Hyundai2011–2019 Critical issues documented

Hyundai i40: common faults & what to check

Thinking about buying a used Hyundai i40 (2011–2019) in New Zealand? We've documented 5 known faults for this model spanning electrical, transmission, and engine. Each researched and verified before it's published. The most serious issues here are rated critical. Every one is listed below with its symptoms and repair cost, and each has its own page with where to look and what to ask the seller. Free, no account needed.

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Odometer history
Money owing
Reported stolen
Ownership history

Official NZ vehicle register data
NZ owned and operated

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Documented faults

Critical

Most serious

$600–$2,800

Typical repair

Service milestones

Which Hyundai i40 are you looking at?

2 generation variants documented. Pick the shape you recognise: the faults, the servicing and the timeline below all narrow to it. Free, no account needed.

Petrol

1 variant documented

2011–2019VF2011–2019VF2.0 petrolPetrolDocumented issues2 knownSee faults & what to checkPhoto: Vauxford via Wikimedia Commons, CC BY-SA 4.0.

Diesel

1 variant documented

2011–2019VF2011–2019VF1.7 dieselDieselDocumented issues3 knownSee faults & what to checkPhoto: Vauxford via Wikimedia Commons, CC BY-SA 4.0.

Now narrow it to the engine

A 1.8 and a 2.4 of the same car do not fail the same way, so the faults below narrow to the engine as well as the year. Free, no account needed.

Which engine is in it? These cover every year of this model.

1.7 diesel· 1.7 litre diesel 2.0 petrol· 2.0 litre petrol

Start your free check on this Hyundai i40

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Hyundai i40Engine not picked yet

Pick the engine above first: the i40 came with 2, and without it the report has to show all of their faults. Pick the engine

Can't confirm for this car

Hyundai i40

Nothing has been narrowed yet, so nothing below is a claim about a particular car. Pick a year and an engine to see which faults apply.

Tell us the engine, or check the engine code on the car, before relying on this.

matched on no vehicle context

What to look out for

The checks worth doing on a Hyundai i40 before you hand over any money. Every documented fault is listed below, each with its own page.

Costly issue
Scan for DPF/EGR fault codes and, if the tool allows, read DPF soot load and distance-since-last-regen.
See why
1.7 CRDi diesel particulate filter (DPF) clogging
The 1.7L CRDi turbo-diesel (sold new in Australia and some NZ imports) uses a DPF that must reach temperature on a sustained run to burn off (regenerate) trapped soot. Cars used mainly for short, low-speed trips never complete regeneration, so the filter blocks. Owners commonly report trouble from roughly 80,000 to 120,000 km on short-trip use. Related EGR valve sooting and failed regen attempts compound the problem. No safety recall; this is a use-pattern and maintenance issue.
What you would notice
- DPF / engine warning light on the dash
- Reduced power or limp mode
- Frequent or never-completing regeneration cycles
- Increased fuel use and, in bad cases, exhaust smoke
Typically $600–$3,200 to put right.
Costly issue
Ask for a recent scan report and check for stored/pending misfire codes (P0300-P0304).
See why
2.0 GDI intake valve carbon build-up
The 2.0L Nu GDI (gasoline direct-injection) petrol sprays fuel straight into the cylinder, so no fuel washes over the back of the intake valves. Oil vapour and blow-by from the crankcase ventilation bakes onto the valves and ports, restricting airflow. Deposits accumulate gradually and typically become noticeable from around 80,000 to 150,000 km, sooner on short-trip city cars. No recall covers this; it is an inherent GDI design characteristic and a maintenance item.
What you would notice
- Rough or lumpy idle, especially when cold
- Cold-start misfire or hesitation (P0300-P0304 codes)
- Gradual loss of power and throttle response
- Reduced fuel economy over time
Typically $400–$1,200 to put right.
Costly issue
Arrange to see the car stone cold — ask the seller not to start it before you arrive, and touch the bonnet on arrival to confirm.
See why
D4FD 1.7 CRDi timing chain and tensioner wear — cold-start rattle (chain-driven, not a belt)
The i40's 1.7 diesel (D4FD, U-II family) drives its camshafts by chain, not belt — there is no scheduled cambelt change on this engine. The chain and its tensioner are documented to wear from roughly 150,000-200,000 km: the first sign is a rattle for the opening seconds of a cold start that fades as oil pressure builds, with reports concentrated on 2013-on cars. Ignored long enough, a stretched chain can jump timing and wreck the engine, and replacement is a labour-heavy front-of-engine job, so the cold-start listen is one of the most valuable checks on a diesel i40. Oil-change discipline is what decides chain life, so the service history matters as much as the noise.
What you would notice
- Rattle from the front of the engine for the first seconds of a cold start
- Rattle fades as the engine warms and oil pressure builds
- Diesel clatter noticeably harsher than usual at idle
- Check-engine light with cam/crank correlation codes in advanced wear
Typically $1,500–$2,800 to put right.

Hyundai i40 service schedule

What falls due, and at what distance, for each generation of the Hyundai i40. These are the model’s intervals — the car’s own service book is the only thing that can tell you what has actually been done to it.

Hyundai i40 First Generation (VF) Facelift · 2015–2019 · 2.0L GDi - Sport trim

Petrol

Due by distance

100,000 km
Inspect suspension bushes and verify the transmission fluid has been serviced.
130,000 km
Check the accessory drive belt and the high-pressure fuel pump components' health.
150,000 km
Comprehensive cooling system health check, radiator and hoses included.

Hyundai i40 First Generation (VF) Facelift · 2015–2019 · 1.7L CRDi (High Power) - Elite/Premium trim

Diesel

Due by distance

100,000 km
Significant transmission fluid flush due, plus a check of the suspension bushings.
150,000 km
Check the turbocharger's integrity and inspect the timing chain components for stretching or noise.
200,000 km
Comprehensive cooling system health check, plus potential alternator or starter motor refurbishment.

Hyundai i40 First Generation (VF) · 2011–2019 · 1.7L CRDi (D4FD) - Entry level Diesel

Diesel

Due by distance

100,000 km
Verify the fuel filter replacement history to maintain engine efficiency.
150,000 km
Check the suspension struts and mounting points for optimal road comfort.
200,000 km
A deep assessment of the DPF (diesel particulate filter) cleaning or regeneration status may be due here.

Hyundai i40 First Generation (VF) · 2011–2019 · 2.0L GDi (Nu) - Standard Petrol

Petrol

Due by distance

100,000 km
Inspect the auxiliary drive belt and verify the coolant flush has been completed to protect the engine internals.
150,000 km
Have a specialist inspect the suspension components, front lower control arm bushes and rear shock absorber performance specifically.
200,000 km
Assess the fuel injectors and ensure the engine intake manifold is relatively free of excessive carbon buildup, common in direct-injection engines.

See all 5 documented issuesEverything researched for the Hyundai i40, including 1 rated critical.

Depends on which engine this Hyundai i40 has — 5Each of these is documented for one particular engine. Pick the year and engine above to see which of them apply.

Engine, transmission & cooling4

017-speed DCT (D7UF1) clutch-pack wear and engagement faults on 1.7 CRDi automatics

Facelifted diesel i40 automatics use Hyundai's 7-speed dry-clutch DCT, and it is the weakest part of the car.diesel2015–2019TransmissionCan't confirm for this car$2,500–$5,500Read the full fault: symptoms, where to look, what to ask the seller

021.7 CRDi diesel particulate filter (DPF) clogging

Scan for DPF/EGR fault codes and, if the tool allows, read DPF soot load and distance-since-last-regen.diesel2011–2019EngineCan't confirm for this car$600–$3,200Read the full fault: symptoms, where to look, what to ask the seller

03D4FD 1.7 CRDi timing chain and tensioner wear — cold-start rattle (chain-driven, not a belt)

Arrange to see the car stone cold — ask the seller not to start it before you arrive, and touch the bonnet on arrival to confirm.diesel2011–2019EngineCan't confirm for this car$1,500–$2,800

OccasionalEngine $1,500–$2,800 to fix

Can't confirm for this car

The i40's 1.7 diesel (D4FD, U-II family) drives its camshafts by chain, not belt — there is no scheduled cambelt change on this engine. The chain and its tensioner are documented to wear from roughly 150,000-200,000 km: the first sign is a rattle for the opening seconds of a cold start that fades as oil pressure builds, with reports concentrated on 2013-on cars. Ignored long enough, a stretched chain can jump timing and wreck the engine, and replacement is a labour-heavy front-of-engine job, so the cold-start listen is one of the most valuable checks on a diesel i40. Oil-change discipline is what decides chain life, so the service history matters as much as the noise.

Symptoms to notice

Rattle from the front of the engine for the first seconds of a cold start
Rattle fades as the engine warms and oil pressure builds
Diesel clatter noticeably harsher than usual at idle
Check-engine light with cam/crank correlation codes in advanced wear

What to check

Arrange to see the car stone cold — ask the seller not to start it before you arrive, and touch the bonnet on arrival to confirm. Start it yourself and listen at the front of the engine for a metallic rattle in the first few seconds that then fades; that fading rattle is the chain tensioner sign. Go through the service history counting oil changes — long gaps between services are what kill these chains. Be wary if a seller claims the 'cambelt was done': this engine has no belt, and that claim suggests they do not know the car. If a workshop inspection is possible: scan for camshaft/crankshaft correlation fault codes and have the chain stretch assessed before committing to a high-kilometre example.

Where to look: Timing chain behind the cover at the front (belt end) of the engine — listen from directly in front of the engine bay

Parts involved: Timing chain.

Ask the seller

“Can I hear it started from stone cold?”
“How regularly has the oil been changed, and are there receipts?”
“Has the timing chain or tensioner ever been replaced?”

042.0 GDI intake valve carbon build-up

Ask for a recent scan report and check for stored/pending misfire codes (P0300-P0304).petrol2011–2019EngineCan't confirm for this car$400–$1,200

CommonEngine $400–$1,200 to fix

Can't confirm for this car

The 2.0L Nu GDI (gasoline direct-injection) petrol sprays fuel straight into the cylinder, so no fuel washes over the back of the intake valves. Oil vapour and blow-by from the crankcase ventilation bakes onto the valves and ports, restricting airflow. Deposits accumulate gradually and typically become noticeable from around 80,000 to 150,000 km, sooner on short-trip city cars. No recall covers this; it is an inherent GDI design characteristic and a maintenance item.

Symptoms to notice

Rough or lumpy idle, especially when cold
Cold-start misfire or hesitation (P0300-P0304 codes)
Gradual loss of power and throttle response
Reduced fuel economy over time

What to check

Ask for a recent scan report and check for stored/pending misfire codes (P0300-P0304). On a test drive feel for hesitation and rough idle from cold. Check the service history for oil-change intervals - stretched intervals accelerate deposit build-up. If a workshop inspection is possible: If accessible, borescope the intake valves through the intake manifold, or ask whether an intake/walnut-blast decarbon has ever been done.

Where to look: Intake valves and intake ports, cylinder head (petrol 2.0 GDI)

Parts involved: PCV / oil separator.

Ask the seller

“Has the intake ever been decarbonised or walnut-blasted?”
“Does it idle smoothly from a cold start?”
“Is it mostly short city trips or longer highway running?”
“Do you have the full oil-change service history?”

Electrical1

01ABS module brake-fluid leak / engine-bay fire risk (recall REC-006041)

Subject to Australian safety recall REC-006041 (Hyundai Motor Company; also covers Veloster, ix35, Accent, Santa Fe, iMax/iLoad).2011–2014ElectricalCan't confirm for this car$0–$2,500

OccasionalElectrical $0–$2,500 to fix

Can't confirm for this car

Subject to Australian safety recall REC-006041 (Hyundai Motor Company; also covers Veloster, ix35, Accent, Santa Fe, iMax/iLoad). A manufacturing defect can let brake fluid leak into the ABS control (HECU) module, causing an electrical short that can start an engine-compartment fire while parked or driving. The remedy is a free multi-fuse installation at a Hyundai dealer (the same defect family as overseas 'ABS Fuse / Recall 251' campaigns). No stated expiry - the free recall remedy remains available; owners are advised to park affected cars away from structures until fixed.

Symptoms to notice

Burning smell or smoke from the engine bay
ABS / brake warning lights illuminated
Electrical faults or blown fuses around the ABS unit
In worst cases, an engine-compartment fire

What to check

Confirm the recall has been completed: run the VIN through Hyundai's recall lookup or Product Safety Recalls Australia (REC-006041) and ask the seller for proof the free multi-fuse remedy was fitted.
Inspect the ABS module and surrounding harness in the engine bay for fluid staining, corrosion or heat damage.
Check ABS/brake warning lights extinguish after start-up.

Where to look: ABS control (HECU) module in the engine compartment

Ask the seller

“Has safety recall REC-006041 (ABS multi-fuse) been carried out?”
“Can you show the dealer paperwork confirming the recall fix?”
“Have there ever been ABS or brake warning lights?”
“Any electrical smells or smoke from the engine bay?”

Hyundai i40 faults in detail

Each of these has its own page: the symptoms, where to look, what to ask the seller and what the repair costs. Free, no account needed.

1.7 CRDi diesel particulate filter (DPF) cloggingMajor · Engine 7-speed DCT (D7UF1) clutch-pack wear and engagement faults on 1.7 CRDi automaticsMajor · Transmission

What these repairs cost on other cars

Some of the Hyundai i40’s documented faults are repairs other models share. Each page lists the documented NZ cost for every model it affects.

Other Hyundai models

Hyundai Tucson42 documented faults Hyundai ix3541 documented faults Hyundai Elantra30 documented faults Hyundai Palisade5 documented faults Hyundai Santa Fe29 documented faults Hyundai i3028 documented faults

Hyundai i40 buyer questions

Is the Hyundai i40 reliable?

Like any used car, it depends on the specific example and its service history. Across the 5 documented faults for the Hyundai i40, the recurring problem areas are electrical, transmission, and engine. A Hyundai i40 with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.

What are the most common problems with a used Hyundai i40?

We've catalogued 5 known faults for the Hyundai i40, covering electrical, transmission, and engine. All 5 are written out in full on this page, with the symptoms to notice, what to inspect, and typical repair costs for each. Free to read, no account needed.

How much do repairs cost on a Hyundai i40?

Most single repairs on the Hyundai i40 fall between $600–$2,800 at NZ independent-workshop rates. Some of the 5 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.

Should I get a pre-purchase inspection on a Hyundai i40?

Yes. A Hyundai i40 inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $24.90 far less than the cost of missing one of the faults on this page.