EngineHigh
DPF and EGR faults on the 1.7 CRDi
- Typically appears
- 90,000+ miles
- What to inspect
- Check for regen warnings and run it hot
2011–2019 Hyundai i40 · common problems & known faults
A well equipped estate that sold to fleets, so high mileage cars are common but often well documented.
Compiled & reviewed by the VehicleFaults Research Team · last reviewed August 2026
Quick answer
The most commonly reported faults on the 2011–2019 Hyundai i40 are DPF and EGR faults on the 1.7 CRDi, Clutch judder when pulling away in first gear or a rattling noise at idle, indicating dual-mass flywheel (DMF) wear on manual 1.7 CRDi models and Rhythmic ticking or metallic rattling from the engine bay on cold start due to timing chain stretch and tensioner wear on the 1.7 CRDi. 3 of the documented issues are rated high severity · inspect these first. Full inspection points, onset mileage and what to check are listed below.
Reliability snapshot
Based on the documented faults on this page for the Hyundai i40.
4.3/ 10
- Critical
- 0
- High
- 3
- Medium
- 4
- Low
- 1
Guidance only · reflects reported patterns, not a specific car's condition.
Hyundai i40 problems by year
Which faults an average example has usually reached depends on its age. Pick a model year for the faults that matter on that build.
Known faults to check
SuspensionMedium
Front bush and drop link wear
- Typically appears
- 70,000+ miles
- What to inspect
- Listen for knocks over rough roads
ElectricalLow
Parking sensor and camera faults
- Typically appears
- Age-related
- What to inspect
- Test all sensors and the reversing camera
BrakesMedium
Rear caliper seizing on low mileage cars
- Typically appears
- Age-related
- What to inspect
- Check for uneven rear pad wear
SteeringMedium
Clicking or clunking noise when turning the steering wheel side to side, caused by a worn flexible coupling inside the electronic power steering (EPS) motor.
- Typically appears
- 50,000-80,000 miles
- What to inspect
- With the engine running and the vehicle stationary, gently rock the steering wheel left and right. Listen for a distinct click or clunk echoing from behind the dashboard.
TransmissionHigh
Clutch judder when pulling away in first gear or a rattling noise at idle, indicating dual-mass flywheel (DMF) wear on manual 1.7 CRDi models.
- Typically appears
- 70,000-100,000 miles
- What to inspect
- Start the engine from cold. Listen for a metallic rattle that disappears when the clutch pedal is depressed. Test a pull-away in first gear to feel for driveline judder.
Interior ElectricalMedium
Touchscreen infotainment and sat-nav unit freezing, rebooting randomly, or displaying a blank screen due to software corruption or mainboard failure.
- Typically appears
- 5-8 years
- What to inspect
- Turn the ignition on and immediately test the touchscreen responsiveness. Cycle rapidly through the radio, media, and sat-nav menus to ensure the system does not lag, freeze, or crash.
EngineHigh
Rhythmic ticking or metallic rattling from the engine bay on cold start due to timing chain stretch and tensioner wear on the 1.7 CRDi.
- Typically appears
- 80,000-120,000 miles
- What to inspect
- Ensure the engine is completely cold. Start the car with the bonnet open and listen closely to the timing chain cover area on the left side of the engine for a harsh metallic rattle.
Inspecting a Hyundai i40?
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Check this exact carFrequently asked questions
Is the i40 a bargain?
Yes, values are low and fleet history is often complete.
Main watch out?
DPF condition on short journey cars.
Estate or saloon?
The estate is far easier to sell.
What is the reliability of the 7-speed DCT automatic gearbox?
The 7-speed dual-clutch transmission, introduced during the 2015 facelift, offers smoother shifts but requires careful inspection. It is prone to clutch pack wear and mechatronic unit faults, often manifesting as juddering at low speeds or hesitation when pulling away. Manual gearboxes are generally more robust, provided the dual-mass flywheel is healthy.
Does the 1.7 CRDi engine use a timing belt or a timing chain?
The 1.7 CRDi engine utilises a steel timing chain rather than a rubber timing belt. While designed to last the lifetime of the vehicle, the chain and its tensioners can stretch or wear on higher-mileage examples, especially if the vehicle has missed scheduled oil changes. Always listen for cold-start rattling.
Does the i40 still benefit from Hyundai's manufacturer warranty?
Hyundai supplied the i40 with a five-year, unlimited-mileage warranty from new. As production ceased in 2019, even the very last registered models have now fallen outside this manufacturer coverage. Dealers must ensure any aftermarket warranties offered cover known weak points like the dual-mass flywheel, steering coupling, and infotainment unit.
Sources & further reading
Faults are compiled from documented recalls, technical bulletins, owner reports and mechanic sources, then reviewed for accuracy. This is guidance only · not a substitute for a professional inspection.