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Hyundai i40: 1.7 CRDi diesel particulate filter (DPF) clogging

1.7 CRDi diesel particulate filter (DPF) clogging is a common engine fault on the Hyundai i40 on the 2011–2019 cars, and we rate it major. Putting it right costs $600 to $3,200 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 5 documented faults on the Hyundai i40.

Vehicle
Hyundai i40
Engine
1.7L
Years
2011–2019
Fuel
diesel
System
Engine

This page covers the Hyundai i40 as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Hyundai i40 faults5 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the Diesel particulate filter yet. We would rather show none than show a picture of a different part.

What goes wrong

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

How to check it

Where to look. Diesel particulate filter in the exhaust after the turbo; EGR valve on the intake side (1.7 CRDi diesel)

  1. Scan for DPF/EGR fault codes and, if the tool allows, read DPF soot load and distance-since-last-regen.

  2. On the test drive confirm the car makes full power and does not go into limp mode.

  3. Ask whether the car has lived on short city trips (worst case) or regular highway running.

  4. Check history for prior forced regens, DPF cleaning or replacement, and EGR work.

Parts involved: Diesel particulate filter.

What it costs to put right

$600 to $3,200 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

  • “Is it driven mostly on short trips or longer highway runs?”
  • “Has the DPF ever been cleaned or replaced?”
  • “Has the EGR valve been cleaned or replaced?”
  • “Does the DPF or engine warning light ever come on?”

Now check the Hyundai i40 you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Hyundai i40 buyer questions

Is 1.7 crdi diesel particulate filter (dpf) clogging serious on a Hyundai i40?

We rate it major and common on the Hyundai i40. 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.

How much does it cost to fix on a Hyundai i40?

$600 to $3,200 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Hyundai i40 years are affected?

Our research records this fault on the 2011–2019 Hyundai i40. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.

How do I check for it before I buy?

Scan for DPF/EGR fault codes and, if the tool allows, read DPF soot load and distance-since-last-regen. On the test drive confirm the car makes full power and does not go into limp mode. Ask whether the car has lived on short city trips (worst case) or regular highway running. Check history for prior forced regens, DPF cleaning or replacement, and EGR work. Look here: Diesel particulate filter in the exhaust after the turbo; EGR valve on the intake side (1.7 CRDi diesel)