Hyundai i40 Catalytic Converter (2011-2019)

The Hyundai i40 comes with various catalytic converters depending on engine type and generation:

• Gasoline engines: 1.6 GDI (G4FD) and 2.0 GDI (G4NC) with Euro 5 standards. Examples include direct bolt-on manifold catalytic converters suitable for 2.0 GDI engines.
• Diesel engines: 1.7 CRDi (D4FD) often combined with Diesel Particulate Filter (DPF) systems, mostly Euro 5 compliant.

OEM and aftermarket references exist, with parts designed to comply with original specifications.

Hyundai i40 catalytic converters comply with strict regulations, typically Euro 5 standards. Key points include:

• Compatibility confirmed by OEM codes (e.g., 28510-2BEF1 for 1.6 GDI engines).
• Certified according to UNECE Regulation No. 103 (Rev.1 + Amend.1) ensuring emission compliance.
• Delivered with mounting kits, installation instructions, and often a legal warranty of 24 months or more.
• No requirement for special registration or individual inspection if E-mark certified.

Parts are designed to maintain the vehicle’s original emission standards without modifications.

Replacement costs vary widely based on model and part type:

• Full replacement cost ranges between 500 and 3000 AUD including labor, influenced by part complexity (e.g., integrated manifold cats are pricier).
• New aftermarket catalytic converters can cost around 624 AUD on average, depending on the reference and supplier.
• Used catalytic converters have scrap values ranging from approximately 50 to 433 USD depending on engine type and precious metal content.

These prices help assess the net replacement cost after factoring in recycled part value.

Typical symptoms of catalytic converter failure include:

• Check Engine Light illumination with codes such as P0420 or P0430 related to catalyst efficiency.
• Loss of engine power, especially at high RPMs, often due to clogging.
• Increased fuel consumption and unusual exhaust odors or abnormal smoke emissions.
• Metallic rattling noises from substrate damage.
• For diesel engines, additional risk of clogging related to combustion or DPF operation.

Proper diagnosis is crucial to distinguish between catalytic converter and DPF faults in diesels.

Key replacement and installation guidelines are:

• Confirm OEM reference number and vehicle details (body style, chassis code VF, engine code).
• Opt for professional installation, especially to ensure proper mounting and sensor alignment.
• Replace all supplied gaskets, bolts, and retainers included in the kit.
• Check and replace oxygen sensors (lambda sensors) and NOx sensors if mileage is high.
• Reset fault codes and perform a road test post-installation.

Following proper procedures maintains emissions compliance and vehicle performance.

Yes, high-flow catalytic converters designed to increase power and torque are available, featuring:

• Reduced exhaust backpressure for better engine performance across RPM ranges.
• Commonly sold as "Hi-Flo" cats, sometimes integrated into manifold designs.
• Often require accompanying engine remapping (tuning) to optimize benefits.
• Note: Such performance cats may not be street-legal or approved for emission tests in many countries.

Customers should consider regulatory restrictions and potential impact on emissions diagnostics.

Catalytic converters must:

• Bear an E-mark certification indicating compliance with UNECE Regulation 103.
• Maintain the original Euro emission standard of the vehicle (Euro 5 for most i40s sold in Europe).
• Not require individual vehicle approval or additional regulatory checks if properly certified.
• Be equivalent in efficiency and performance to original equipment to meet environmental laws.

Using homologated parts ensures legal compliance and pollution control adherence.

Used catalytic converters for Hyundai i40 (especially diesel variants) are available from salvaged vehicles. Consider:

• Advantages: Lower cost and rapid availability.
• Disadvantages: Unknown remaining lifespan, usually shorter warranty or none, and no guarantee on performance efficiency.
• Used parts usually undergo visual inspection but rarely full functionality testing.

Careful evaluation is recommended to balance savings against reliability risks.

For assurance on quality and warranty, new homologated catalytic converters are preferable.