I have now completed a D4HB 2.2 CRDi to D4HA 2.0 CRDi engine swap on my 2016 Hyundai Santa Fe DM Premium 4WD Automatic.
The donor was a 2017 Hyundai Tucson TL 2.0 CRDi D4HA 4WD Automatic.
I had the complete donor drivetrain, including the D4HA engine, engine wiring loom, automatic gearbox and transfer case.
The swap is now running and driving well, so I thought I would document what actually fitted and what had to be modified for anyone considering doing the same conversion.
Engine and gearbox
The D4HA fits the Santa Fe DM very well.
One important point: although my Tucson donor was also 4WD automatic and I had the complete Tucson automatic gearbox, the Tucson gearbox does NOT fit the Santa Fe installation.
I therefore retained the original Santa Fe automatic gearbox and fitted it to the D4HA.
The D4HA works with the Santa Fe transmission setup and the vehicle is now driving normally.
The drive plate/flexplate used in these applications is Hyundai/Kia 23221-2F000.
Transfer case
There was no need to change the transfer case because of compatibility.
I used the Tucson transfer case simply because the Tucson unit I had was in better condition than the Santa Fe one.
Both units I had were marked 3B800 / 47300-3B800.
So don't take the use of the Tucson transfer case as meaning the Santa Fe transfer case won't work — mine was changed purely because I had a better unit available.
Wiring and ECU
I used the Tucson D4HA engine wiring loom.
The Santa Fe ECU was retained, with the D4HA engine calibration being used/adapted for the 2.0 engine.
CAN communication works and the car starts and runs normally.
Oil level and oil pressure sensors
There are some small differences in the engine wiring/sensor arrangement.
The D4HA loom had an oil-level sensor connection which wasn't required by the Santa Fe setup, so that connector was left unused and properly sealed.
The oil-pressure sensor position had to be changed/repositioned because of the difference in connector/wiring reach.
Neither was a major problem.
Cooling system and turbo
This was one of the more noticeable differences.
The original Santa Fe D4HB turbo has a water-cooling circuit, while the Tucson D4HA turbo used in this conversion does not use the same arrangement.
The additional coolant pipe arrangement from the water pump to the expansion tank therefore had to be changed to suit the D4HA setup.
For the main cooling system I used the Santa Fe radiator/heater hoses.
Air intake
The Santa Fe air-intake hose/pipework was used because its routing suited the Santa Fe engine bay.
Exhaust
The exhaust required a small modification.
I used the Tucson D4HA flexi/front pipe and modified/welded it to connect to the existing Santa Fe exhaust.
One small issue caused by this is the exhaust hanger position. The hanger on the Tucson flexi and the hanger on the Santa Fe body are positioned approximately 90 degrees to each other, so the standard flat exhaust rubber isn't ideal.
A cross-axis/90-degree exhaust hanger rubber or a small modification to the hanger is required.
Injectors
I retained the D4HA 2.0 injectors with the D4HA engine.
There is no need to install the 2.2 D4HB injectors simply because the engine is being installed in a Santa Fe.
Parts/setup used in my conversion
2016 Hyundai Santa Fe DM Premium 4WD Automatic
2017 Hyundai Tucson TL 2.0 CRDi D4HA 4WD Automatic donor
Tucson D4HA 2.0 engine
Santa Fe automatic gearbox
Tucson transfer case 47300-3B800 – used because it was in better condition
Tucson D4HA engine wiring loom
Santa Fe ECU, adapted/calibrated for the D4HA
D4HA 2.0 injectors
Santa Fe radiator/heater hoses
Santa Fe air intake pipework
Tucson D4HA flexi/front exhaust section, modified to meet the Santa Fe exhaust
Conclusion
The D4HA 2.0 CRDi can successfully be installed in a Santa Fe DM originally fitted with the D4HB 2.2 CRDi.
The conversion turned out to be much more straightforward than I initially expected.
The biggest thing worth knowing beforehand is the gearbox situation:
My D4HA donor was a 4WD automatic Tucson and I had the complete Tucson automatic gearbox, but the Tucson gearbox did not fit the Santa Fe. I retained the original Santa Fe automatic gearbox and fitted it to the D4HA instead.
Most of the remaining differences were relatively minor — coolant/turbo pipework, a couple of sensor/wiring details, and adapting the Tucson flexi pipe to the Santa Fe exhaust.
The conversion is now complete and the Santa Fe starts, drives and runs very well.