Volvo 2.0 D4204T Engine Specs, Problems, Reliability

Of the features of the engines of the D4204T series, the presence of a double turbocharger, an in-line four-cylinder layout and a Common Rail injection system stands out. This family of engines was specially developed by the Swedish company for S90/V90/XC90 cars. Serial production has been established to this day.

Modifications of the diesel D4 family

8 popular engine options are found in the D4204T line. It is noteworthy that fuel consumption does not exceed 5.7 liters of diesel fuel in the combined cycle (on some versions – less than 4 liters). The engines operate exclusively on diesel fuel, the operational life is estimated at 400,000 km or more. Engines are able to serve another 300 thousand km after overhaul. But the deadline depends on the quality of service.

  1. One of the versions of the series – D4204 T23 – develops 235 hp. With. For a diesel engine, this figure is surprising, because this power was squeezed out of a 2-liter internal combustion engine. The exact displacement is 1969 cm3, the torque is 480 Nm at 2250 rpm.
  2. Another exclusive version can be called D4204 T11. This version develops slightly less power. But it also consumes less – only about 4.5 liters per 100 km in the combined cycle. Less here and the rate of emissions of harmful substances. Otherwise, the same twin-turbo diesel engine.
  3. The next development is D4204 T20. The result of creating an idea with a turbo and super economical engine also belongs to the Swedes. The power of the engine is only 120 liters. with., but it consumes surprisingly little – 3.8 liters in the combined cycle. This was achieved by increasing the compression ratio to 16 engines. There is no twin turbo, so the torque is only 280 Nm.
  4. Another economical version can be called D4204 T14. Assumes the same design with 4 cylinders, direct injection and forced air injection. However, here it was possible to use a double turbocharging without increasing fuel consumption and compression ratio (remained at the level of 15.8 engine).
  5. The D4204 T16 single turbocharger version is available with M76 R7.0, M66F and AW TG-81SC gearboxes. Also, this engine is equipped with an SCR system, and the emission level complies with the latest Euro-6 standards. The engine is installed not only on the Volvo V40CC, but also on the XC40, V60 2 and S90 2.
  6. D4204 T4 – High emission version, but Euro 6 compliant. However, the power of the engine is high – it reaches 150 hp. with., and the torque is 350 Nm. The compression ratio is the same as that of the main modifications – 15.8 engines.
  7. The 181 hp D4204 T5 delivers 400 Nm of torque. It has twin turbochargers. The level of CO2 emissions is Euro-6. The engine was placed under the hood of the XC90 2.
  8. A similar version of the D4204 T8 with a compression ratio of 16 engines. The power of the engine is 120 liters. with., torque – 280 Nm. The engine was installed on Volvo V40 2, V40 CC, S60 2 and V.

D4 Engine Specs

D4204T23D4204T11D4204T20D4204T5
Engine volume, cc1969196919691969
Maximum power, hp235 – 240225 – 233120181
Maximum torque, N * m (kg * m) at rpm.500 (51) / 2250470 (48) / 2500280 (29) / 2250400 (41) / 2500
Fuel usedDiesel fuelDiesel fuelDiesel fuelDiesel fuel
Fuel consumption, l/100 km5.7-64.5 – 5.73.8 – 4.13.7 – 4.6
engine’s typeInline, 4-cylinderInline, 4-cylinderInline, 4-cylinderInline, 4-cylinder
Add. engine informationdirect injectiondirect injectiondirect injectiondirect injection
CO2 emissions, g/km142 – 158119 – 15299 – 10997 – 107
Cylinder diameter, mm82828282
Number of valves per cylinder4444
Maximum power, hp (kW) at rpm235 (173) / 4000; 240 (177) / 4000225 (165) / 4250; 233 (171) / 4250120(88)/3750181 (133) / 4250
SuperchargerTwin turboTwin turboSingle turbochargerSingle turbocharger
Start-stop systemyesyesyesyes
Compression ratio15.815.81615.8
Piston stroke, mm93.293.293.293.2
D4204T14D4204T16D4204T4D4204T8
Engine volume, cc1969196919691969
Maximum power, hp190 – 200148150120
Maximum torque, N * m (kg * m) at rpm.400 (41) / 2500; 440(45)/2500320350(36)/2500280 (29) / 2250
Fuel usedDiesel fuelDiesel fuelDiesel fuelDiesel fuel
Fuel consumption, l/100 km3.8 – 5.83.8 – 4.14.63.8
engine’s typeInline, 4-cylinderInline, 4-cylinderInline, 4-cylinderInline, 4-cylinder
Add. engine informationdirect injectiondirect injectiondirect injectiondirect injection
CO2 emissions, g/km99 – 15399 – 109120101
Cylinder diameter, mm82828282
Number of valves per cylinder4444
Maximum power, hp (kW) at rpm190 (140) / 4250, 200 (147) / 4250120(88)/3750150 (110) / 4250120 (88) / 3720, 120 (88) / 3750
SuperchargerTwin turboSingle turbochargerSingle turbochargerSingle turbocharger
Start-stop systemyesyesyesyes
Compression ratio15.81615.816
Piston stroke, mm93.293.293.293.2

D4204T Engine Performance Summary

Here, we will investigate the characteristics of this engine by referring to the data of the turbo engine of the D4204T type installed in Volvo’s MD4204 type V40 D4 R-design Polestar-Edition 2017/01 model.

VOLVO V40 D4204T Engine
Volvo’s MD4204 type V40
Vehicle modelLDA-MD4204T type
Car name & gradeV40
D4 R-design Polestar-Edition
Engine modelD4204T
typeIn-line 4-cylinder
Displacement1968cc
Inner diameter x stroke82.0 mm x 93.2 mm
Bore stroke ratio1.14
Single cylinder volume492.2cc
Compression ratio15.8
Intake methodturbo
Fuel useddiesel
Maximum output200PS / 4000rpm
Maximum torque44.9kgm / 1750-2250rpm

First of all, the D4204T engine is a long stroke engine with a bore (inner diameter) of 82.0 mm, a stroke (stroke) of 93.2 mm, and a bore stroke ratio of 1.14 (the stroke amount is larger than the piston diameter).

When the displacement and the number of cylinders are the same, the engine has better torque characteristics in the low rpm range than the short stroke type and is easy to handle, but in the high rpm range, the filling efficiency deteriorates and the sliding resistance increases. There is a concern that the output will drop.

Moreover, when the number of revolutions is the same, the average piston speed tends to be higher than that of the short stroke type, so the load on the engine tends to be heavier.

Among the models registered on this site, the oldest model equipped with the D4204T turbo engine is the second generation V40 [MD4204T | 2015/07] released from 2013/02, and the newest model is 2017 /. It is the second generation V90 [PD4204T type | 2018/07] released from 02, and all 10 models of NA cars are registered, 0 models, and turbo / SC cars are 10 models.

Evaluation from the viewpoint of transient characteristics and liter equivalent horsepower

Image of engine performance curve
D4204T engine performance curve diagram
Changes in horsepower109.7PS → 200PS
Transition of torque44.9kgm → 35.8kgm
Liter horsepower101.63PS / L
Liter torque22.8kgm / L

The V40 in-line 4-cylinder 1968cc, compression ratio 15.8, diesel specification turbo engine, which is the reference vehicle this time, produces a maximum output of 200 horsepower at 4000 rpm and a maximum torque of 44.9 kgm at 4000 rpm.

If you know the horsepower and the number of revolutions, you can know the torque, and if you know the torque and the number of revolutions, you can know the horsepower. The torque at 4000 rpm is 35.8kgm.

The horsepower per liter of displacement is 101.63PS / L and the torque is 22.8kgm / L, and the horsepower per cylinder (single cylinder volume 492.2cc) is 50.0PS and the torque is 11.2kgm.

When the D4204T turbo engine is applied to a 10-step evaluation based on deviation values ​​aggregated from all turbo cars registered on this site, the evaluation is ” standard ” with a converted horsepower of [ 6 ] and a converted torque of [ 10 ]. It is categorized as ” engine with high output (upper middle) “.

By the way, among the models equipped with the D4204T turbo / SC engine, the one with the highest output was the MD4204T V40 with 200PS / 44.9kgm, and the smallest was the MD4204T V40 with 190PS / 40.8kgm.

Displacement increase, compression ratio increase, bore stroke ratio change

Normal displacement and compression ratio
BoreStrokeDisplacementCompression ratioB / S ratio
82.093.21968cc15.81.14
Displacement expansion by bore up
82.593.21993cc16.01.13
83.02017cc16.11.12
83.52041cc16.31.12
84.02066cc16.51.11
84.52091cc16.71.10
85.02115cc16.91.10
Displacement expansion by increasing stroke
82.094.21990cc15.91.15
95.22011cc16.11.16
96.22032cc16.31.17
97.22053cc16.41.19
98.22074cc16.61.20

There are three factors that determine the engine displacement: the number of cylinders, the bore diameter, and the stroke amount. By increasing or decreasing these, engines with various displacements are created.

Here, regardless of whether it is actually possible, the displacement when the piston diameter is expanded from the genuine 82.0 mm to 85.0 mm in 0.5 mm increments and when the stroke is extended from the genuine 93.2 mm to 98.2 mm in 1 mm increments. And, the change of the compression ratio when it is assumed that the volume of the combustion chamber does not change is listed.

* It is easy to say stroke up, but if you want to make a long stroke, you need a crankshaft and a compatible connecting rod, and if you can not divert it, you have to make it in one-off, so it is expensive anyway. It is a menu that requires considerable preparedness to put out.

Regarding the compression ratio, in most cases, the uneven capacity of the top surface of the piston changes as the diameter of the piston increases, so the compression ratio values ​​in the list do not match, but the displacement. Please enjoy the atmosphere that the compression ratio will naturally increase as you increase the size.

The B / S ratio is an abbreviation for the bore stroke ratio, and as the bore diameter is widened, the characteristics of the long stroke type, square type, or short stroke type are approached. In the case of the D4204T engine, the ratio changes from 1.14 to 1.10 when the bore is increased by + 3.0mm from the genuine piston.

Increased displacement with engines with similar piston diameters

Since there are 13 engines with pistons that are close in size to the piston diameter of 82.0 mm of the D4204T type engine, let’s calculate the displacement when the bore is increased by diversion of the piston as a sideshow.

Eg modelPiston diameterDisplacement
Mitsubishi
4D68 type
82.7mm
[+ 0.7mm]
2002cc
[+ 34cc]
Nissan
m274 type
83.0mm
[+ 1.0mm]
2017cc
[+ 49cc]
Mazda
BP type
83.0mm
[+ 1.0mm]
2017cc
[+ 49cc]
Toyota
7M type
83.0mm
[+ 1.0mm]
2017cc
[+ 49cc]
Nissan
CA18 type
83.0mm
[+ 1.0mm]
2017cc
[+ 49cc]
Nissan
274930 type
83.0mm
[+ 1.0mm]
2017cc
[+ 49cc]

Engines with similar piston diameters are Mitsubishi: 4D68 type 1998cc 82.7mm mounted on N28WG type RVR, Nissan: m274 type 1991cc 83.0mm mounted on YV37 type Skyline, Mazda: BP mounted on NB8C type roadster. Type 1839cc 83.0mm, Toyota: 7M type 2954cc 83.0mm mounted on MZ20 type Soara, Nissan: CA18 type 1809cc mounted on S13 type Sylvia 83.0mm, Nissan: 274930 type 1991cc mounted on ZV37 type Skyline 83.0mm etc. is applicable.

(Although the number of people who find pleasure in such a quest has decreased) No matter how close the diameter is, there are factors such as the diameter of the piston pin, the height of the piston, and the convenience of valve recess, so if possible, the same manufacturer, If possible, if you choose the same fuel and the same intake method, and if possible, the one with a similar displacement, the possibility of genuine diversion may increase.

Average piston speed

strokeMaximum torque
1750rpm
Maximum output
4000 rpm
93.2mm5.4m / s12.4m / s
Rotation speed / minuteper secondSpeed
2000rpm6.2m / s22km / h
4000rpm12.4m / s45km / h
6000rpm18.6m / s67km / h
8000rpm24.9m / s90km / h
10000rpm31.1m / s112km / h

Next, let’s look at the average piston speed. An engine with a stroke of 93.2 mm produces a maximum output, and the average piston speed at 4000 rpm is 12.4 m / s, which is a piston speed that travels a distance of 12.4 meters per second (44.6 km / h at speed). It means that is moving up and down.

At 1750 rpm, which produces the maximum torque, 5.4 m / s, and when 4500 rpm, which is 500 rpm higher than 4000 rpm, which produces the maximum output, is assumed to be the rev limit, the average speed is 14.0 m / s.

For reference, I calculated the change in piston speed when the D4204T engine with a stroke of 93.2 mm is rotated up to 10000 rpm. Looking at this, it seems that the speed increases by approximately 6.23 m / s as the number of revolutions increases by 2000 revolutions.

Considering only 20.0 m / s, which is a guideline for a general engine assuming mass production, it is mechanical to set the upper limit of high rpm to about 6440 rpm (whether it rotates or not). It seems to be preferred both mentally.

Read Also: 2.2 HDi Engine DW12 Specs, Fuel, Problems, Reliability

D4204T Engine Typical Malfunctions And Repair

  1. Repairing a 2-liter D4204T diesel engine is a difficult task. As a rule, problems begin with the injection pump. After a run of 200-250 thousand km. nozzles are clogged. Cleaning sometimes does nothing, the result becomes completely unsuccessful on older engines. But replacing the pump and nozzles with the simultaneous cleaning of the lines and the tank is much more productive.
  2. The intake manifold should also be cleaned along with the particulate valve. Be sure to replace the O-rings (they are placed on the sealant).
  3. One of the most common “sores” of a diesel engine is stopping the fuel supply. This is primarily due to the ingress of water into the system. The reason is almost always the same for inexperienced drivers who have not drained condensate for a long time. It all starts at a gas station, where the owner goes to refuel. If the tank is empty, then immediately after filling it is impossible to start the engine. It is necessary to drain the moisture formed in the fuel filter, otherwise it will quickly disrupt the normal operation of the engine.
  4. Draining the condensate from the external filter is recommended to be carried out regularly, in accordance with the maintenance intervals.
  5. In addition, a DPF coarse filter is installed on diesel engines. Its task is to clean the fuel more efficiently by burning debris particles. Regeneration occurs after the engine reaches a temperature of 90 degrees. This process is spontaneous, it does not require manual intervention, and is repeated from time to time. The procedure takes 10 to 20 minutes. If the movement speed is average, then it may take a little longer to clear. This can also contribute to a temporary increase in fuel consumption.
  6. Obviously, in winter, regeneration is more difficult, since the engine temperature does not rise above 70-80 degrees. The filter may not be cleaned for a long time, and when the yellow symbol starts flashing on the car’s instrument panel, this will indicate a critical level of contamination of the element. To clean the filter, you need to go to the track, where you can increase the speed and engine speed. After the engine reaches the operating mode, the regeneration process will start automatically. But, if the element is completely clogged, the engine will be difficult to start and the filter will need to be replaced. To prevent such situations, a parking heater is provided. Its purpose is to help the diesel engine heat up faster in cold weather.

Tuning prospects

To increase the power of the D4204T engine, you can carry out the following manipulations:

  • chip tuning and competent tuning;
  • installation of a direct-flow exhaust system;
  • boost pressure adjustment;
  • change inlet and outlet systems.

Note that these are standard solutions for increasing the power of turbocharged diesel engines. However, auto mechanics warn that all such work negatively affects the resource of the internal combustion engine.

Diesel or gasoline: which engine is better

No matter how good a diesel engine is considered, nevertheless, it is inferior to gasoline counterparts on the highway. For example, cars with a D4204T16 engine accelerate to hundreds in 10.4 fractions of a second, while a gasoline T4 of the same volume takes 8.5 seconds.

On the other hand, the diesel feels better in traffic jams when the movement is generally slow. It is much more economical than gasoline counterparts (almost 2 liters / 100 km), and the peak moment is realized at the bottom. More reliable and piston engine, powered by diesel fuel.

Engines that are integrated with an 8-speed automatic transmission are especially good. This box allows the engine to keep the optimum speed. In addition, the more short gears, the less noticeable the difference between the initially slow diesel and gasoline engine will be.

Another point that speaks in favor of a diesel installation. All D4 four-cylinder, time-tested. But few people can say that about 3-cylinder gasoline Volvo engines.

Conclusion

The D4204T engine is an in-line, 4-cylinder diesel engine with a displacement of 2 liters. The maximum engine power is 136 hp. with a torque of 320 Nm. The compression ratio is 18.5. During the development of this engine, engineers equipped it with a twin turbocharger and Common Rail injection system. ICE is found under the hoods of V90, S90, XC90 and other Volvo models.

Specialists of the Swedish automaker have placed great emphasis on the quality, reliability and service life of the engine. So, with careful operation, timely maintenance and the use of high-quality fuels and lubricants, the engine is able to travel up to 300,000 km without major repairs.

The D4204T engine is quite economical. Consumption in the combined cycle is approximately 5.5 liters per 100 km. In the manufacture of the cylinder block and cylinder head, aluminum was used, which made it possible to minimize the weight of the structure.

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