Engine Hyundai D4BF

The company assembled the Hyundai D4BF 2.5-liter turbo diesel engine from 1991 to 2004 and installed it on the popular H1, Starex and Grace minibuses, as well as Galloper SUVs. This motor, in essence, was only one of the modifications of the Mitsubishi 4D56 turbodiesel.

In 1993, a turbocharged power unit appeared in the Hyundai diesel family, which in fact was another clone of the Mitsubishi 4D56 prechamber diesel engine. It has a cast-iron cylinder block and an aluminum 8-valve head without hydraulic lifters, a timing belt drive and a fuel pump from Zexel, as well as a block of balancers with its own belt. The Garrett GT1749S turbine was most often responsible for supercharging this unit, but analogues were also installed.

This diesel engine had a large number of different modifications, and this is especially true for commercial vehicles.

This family also includes diesels: D4BA, D4BB and D4BH.

The engine was installed on:

  • Hyundai Galloper 1 (JI) in 1993 – 1997; Galloper 2 (JK) in 1997 – 2003;
  • Hyundai Grace 1 (P1) in 1993 – 2003;
  • Hyundai Starex 1 (A1) in 1997 – 2004.

Specifications

Production years 1991-2004
Displacement, cc 2477
Fuel system prechambers
Power output, hp 80 – 85
Torque output, Nm 194 – 208
Cylinder block cast iron R4
Block head aluminum 8v
Cylinder bore, mm 91.1
Piston stroke, mm 95
Compression ratio 21
Hydraulic lifters no
Timing drive belt
Turbocharging yes
Recommended engine oil 5W-40, 10W-40
Engine oil capacity, liter 6.5
Fuel type diesel
Euro standards EURO 1/2
Fuel consumption, L/100 km (for Hyundai Grace 2000)
— city
— highway
— combined
12.6
9.0
10.3
Engine lifespan, km ~450 000
Weight, kg 204.8

Disadvantages of the Hyundai D4BF engine

  • Most versions of such diesel engines were equipped with a Zexel VE4 distribution injection pump, that is, a clone of the reliable Bosch VE fuel pump. But at high mileage, there are often problems with starting a warm engine due to banal mechanical wear. Owners are also often faced with the need to replace injector nozzles.
  • According to the official regulations, the timing belt changes every 90,000 kilometers, but often it bursts much earlier, and especially if you do not tighten it every 30,000 km. Also, the balance shaft belt can break here, and at the same time it usually falls under the timing belt and it also breaks. It’s good that when it breaks, only the rocker breaks off.
  • This diesel categorically does not tolerate overheating and the cylinder head gasket immediately breaks through it. In this case, changing the gasket is indispensable and it is necessary to grind the mating surfaces. Also, on long runs, cracks are often found around the prechambers or valves, and most often they cannot be welded. And such a cylinder head is very expensive.
  • The weak points of such a diesel power unit also include a vacuum pump, a crankshaft, which often bursts when driving for a long time at low engine speeds, a crankshaft key, it simply cuts off and the attachment drive stops, as well as unreliable seals, so the oil constantly climbs and from everywhere. And do not forget to check the valve clearance every 20,000 km or they will simply burn out.

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