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Car engine swap in boat D3/D5

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Orangecap

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Currently have a VP d3-220 and apparently these engines tend to crater before 2000 hours. New VP engines don’t exist but there are plenty of Volvo D3/D5 car engines from Europe that go for $3-5k. Is it possible to get a car long block, swap all the marine bits onto it, and have an equivalent VP engine?
 
Currently have a VP d3-220 and apparently these engines tend to crater before 2000 hours. New VP engines don’t exist but there are plenty of Volvo D3/D5 car engines from Europe that go for $3-5k. Is it possible to get a car long block, swap all the marine bits onto it, and have an equivalent VP engine?
By the way, if you're planning to buy a car, it's a good idea to use services like https://www.faxvin.com/license-plate-lookup/south-carolina to check the car's license plate and history. It's a useful tip that I think everyone here could benefit from!
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It's theoretically possible to take a car long block and convert it for marine use by swapping over the marine-specific components, but there are a few things to consider. Marine engines are built to withstand harsher environments and have key differences, including stronger internal components, corrosion-resistant materials, and cooling systems designed for marine applications.
 
Yea that’s why the d3s fail with 1000-1500 hours and don’t even outlast marine gas engines. Mine blew at 1200 hours. They’re car engines not marinized. There’s no difference in the block or internals after researching this it’s a standard car engine with different ecu and bolt on heat exchanger. All the accessories such as alternators are the same.
 
That's not correct, the part number for the alternator on a D3 cross references to a car alternator. Same for starter. Diesel marine engines do not need to be ignition protected. Trust me, I went down this rabbit hole the exact same part is 2-3x the price if you buy from volvo penta vs volvo cars. Same part number, same product.
According to volvopenta.com with my serial # the alternator part is 31419556 for $1640

Volvo S60 Alternator - 36012619 | DARCARS Volvo Cars, Rockville MD

Alternator. Volvo S60. Genuine Volvo Part - 36012619 (36001341). Ships from DARCARS Volvo Cars, Rockville MD
parts.darcarsvolvocars.com
Car part $553.14 note there's several revisions for the car but none are ignition protected

Starter part 30782228 for $742 for penta

Volvo S60 Starter Motor - 36002642 | DARCARS Volvo Cars, Rockville MD

Starter Motor. Volvo S60. Genuine Volvo Part - 36002642. Ships from DARCARS Volvo Cars, Rockville MD
parts.darcarsvolvocars.com
Car part for $508. not ignition protected.

In fact the D3 engine is a D5244T22 engine out of several model cars such as an XC60 15-17. With a remapped ECU for differing torque curve, a different flywheel (since car engines change rpms frequently smaller flywheel vs marine spools up then runs at a single rpm heavier flyweel is better), and bolted on heat exchanger. Everything else is identical other than they slap a thicker coat of paint on the block.



That's why these engines are considered so fragile useless and why it was discontinued. They are not marine grade and failing with hours in the single 1000's is not acceptable for a diesel. Even a Mercruiser 5.7L will last longer and can be rebuilt while the D3 cannot be rebuilt due to the thin walls and the head provides structural support to keep it square. My volvo tech said they are "disposable engines" and cannot be sleeved.

In Europe snowy regions where Volvos sell the most, daily driver cars have a useful life of 7-10 years then they're disposed of due to the salt destroying the car. It's no point building an engine that lasts 20 years if the car shell rusts out in 7. That's why you won't find a boat with a D3 older than 10 years with any amount of meaningful hours and an extreme rarity with 2000+ hours. Whereas cummins, yanmar you'll find 3k, 4k hours easily. There's scores of boats out there that are 2017 era with 1 2017 engine and a 2020 engine meaning they blew early on. But now you can't buy a D3 so your only option is to spend $120-150k repowering with a Yanmar or another Volvo D4/D5/D6 (lol).

Venting but Volvo's poor choice in the D3 cost me a small fortune for a minor problem on a low hour engine which necessitated repowering. Someone who has a shop can make a fortune importing D5 car engines and swapping the bits over vs $150k on a repower.
 
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