How To Resolve a Hyundai Tucson TL 2.0L GDI Cat Converter Blockage

Date Posted: 28 January 2025

The Hyundai Tucson is one of the most popular cars on Australian roads, for good reason. But if you own a Tucson TL 2.0L GDI, you may have encountered a common issue - catalytic converter blockages. This problem can lead to poor engine performance, reduced fuel efficiency, and potentially costly repairs. If you're dealing with this issue, you're not alone. In this guide, we’ll walk you through the causes of the blockage, how to identify the symptoms, and how to resolve it effectively without breaking the bank.

Explaining the Manifold Cat Converter

The Hyundai Tucson TL 2.0L GDI has a manifold catalytic converter - a cat converter that is installed directly into the exhaust manifold. This design helps treat harmful emissions right as they exit the engine. Unlike standard cat converters, which are located further along the exhaust system, the manifold cat converter combines the functions of the manifold (collecting exhaust gases from the engine cylinders) and the catalytic converter (breaking down harmful pollutants).

While this setup is efficient and compact, it can be more prone to clogging due to its proximity to the engine, where exhaust gases are the hottest and most concentrated.

What Could Be the Causes of Blocking in the Tucson TL 2.0L GDI?

Catalytic converter blockages are a common issue for the Hyundai Tucson TL 2.0L GDI, and they can leave you dealing with reduced performance and frustrating repairs. So what causes them? One major culprit is carbon build-up. Over time, unburned fuel or oil residues can clog the converter's internal honeycomb structure.

Another common issue is a rich fuel mixture, where too much fuel and not enough air enter the engine, leading to more deposits. If your engine burns oil, be it due to worn seals or piston rings, this can also contribute to clogging. Finally, excessive heat from engine misfires or unburned fuel can actually melt parts of the converter, blocking exhaust flow entirely.

Symptoms of Blockage

If you believe that the cat converter in your Hyundai Tucson TL 2.0L GDI is causing the blockage, you can try to diagnose a clogged cat converter by checking for:

Reduced Engine Performance - If your Tucson struggles to accelerate or feels sluggish, a clogged catalytic converter might be to blame.
Poor Fuel Economy - A blockage can force the engine to work harder, using more fuel than normal.
Unusual Exhaust Smells - A sulphur or rotten egg smell from the exhaust is a common sign of catalytic converter issues.
Engine Warning Light: The check engine light can often indicate issues with emissions.
Excessive Heat: If the engine bay feels unusually hot, it might mean the converter is overheating due to a blockage.

Recognising these symptoms early can help prevent further damage to your vehicle and pinpoint whether the cat converter is the issue.

How to Resolve the Blockage

A replacement cat that can fix a cat converter blockages on the Hyundai Tucson TL.

In case you know that the cat converter is causing the blockage, you essentially have two options:

Getting an Original Hyundai Part - As of the writing of this article, a discounted OEM cat converter is somewhere in the range of $2,000. While original parts ensure compatibility and performance, the steep price tag makes this an impractical solution for many owners, particularly because a cat blockage in the Hyundai Tucson TL 2.0L GDI is common enough that it’s not unreasonable to expect it to happen again. For a cost-effective repair, most people prefer to explore alternatives.
Installing a Replacement Part - If you're looking for a more affordable and reliable solution, you can opt for our Hyundai Tucson catalytic converter. Our manifold cat converter is an aftermarket part manufactured to fit the Tucson TL 2.0L GDi (1/2015-12/2020) - it offers the same functionality as the original at a much lower cost. Plus, not only will it resolve your blockage, but it also comes with a full manufacturer's warranty for your peace of mind. You can easily order it online, and we’ll ship it anywhere in Australia, making the replacement process as smooth and convenient as possible.

If you’re unsure that this will fix your problem or have any other questions, feel free to contact us, and we’ll gladly help you out.