If you drive a Hyundai iLoad, you already know it’s one of the most popular vans on Australian roads. Known for its spacious interior, solid handling, and practicality, the iLoad is a top pick for tradies, delivery drivers, and business owners. But like any vehicle that works hard, its engine can face issues over time.
Whether you’re considering buying a second-hand iLoad, already dealing with engine problems, or thinking about a replacement, it’s important to understand what the engine offers — and what to look out for.
The Engine Behind the Workhorse
The majority of Hyundai iLoad vans in Australia come equipped with the 2.5L CRDi turbo-diesel engine, known by its engine code D4CB. This is a 4-cylinder, common rail, direct-injection engine designed to handle heavy use while delivering reasonable fuel economy.
Depending on the year and variant, the iLoad’s D4CB engine delivers between 100 kW and 125 kW, with plenty of torque to pull a full load, even on steep climbs. It’s paired with either a manual 6-speed or a 5-speed automatic gearbox.
This engine is generally robust and capable of high mileage — but only if it’s maintained properly and not pushed beyond its limits.
Known Issues with the Hyundai iLoad Engine
Even good engines can have weak points. The iLoad engine isn’t perfect, and over the years, several common issues have been reported:
1. Injector Seal Failure
One of the most common problems is leaking injector seals. This can lead to carbon build-up around the injectors, often referred to as the “black death.” If not fixed early, it can damage the cylinder head and affect engine performance.
2. Turbocharger Wear
The turbo is vital to the iLoad’s diesel performance, but after 150,000–200,000 km, it’s not unusual to see signs of turbo wear — especially in vehicles used for heavy towing or stop-start driving. Symptoms include reduced power, whining noises, and smoke from the exhaust.
3. DPF (Diesel Particulate Filter) Blockages
Vehicles that aren’t driven long distances often suffer from a clogged DPF. If the van doesn’t reach highway speeds often enough to burn off soot, it can trigger engine warning lights or force the vehicle into limp mode.
4. Timing Chain Rattle
Timing chain issues can start with a faint rattle on cold starts. Left unchecked, it can lead to poor timing, misfires, or — in worst cases — complete engine failure.
5. Oil Leaks and Head Gasket Issues
High-mileage iLoads are also prone to oil leaks, especially from the rocker cover or sump. A failed head gasket, while less common, can result in coolant mixing with oil — something you’ll want to catch early.
When Does an Engine Need Replacement?
Not every engine fault calls for a full replacement. But in some cases, it’s the most practical and cost-effective option — especially if your iLoad is still in good condition otherwise.
Consider an engine replacement if:
- You’ve experienced total engine failure (e.g., seized engine or snapped timing chain)
- Repair costs are too high or uncertain
- There’s severe internal damage like piston failure, block cracking, or turbo collapse
- You’re getting recurring issues even after major repairs
Many business owners choose to replace the engine rather than start over with a new van — especially if the iLoad has been well-maintained overall.
Engine Replacement Options for Hyundai iLoad
When you’ve decided to replace the engine, there are typically three routes you can go down:
1. Brand New Engine (OEM)
A new engine straight from Hyundai (Original Equipment Manufacturer) gives you peace of mind — but comes with a higher price tag. This is the best option if you want a fresh start and plan to keep the van long-term.
2. Reconditioned or Rebuilt Engine
A popular option for many iLoad owners. These engines have been fully stripped, cleaned, and fitted with new components (such as pistons, bearings, gaskets, and seals). They’re often covered by warranties and can be just as reliable as new, at a fraction of the cost.
3. Second-Hand Engine (Used)
A used iLoad engine is the cheapest upfront, but also the riskiest. Make sure it comes from a reputable supplier with a verified service history and warranty. Always ask about the engine’s kilometres and testing.
What to Expect During Engine Replacement
Replacing an engine is a complex job that usually takes 2 to 5 working days depending on availability and installation time. A good replacement service should include:
- Removal of the old engine
- Supply of the replacement unit
- New oil, filters, coolant, and belts
- Replacement of common wear parts (e.g., timing kit, water pump)
- Road testing and diagnostics
Always check that the workshop provides a warranty on both parts and labour.
Choosing the Right Engine Supplier or Workshop
Don’t just shop based on price — quality and experience matter, especially with diesel engines. Look for:
- Mechanics experienced in Hyundai diesel engines
- Australian-based suppliers that offer fitting services
- Minimum 6-month to 12-month warranty
- Reviews or word-of-mouth recommendations
- Clear explanations and no hidden costs
Melbourne, Sydney, Brisbane, and other major cities all have specialists in Hyundai engine replacements — many of whom will even offer delivery and installation.
Final Thoughts
The Hyundai iLoad is a dependable, no-nonsense van built to work. But when the engine starts showing its age, you need to act quickly. Whether you’re tackling turbo issues, injector faults, or a full engine failure, knowing your options can help you make the right decision.
Replacing your iLoad engine with a reliable unit — whether new, rebuilt, or second-hand — can breathe new life into your vehicle and keep your business moving without the cost of a full upgrade.
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