Volvo Penta · Inboard diesel

Volvo Penta D4

The D4 is Volvo Penta’s 3.7-litre four-cylinder common-rail diesel for planing and semi-displacement motorboats, built since 2004 as a shaft inboard, as an Aquamatic sterndrive package or, as D4-260D and D4-300D, with the IPS 350/400 pod drive. Versions A–F (2004–2019) were rated D4-180 to D4-300; the G series (since 2019) runs from D4-145 to D4-320. Filters, belts, seawater pumps and service kits changed between versions, most of all from F to G, so the letter after the rating (D4-300I-F, D4-300I-G) decides which number fits. The six-cylinder D6 is its sibling and shares many service parts, but it is not covered here, and neither are the anodes, which belong to the drive.

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 D4/D6, version A (D4-210, D4-260) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D4/D6, version B (model year 2006) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D4/D6, version C (2008) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D4/D6, version D (EVC-C3, 2009) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D4/D6, version E Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D4/D6, version F (2019 edition) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D4/D6, version G (2026 edition) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D4/D6 with IPS 350/400, version D (2009) Operation manual pubs.volvopenta.com · PDF · EN
Operator’s manual D4/D6 with IPS 350/400, version F (2019) Operation manual pubs.volvopenta.com · PDF · EN
Service and Maintenance D4, D6, versions A–F (to 2019) Service manual pubs.volvopenta.com · PDF · EN
Service and Maintenance D4-G, D6-G (from 2019) Service manual pubs.volvopenta.com · PDF · EN
Service protocol D4/D6 inboard, versions A–F (2016) Service protocol pubs.volvopenta.com · PDF · EN
Service protocol D4/D6 Aquamatic DPH/DPR (2017) Service protocol pubs.volvopenta.com · PDF · EN
Service protocol D4/D6 IPS 350/400 (2016) Service protocol pubs.volvopenta.com · PDF · EN
Service protocol D4-300I-G, generated by Volvo per engine (for another G rating, change the designation in the address) Service protocol productcenter.volvopenta.com · PDF · EN
Workshop manual D4/D6 versions A–F, repair and specifications, groups 21–26 Printed manual (to order) volvopenta.mis.elanders.com · EN
Workshop manual D4-G, D6-G, repair and specifications, groups 20–26 Printed manual (to order) volvopenta.mis.elanders.com · EN
Volvo Penta online parts catalogue (D4 service-kit section) Parts catalogue volvopenta.com · EN
Volvo Penta D4 product page (current range) Product page volvopenta.com · EN

Wear parts & part numbers

Part	OEM number	Also fits	Note
Impeller kit (with gasket)	`3588475`^1,2,3	—	For the original seawater pump 3584062: versions A–D and the E/F engines that still have it (mostly inboards; Volvo lists the pump for D4-180I-B to F, D4-210, D4-225I-B to F and D4-260/300 A–D). Kit with impeller 3583601, O-ring, sealing washer and grease. Check which pump you have before ordering.
Impeller kit (with gasket)	`21951356`^4,5,6replaces 3841697replaces 21422647	—	For the later seawater pump 21419374 (replaced by 22901573): E Aquamatic/IPS engines, F engines with this pump and all G engines. Impeller 21422632. The SOLAS pump 23121350 takes kit 21951366 instead.
Impeller kit (with gasket)	`24139377`^7,8,9	—	Current kit for version G (pump 22901573): the same impeller 21422632 as kit 21951356, packed with O-ring, gasket 808275 and impeller lubricant. Also the impeller kit in G service kit 24272027.
Engine oil filter	`3582732`^10,11,12,13	—	Full-flow filter, versions A–F (all ratings: inboard, Aquamatic and IPS); always change it together with the bypass filter. Volvo’s current A–F service kit 22383875 ships the G-type pair 22030848/22030852 instead.
Bypass oil filter	`21632901`^10,11,14	—	Versions A–F, mounted next to the full-flow filter; replace both at every oil change.
Engine oil filter	`22030848`^15,16,17,18	—	Full-flow (long-life) filter, version G, all ratings. Also in the A–F service kit 22383875 (engine serial 2004033317 onwards).
Bypass oil filter	`22030852`^15,16,17,19	—	Version G, all ratings; also in the A–F service kit 22383875.
Fuel filter (engine)	`21718912`^20,17,21	—	Fine filter element, versions A–F incl. IPS, for the engine-mounted filter assembly 22996879 (Volvo’s chain: 3588199 → 21540371 → 22677437 → 22996879).
Fuel filter (engine)	`24215091`^22,23,24,25	—	Fine filter element, version G, for filter assembly 24215090; the fuel-filter section and G service kit 24272027 use this number. Volvo’s maintenance page names 22984478 as the main filter instead, without showing a supersession: compare with the element on your engine.
Fuel pre-filter	`861014`^26,16,27	—	10-micron element for the Volvo pre-filters 877762/877763/877764/22677639, all versions A–G. Alternatives: 1147147 (2 micron) and 3581760 (30 micron). The pre-filter is usually fitted by the boatbuilder, so check the housing first.
Air filter	`3818541`^28,29,30replaces 3583654	—	Versions A–E: insert for air filter 3818355 (inboard/IPS) and for the compressor air filter 3817476 (D4-225A and the D4-260/300 Aquamatic and IPS).
Air filter	`21702999`^{31,32,33,34,35}	—	All version F engines (inboard/IPS air cleaner 23421381, earlier 3595019; compressor air cleaner 23421045, earlier 22469302) and all G engines. Also in the A–F service kit 22383875.
Alternator V-belt	`3583729`^36,37,38	—	Alternator belt, versions A–E, standard installation (SOLAS engines: 991587).
Alternator V-belt	`21405494`^39,40,16,41	—	Alternator belt, versions F and G, standard installation (SOLAS: 991587 on F, 22757103 on G). Belt tensioner 23272815.
Drive belt	`3582696`^36,37,42	—	Power-steering pump belt, versions A–E, standard installation (SOLAS: 991591).
Drive belt	`21407028`^39,40,16,43	—	Belt for the power-steering pump or an extra alternator, versions F and G, 6PK × 2196 mm, standard installation (SOLAS: 991591 on F, 22757107 on G).
Drive belt	`23324914`^16,44	—	Compressor belt for the G engines with a mechanical compressor: D4-270A-G, D4-300A-G and D4-320A-G. The belt for the A–F compressor engines was not looked up.
Thermostat	`8149182`^45,17,46replaces 8149517	—	Versions A–F, in thermostat housing 888456; starts to open at 82 °C. Kit 3588438 adds the two O-rings and the sealing ring. G thermostat not confirmed: Volvo’s catalogue does not tie a number clearly to the G engine’s main thermostat.
Crankcase breather element	`3584145`^47,48,49	—	Crankcase ventilation filter insert for filter 3584144, versions A–F; renewed at every 200-hour service. G engines have separator 23020724 instead.
Service kit	`22383875`^17,50,51	—	Versions A–F from engine serial 2004033317: impeller kit 21951356, fuel filter 21718912, crankcase insert 3584145, air filter insert 21702999 and the newer G-type oil filters 22030848 + 22030852 (not 3582732/21632901). The older kit 21704968 holds impeller kit 3588475, oil filters 3582732 + 21632901 and fuel filter 3583443. Make sure the impeller kit matches your pump.
Service kit	`24272027`^24,52	—	Version G: air filter insert 21702999, impeller kit 24139377, oil filters 22030848 + 22030852 and fuel filter 24215091.
Onboard spares kit	`3819656`^17,50,24,53	—	Listed for all versions A–G: impeller kit 3588475 (the one for the original pump), both drive belts, expansion plug, gaskets, hose clamps and cable ties. The belts follow the version: 3583729/3582696 on A–E, 21405494/21407028 on F and G.
Inlet strainer	`21368504`^54,55,56	—	Insert for the engine-mounted seawater filter 21368500 on the version F D4-180I, D4-225, D4-260 and D4-300 and on the E Aquamatic/IPS engines. G engines use filter kit 23637930 in the same filter 21368500.
Inlet strainer	`3583341`^57,58	—	Insert for seawater filter 3889148 (earlier 3809070) on the D4-210A, D4-225A/I-B, D4-260A/D and D4-300A/D, versions A–D.
Compressor oil	`1141641`^59,60,61	—	0.1 l of Volvo Penta oil 1141641 per change, only on engines with a mechanical compressor (A–F: D4-225A, D4-260A/D, D4-300A/D; G: D4-270A, D4-300A, D4-320A).

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
Engine oil change	A–F: every 200 h or 12 months. G: every 200 h or 24 months. The version A manual cuts it to 100 h if the fuel contains more than 1 % sulphur^{62,63,64,60,61}
Oil filter	Both filters, full-flow and bypass, at every oil change^62,63,64
Fuel filter	Every 200 h or yearly^62,63,64
Fuel pre-filter	Every 200 h or yearly^62,63,64
Air filter	A–F: every 200 h or 12 months. G: every 200 h or 24 months^62,63
Crankcase ventilation	Versions A–F: new filter insert every 200 h or 12 months^63,64
Raw water impeller	Versions A–D, and E/F engines without an engine-mounted seawater filter: new impeller every 200 h or 24 months. Other E/F engines and G: inspect at 200 h, replace every 400 h or 24 months. Volvo’s generated protocol for the D4-300I-F says 200 h or 24 months^{64,62,65,66,63}
Sea water strainer	Every 200 h or yearly⁶²
V-belt check	Every 200 h or yearly^62,63
V-belt replace	Every 800 h or 48 months; inspect the tensioner and idler bearings at the same time^62,63
Coolant change	Every 2000 h or every 4 years^62,63,64
Water pump	Overhaul the seawater pump every 2000 h or 48 months^62,63
Compressor oil change	Engines with a mechanical compressor only: A–F every 800 h or 48 months, G every 2000 h or 48 months^67,65,64
Gearbox oil change	Inboard reverse gear: oil and filter every 200 h or 12 months, plus once after the first 25 h or 6 months⁶²
Drive oil change	Aquamatic DPI (G): oil, filter and strainer every 200 h or 24 months. IPS 350/400 (F): oil and filter every 400 h or 12 months^67,66
Bellows & U-joints	Sterndrive: inspect the exhaust and U-joint bellows every 12 months (at 200 h on A–F, 400 h on G), replace every 800 h or 24 months^67,65
Anode	Inspect every 200 h or 12 months (G Aquamatic: 400 h or 12 months). The anodes sit on the drive (DPH/DPR, DPI, IPS) or on the shaft and are not listed on this page^63,67

Hours or time, whichever comes first. Taken from Volvo Penta’s D4/D6 inboard service protocol (2016), the protocols Volvo generates per engine (D4-300I-F, D4-300A-F, D4-300D-F, D4-300I-G, D4-300A-G) and the operator’s manuals. Two points depend on the version: G engines change oil at 200 h or 24 months instead of 12, and the impeller interval is not consistent: the inboard protocol says 200 h for versions A–D and for E/F engines without an engine-mounted seawater filter and 400 h for the rest, while the generated D4-300I-F protocol prints 200 h or 24 months. When in doubt, use the shorter interval.

Specifications

Cylinders	4 in-line; cast-iron block and head, balance shafts, two overhead camshafts driven by chain, 4 valves per cylinder^68,69
Displacement	3.7 l (3.67 l)^59,60
Bore × stroke	103 × 110 mm^59,60
Compression ratio	17.5:1 (A–F), 18.0:1 (G)^59,60
Power	A–F: D4-180I 132 kW (180 hp), D4-210 154 kW (210 hp), D4-225 165 kW (225 hp), D4-260 191 kW (260 hp; as D4-260D with IPS 350), D4-300 221 kW (300 hp; as D4-300D with IPS 400). G: D4-145I 107 kW, D4-150A 110 kW, D4-175I 129 kW, D4-230 168–169 kW, D4-270 199 kW, D4-300 221 kW, D4-320 235 kW. Crankshaft power to ISO 8665^59,60,68,70
Rated speed	2800–3500 rpm (A–F), 2800–3600 rpm (G): D4-145/175 2800, D4-230 3400, D4-210/270/300 3500, D4-320 3600 rpm^60,59,71,72
Idle speed	700–750 rpm^60,59
Injection	Common rail^73,71
Aspiration	Turbocharger with aftercooler; an additional mechanical compressor on the A–F Aquamatic and IPS ratings D4-225A, D4-260A/D and D4-300A/D and on the G Aquamatic D4-270A/300A/320A (inboard D4s have none)^73,29,32,71
Engine oil capacity	12 l incl. filters (F and G manuals; 1.2 l between MIN and MAX); the version A manual gives 12.5 l, of which 1.6 l in the filter. Compressor engines also hold 0.1 l of Volvo Penta oil 1141641 in the compressor^60,59,61
Engine oil grade	SAE 15W-40 (viscosity by ambient temperature); VDS-3 or VDS-4.5 (F), VDS-4.5 (G); version A: VDS-2 together with ACEA E7, Global DHD-1 or API CH-4/CI-4^60,59,61
Coolant capacity	approx. 13 l (manuals for versions A, F and G)^60,59,61
Coolant	Volvo Penta coolant VCS, OAT-based (the G parts catalogue lists VCS-2, orange); never mix coolant types^59,74
Thermostat opens at	82 °C, fully open at 92 °C (A–F); 78 °C, fully open at 90 °C (G)^59,60
Alternator	14 V / 115 A or 28 V / 80 A (A–F); 13.5 V / 150 A or 27 V / 80 A (G)^59,60
Dry weight	Engine only 483 kg (F manual), 510–525 kg (G). Packages: D4-210 with HS45AE 546 kg, with DPH drive 644 kg; D4-300 (F) with HS63AE 559 kg; G inboard with ZF68/HS68A 565–580 kg, with HS68IV 595–610 kg; G Aquamatic with DPI 670 kg; IPS 350/400 package 780 kg^{60,59,68,75,76,72,73,70}
Gearbox	Inboard: HS45AE, HS63AE/HS63IVE, HS68A, HS80AE, HS85AE (A–F); ZF68, HS45A, HS68A, HS68IV, HS85A (G). Aquamatic Duoprop sterndrive DPH (A–F; DPR also on the D4-300A) and DPI (G). IPS 350/400 pods (D4-260D/D4-300D, A–F)^{71,59,68,76,70,73}
Years built	Versions A–F from 2004 to 2019; version G since 2019 and still in production (operator’s manual dated 05-2026)^68,77,78,60

Good to know

The D4 has two oil filters, a full-flow and a bypass filter: replace both at every oil change. Volvo’s current service kit for A–F engines (22383875) comes with the G-type pair 22030848 and 22030852.¹⁷
Two seawater pump designs were fitted. The original pump 3584062 takes impeller kit 3588475; the later pump 21419374/22901573 takes 21951356 or the G kit 24139377. Look at the pump, not just the engine name, before ordering.^4,1
On versions A–D, and on E/F engines without an engine-mounted seawater filter, Volvo’s inboard protocol calls for a new impeller every 200 hours (and at least every two years) instead of every 400 hours.⁶⁴
Engines with a mechanical compressor need its small oil charge changed too: 0.1 l of Volvo Penta oil 1141641, every 800 h or four years on A–F and every 2000 h or four years on G.^59,65,67
There is no timing belt to budget for: the D4’s camshafts are driven by chain, unlike those of the smaller D3.⁶⁹
On G engines the oil-change limit is 200 hours or 24 months, with the VDS-4.5 oil the G manual specifies; A–F engines stay at 200 hours or 12 months.⁶⁰

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Sources

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