Volvo Penta · Inboard diesel

Volvo Penta D3

The Volvo Penta D3 is a 2.4-litre five-cylinder common-rail diesel with a variable-geometry turbo and aftercooler, built from 2003 to 2022 for fast motorboats, RIBs and day cruisers. It came as an inboard shaft engine with an HS25, HS45 or HS63 reverse gear or as an Aquamatic package with an SX or Duoprop sterndrive, rated from 110 to 220 hp (D3-110 to D3-220). The letter after the rating on the type plate is the version: A–C up to 2009, then the second generation D–H from 2010 with 1800-bar piezo injection and new ratings such as the D3-140. Oil, fuel and air filters, belts, seawater pump and service kit changed between C and D, and the camshafts are driven by a toothed belt with a fixed replacement interval; the four-cylinder D4 is the next size up.

Manuals & documents
Wear parts & part numbers
Service intervals
Specifications
Good to know
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 D3, version A (D3-110i, D3-130, D3-160) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D3, version B (D3-110i to D3-190) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D3, version C Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D3, version D (2010) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D3, version E (2011) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D3, version F (2012) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D3, version G (2014) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D3, version H (2015) Operation manual pubs.volvopenta.com · PDF · EN
Service and Maintenance D3, versions D–H (2023) Service manual pubs.volvopenta.com · PDF · EN
Service protocol D3 inboard, generated per engine (example D3-220I-H; put your own designation in the link) Service protocol productcenter.volvopenta.com · PDF · EN
Service protocol D3 Aquamatic, generated per engine (example D3-220A-H) Service protocol productcenter.volvopenta.com · PDF · EN
Service protocol D3, versions A–C (2019) Service protocol pubs.volvopenta.com · PDF · EN
Workshop manual D3, versions D–H, groups 20–26 (region and login required) Printed manual (to order) volvopenta.mis.elanders.com · EN
Volvo Penta parts catalogue: D3 sections, fitment per version Parts catalogue volvopenta.com · EN
Volvo Penta product archive: D3 Manual portal volvopenta.com · EN

Wear parts & part numbers

Part	OEM number	Also fits	Note
Impeller kit (with gasket)	`21951352`^1,2,3,4,5replaces 3593660replaces 21381693	—	All D3, versions A–H, inboard and Aquamatic. Kit with impeller 3595485 and O-ring. The pump bodies differ between A–C and D–H, the impeller kit does not.
Engine oil filter	`8692305`^6,7,8	—	Versions A–C only. Insert for filter housing 30677920 (cover 8692306).
Engine oil filter	`30788490`^9,10,11	—	Versions D–H only (D3-110 to D3-220, inboard and Aquamatic). Kit with insert and O-ring.
Fuel filter (engine)	`31261191`^12,13,14replaces 8683212	—	Versions A–C only. Filter housing kit 3884825.
Fuel filter (engine)	`21139810`^15,16	—	Versions D–H only. Cartridge for the engine-mounted filter 21286999 (complete with housing and water-in-fuel sensor 3808616).
Fuel pre-filter	`861014`^17,18,19	—	All D3, versions A–H: the standard 10-micron element for Volvo Penta pre-filters 877762, 877763, 877764 and 22677639 (on A–C in pre-filter 3582350). Also made as 1147147 (2 micron) and 3581760 (30 micron). The boatbuilder often fitted the pre-filter, so check the housing first.
Air filter	`21646645`^20,21	—	Version A only: D3-110i-A, D3-130A-A, D3-130i-A, D3-160A-A and D3-160i-A (air filter 21782391). The D3-190i-A takes the B/C insert.
Air filter	`21171277`^22,23	—	Versions B and C, plus the D3-190i-A (air filter 21171248).
Air filter	`21379288`^24,25	—	Versions D–H, all ratings. Supplied as the complete air cleaner.
Alternator V-belt	`30731809`^26,27,28replaces 8627228	—	Versions A–C only. Belt tensioner 31251252 or 31251251, depending on the engine serial number.
Alternator V-belt	`22283751`^29,30,31	—	Versions D–H on engines without power steering. Belt tensioner kit 24204919.
Alternator V-belt	`22352491`^32,33	—	Engines with power steering: Volvo’s fitment list names versions D–F (inboard and Aquamatic) and G–H Aquamatic. Volvo’s page for the version H power-steering adapter shows 22283751 instead, so the fitment is ambiguous: compare the old belt before ordering.
Timing belt	`31258305`^34,35,36	—	Versions A–F. Kit with belt 31258306, idler pulley 8692561 and tensioner 31339542 (formerly 30731774); the tensioner is the same on all D3.
Timing belt	`31359568`^37,38	—	Versions G and H only. Kit with belt 30777779, tensioner 31339542 and idler pulley 8692561; only the belt differs from the A–F kit, the tensioner is the same on all D3.
Thermostat	`3840816`^39,40,41replaces 3584474	—	All D3, versions A–H. On D–H it sits in the heat-exchanger housing. Gasket 3584299.
Thermostat gasket	`3584299`^39,40,42	—	All D3, versions A–H.
Crankcase breather element	`21368879`^43,44,45	—	Versions D–H only: insert for oil trap 21690243, replaced at every 200-hour service. Not in the service kit.
Raw water pump	`21141637`^3,4,46	—	Versions A–C only, all ratings. Shaft kit 21951439, screw kit 21951334.
Raw water pump	`21379102`^2,1,47	—	Versions D–H only. Wear kit 21951386, screw kit 21951330. On these engines the pump runs on its own belt (21160912).
Seawater pump belt	`21160912`^32,48	—	Versions D–H only, inboard and Aquamatic: the separate V-ribbed belt that drives the seawater pump.
Service kit	`21105842`^49,50	—	Versions A–C only: fuel filter 31261191, oil filter 8692305 and impeller kit 3593660 (now 21951352).
Service kit	`21759184`^32,51	—	Versions D–G per Volvo’s fitment list: impeller kit 21381693 (now 21951352), oil filter kit 30788490 and fuel filter 21139810. Volvo lists no service kit for version H; buy those three parts separately.
Onboard spares kit	`21348726`^49,52	—	Versions A–C only: impeller kit, drive belt 30731809, puller screw, hose clamps, fuses and tape.
Onboard spares kit	`21408029`^32,53	—	Versions D–F only: all three V-ribbed belts (22352491, 22283751, 21160912), puller screw, fuses and clamps.
Inlet strainer	`21880390`^54,55	—	Versions D–H: strainer insert for seawater filter 21880386.
Inlet strainer	`3593606`^4,56	—	Versions B and C, Aquamatic only (D3-130A, D3-160A, D3-190A): insert for seawater filter 3812612.
Anode (transom shield)	`3888817`^57,58,59	—	Zinc kit for salt water. Goes by drive, not by engine version: any D3 Aquamatic with an SX-A or DPS-A/DPS-B drive. Aluminium 3888816 for salt or brackish water, magnesium 3888818 for fresh water.
Anode (lower unit)	`3888814`^57,60,61	—	Cavitation-plate anode kit, zinc, for salt water: any D3 Aquamatic with an SX-A or DPS-A/DPS-B drive, whatever the engine version. Aluminium 3888813, magnesium 3888815 for fresh water.

Numbers checked against the sources below on 13 October 2026. Always confirm against your serial number and exact type before ordering.

Service intervals

Task	Interval
First service	Inboard reverse gear: oil and filter after the first 25 h or 6 months⁶²
Engine oil change	Oil and oil filter every 200 h or yearly; every 100 h if the fuel has more than 1 % sulphur^62,63,64
Fuel filter	Fine filter and pre-filter element every 200 h or yearly^62,64
Air filter	D–H: every 400 h or every 2 years; A–C: every 200 h or yearly^62,64
Crankcase ventilation	D–H: replace the filter every 200 h or yearly⁶²
Raw water impeller	Inspect every 200 h or yearly, replace every 400 h or every 2 years (A–C protocol: inspect every 200 h or yearly, replace when worn)^62,65,64
Sea water strainer	Every 200 h or yearly⁶²
V-belt check	Inspect every 200 h or yearly; replace every 800 h or every 4 years and check the tensioner and idler bearings at the same time (the 2015 version H operator’s manual still said 600 h)^62,65,63
Timing belt	Replace every 1400 h or every 8 years, all versions^62,64,63
Coolant change	D–H: every 2000 h or every 4 years; A–C protocol: every second year^62,64
Gearbox oil change	Inboard reverse gear: oil every 200 h or yearly (A–C: oil and filter)^62,64
Gear oil change	Aquamatic drive: oil every 200 h or yearly^65,64
Anode	Inspect every 200 h or yearly (A–C protocol: replace the drive anodes every 200 h or yearly); never paint them^65,64,63
Exhaust hose	Inboard: inspect every 200 h or yearly, replace every 800 h or every 4 years⁶²
Bellows & U-joints	Aquamatic: inspect the exhaust and U-joint bellows every 200 h or yearly, replace every 800 h or every 4 years (A–C protocol: replace every 4th year)^65,64

Hours or time, whichever comes first. The schedule is Volvo Penta’s current service protocol, which Volvo generates per engine designation (examples D3-220I-H for inboard and D3-220A-H for Aquamatic; the D–H engines share its tasks). Versions A–C have their own protocol (7747041, 2019); where it differs, the A–C figure is given separately. The 2015 operator’s manual for version H still listed shorter intervals for the air filter (200 h) and the drive belts (600 h); the current protocol replaces them.

Specifications

Versions	A–C (to 2009): D3-110, D3-130, D3-160, D3-190. D–H (from 2010): D3-110, D3-140, D3-150, D3-170, D3-200, D3-220. Inboard (i) or Aquamatic (A), the D3-110 and D3-150 inboard only; the letter after the rating on the type plate is the version, e.g. D3-170I-F^64,63,66,67
Cylinders	5 in-line; aluminium block and head, double overhead camshafts, 4 valves per cylinder, hydraulic lash adjusters^68,69
Displacement	2.4 l (2401 cm³)^63,70
Bore × stroke	81 × 93.2 mm^63,70
Compression ratio	18:1 (version A product bulletin), 17.3:1 (B/C), 16.5:1 (D–H)^63,68,66
Power	At the crankshaft (ISO 8665). A–C: D3-110i 81 kW (110 hp), D3-130 96 kW (130 hp), D3-160 120 kW (163 hp), D3-190 140 kW (190 hp). D–H: D3-110i 82 kW (110 hp), D3-140A 104 kW (140 hp), D3-150i 111 kW (150 hp), D3-170 127 kW (170 hp), D3-200 149 kW (200 hp), D3-220 164 kW (220 hp)^63,66,70,71
Rated speed	4000 rpm; D3-110 and D3-150: 3000 rpm^72,70,66
Idle speed	700 rpm^72,63
Injection	Common rail with electronic control (EVC); from version D (2010) 1800 bar with piezo injectors^67,68
Aspiration	Variable-geometry turbocharger (VGT) with aftercooler^67,68
Engine oil capacity	Approx. 6.3 l incl. filters (D–H manuals); B/C manuals: 6.5 l max, 4.8 l min; the version A manual gives 8.0 l incl. filter^{63,73,66,74,75}
Engine oil grade	VDS-3 minimum (D–H); version A manual: VDS-2 or VDS-3, ACEA E5 or API CH-4; typically SAE 15W-40, viscosity by ambient temperature^63,75
Coolant capacity	Approx. 8.7 l incl. heat exchanger (E–H manuals); 8.2 l (B/C manuals); the A and D manuals give 12.5 l^{63,76,66,74,73,75}
Coolant	Volvo Penta VCS (yellow) on later engines; never mix different coolant types⁶³
Thermostat opens at	80 °C, fully open at 95 °C⁶³
Alternator	14 V / 140 A (A–C), 115 A (D manual), 150 A (E–G), 180 A (H)^63,66,76
Dry weight	A–C: 227 kg engine only, 264 kg with HS25A. D–H: 260 kg engine only, 297–301 kg with HS25AE/HS45AE, 335 kg with HS63IVE; Aquamatic DPS package 363 kg incl. propellers and power steering^63,66,70,71
Gearbox	Inboard: HS25A(E) 1.92 or 2.48:1, HS45A(E) 2.03 or 2.43:1, HS63IV(E) 1.99 or 2.48:1. Aquamatic: SX (1.66:1), DP-S/DPS-A Duoprop (1.78–2.14:1), early engines also XDP^63,75
Gear oil capacity	HS25AE 1.8 l, HS45AE 2.5 l, HS63IVE 4.8 l (ATF Dexron II/III); DPS-A 2.25 l, SX-A 2.44 l (synthetic API GL5, SAE 75W-90); power trim 1.6 l ATF⁶³
Years built	2003–2022 per Volvo Penta’s product archive; first marine D3 bulletins for model year 2005, second generation (version D) launched in 2010, last version H^69,68,67

Good to know

Renew the timing belt every 1400 hours or 8 years, whichever comes first, even on a boat with few hours. The kit depends on the version letter: 31258305 for A–F, 31359568 for G–H.^62,34,37
Read the version letter on the type plate (e.g. D3-170I-F) before ordering: oil, fuel and air filters, belts, seawater pump and service kits changed between C and D. Common to all D3 are the impeller kit 21951352, thermostat 3840816 with gasket 3584299, pre-filter element 861014 and timing-belt tensioner 31339542.^9,5,41
On D–H engines the crankcase ventilation filter (21368879) is replaced at every 200-hour service, together with the oil, fuel filter and pre-filter. It is easy to forget because it is not in the service kit.^62,51
D–H engines drive the seawater pump with their own small V-ribbed belt (21160912). Carry one along with the alternator belt; the D–F on-board kit 21408029 contains all three belts.³²
Top up the coolant only with the type already in the engine; later engines use Volvo Penta VCS (yellow), and different coolant types must not be mixed.⁶³
Sterndrive boats: pick the anode material for the water you use (zinc for salt, aluminium for salt or brackish, magnesium for fresh water) and never paint the anodes.^63,57

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Sources

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