Volvo Penta · Inboard diesel

Volvo Penta 2003

The Volvo Penta 2003 is the three-cylinder, 1.28-litre engine of the 2000 series (2001, 2002, 2003, 2003T): a direct-injection diesel with decompression lever and a large flywheel, rated at 20.5 kW (28 hp) at 3200 rpm at the propeller shaft. It was sold as the 2003R with the MS2 reverse gear, the 2003V with the MS2V V-drive and the 2003S with the 120S saildrive, and was a very common auxiliary in 28–36 ft sailing yachts; later versions carry the suffixes B, D and AG/BG. Most engines are seawater-cooled with a zinc pencil anode in the block; freshwater cooling with a heat exchanger was an option and is standard on the turbocharged 2003T — the cooling system decides more part numbers than the version letter does. This page also serves the 2003T and the smaller siblings: the one-cylinder 2001 (0.43 l, seawater-cooled only) and the two-cylinder 2002 (0.85 l, seawater- or freshwater-cooled) share the raw-water pump, impeller, filters, thermostats, pencil anode and exhaust elbow with the 2003. What differs is the 2001’s V-belt, the head and valve-cover gaskets and gasket sets (one per cylinder count) and, by version, the injectors; the parts list gives the number for each engine. The MD2030 and later the D1-30 took over from the 2003.

Manuals & documents
Wear parts & part numbers
Service intervals
Specifications
Good to know
Videos & how-tos
Fitted in
On the marketplace

Manuals & documents

The links go straight to Volvo Penta. We host no manuals or drawings — the manufacturer’s copy is the current one.

Operator’s manual 2001, 2002, 2003, 2003T (1998, scanned) Operation manual pubs.volvopenta.com · PDF · EN
Sales sheet 2003 (1988): data, standard equipment, transmissions Spec sheet pubs.volvopenta.com · PDF · EN
Product bulletin 2001: data, standard equipment, transmissions Spec sheet pubs.volvopenta.com · PDF · EN
Service protocol 2001–2003, 2003T, 2003TB (2006) Service protocol pubs.volvopenta.com · PDF · EN
Volvo Penta manuals & handbooks: 2003 (all publications; 2003T, 2003B, 2001 and 2002 have their own pages) Manual portal volvopenta.com · EN
Volvo Penta manuals & handbooks: 2001 Manual portal volvopenta.com · EN
Volvo Penta manuals & handbooks: 2002 Manual portal volvopenta.com · EN
Volvo Penta parts catalogue, filtered to 2003 Parts catalogue volvopenta.com · EN
Volvo Penta parts catalogue, filtered to 2001 Parts catalogue volvopenta.com · EN
Volvo Penta parts catalogue, filtered to 2002 Parts catalogue volvopenta.com · EN
Parts catalogue: sea water pump 840557 (2001, 2002, 2003) Parts catalogue volvopenta.com · EN
Parts catalogue: sea water pump 858150 (2003T, 2003TB) Parts catalogue volvopenta.com · EN
Parts catalogue: repair kits 2001 (decarbonizing kit 876307) Parts catalogue volvopenta.com · EN
Parts catalogue: repair kits 2002 (decarbonizing kit 876308, circulation pump kit 876270) Parts catalogue volvopenta.com · EN

Wear parts & part numbers

Part	OEM number	Also fits	Note
Raw water pump impeller	`21951342`^1,2,3replaces 3586496	—	Kit for the standard pump 840557 on the 2001, 2002 and 2003 (all versions) — not for the 2003T. Also the impeller in service kit 877194.
Raw water pump impeller	`21951346`^4,5replaces 3862281replaces 877400	—	2003T and 2003TB only, for their pump 858150; does not fit the 2001/2002/2003.
Pump cover gasket	`833994`^1,6,7	—	Pump 840557 on the 2001, 2002 and 2003; the catalogue shows it at cover and housing. Fit a new one whenever the cover comes off.
Raw water pump	`840557`^{1,8,9,10,11,12,13}	—	2001, 2002 and 2003 incl. B, D, AG and BG, seawater- and freshwater-cooled. Dealers supply it as the Johnson-built genuine pump with engine O-ring and pipe seals.
Raw water pump	`858150`^4,14,15,16	—	2003T, 2003TB and 2003TR only. Dealers supply 24761270 as the current replacement; Volvo Penta’s page for that number shows no fit list.
Engine oil filter	`834337` · `22057107`^{17,18,3,19,20,21,22,23,24}	—	834337 is the number in Volvo Penta’s catalogue for the whole 2000 series (2001, 2002, 2003 and 2003T/TB); dealers now supply 22057107 for the same engines, which is also the filter in service kit 877194 (spin-on, 76 mm diameter, 59 mm long).
Fuel filter (engine)	`829913` · `21492771`^{25,26,27,3,28,29,30,31,32,33}	—	829913 is the element inside the fuel filter assembly 840532 in Volvo Penta’s catalogue (2001, 2002, 2003 and 2003T/TB); dealers now supply 21492771, the filter in service kit 877194 (spin-on, 76 mm diameter, 80 mm long).
Fuel pre-filter	`3581078`^35,34,36,37	Perkins `4326658`³⁴	Element for Volvo Penta’s water-separating pre-filter 877766 (metal) or 877767 (plastic) — only if that filter is fitted; many boats carry another make. Fit list names 2001, 2002, 2003 and 2003T.
Alternator V-belt	`966900`^38,39,6,40	—	Seawater-cooled 2002 (incl. AG, B, BG, D) and 2003 (incl. B, D) without circulation pump; the 2001 has its own belt 966903. Right tension: about 5 mm give under thumb pressure midway between the pulleys.
Alternator V-belt	`966906`^38,41,42,40	—	Engines with circulation pump (freshwater cooling): 2002, 2003 and 2003T/TB; drives alternator and circulation pump. Not for the 2001, which is seawater-cooled only.
Alternator V-belt	`966903`^43,40,44,45	—	2001 only, all versions (incl. AG, B/BG and D); the 2002 and 2003 use 966900 or 966906. Same tension as the others: about 5 mm give under thumb pressure.
Thermostat	`877355`^{46,47,48,49,50}	—	60 °C, seawater-cooled 2001, 2002 and 2003 incl. B, D, AG, BG and SOLAS; every 2001 takes this one. Comes with seal.
Thermostat	`875795`^51,47,52,50	—	74 °C, freshwater-cooled 2002, 2003, 2003B, 2003D and the 2003T/2003TB; not for the 2001. Comes with seal.
Anode (engine)	`838929`^{53,54,6,55,56}	—	Pencil anode in the block/head of every 2001 and of seawater-cooled 2002 and 2003 — none on freshwater-cooled engines. M8 internal thread, 7/16 in UNC outside, 30 mm long.
Exhaust mixing elbow	`840690`^{57,58,59,48,52,60}	—	Cast iron, water-injected, 1¾ in (44.5 mm) hose outlet, can be turned through 90°; 2001, 2002 and 2003 incl. B, D, AG, BG. Dealers also sell a stainless replacement.
Exhaust elbow gasket	`840902`^61,62,48,63	—	2001, 2002, 2003 and 2003T/TB (also MD6/MD7).
Pressure cap	`844624`^64,65,66,67	—	30 kPa cap for the expansion tank of freshwater-cooled 2002 and 2003 (incl. B, D, AG/BG). Volvo Penta’s expansion-tank section gives the 2003T/TB cap 1542591 instead. Seawater-cooled engines, and so every 2001, have no expansion tank.
Coolant pump	`860358`^{41,68,69,70,71,72}replaces 840710	—	Freshwater-cooled 2002, 2003 and 2003T/TB; the 2001 has none. Volvo Penta lists repair kit 876270 (rotor, gasket, seal, bearing) for pumps 840710 and 860358, and a further kit 3812230.
Service kit	`877194`^3,73	—	Oil filter 22057107, fuel filter 21492771, impeller 21951342, gasket and lubricant. Fitment 2001, 2001B, 2001D, 2002, 2002B, 2002D, 2003, 2003B, 2003D and 2003TB stated by one UK Volvo Penta distributor (one source); Volvo Penta’s own page lists the kit without fit list. The impeller is the one for pump 840557 — check it suits your 2003TB.
Saildrive anode	`876286`^74,75replaces 851983	—	Ring anode for the 120S saildrive (2001S, 2002S, 2003S) — fit list 2001, 2002, 2003, 2003B/D/T/TB with 120S-D/E. Dealer dimensions: 97 mm outer, 40 mm inner diameter, 27 mm high.
Cylinder head gasket	`840569`^55,76,77	—	2001 only, all versions.
Cylinder head gasket	`859094`^56,78,72,79replaces 840328	—	2002 only, all versions, seawater- and freshwater-cooled.
Cylinder head gasket	`859093`^{80,81,82,83,84}replaces 840405	—	2003 (all versions, seawater- and freshwater-cooled) and 2003T/TB.
Valve cover gasket	`859042`^55,76,85replaces 840572	—	2001 only.
Valve cover gasket	`859043`^56,72,86replaces 840440	—	2002 only.
Valve cover gasket	`859044`^80,82,83,87replaces 840461	—	2003 and 2003T/TB.
Gasket set	`876307`^76,88,89	—	Decarbonizing (top-end) kit for the 2001: head gasket 840569, valve cover gasket 859042, two valve stem seals, exhaust elbow gasket and the small seals.
Gasket set	`876308`^72,90,91,92	—	Decarbonizing kit for the 2002: head gasket 859094, valve cover gasket 859043, four valve stem seals and the same small seals as the 2001 kit.
Gasket set	`876309`^83,93,94,95	—	Decarbonizing kit for the 2003 (incl. B, D, AG and SOLAS): head gasket 859093, valve cover gasket 859044, six valve stem seals and the small seals. For the 2003T/TB the catalogue lists kit 876310.
Fuel injector	`840595`^{96,30,97,31,98,99,100,101}	—	Standard injector of the 2001, 2002 and 2003, also 2001AG, 2002AG and 2003 SOLAS; nozzle 840597. Check the product number on the engine plate: some engines have 860340 or 860176 (next rows), the B, BG and D versions have their own, and the 2003T/TB has a different one.
Fuel injector	`860340`^{30,31,99,102,103}	—	Engines with product no. 868231 (2001), 868232 (2002) or 868233 (2003) on the engine plate; nozzle 859461.
Fuel injector	`860176`^99,104,105	—	2003 with product no. 868100–868103 or 868219–868222 (from serial no. 2300042660), and the 2003AG; nozzle 860177.
Fuel injector	`860556`^{106,107,108,109}	—	2001B and 2001BG; nozzle 860557.
Fuel injector	`860792`^{110,111,112,113,114,115}	—	2002B, 2002BG, 2003B and 2003BG; nozzle 860791.
Fuel injector	`860948`^{116,117,118,119}	—	2002D and 2003D; nozzle 860949.

Numbers checked against the sources below on 12 October 2026. Always confirm against your serial number and exact type before ordering.

Service intervals

Task	Interval
Engine oil change	Every 100 h or yearly⁶
Oil filter	1998 manual: first after 20 h, then at every second oil change; 2006 service protocol: with every oil change (100 h / yearly)^6,120
Fuel filter	Engine filter and pre-filter element every 200 h or yearly, also before laying up¹²⁰
Raw water impeller	Check every 100 h or at least once a year; replace if worn or damaged¹²⁰
V-belt check	Check tension every 14 days (about 5 mm give); check and adjust every 100 h, replace worn or cracked belts⁶
Sea water strainer	Clean every 100 h or yearly (if one is fitted)¹²⁰
Anode	Engine anode (seawater-cooled engines), saildrive and folding-propeller anodes: check every 200 h or yearly, and at launching¹²⁰
Gear oil change	Reverse gear or saildrive: change every 400 h or yearly per the 1998 manual (every 200 h or yearly in the 2006 protocol); check the level every 14 days^6,120
Valve clearance	Every 200 h or yearly (authorised dealer)¹²⁰
Injectors	Test pressure every 400 h or every 2 years¹²⁰
Coolant change	Freshwater-cooled engines and 2003T: change coolant and clean the heat exchanger every 400 h or every 2 years; keep a 50/50 glycol mix¹²⁰
Air filter	Intake silencer: clean every season (wash in diesel); 2003T: replace every 400 h or 2 years⁶
Cooling system	Vacuum valve (siphon break): dismantle and clean at least once a season⁶
Strainer clean	Feed pump fuel strainer: clean every 200 h or yearly¹²⁰
Saildrive diaphragm	120S: replace the rubber seal every 7 years (authorised dealer)⁶
Propeller	Folding propeller: tab washer and locking screw every 4 years¹²⁰
Battery	Check electrolyte level every 14 days⁶
Shaft seal (stuffing box)	Rubber stuffing box on shaft-drive boats: check every 200 h, replace every 500 h or 5 years⁶

Hours or time, whichever comes first. From the 1998 operator’s manual for the 2001–2003T and Volvo Penta’s 2006 service protocol; where the two differ, both are given.

Specifications

Cylinders	3 (2001: 1, 2002: 2), in-line, direct injection⁶
Displacement	1.28 l (2003, 2003T); 2001: 0.43 l; 2002: 0.85 l⁶
Bore × stroke	79 × 87 mm⁶
Power	2003: 20.5 kW (28 hp) at 3200 rpm at the propeller shaft (DIN 6270 B), 1988 sales sheet; 2001: 6.6 kW (9 hp) at 3200 rpm at the propeller shaft (DIN 6270 B), product bulletin 7791100; no Volvo Penta figure for the 2002 is online^59,121
Full-throttle range	2800–3200 rpm, max. 3200 rpm⁶
Idle speed	850 rpm⁶
Cooling	Seawater cooling with thermostat, engine-mounted impeller pump and zinc anode in the cylinder head as standard, and the only option on the 2001; freshwater cooling with heat exchanger and circulation pump optional on the 2002 and 2003, standard on the 2003T^59,6
Thermostat opens at	Seawater-cooled: 60 °C, fully open at 75 °C; freshwater-cooled and 2003T: 74 °C, fully open at 87 °C⁶
Engine oil capacity	4.1 l incl. filter (2003); 4.3 l (2003T); 1.4 l (2001); 2.75 l (2002)⁶
Engine oil grade	API CD, SAE 15W-40⁶
Coolant capacity	Freshwater-cooled engines only: 5.5 l (2003), 7 l (2003T), 4 l (2002), 50/50 glycol mix; the 2001 has no freshwater circuit⁶
Valve clearance (hot)	0.30 mm inlet and exhaust, 2001 to 2003T; decompression lift 0.50 mm⁶
Alternator	14 V / 50 A⁶
Starter motor	1.4 kW (2001: 0.8 kW); 12 V, starter battery max. 70 Ah⁶
Dry weight	2003: 159 kg with MS2 reverse gear, 165 kg with MS2V V-drive, 173 kg with 120S saildrive; 2003T: 176 kg / 182 kg; 2001: 112 kg / 118 kg / 126 kg; 2002: 139 kg / 145 kg / 153 kg⁶
Gearbox	MS2 reverse gear (2.4:1 or 3.0:1, output 7° down), MS2V V-drive (output 20°), 120S saildrive (2.2:1)⁶
Gear oil capacity	MS2 0.8 l, MS2V 1.8 l, 120S approx. 2.8 l; same oil as the engine (API CD, SAE 15W-40)⁶
Tightening torques	Injector nut 20 Nm⁶
Versions	2003R (MS2 reverse gear), 2003V (MS2V V-drive), 2003S (120S saildrive); later 2003B, 2003D, 2003AG/BG and SOLAS versions; 2003T/2003TB turbocharged. Siblings with mostly the same parts: 2001 (1 cyl.) and 2002 (2 cyl.), each also as B, D, AG and BG versions^{59,6,46,14,120,97,98}
Max. installation angle	10° fore and aft, 30° sideways⁶

Good to know

Find out whether your engine is seawater- or freshwater-cooled before ordering: thermostat (60 °C vs 74 °C), V-belt, pencil anode and pressure cap all differ, and the 2003T has its own raw water pump and impeller.^38,46,51
Seawater-cooled engines rely on a small zinc pencil anode in the block; the service protocol has it checked every 200 hours or yearly. It is cheap — carry a spare.¹²⁰
Belt tension is right when the belt gives about 5 mm midway between the pulleys under thumb pressure; loosen the alternator nuts to adjust, and replace a cracked belt.⁶
The 1998 manual lets the oil filter stay for two oil changes, Volvo Penta’s 2006 service protocol changes it with every one — the filter is cheap, follow the protocol.^120,6
Winterising a seawater-cooled engine: drain, take the thermostat out so the whole block fills, run a 50/50 antifreeze mix through the pump at idle (never let the pump run dry), and refit the thermostat with a new seal in spring.⁶
The cast-iron exhaust elbow is the known weak point of the 2000 series: it corrodes from the inside until the water passages block and the engine overheats. Inspect it whenever it is off, and budget for a stainless replacement.⁵⁸

Videos & how-tos

Links to YouTube, nothing embedded. The maker’s own channel comes first; the rest are channels we found clear and correct for this model.

Changing the raw water pump impeller on a 2003 (French) Video Cyril Cob · FR · 10 min
Oil change with new oil and fuel filters on a 2003 (French) Video Cyril Cob · FR · 15 min
Adjusting the valve clearance on a 2002 Video Wendell Crim · EN · 6 min
Replacing the engine anode on a 2002 Video Simon Connor · EN · 7 min

Fitted in

Boats whose builder lists it as standard or optional equipment:

Hallberg-Rassy 352 — Volvo Penta 2003T (From late 1984; December 1987 specification: three-cylinder turbo diesel with direct injection, fresh-water cooled with oil cooler, 32 kW (43 hp) at 3200 rpm; tachometer, temperature gauge and warning lights with buzzer)
Moody 376 — Volvo Penta 2003T (Option: 43 hp at 3200 rpm, turbocharged, with a 2.4:1 gearbox in the boat list; one boat with a 2003T in the 1987 build register; listed in the exhaust table of October 1990)
Sadler 32 — Volvo Penta 2002 (Standard from 1986, the same engine as in the Sadler 29, with a 16 × 10.5 in propeller)
Valiant 40 — Volvo Penta 2003T (Late in production, on the Texas-built boats: Practical Sailor’s late-1980s test boat had the three-cylinder turbo 2003T, rated at 42 hp at 3000 rpm, with a V-drive and 3:1 reduction)

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Sources

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