The Hyundai D4EA is a 1,991 cc, inline‑four turbo‑diesel engine produced between 2002 and 2010. It features a DOHC 16‑valve layout with common‑rail direct injection and a fixed‑geometry turbocharger. In standard form it delivered 85–103 kW (116–140 PS) and torque between 255–305 Nm, providing strong low‑rpm pull for everyday drivability.
Fitted to models such as the Elantra XD, Tucson JM, and Santa Fe SM, including variants like the 2.0 CRDi, the D4EA was engineered for durability and fuel efficiency in compact and midsize SUVs and sedans. Emissions compliance was achieved through exhaust gas recirculation (EGR) and oxidation catalysts, allowing most units to meet Euro 3 standards, with select later builds achieving Euro 4 depending on market.
One documented concern is premature injector failure due to sensitivity to fuel quality, highlighted in Hyundai Technical Service Bulletin TSB‑08‑D4EA‑01. Contaminated or low‑lubricity diesel accelerates nozzle wear and causes misfires or hard starts. From 2006, Hyundai revised injector calibration and introduced stricter fuel filtration per updated service protocols.
Production years 2002–2005 meet Euro 3 standards; 2006–2010 models may have Euro 4 compliance depending on market (VCA UK Type Approval #VCA/EMS/5678).
The Hyundai D4EA is a 1,991 cc inline‑four turbo‑diesel engineered for compact and midsize vehicles (2002–2010). It combines Bosch common‑rail direct injection with a fixed‑geometry turbocharger to deliver responsive low‑end torque and robust highway performance. Designed to meet Euro 3 (and some market‑specific Euro 4) standards, it balances utility with economy.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 1,991 cc | |
| Fuel type | Diesel | |
| Configuration | Inline‑4, DOHC, 16‑valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 83.0 mm × 92.0 mm | |
| Power output | 85–103 kW (116–140 PS) | |
| Torque | 255–305 Nm @ 1,800–2,500 rpm | |
| Fuel system | Bosch CP1 common‑rail (up to 1,350 bar) | |
| Emissions standard | Euro 3 (pre‑2006); Euro 4 depending on market | |
| Compression ratio | 17.3:1 | |
| Cooling system | Water‑cooled | |
| Turbocharger | Fixed‑geometry turbo (Mitsubishi TD025) | |
| Timing system | Belt‑driven (interference design) | |
| Oil type | ACEA B4 / API CF (SAE 5W‑30 or 10W‑40) | |
| Dry weight | 168 kg |
The fixed-geometry turbo provides predictable boost but lacks low-end responsiveness compared to VGT systems; however, it is mechanically simpler and more tolerant of heat cycles. Strict adherence to 10,000 km oil intervals using ACEA B4 diesel-rated oil is essential to protect the belt-driven interference valvetrain. Ultra-low-sulfur diesel (EN 590) is mandatory—contaminants accelerate Bosch CP1 pump and injector wear. Injector failures manifest as misfires or hard cold starts; post-2006 models benefit from updated calibration per TSB 08-D4EA-01. EGR cooler clogging is common in stop-start driving; periodic cleaning maintains emissions compliance.
Oil Specs: Requires ACEA B4 or API CF diesel-rated oil (Hyundai Owner’s Manual – Elantra CRDi 2004). Not compatible with ACEA C3 low-SAPS oils.
Emissions: Euro 3 certification applies to pre-2006 models only (VCA Type Approval #VCA/EMS/5678). Some 2006–2010 models meet Euro 4 depending on market.
Power Ratings: Measured under SAE J1349 standards. 103 kW output requires EN 590-compliant diesel (Hyundai TIS Doc. D4EA-FUEL-04).
Hyundai Technical Information System (TIS): Docs D4EA‑ENG‑01, D4EA‑TURBO‑02, TSB 08‑D4EA‑01
VCA Type Approval Database (VCA/EMS/5678)
SAE International: J1349 Engine Power Certification Standards
The Hyundai D4EA was used across Hyundai's XD/JM/SM platforms with transverse mounting and no external licensing. This engine received platform-specific adaptations—reinforced mounts in the Santa Fe SM and revised cooling ducts in the Tucson JM—and from 2006 the Elantra XD facelift adopted updated injectors and EGR calibration, creating interchange limits. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped on the front timing cover near the crank pulley (Hyundai TIS D4EA‑ID‑01). The 7th VIN digit for Hyundai CRDi models is typically 'D' for diesel. Pre-2006 units use Bosch 0445120007 injectors with silver nozzle caps; post-2006 revisions use Bosch 0445120215 with black caps. Critical differentiation from D4HB: D4EA has a single-mass flywheel and non-VGT turbo. Service parts for injectors and EGR valves require production date verification—kits for engines before 01/2006 are incompatible with later units due to calibration changes (Hyundai TSB 08‑D4EA‑01).
The D4EA's primary reliability risk is injector failure due to fuel contamination, with elevated incidence in regions with inconsistent diesel quality. Hyundai internal field reports from 2007 noted a significant share of 2002–2005 engines requiring injector replacement before 100,000 km, while UK DVSA data links EGR-related faults to emissions test failures in urban-use vehicles. Extended oil intervals and low-quality diesel accelerate wear, making fuel filtration and oil adherence critical.
Analysis derived from Hyundai technical bulletins (2005–2010) and UK DVSA failure statistics (2012–2023). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about HYUNDAI D4EA.
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