Characteristics
| Parameter | Value |
|---|---|
| Manufacturing | Ulsan plant |
| Engine make | D4CB |
| Years of manufacture | 2001-present |
| Cylinder Block Material | cast iron |
| Engine type | diesel |
| Configuration | row |
| Number of cylinders | 4 |
| Valves per cylinder | 4 |
| Piston stroke, mm | 91 |
| Cylinder diameter, mm | 96 |
| Compression ratio | 16.4 17.6 17.7 18.0 |
| Engine displacement, cc | 2497 |
| Engine power, hp/rpm | 110/3800 136/3800 140/3800 140/3800 140/3800 163/3800 170/3800 170/3600 |
| Torque, Nm/rpm | 343/1750-2250 392/2000-2500 314/2000 314/1850 314/2000 392/2000 392/2000-2500 441/2000-2250 |
| Environmental regulations | Euro 3 (up to 2006) Euro 4 (2006-2011) Euro 5 (2011+) |
| Turbocharger | MHI TD03L4-10 KKK BV43 Garrett GT1549S Garrett GT1752S |
| Engine weight, kg | 263 |
| Fuel consumption, l/100 km (for KIA Sorento) | 10.0 (city) 6.7 (highway) 7.9 (mixed) |
| Oil consumption, gr./1000 km | to 600 |
| Engine oil | 0W-30 10W-30 |
| How much oil in the engine, liters | 7.4 |
| Oil change is carried out, km | 10000 (better 5000) 15000* (better 7500) |
| Operating temperature of the engine, deg. | ~90 |
| Engine life, thousand kilometers | – (according to the factory data) 400+ (in practice) |
| Tuning, h.p. | 200 (potential) – (without loss of resource) |
| Motor installed | KIA Sorento Hundai Porter Hyundai Starex/H-1 KIA Bongo |
* – since 2006 (starting from 2nd generation)
Reliability, problems and repair of D4CB engines
This powerplant was first installed in 2001 on the Hyundai H1, and then on the first generation KIA Sorento. This motor was a replacement for the D4BH (Mitsubishi 4D56) and belongs to the Hyundai-KIA A series. It features a cast iron cylinder block with 91 mm stroke crankshaft and 8 counterweights, 158 mm long connecting rods, 96 mm diameter and 54.2 mm high pistons, which are oil-cooled. A balancer shaft block is installed for smoother operation.
The cylinder head is made of aluminum, has two camshafts and 16 valves. The intake valves are 31.8 mm, the exhaust valves are 28 mm, and the valve stem diameter is 7 mm. Hydrocompensators are also used here. The camshafts are driven by the timing chain, there are three of them at once. Service life of timing chains is more than 200 thousand kilometers, but with intensive use this period can be reduced to 100-150 thousand kilometers. It is recommended to check the condition every 100 thousand kilometers.
Common Rail injection with pressure up to 1360 bar is used on these engines. It is controlled by Bosch EDC15C7 control unit, and overpressure is created by Garrett GT1752S turbine. As a result, we get a boost pressure of 0.6 bar, power of 140 hp at 3800 rpm and torque of 314 Nm at 2000 rpm.
Since 2004, the motors were supplemented with a new intercooler, the power figures remained unchanged, but the torque increased to 343 Nm at 1850 rpm.
In early 2006, the engine was modernized: a new Common Rail injection system with injection pressure of 1600 bar was installed, environmental standards increased from Euro-3 to Euro-4, the turbocharger was replaced by BorgWarner BV43 with variable geometry (170 hp), and the control unit was replaced by Bosch EDC16C39. Power of these D4CB engines is 170 hp at 3800 rpm, and torque is 392 Nm at 2000-2500 rpm.
The most powerful versions were equipped with Garrett GT1549S turbines.
In 2011 the engine was adapted to the Euro-5 standard, changes include:
- new pistons with a compression ratio of 16.4,
- a modified crankshaft,
- a new oil pump,
- Delphi Common Rail injection system with 1800 bar pressure,
- MHI TD03L4-10 turbo,
- timing chain,
- spark plugs,
- particulate filter,
- modernized cylinder head and other small parts.
Such motors have a power of 170 hp and torque of 441 Nm, their appearance differs with a plastic receiver and a different valve cover.
In 2009, the D4CB A-series diesel motor was removed from the Hyundai Sorento and replaced by the D4HA and D4HB from the Hyundai-KIA R family. On other vehicles, the old 2.5 CRDi is still available.
Challenges and disadvantages of the KIA/Hyundai D4CB engines
- Risk of connecting rod breakage. This is the most well known problem with these engines, however it is extremely rare and only occurs on motors manufactured from 2008 through August 2009. This is caused by faulty connecting rod bolts, but it happens at low mileage. Today, you are unlikely to be at risk.
- Increased oil consumption, loss of power, soot buildup. You probably have burned out copper injector rings, which is a common problem with D4CB diesel engines. This can cause fouling on the injectors and get into the oil, with serious consequences for the engine. This can lead to clogged oil passages, worn liners, engine blockage and the like. It is recommended to regularly monitor the condition of the rings at least once every 50 thousand kilometers, so that the problem has not had time to worsen.
The resource of the turbine is more than 200 thousand kilometers when using original spare parts and double oil changes compared to the usual schedule. However, under normal conditions, few people follow these recommendations, so turbines often fail at around 100 thousand kilometers. It is important to monitor the temperature regime and avoid overheating of the diesel engine, otherwise the consequences can be serious.
In general, with proper maintenance, the motor works reliably, but if you follow and perform all the work qualitatively, the resource of the D4CB engine can exceed 400 thousand kilometers.
Tuning of D4CB engine
Chip tuning
The oldest motors up to 2004 at 140 hp with the usual firmware can be turned into 170 hp, and the torque can be increased from 314Nm to +/- 380 Nm. If your engine was released between 2004 and 2006, it can be flashed from 140hp to the same 170hp, but the torque from 341Nm can reach +/- 400Nm.
D4CB 2nd generation diesel engines (after 2006) at 163 or 170 hp with Stage 1 firmware can develop in the neighborhood of 200 hp, torque increases from 392 Nm to ~450 Nm. Euro-5 modifications at 170 horses reach around 210 hp on the firmware, and the torque can reach 550 Nm. That’s all just on Stage 1 firmware alone, but if you work on the exhaust and do Stage 2, it can give another 10hp.
ENGINE RATING: 4