COMPLETE ENGINE : Engine Hyundai-Kia D4CB

The 2.5-liter Hyundai D4CB or 2.5 CRDi diesel engine has been assembled in Korea since 2001 and has undergone three major upgrades during this time: for EURO 3, 4, 5, respectively. They put it on the minibuses of the H-1 series, and it is also known for the first generation of Kia Sorento.

product details

PRODUCT INTRODUCTION

In 2001, a 2.5-liter diesel engine debuted on the H-1 and Starex minibuses. Prior to this, Hyundai-Kia produced Mitsubishi 4D56 clones, and the new engine was seriously different: it was no longer a vortex-chamber diesel engine, but a completely modern unit with a Common Rail system. There is a cast-iron block for 4 cylinders, a 16-valve aluminum head with hydraulic lifters, a fancy three-chain timing drive, an intercooler and, of course, a block of balance shafts.

In total, there were three generations of such diesel engines, for EURO 3, 4 and 5, respectively.

1.The first generation of the unit was equipped with a Bosch Common Rail system with a pressure of up to 1360 bar, a Garrett GT1752LS turbine and developed 116 – 140 hp, as well as 314 – 343 Nm of torque.

2.The second generation was introduced in 2006, with a 1600 bar Bosch CR system and a BorgWarner BV43 variable geometry turbine, power increased to 170 hp and 392 Nm.

3.The third generation appeared in 2011, here is a different CR Delphi at 1800 bar and an MHI TD03L4 turbine. The compression ratio was lowered from 17.7 to 16.4, the power remained the same, and the torque increased to 441 Nm.

The engine was installed on:

Hyundai Starex 1 (A1) in 2001 – 2007;

Hyundai Starex 2 (TQ) since 2007;

Kia Sorento 1 (BL) in 2002 – 2009.

Specifications

Production years	since 2001
Displacement, cc	2497
Fuel system	Common Rail
Power output, hp	116 – 177
Torque output, Nm	314 – 441
Cylinder block	cast iron R4
Block head	aluminum 16v
Cylinder bore, mm	91
Piston stroke, mm	96
Compression ratio	16.4 – 17.7
Hydraulic lifters	yes
Timing drive	chain
Turbocharging	yes
Recommended engine oil	5W-30, 5W-40
Engine oil capacity, liter	8.2
Fuel type	diesel
Euro standards	EURO 3/4/5
Fuel consumption, L/100 km (for Kia Sorento 2008) — city — highway — combined	10.1 6.7 7.9
Engine lifespan, km	~350 000
Weight, kg	263.2

Disadvantages of the Hyundai D4CB engine

In 2008 and 2009, the engine was changed under warranty: a connecting rod broke due to defective bolts. In engines after 2011 with Common Rail Delphi, the fuel pump often drove chips.

The most famous failure of this diesel engine is the burnout of copper washers under the nozzles, which leads to rapid coking of the engine with very sad consequences.

Another common problem with such a motor is a clogged oil receiver. It is advisable to check it periodically or unexpectedly it can turn the liners.

The gas distribution mechanism consists of three chains and the weakest here is the lower one, which rotates the oil pump and balancers. With its breakage, the main timing chain usually also breaks.

The crankshaft liners, hydraulic lifters, the vacuum control system and the turbocharger geometry change system and the EGR valve have not the highest resource here.