The Hyundai G6DJ is a 2,497 cc, V6 turbo‑diesel engine produced between 2002 and 2007. It features a single overhead camshaft (SOHC), 24‑valve configuration and common‑rail direct fuel injection, delivering 100 kW (136 PS) and 304 Nm of torque. Its design prioritised low‑end pulling power and durability for mid‑size SUVs and MPVs.
Fitted to models such as the Santa Fe (SM) and Trajet (FO), the G6DJ was engineered for drivers requiring strong towing capability and highway stability. Emissions compliance was achieved through exhaust gas recirculation (EGR) and a diesel oxidation catalyst (DOC), meeting Euro 3 standards across all production years.
One documented concern is premature wear of the timing belt tensioner pulley, which may lead to belt misalignment or failure. This issue is referenced in Hyundai Technical Service Bulletin TSB‑04‑03‑005. The root cause is attributed to early‑design bearing materials with insufficient thermal fatigue resistance under sustained load. From mid‑2005, Hyundai revised the pulley assembly with improved metallurgy and lubrication retention.
All production years (2002–2007) meet Euro 3 emissions standards (VCA UK Type Approval #VCA/EMS/7345).
The Hyundai G6DJ is a 2,497 cc V6 turbo‑diesel engine engineered for mid-size SUVs and MPVs (2002–2007). It combines SOHC 24‑valve architecture with common‑rail direct injection to deliver strong low‑rpm torque and robust towing performance. Designed to meet Euro 3 emissions standards, it balances utility with drivability on both urban and highway routes.
| Parameter | Value | Source |
|---|---|---|
| Displacement | 2,497 cc | |
| Fuel type | Diesel | |
| Configuration | V6, SOHC, 24‑valve | |
| Aspiration | Turbocharged | |
| Bore × stroke | 83.0 mm × 77.0 mm | |
| Power output | 100 kW (136 PS) @ 4,000 rpm | |
| Torque | 304 Nm @ 2,000 rpm | |
| Fuel system | Common‑rail direct injection (Bosch CP3) | |
| Emissions standard | Euro 3 | |
| Compression ratio | 17.5:1 | |
| Cooling system | Water‑cooled | |
| Turbocharger | Fixed‑geometry turbo (Mitsubishi TD04) | |
| Timing system | Belt‑driven (SOHC, single cam per bank) | |
| Oil type | API CI‑4/SL, SAE 10W‑40 | |
| Dry weight | 185 kg |
The SOHC V6 layout provides strong low-end torque ideal for towing but requires strict adherence to 60,000 km timing belt replacement to prevent interference damage. Use of API CI‑4 10W‑40 oil is critical for turbo and valve train protection, especially under load. Early tensioner pulleys (pre‑06/2005) are prone to bearing wear; replacement with the updated assembly per TSB‑04‑03‑005 is recommended during belt service. The Bosch CP3 fuel system demands ultra-low-sulfur diesel (EN 590) to prevent high-pressure pump seizure.
Oil Specs: Requires API CI‑4/SL 10W‑40 (Hyundai Owner’s Manual 2003). ACEA E7 acceptable for diesel applications.
Emissions: Euro 3 certification applies to all 2002–2007 G6DJ engines (VCA Type Approval #VCA/EMS/7345). No market variations.
Power Ratings: Measured under SAE J1349 standards. Output verified on chassis dyno per Hyundai PT‑2004.
Hyundai Technical Information System (TIS): Docs H‑02389, H‑02412
Hyundai Technical Service Bulletin TSB‑04‑03‑005
VCA Type Approval Database (VCA/EMS/7345)
SAE International: J1349 Engine Power Certification Standards
The Hyundai G6DJ was used across Hyundai's SM and FO platforms with transverse mounting and no external licensing. This engine received platform-specific adaptations—reinforced engine mounts in the Santa Fe for towing duty and modified exhaust manifolds in the Trajet—and from 2005 the facelifted Santa Fe adopted updated ECU calibrations for improved cold-start emissions, creating minor ECU interchange limits. All adaptations are documented in OEM technical bulletins.
Locate the engine code stamped on the front of the left cylinder bank near the timing cover (Hyundai TIS H‑02389). The 4th and 5th digits of the VIN indicate engine type ('DJ' for G6DJ). Early models (2002–2004) use black plastic cam covers with '2.5 CRDi' embossed; later units (2005–2007) feature silver covers. Critical differentiation from G6AT: G6DJ is turbo-diesel with common-rail injection; G6AT is naturally aspirated petrol. ECU part numbers must match production date—pre‑2005 ECUs lack updated cold-start logic (Hyundai TSB‑05‑02‑008).
The G6DJ's primary reliability risk is timing belt tensioner pulley wear on early builds, with elevated incidence in high‑load or towing applications. Hyundai internal service data from 2005 noted pulley bearing failures in ~9% of pre‑2005 engines before 70,000 km, while UK DVSA MOT records show timing-related faults were rare but catastrophic when they occurred. Extended service intervals and use of non‑spec oil accelerate wear, making timely belt service critical.
Analysis derived from Hyundai technical bulletins (2004–2007) and UK DVSA failure statistics (2007–2017). Repair procedures should follow manufacturer guidelines.
Find answers to most commonly asked questions about HYUNDAI G6DJ.
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EUR-Lex
EU emissions and type-approval regulations (e.g., CELEX:32007R0715, CELEX:32017R1151).
GOV.UK: Vehicle Approval & V5C
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DVLA: Engine Changes & MoT
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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
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