[JohnT]

Hi all.
Just wanted to share this and see if anyone else has had similar issues.
Had my 150k service done recently by the dealer I bought the car from. (new)  I was asked if there were any issues when booking it in, and told them it sometimes had to be cranked a little longer than usual before it started.  I didn't consider it a big issue, as it is running fine otherwise.

When I collected it after the service, old mate informed me they had found a "small ammount" of metal in the fuel filter, and that they would be replaceing the pump, fuel rail, injectors and flushing the tank !!  all under warrenty   I was very impressed.  Dealer is Sunco Hyundai Maroochydore.

Anyone else had fuel system probs ?

[tla]

  Impressive.  Kudos to Sunco Hyundai.

Many other manufacturers/dealers would say/do nothing, and hope nothing major happens before the warranty expired.

[Doggie 1]

That's good service and good on you for naming them.
It also means that the matter is recorded in the unlikely event that there problems in the future arising from this incident.
Top stuff.

[Shambles]

... and flushing the tank ...

They're just after some of your fuel mate

I was very impressed.

We all are mate... that's on the extraordinary side of amazing. Maybe I should drive up there and have them listen to my clonking UJ joint in my steering.  No-one I've tried here is interested.

[Talking Hoarse]

We all are mate... that's on the extraordinary side of amazing. Maybe I should drive up there and have them listen to my clonking UJ joint in my steering.  No-one I've tried here is interested.

I had same rebuff from a dealer when my car was 7 0r 8 months old.  So I gave up and lived with it, I also found another dealer for 1st service a couple of months later as I was unimpressed with 1st dealer.  But then at its 2nd service  the receptionist rematked on the clonking steering, had it looked at and asked if I wanted it sorted.  The subsequent dismantle (and lubricate & rebush I think) didnt work, upset the ESP, and a new steering column was fitted a couple of days later.  Result - steering no longer clonks.  Answer may be to try another dealer, or at least escalate to service or workshop mgr.
Ed

[Dazzler]

That was a brilliant result JohnT  (Wish all dealers were like that)

[babis_xo]

I had this issue (the colder the engine was the more cranks were required) when dealer misplaced the pump's sealing ring, during fuel filter replacement. Replacing the ring had no effect, had to replace the pump.

[Phil №❶]

@Babis_xo

What have you done, to deserve these problems 

[Surferdude]

JohnT. Great result and just reinforcing my previous comments about this dealer. I use their Currimundi branch but obviously the attitude is part of the company culture.

[babis_xo]

@Babis_xo

What have you done, to deserve these problems 

I have had a Toyota maybe? And now I'm paying back

[Phil №❶]

I feel for you 

[JohnT]

It goes in tonight, and should be ready for pickup Wed. afternoon.  will report back on the result.  Thanks for the encourageing responses.

Cheers,

[babis_xo]

I wish for the best result

[JohnT]

The plot thickens..  Hyundai rang today to tell me they found the inlet manifold heavily carboned (?) up, and they would be pulling the head and sump to check things out.

Service manager is telling me it looks like leaking injector seals, and has probably had the problem from early in it's life.  Will keep you posted.

[komaterpillar]

the only places carbon in an intake manifold can come from are - burnt intake valve leaking back into intake (this will normally only have a carbon build up in one intake port, the one with the faulty valve), egr system, turbo shaft seal leaking and dumping oil into intake and this turning into carbon,  pcv system dumping oil into intake and this turning to carbon,

the pcv one could be caused by leaking injector seals. if the seals where the injectors seat in the head are leaking then this would allow combustion gasses to escape past this into the area under the rocker cover, effectively pressurising the crank case, wich would then make the pcv  system work over time to scavenge all these gasses which in turn could see quite a bit of oil getting sucked into the intake

at least they are having a bit of a go - pulling the head and sump, i reckon they're looking for a burnt valve, because you don't pull the head off to just do injector seals

*edit - can also come from leaking valve stem seals allowing oil down the valve guide and making a build up of carbon on the back of the valve head.

[JohnT]

There are certainly a few possibilities.  Service Mgr. also mentioned 'blowby' as a factor.  Sounds abit unlikely to me, it's had a penrite oil change every 7500k from new and probably 90% of that 150k total have been on the highway in cruise mode.

  As far as a positive diagnosis goes, I'm taking it all with a grain of salt at this stage.  Don't think I (we) will get the real story until they actually get it apart.  And even then they can tell me whatever they want..

I work in a mechanical trade, mostly involving engines.  I'll let old mate know this and hopefully I wont get a dumbed down explaination.  They're telling me probably ready 14th.

will pass on whatever I find out.  Cheers,  John

[Dazzler]

Will be interested to hear the final verdict 

[JohnT]

Hi all.  spoke to the Service Mgr. again today.
They're telling me the crush washer type injector seals have been leaking.  The 'blowby' they mentioned was compression pressure leaking past these seals.  These seals have been revised, but they haven't recalled them as it's not a safety issue.  (quote from serv.mgr.)  Could this be a ticking time bomb for some diesels ?  It was really only luck that it was discovered on mine. it's an '09 model.  He didn't say when they were revised.
I'm still at a loss to see how that could carbon up the inlet manifold..

At this stage, head has been stripped and sent to a reconditioners for cleaning.

Apparently the timing cover and sump have to be removed to get the head off, that's why they pulled the sump.

finished mid-late next week..

will post an update when I get it back.
cheers,  J

I wonder if this topic has any bearing?
https://i30ownersclub.com/forum/index.php?topic=7762.msg91805#msg91805

[Phil №❶]

I wish I had a little camera like David Attenborough uses to film ants etc, I'd like to peer in there now 

That's the mechanical equivalent of an endoscopy 

[Doggie 1]

....as opposed to checking the exhaust pipe. 

[Phil №❶]

That would be a colonoscopy, and very black 

[JohnT]

Just re-read your post komaterpillar.  The pcv explaination would make sense.

[JohnT]

Got the car back today.  done about 100 kays and all seems good.  Had a look under the engine cover and all the fuel system components certainly look new. 

It's definitely livelier than it was.  I hadn't really noticed a decline in performance, but there must have been, because now it feels like it did when it was new.

So far, a happy ending !

[Doggie 1]

Everyone loves a happy ending. 

[Phil №❶]

Excellent result 

[Surferdude]

 

[Dazzler]