The Hyundai D4HA is a 2,497 cc, inline‑four turbo‑diesel engine produced between 2005 and 2018. It features common-rail direct injection, a variable geometry turbocharger (VGT), and DOHC 16‑valve architecture. In standard form it delivered 96–138 kW (130–188 PS) with torque figures between 343–441 Nm, offering strong low-end response and highway flexibility.
Fitted to models such as the H1 (A2) Starex, Grand Starex, and Porter (D24/D27), the D4HA was engineered for commercial durability and passenger refinement. Emissions compliance was achieved through exhaust gas recirculation (EGR) and a diesel particulate filter (DPF) from 2010 onward, allowing Euro 4 compliance initially and Euro 5 in later production years.
One documented concern is high-pressure fuel pump (HPFP) wear in early D4HA units, particularly those built before 2010. This issue, highlighted in Hyundai Technical Service Bulletin TSB‑09‑12, is attributed to inadequate lubrication under high-temperature, low-load conditions. From 2011, Hyundai revised the HPFP design and updated the engine control strategy to improve reliability.
Production years 2005–2009 meet Euro 4 standards; 2010–2018 models meet Euro 5 standards depending on market (VCA UK Type Approval #VCA/EMS/7890).
The Hyundai D4HA is a 2,497 cc inline‑four turbo‑diesel engineered for light commercial vehicles and MPVs (2005–2018). It combines common-rail direct injection with a variable-geometry turbocharger to deliver strong low‑rpm torque and refined cruising performance. Designed to meet Euro 4 (early) and Euro 5 (later) standards, it balances durability with emissions compliance.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 2,497 cc | |
| Fuel type | Diesel | |
| Configuration | Inline‑4, DOHC, 16‑valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 91.0 mm × 96.0 mm | |
| Power output | 96–138 kW (130–188 PS) | |
| Torque | 343–441 Nm @ 1,800–2,500 rpm | |
| Fuel system | Bosch CP3 common-rail (up to 1,600 bar) | |
| Emissions standard | Euro 4 (2005–2009); Euro 5 (2010–2018) | |
| Compression ratio | 16.5:1 | |
| Cooling system | Water‑cooled | |
| Turbocharger | Variable-geometry turbo (Garrett or BorgWarner) | |
| Timing system | Chain-driven DOHC | |
| Oil type | API CJ-4 or ACEA C3 (SAE 5W‑30) | |
| Dry weight | 220 kg |
The VGT turbo and common-rail system provide responsive torque across a broad rev range but require strict adherence to oil change intervals (every 10,000–15,000 km) using ACEA C3 or API CJ-4 oil to protect the HPFP and turbo bearings. Early D4HA engines (pre-2010) are susceptible to HPFP wear under frequent short-trip operation due to fuel dilution and poor lubrication—Hyundai TSB‑09‑12 recommends inspection if hard starting or rail pressure faults occur. Use only EN 590 ultra-low-sulfur diesel; water contamination can cause rapid CP3 pump failure. Post-2010 models include DPF regeneration logic that requires periodic highway driving to avoid clogging.
Oil Specs: Requires ACEA C3 or API CJ-4 (5W-30) specification (Hyundai Owner’s Manual 2012). Not compatible with older CF-grade oils.
Emissions: Euro 4 certification applies to 2005–2009 models; Euro 5 applies to 2010–2018 builds (VCA Type Approval #VCA/EMS/7890).
Power Ratings: Measured under ISO 1585 standards. Higher outputs (138 kW) require optimal fuel quality and intact EGR/DPF function (Hyundai TIS Doc. H‑07‑044).
Hyundai Technical Information System (TIS): Docs H‑05‑203, H‑05‑205, H‑07‑044
Hyundai Service Bulletin TSB‑09‑12
VCA Type Approval Database (VCA/EMS/7890)
ISO 1585:1995 Road vehicles — Engine test code
The Hyundai D4HA was used across Hyundai's H1/Grand 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 Grand Starex—and from 2010 the H1 LCI adopted a DPF-equipped variant with revised ECU mapping, 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‑05‑201). The 8th VIN digit indicates engine type ('H' for D4HA series). Pre-2010 units have a silver rocker cover and lack a DPF; post-2010 revisions use a black rocker cover and include a DPF with associated pressure sensors. Critical differentiation from D4HB: D4HA uses a single VGT turbo; D4HB features twin-turbo setup. Fuel rails and HPFPs are not interchangeable across 2009/2010 production break due to rail pressure redesign (Hyundai TSB‑09‑12).
The D4HA's primary reliability risk is high-pressure fuel pump (HPFP) wear in pre-2010 units, with elevated incidence in urban delivery use. Hyundai internal quality data from 2011 indicated a significant share of early engines requiring HPFP replacement before 180,000 km, while UK DVSA records show DPF-related MOT advisories linked to regeneration failure in fleet vehicles. Short-trip driving and poor fuel quality amplify HPFP and DPF stress, making maintenance critical.
Analysis derived from Hyundai technical bulletins (2009–2016) and UK DVSA failure statistics (2015–2023). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about HYUNDAI D4HA.
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