Hyundai i40 1.7 CRDi Engine ReplacementCompare Prices & Get Quotes
Get quotes today from trusted UK Hyundai i40 1.7 CRDi engine specialists. Compare prices on reconditioned, rebuilt and used engines for your D4FD diesel.
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12-Month Warranty
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From £2,000 to £3,800 [EM-QUOTE]
Used from £400 · Reconditioned from £1,200 · Common codes: D4FD
From £400
Tested, bare/short engine
From £1,200
Rod bearings addressed, tested
From quote
Upgraded bearings, full teardown, revised valvetrain
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3 Simple Steps3 Simple Stepsto Finding the Best Hyundai i40 1.7 CRDi Replacement Engineto Finding the Best Hyundai i40 1.7 CRDi Replacement Engine
Most replacements completed within 3-5 days.
Variant HistoryHyundai i40 1.7 CRDi - Engine History & Specs at a Glance
The Hyundai i40 1.7 CRDi launched in 2011 as the diesel mainstay of Hyundai's mid-size family car range. Built around the D4FD engine, it evolved through three power outputs before production ended in 2019, with the Tourer continuing until 2020.
Variant HistoryHyundai i40 1.7 CRDi - Engine History & Specs at a Glance
The Hyundai i40 1.7 CRDi launched in 2011 as the diesel mainstay of Hyundai's mid-size family car range. Built around the D4FD engine, it evolved through three power outputs before production ended in 2019, with the Tourer continuing until 2020.
Hyundai i40 1.7 CRDi
Fuel TypeDiesel
Engine Size Range1.7-litre (1,685cc)
Power Output Range116-141hp across the variant's historyEngine History Timeline
D4FD 1.7-litre, 116hp (85kW) - launch variant, also known as the 1.7 CRDi 116
D4FD 1.7-litre, 136hp (100kW) - high-output variant introduced, frequently badged as Premium or Style
D4FD 1.7-litre, 141hp (104kW) - facelift variant introduced alongside the refreshed i40, replacing the 136hp version
End of production for the i40 saloon; Tourer continued until 2020
Key Specs Snapshot
Fuel TypeDieselEngine Size Range1.7-litre (1,685cc)Power Output Range116-141hp across the variant's historyYears Produced2011-2019Every engine fitted to the Hyundai i40 1.7 CRDi is covered below, with UK rebuilt pricing and known failure points.
Hyundai i40 1.7 CRDi Engine Codes - Specifications & Replacement CostHyundai i40 1.7 CRDi Engine Codes - Specifications & Replacement Cost
1.7-litre Diesel (2011-2019)
Power Output116hp / 136hp / 141hp (three power variants across production life)Years Fitted2011-2019
Compatible Trim Levels
- 1.7 CRDi 116
- 1.7 CRDi 136
- 1.7 CRDi 141
- 1.7 CRDi Premium
- 1.7 CRDi Style
- 1.7 CRDi Blue Drive
- 1.7 CRDi Business SE Nav
Find your exact engine code, specs and UK replacement cost guide.
Used
Tested, ready-to-fit engine
£400-£1,200 [EM-QUOTE]
Reconditioned
Addressed known issues, tested
£1,200-£2,200 [EM-QUOTE]
Rebuilt
Full teardown, upgraded internals
£2,000-£3,800 [EM-QUOTE]
Common Failure
D4FD engines are known for DMF failure typically between 80,000-120,000 miles, DPF blockages from urban driving patterns, and timing chain stretch on higher-mileage units. EGR valve clogging is also frequently reported [EM-INTERVIEW][THIRD-PARTY].
The Hyundai i40 1.7 CRDi (D4FD) has three dominant failure points that drive replacement decisions: DMF failure, DPF blockage, and timing chain stretch. Rebuilt engines through EnginesMarket include upgraded components addressing the original failure points, plus a minimum 12-month unlimited-mileage warranty.
Why the Hyundai i40 1.7 CRDi D4FD Wears Prematurely
Affected Vehicles
Hyundai i40 1.7 CRDi (D4FD, 2011-2019)
Typical Failure Mileage
80,000-120,000 miles
Root Cause
The DMF is designed to smooth engine vibrations but wears due to the diesel engine's torque characteristics. Symptoms include clutch judder, metallic rattling on startup, and vibration through the pedal [THIRD-PARTY].
Why It Happens
The DMF is designed to smooth engine vibrations but wears due to the diesel engine's torque characteristics. Symptoms include clutch judder, metallic rattling on startup, and vibration through the pedal [THIRD-PARTY].
Dealer (parts + labour)
£1,000-£1,400
Specialist (parts + labour)
£800-£1,200
What it involves
Replace dual mass flywheel and clutch assembly
Suitability
Viable if DMF is the only issue; usually 100,000-mile lifespan
1 - 2 daysDealer (parts + labour)
£3,500-£5,000
Specialist (parts + labour)
£2,000-£3,800 (matches Section 4 rebuilt figure)
What it involves
Supply & fit, upgraded components addressing the original failure point, 12-month warranty
Suitability
When DMF failure has caused further engine damage
1 - 2 daysAll prices are indicative UK market ranges based on current UK specialist supplier data.| Repair Tier | Dealer (Parts + Labour) | Specialist (Parts + Labour) | What It Involves | Suitability | Estimated Time |
|---|---|---|---|---|---|
 DMF Replacement Minor | £1,000-£1,400 | £800-£1,200 | Replace dual mass flywheel and clutch assembly | Viable if DMF is the only issue; usually 100,000-mile lifespan | 1 - 2 days |
 Full Replacement - rebuilt engine Best Value | £3,500-£5,000 | £2,000-£3,800 (matches Section 4 rebuilt figure) | Supply & fit, upgraded components addressing the original failure point, 12-month warranty | When DMF failure has caused further engine damage | 1 - 2 days |
Vehicle Value Check
Vehicle Value Check
A typical 2014-2016 i40 1.7 CRDi with 80k-100k miles is worth approximately £3,000-£8,000 [THIRD-PARTY][INDUSTRY ESTIMATE]. - Vehicle worth under ~£5,000: DMF replacement makes more sense than a full rebuilt unit. - Vehicle worth ~£5,000-£8,000: evaluate both; reconditioned is viable if keeping the car 2+ years. - Vehicle worth ~£8,000-£15,000: reconditioned/rebuilt usually justifies the premium via warranty and reliability. - Vehicle worth £15,000+: replacement cost is typically small relative to vehicle value.
Our Recommendation
Our Recommendation
For a high-mileage i40 (120k+), a full rebuilt engine with updated components can be more cost-effective than repeated repairs if the DMF has failed and caused collateral damage. If the car is worth under £4,000 and the DMF has failed without further engine damage, a specialist DMF replacement is the more sensible financial decision [EM-INTERVIEW].
Don't Let Engine Failure Write Off Your Hyundai i40 1.7 CRDi
The Hyundai i40 1.7 CRDi is a solid family car when maintained properly, but its D4FD engine has known weaknesses that can turn costly. A full rebuilt engine from EnginesMarket includes upgraded components addressing these failure points, backed by a minimum 12-month unlimited-mileage warranty. Compare quotes across used, reconditioned and rebuilt options - and get the work done by specialists, not main dealers.
Compare rebuilt D4FD Hyundai i40 1.7 CRDi engine prices
12-Month Minimum
UK Specialists Vetted
Best Price GuidanceImportant Information
Important Information
"All prices are indicative UK market ranges based on historical quote data and repair requests from our network of engine specialists. Dealer pricing is estimated based on published main dealer labour rates and genuine OEM parts pricing. Specialist pricing reflects actual quote data from EnginesMarket's UK network. Actual costs vary depending on damage severity, vehicle condition, variant, and workshop location within the UK. Use our free comparison tool to get tailored quotes for your specific Hyundai i40 1.7 CRDi. Every engine supplied through EnginesMarket carries a minimum 12-month unlimited mileage warranty - always confirm exact terms with your chosen supplier."
Hyundai i40 1.7 CRDi Engine ReplacementFrequently Asked Questions
Question 1How much does a Hyundai i40 1.7 CRDi engine replacement cost-
A used Hyundai i40 1.7 CRDi engine (D4FD) costs £400-£1,200 supply-only, while a reconditioned unit is £1,200-£2,200 and a full rebuilt engine £2,000-£3,800 [EM-QUOTE]. Fitted costs add £520-£650 labour at a specialist. Compare quotes through EnginesMarket to find the best deal for your exact year and mileage.
- Used: £400-£1,200 supply-only
- Reconditioned: £1,200-£2,200 supply-only
- Rebuilt: £2,000-£3,800 supply-only
Question 2What are the signs of DMF failure in a Hyundai i40 1.7 CRDi-
Symptoms include clutch judder when pulling away, metallic rattling on startup, and vibration through the clutch pedal. If you hear a "knocking" sound at idle that disappears when the clutch is depressed, that's also a classic DMF warning sign. These failures typically occur between 80,000-120,000 miles [THIRD-PARTY].
- Rattling noise on startup or at idle
- Juddering or vibration when pulling away
- Clutch pedal vibration or unusual feel
Question 3Is it worth replacing the engine in a Hyundai i40 1.7 CRDi-
A full rebuilt D4FD engine costs around £2,000-£3,800 supply-only [EM-QUOTE]. For a 2011-2014 i40 worth £3,000-£6,000, replacement may represent 50-80% of vehicle value - often borderline. For a 2016+ facelift i40 worth £6,000-£9,000, replacement is more financially sensible. Always factor in labour (£520-£650) and the value of a 12-month warranty vs. scrapping.
- 2011-2014 values £3,000-£6,000: evaluate carefully
- 2015-2019 values £6,000-£9,000+: replacement is viable
- Always factor in labour and warranty value
Question 4How long does a Hyundai i40 1.7 CRDi engine replacement take-
A specialist workshop typically completes a full D4FD engine swap in 8-10 hours. With parts sourcing and delivery factored in, allow 2-3 days from quote to car back on the road. Supply & fit options through EnginesMarket streamline the process by pairing you with a specialist who has the engine in stock.
- 8-10 hours specialist labour
- 2-3 days typical turnaround
- Supply & fit options available
Question 5What's the difference between the Hyundai i40 1.7 CRDi 116 and the 136/141 versions-
All three use the same D4FD engine block, but with different ECU mapping and sometimes slightly different injectors. The 116hp (85kW) was the original launch variant (2011-2015), the 136hp (100kW) arrived in 2012, and the 141hp (104kW) was introduced with the 2015 facelift. All are compatible with the same core replacement engine - the supplier will match the correct ECU tune to your vehicle [THIRD-PARTY].
- Same D4FD block, different mapping
- 116hp: 2011-2015, 136hp: 2012-2015, 141hp: 2015-2019
- One D4FD engine fits all; supplier matches tune
Question 6Does the Hyundai i40 1.7 CRDi have a timing belt or chain-
The Hyundai i40 1.7 CRDi uses a timing chain, not a belt [THIRD-PARTY]. This is confirmed by main dealers and owners' forums. The chain does not need routine replacement like a belt, but can stretch on higher-mileage examples (100k+). A rattling noise at startup or unusual diesel knock can indicate chain wear - which a specialist should inspect immediately [EM-INTERVIEW].
- Timing chain, not belt
- No routine replacement interval
- Rattling noise = chain wear warning
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