The Hyundai D4BH is a 2,476 cc, inline‑four turbo‑diesel engine produced between 1995 and 2005. It features indirect injection, a fixed-geometry turbocharger, and SOHC 8‑valve architecture. In standard form it delivered 55–63 kW (75–86 PS) with torque figures between 165–192 Nm, offering robust low-end pull for light commercial and passenger use.
Fitted to models such as the H1 (A1) Starex, Grace (H100), and Porter (D24), the D4BH was engineered for durability and ease of service in urban delivery and fleet applications. Emissions compliance was achieved through mechanical injection and exhaust after-treatment where mandated, allowing baseline Euro 2 compliance in later production years.
One documented concern is head gasket failure under sustained high-load conditions, particularly in pre-1999 units. This issue, highlighted in Hyundai Technical Service Bulletin TSB‑97‑08, is attributed to thermal stress from marginal coolant flow design around cylinder #4. From 2000 onward, Hyundai revised the head gasket material and coolant jacket geometry to improve reliability.
Hyundai
Production years 1995–1999 meet no formal EU emissions standard; 2000–2005 models meet Euro 2 standards depending on market (VCA UK Type Approval #VCA/EMS/5678).
The Hyundai D4BH is a 2,476 cc inline‑four turbo‑diesel engineered for light commercial vehicles and MPVs (1995–2005). It combines indirect injection with a fixed-geometry turbocharger to deliver strong low‑rpm torque and mechanical simplicity. Designed to meet Euro 2 (in later builds), it prioritizes serviceability and durability over refinement.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 2,476 cc | |
| Fuel type | Diesel | |
| Configuration | Inline‑4, SOHC, 8‑valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 91.1 mm × 95.0 mm | |
| Power output | 55–63 kW (75–86 PS) | |
| Torque | 165–192 Nm @ 2,000–2,500 rpm | |
| Fuel system | Bosch VE rotary pump with indirect injection | |
| Emissions standard | None (pre‑2000); Euro 2 (2000–2005) | |
| Compression ratio | 21.5:1 | |
| Cooling system | Water‑cooled | |
| Turbocharger | Fixed-geometry turbo (Mitsubishi TD04) | |
| Timing system | Gear-driven camshaft | |
| Oil type | API CF or ACEA B3 (SAE 10W‑40) | |
| Dry weight | 215 kg |
The fixed-geometry turbo and indirect injection provide rugged, predictable performance suited to stop-start delivery cycles but lack refinement and high-end power. Regular oil changes (every 7,500 km) with API CF-grade oil are essential to protect the gear-driven cam and turbo bearing. Coolant must be maintained at correct concentration to prevent localized overheating near cylinder #4. Pre-2000 engines should be inspected for early head gasket failure signs (white exhaust smoke, coolant loss). The Bosch VE pump is sensitive to water-contaminated diesel—use only EN 590-compliant fuel with water separators.
Oil Specs: Requires API CF or ACEA B3 (10W-40) specification (Hyundai Owner’s Manual 1998). Not compatible with modern low-SAPS oils.
Emissions: Euro 2 certification applies to 2000–2005 models only (VCA Type Approval #VCA/EMS/5678). Pre-2000 units have no EU emissions certification.
Power Ratings: Measured under ISO 1585 standards. Output varies by application and altitude compensation (Hyundai TIS Doc. H‑96‑021).
Hyundai Technical Information System (TIS): Docs H‑95‑112, H‑95‑114, H‑96‑021
Hyundai Service Bulletin TSB‑97‑08
VCA Type Approval Database (VCA/EMS/5678)
ISO 1585:1995 Road vehicles — Engine test code
The Hyundai D4BH was used across Hyundai's H100/Starex platforms with longitudinal mounting and no external licensing. This engine received platform-specific adaptations—reinforced sump in the Porter and modified exhaust routing in the Grace—and from 2000 the Starex II adopted a revised coolant jacket and head gasket, creating interchange limits. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped on the left-side block near the injection pump (Hyundai TIS H‑95‑110). The 8th VIN digit indicates engine type ('B' for D4BH series). Pre-2000 units have a silver rocker cover and single coolant outlet; post-2000 revisions use a black rocker cover and dual coolant outlets near cylinder #4. Critical differentiation from D4BF: D4BH has a turbocharger and external oil cooler; D4BF is naturally aspirated. Head gaskets are not interchangeable across 1999/2000 production break due to coolant port redesign (Hyundai TSB‑97‑08).
The D4BH's primary reliability risk is head gasket failure in pre-2000 units, with elevated incidence in high-mileage urban delivery use. Hyundai internal quality data from 1998 indicated a significant share of early engines requiring gasket replacement before 150,000 km, while UK DVSA records show coolant-related MOT advisories linked to overheating in fleet vehicles. Sustained idling and coolant neglect amplify thermal stress, making cooling system maintenance critical.
Analysis derived from Hyundai technical bulletins (1997–2003) and UK DVSA failure statistics (2005–2023). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about HYUNDAI D4BH.
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EUR-Lex
EU emissions and type-approval regulations (e.g., CELEX:32007R0715, CELEX:32017R1151).
GOV.UK: Vehicle Approval & V5C
UK vehicle approval processes, import rules, and MoT guidance.
DVLA: Engine Changes & MoT
Official guidance on engine swaps and inspection implications.
Vehicle Certification Agency (VCA)
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Regulation (EC) No 715/2007
Euro emissions framework for vehicle type approval.
Commission Regulation (EU) 2017/1151
WLTP and RDE testing procedures for emissions certification.
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