-speed power.
Exhaust System: A wet elbow design mixes cooling water with exhaust
gases. The exhaust manifold is integrated into the cylinder head. Engine
Management: A comprehensive ECU provides full electronic control,
diagnostic functions via EVC (Electronic Vessel Control), and system
monitoring. An electric solenoid acts as the engine stop.
Length (engine only, from front pulley to flywheel housing): 858 mm
(33.8 inches).
Width (overall, at mounting feet): 758 mm (29.8 inches).
Height (over valve cover): 740 mm (29.1 inches).
Dry Weight (engine with standard DPH sterndrive, without fluids): 445 kg
(981 lbs).
Engine Oil Change Interval: 200 hours or annually, whichever occurs
first.
Oil Filter Change: Every oil change interval.
Fuel Filter Primary (water separator): Drain water weekly. Replace
element every 200 hours.
Fuel Filter Secondary: Replace every 200 hours.
Coolant: Check concentration and condition annually. Replace every two
years or 400 hours.
Raw Water Impeller: Inspect every season; replace every year or 200
hours.
Valve Clearance Inspection: Check every 1000 hours. Adjustment is
performed by replacing shims under the roller finger followers.
Belt Tension: Check and adjust serpentine belt tension for coolant pump
and alternator every 200 hours. Automatic tensioner is fitted.
Cylinder Head Bolts (M11): Tighten in the specified multi-stage
sequence.Final stage: 90 deg angular rotation. Main Bearing Cap Bolts
(M10): 50 Nm + 60 deg angular rotation. (37 lb-ft + 60 deg).
Connecting Rod Cap Bolts (M9): 30 Nm + 90 deg angular rotation. (22
lb-ft + 90 deg).
Flywheel to Crankshaft Bolts (M12): 85 Nm + 30 deg (63 lb-ft + 30 deg).
Injector Clamp Bolt: 8 Nm. (5.9 lb-ft).
Oil Pan Bolts (M6): 10 Nm. (7.4 lb-ft).
The Volvo Penta D3-160 is designed exclusively for marine propulsion in
high-performance recreational vessels. Its primary application is as the
inboard powerplant for planing motor yachts, sport cruisers, and day
boats in the 25 to 35-foot length range. It is commonly paired with
Volvo Penta Duoprop (DPH) sterndrives or inboard drive systems (IPS) for
enhanced maneuverability and efficiency.
The engine is also installed as a single or twin engine configuration in
center console boats and rigid inflatable boats (RIBs) where quick
acceleration and high top speed are required. Its compact dimensions and
high power output make it a suitable choice for repower projects where
space and weight are constrained.
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