Hyundai KIA 1.6 CRDI (D4FB) Engine Problems And Reliability

The 1.6 CRDI engine belongs to a family of small-capacity Korean diesel engines with two-camshaft cylinder heads and 4 valves per cylinder. There are 5 engines in the family from 3-cylinder 1.1-liter to 1.7-liter.

In this article we will talk about the reliability of the 1.6 CRDI engine, consider reviews of its problems and resource, and tell you where to buy a Kia and Hyundai 1.6 CRDI contract diesel engine.

The 1.6-liter engine is very widely used in Kia and Hyundai cars created for the European market and the CIS.

Engine power 1.6 CRDi, depending on the version and year of manufacture, is 90, 110, 115, 128 and 136 hp.

This engine, in the best traditions of the European (not Korean) automotive industry, received a common rail fuel system from Bosch with a CP1 H3 injection pump, an intake manifold with swirl flaps and a GT1544V turbine with variable geometry. The timing drive uses two chains.

Applicability of 1.6 CRDI Engine

  1. Hyundai : Accent (2010-2017), Elantra (2007-present), i20 (2008-2014), i30 (2007-present), ix20 (2010-present).
  2. KIA : Cerato (2006-2013), Seed (2006-2018), Soul (2009-present), Venga (2009-present), Stonic (2017-present).

1.6 CRDI Engine Specs

SpecificationsDetails
Volume (cm3)1582 cm³
Power (hp)90 – 136 hp
Torque235 – 280 Nm
Timing drive2 chains
Environmental classEuro 3/4/5
Fuel typeDT
ICE featuresSwirl Control Valve
Supply systemcommon rail
Hydraulic liftersYes
Cylinder blockCast iron R4
cylinder headAluminum 16cl.
Cylinder diameter77.2 mm
Piston stroke84.5 mm
Compression ratio17.3
Phase regulatorThere are after 2009 onwards.
TurbochargingTurbine with VGT
Engine oil5.7 l. 5W-30, 5W-40
Average resource200,000 – 300,000 km.

Problems and Reliability of the engine 1.6 CRDI (D4FB)

The Korean CRDI turbodiesel turned out to be very successful: powerful, economical and unpretentious. He has several sores that you need to know about and for which you need to prepare.

1. Turbine engine 1.6 CRDI

Turbines on the 1.6 CRDI engine, especially in the first few years of production, “flyed” through one. Turbines failed at ridiculous runs of 30,000 km and rarely lived up to 100,000 km. Many owners were lucky – the turbines were changed under warranty.

Before death, the turbine of the 1.6 CRDI engine often whistles. Moreover, it can whistle for 5 – 10 thousand km, or it can suddenly fail after one trip.

The owners of Korean cars with this diesel set turbo timers, did not turn off the engines for 2-3 minutes after stopping, but this measure did not help much. The manufacturer solved the problem with turbines after 2009.

There is information that the manufacturer changed the ECU firmware, after which the turbines on this engine began to work in a more gentle mode.

A faulty or unworn turbine begins to drive oil very strongly into the intake or exhaust. Her appetite can be up to 400 grams of oil per 1000 km – in this case, you can get to the drainage of oil reserves with all the attendant problems.

And if the turbine drives oil into the intake, then you can also face a water hammer. Fortunately, on the 1.6 CRDI engine, the intercooler stands upright and oil collects in it, like in a bucket, for quite some time.

2. Boost sensor wiring

Suddenly, a car with a 1.6 CRDI (D4FB) engine can stop moving – as if the turbine has stopped “blowing”. But the cause of the loss of traction may be a broken wiring to the boost sensor.

The wiring harness is quite tight and, due to vibrations, one or more wires break in it.

3. Fuel system

The Bosch common rail fuel system is well repaired and relatively inexpensive. The cost of new nozzles does not go off scale, and used ones are even cheaper.

On this engine, it is usually the pressure regulator mounted on the fuel rail that causes trouble. Its purpose is to bleed excess fuel from the rail.

If the regulator fails, it bleeds too much fuel from the rail, as a result, the 1.6 CRDI (D4FB) engine starts very poorly.

The malfunction of the regulator can be checked with the return hose removed from the pump: if fuel flows from it at the time the engine is started, then the regulator is clearly faulty and bleeds the fuel that the engine needs to start.

Also, if the 1.6 CRDI (D4FB) engine starts uncertainly, you need to check the low pressure fuel pump – the boost pump – it can also fail, wear out, although this rarely happens.

The injection pump of the 1.6 CRDI engine usually lasts a long time and without problems.

The return pipes on the injectors can crack and leak. Also, sometimes fittings leak on the 1.6 CRDI (D4FB) engine, because tiny gaskets lose their tightness.

The injectors are quite tenacious, but when replacing them, you need to prescribe their individual codes, which are generated on test stands.

If this is not done, then even good new or used nozzles will knock strongly, the engine will work disgustingly.

4. Glow plugs

Another reason for the poor start of the 1.6 CRDI (D4FB) engine is failed glow plugs. A sign of a malfunction of one or more candles is light smoke from the exhaust system immediately after a cold start.

5. Timing chains

There are two chains in the timing drive. And they tend to stretch, especially the top. Stretching occurs with a run of 120,000 – 150,000 km.

Stretching is “heard” by the characteristic chirp and cannot be neglected – the chain can jump or “chop” chips upon contact with the plastic casing.

A set of timing chains with dampers comes out under $ 300. The kit is the same for engines 1.1, 1.5, 1.6.

Read Also: Most Reliable And Worst Hyundai Engines Of All Time

Advantages And Disadvantages of the 1.6 CRDi D4FB engine

Advantages

  1. Cast iron cylinder block and aluminum cylinder head.
  2. Swirl damper complex.
  3. Free start at temperatures up to -20C.
  4. Reliability was ensured by the timing chain drive, which was subsequently finalized.
  5. The problem was the rather soft material of the chain, which strove to stretch. Even the D4FB engine did not differ in oil consumption.

Disadvantages

  1. At short runs, the timing chain stretches.
  2. Injectors are critically afraid of low-quality fuel.
  3. Problematic maintenance due to the low prevalence of the engine (there are no frequent breakdowns).
  4. There are no analogues of spare parts / accessories.

Typical malfunctions of the 1.6 CRDi D4FB engine Thrust

  1. Failure and loss of power.
  2. Instability and tripling.
  3. Short turbine life on the first batches of the D4FB engine.
  4. The D4FB engine, despite its reliability, also turned out to be an enviable “cleaner”.
  5. It stood out against the background of all Korean diesel engines.
  6. Sometimes, at a fairly low mileage, the manifolds, dampers and the USR valve were clogged.
  7. Therefore, the owners sought to find good fuel in order to forget about cleaning for a long time.

Hyundai D4FA Vs D4FB Vs D4FD Engines

 D4FAD4FBD4FD
Engine power75 kW / 102 hp.90-136115 – 141; 115 (85) / 4000; 136 (100) / 4000; 141 (104) / 4000
Engine volume1493 cu. cm.1582 cu. cm.1685 cu. cm.
Number of cylinders
4 pieces
Number of valves
16 pieces
Engine manufacturer
KIA
What cars did you install it on?Kia Cerato 2005, Kia Pride 2005, Kia Rio 2Kia Ceed station wagon 1st generation 2006-2009; Kia Soul 2014-2016 hatchback 2nd generation; Kia Soul 2008-2011 hatchback 1 generationHyundai i40 station wagon and sedan
Supercharger
Turbine
Max Torque235 Nm at 2000 RPM (rpm)235 (24) / 2500; 255 (26) / 1900; 255 (26) / 2750; 260 (27) / 2000; 260 (27) / 2750255 (26)/2500; 260 (27)/2750; 320 (33)/2500; 340(35)/2500
Fuel
diesel
Consumption4.9-6.45.6-6
CO2 emissions, g/km
134 – 139
Compression ratio17.8 to 1
17.3 to 1
Cylinder diameter75 mm
77.2 mm
piston stroke
84.5 mm
Root supports
5 items
Working volume of the combustion chamber
20.97 cu. cm.
Power index
68 HP per 1 liter (1000 cc) volume

Conclusion

The 1.6 CRDI D4FB engine was a 1.6-liter diesel engine that debuted in 2005. It was introduced along with a smaller 1.5 liter counterpart D4FA.

Differences in the engines were achieved due to the diameter of the cylinders. 1.6 CRDI D4FB engines were intended exclusively for the European market.

Tuning Possibilities It is not easy to rock the D4FB engine by changing the ECU firmware and “games” with the engine parameters.

You will need to replace the entire piston group with a forged one. This will lighten the mass of the engine and allow you to slightly increase the dynamics.

Initially, the Koreans set their sights on creating a durable and productive engine. Therefore, the chances of assigning an extra 30-40 horses to the D4FB engine are unlikely to succeed.

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