[ninjatalli]

Note: Posting this on behalf of a friend. All points below are verbatim from her side.


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We own a Nov 2020 Hyundai Creta Turbo DCT car. It's been ~1.5 years and 15,000 kms driven so far. We've done the regular 1000 km and 10000 km servicing as per schedule. Prior to this, the car has been functioning fine with a healthy mix of city and highway driving. Recently on a long weekend trip to Chikmagalur, the car broke down in the middle of the highway - sharing the details of the same below

Day1: On the highway, the car started making a whistling sound whenever I pressed the accelerator - at any speed if I pressed the accelerator, I got a steady whistling sound. We immediately called the nearest authorized service station and went to the Advaith Hyundai service station at Hassan. The team assessed the car for about 2 hours there and said there is an issue with the Turbo. They added that it was the first time they had experienced this issue and spoke with the service team at Advaith Hyundai ITPL Bengaluru. They then changed the engine oil, did a 10km test drive, and returned the car to us. They said it was safe to drive and we could take the car for our trip ahead.

Day 2: The car seemed totally fine. Drove it around with no apparent issues at all

Day 3: On the highway, the car again started making a whistling sound + started heavily vibrating when I pressed the accelerator. After going ahead for 2-3 km thick white smoke started coming out of the exhaust. We IMMEDIATELY stopped our car on the highway (near Yediyur) and called the Advaith Hyundai ITPL Bengaluru service manager, explaining the whole issue to him. He said the car is NOT safe to drive and we should call the RSA for getting the car towed. We called the RSA at 3:30 PM and finally, the tow vehicle reached our location on the highway at 6:30 PM. We had to wait in the middle of the highway for 3 full hours and no one giving us any updates. That was a horrible turn-around-time. The car reached the nearest service station - BLUE Hyundai Neelamangala by 9:30 PM, and we handed it over to the team there.

Day 4: The team at Blue Hyundai Neelamangala tried to assess the issue and by EOD the service manager told us that there is a breakdown in the Turbo, the problem is a new one and their team is unable to assess it. So they have requested for a team of experts from Hyundai Chennai factory to come to assess and make the report.

Day 5: Post the assessment from the Chennai Hyundai factory expert team, the Blue Hyundai service manager said that there are 3 issues with the car:
1. Turbo Charger damaged
2. Inter cooler damaged
3. Catalytic Converter damaged

The estimated cost for getting these spare parts and replacing them would come to around INR 2 lacs, but since we have the warranty, we won't be charged. The service manager added that none of the parts are available and they have sent an email to Hyundai asking for the parts, so he couldn't give any timeline for the car's return.

Day 6 & 7: Again no update on the timeline for the return. However, today the service manager said that the issue with the car is only with the Turbo Charger, the others are fine and only need cleaning, so the estimated cost is around INR 75k. We have no idea how suddenly from 3 parts needing replacement, it reduced to a single damage - that too after the Chennai factory experts specifically mentioned that 3 parts were damaged and the estimated cost of replacement will be 2 lacs.

Day 8: The service manager said that the Turbo Charger isn't available in India and that the part needs to come from Korea; ETA is 23/May.

Currently, we are on Day 18.
The car is still with Blue Hyundai. Last week we were told by the team that they have procured the Turbo Charger and will get delivered within a week.


The issues we are facing:

1. The service advisor in Blue Hyundai Neelamangala said that the Turbo issue came up in the first instance when we took the car to the Hassan service station. & since it wasn't rectified there, the issue escalated to this level.

2. According to them, 3 parts needed replacement as per the Chennai factory team assessment, they even told me the estimated cost of replacement. All of a sudden that changed to just 1 part needing replacement - how does that make sense?

3. The Turbocharger is getting replaced entirely - how does that affect the rest of the engine's performance; which other associated parts do we need to look out for. Especially since our car is a Turbo DCT variant

Attaching pictures and videos for additional info/details


















Videos

https://youtu.be/ha_3X94SiFk

https://youtube.com/watch?v=CE0HfNW9M6g

https://youtube.com/watch?v=L_qqgbjb2Yk

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Requesting experts and those with more knowledge on this aspect on the forum, to kindly share your views on what should she should expect here and what needs to get done additionally to be assured of no future issues coming up due to this incident? She currently has the extended warranty upto 5 years, but shouldn't this problem warrant a further extension by an additional year atleast?

Also is this a common issue observed with Creta (/the engine variant)? Any support on this is much appreciated.

[sagarpadaki]

Intercooler can be cleaned.

Catalytic converter also can be cleaned. But it is difficult to say that cat is damaged by visually inspecting it. Unless the chucks of the material are breaking out. If that is the case, then it has to be replaced. Usually, the catalytic converter will not get damaged so easily, unless it is soaked in oil

[Jaggu]

Since the vehicle is under warranty get all the parts replaced, even if there is a delay. Yes by cleaning the intercooler, intake and exhaust you can use the car but you never know what is going to give trouble later on. Seems like freak failure of the turbo leading to all these issues.

[SPIKE ARRESTOR]

Seeing the white smoke, I believe, there are high chances the car's catalytic converter might have been damaged. Remove the catalytic converter from exhaust pipe and check for oil and gum deposits, if it is too dirty, with sticky deposits - replace. The catalytic converter should be easily removable (often 2 x 2 Nos. = 4 bolts mounted on an oval shaped flange). Once oil enters the cat-con, it reduces the conversion efficiency of the cat-con, as the precious metals within it get contaminated and their surface area reduced.

Similarly, you should remove the intercooler and check for any unwanted deposits. I would check the whole intake side, starting from dirty hose up to the intercooler inlet for any unwanted deposits. Press for replacement under warranty.

Spike

[GTO]

Now you know why we insist on getting the maximum possible warranty packages, for each & every car brand. If something like this can happen so early in a car's life, the odds of it happening to a 5-year old Creta are way higher.

Am quite concerned with the dip in Hyundai's quality levels. There are way too many threads on new'ish Hyundais (and even Kias) with problems, some minor...but some surprisingly major like this one. Even our test-drive Venue & Seltos had niggles.

The 1.4L turbo-petrol is a complex beast, and so is the dual-clutch AT it comes paired with. I remain concerned about their long-term reliability in India.

[searacer932]

Turbo Petrol + DCT = Not so simple and problematic for Indian conditions!

Failures like these prove that simple NA petrol + CVT/AT combination is always better, at least in the near foreseeable future.

[sandeepmohan]

Was this car used under a lot of engine Start Stop conditions? By the owner as well as the Auto Start Stop function. While there is no evidence of either causing an issue with the Turbo, the latter kicking in frequently is where it go wrong for the Turbo.

Modern Day Turbo petrol motors can last provided you look after them. However; the common man knows nothing about the effects of automatic fuel saving features.

[scorpian]

Unforeseen situation really.
Since the car is in warranty you are safe that all expenses will be borne by hyundai,had it not been so i am sure they would have asked you to replace the inter cooler and cat-converter for sure at your expense.

Currently you can wash the inter cooler and have it cleaned completely of oil and debris if any,cat in my opinion should be replaced as it must have been very deeply contaminated with oil reducing its efficiency to a great extent which may at a later date cause issues with passing of PUC.

The correct way ahead would be the clean the entire intake system, replace turbo,inter cooler and cat-converter.

Also please ensure that you are idling the car for a minute or so post high speed run situations to prolong life of the turbo.

Regards,
Manoj

[bharanidharang]

DCT or AMT or DQ, all of them seem to have some issue or other randomly. CVT seems to be less prone to issues. While it is glad to know that you have warranty, we should not be ending up having a fear on the automatics.

For the amount of road test and abuses the manufactures throw or indicate that they have thrown the vehicle before launching, it is sad to see lemons keep coming up. Is this because of quality control or inherent nature of auto's ?

[nitkel]

If the owner has the time and inclination to follow up and push for a replacement for all parts mentioned, then she should go for it and make sure they get replaced FOC.

If not, then get the turbo replaced and check if the car is working as expected.

She still has 3.5 years of warranty left, so any issues in the near future will be taken care of by Hyundai.

What I would not suggest is to be too aggressive with your demands that it sours the relationship with the service folks and Hyundai.

[Siddarth_Ramani]

I would suggest you to force them to replace all the parts related to turbo. Sure your relationship with dealer might not be the same. But who is going to pay for your dip in resale value. I wouldn't pick a Hyundai with turbo replaced in first year.


For that matter, I wouldn't pick these TGDis from any manufacturers as of now, not even new. I know they have been around for quite some time in western countries. For the amount of boost & power figures they produce, they need good quality fuel. Which I believe is still sub-standard in India. I don't need to tell anything about road conditions. So the engines hardly run at constant RPMs. Continuosly varying boost maybe bad for engine.
Sure the engineers will have accounted for all of these. But this is just paranoid me talking. It's either NA petrol or Diesels for me.

[i74js]

This is interesting. Would you have a documentary evidence on recommendation of Hyundai engineers from Chennai for three replacements?

If yes, make sure you have all the three replaced. You may have to pull strings but being firm on replacements is the only way.

Also, if this is claimed to be the first of its kind issue in Creta, it warrants a root cause analysis and as a customer you have the right to ask for the analysis report.

Stick to the original recommendation and stay firm. Your car will reward you in long run.

[svsantosh]

Had it happened post warranty one would have been tempted to put a larger AFM turbo, oversized IC, remap, high flow injectors and DeCat (or a high flow one). Sigh, what a beautiful engine (GDI Turbo) to work on.

But it is a new car, stick to warranty!

- Post warranty repair let the owner go along with the authorized technician on a long test drive.

- Drive about 30-50kms and turn off the engine and wait for 5mins, restart the car, drive for further 30-50 kms.

- The PCM/ECU has to go through 3-4 drive cycles to log and throw any error. It is mainly linked to coolant temperature and catalytic temperature.

Some good read (source http://www.lyberty.com/car/drive-cycle.html)

Step 1: Ensure there is no check engine light currently on (look at your dashboard)

Step 2: Connect the device and check monitor status and precondition.

Step 3: Ensure fuel tank is between 1/4 and 3/4 full.

Step 4: Start engine at cold temperatures (less than 86 F) and warm up until engine coolant temp is at least 160 F.

Step 5: Speed up to 40-60 mph at 25% throttle (maintain for 5 minutes)

Step 6: Ensure engine coolant temperature reaches and stays above 190 F.

Step 7: Slow down without using the break to 20 mph (or less).

Step 8: Stop vehicle and allow it to idle for 10 seconds.

Step 9: Turn key off, wait 2 minutes to power down PCM.

Step 10: Turn on the car and repeat steps 5 through 9.

NOTE - Different car makers and models have a different Drive Cycle. Ask the technician, they WILL know it.

[LOL_FWD]

Originally Posted by ninjatalli

Day 5: Post the assessment from the Chennai Hyundai factory expert team, the Blue Hyundai service manager said that there are 3 issues with the car:
1. Turbo Charger damaged
2. Inter cooler damaged
3. Catalytic Converter damaged

If there is any mechanical damage is seen on the turbine blades or the compressor housing, it's better to get all three replaced. Oil deposits on the cat are acceptable to some extent but metal deposits in the intercooler/Intake manifold is always a risk. Cleaning might suffice for now but if later on, issues crop up due to the same maybe when the vehicle is out of warranty, Hyundai will wash their hands off. Better be safe than sorry.

[asit.kulkarni93]

Sorry to hear about your friend's experience. Quality lapse in a Hyundai is nothing new and i am glad Team-BHP is one platform which speaks openly about it unlike most media houses who conveniently ignore these issues.

Turbo failure on a new car is surprising. Please check the catalytic converter in person for any damages. Intercooler can definitely be cleaned. To be honest, the car has stayed at the SVC for long enough. If you insist on the replacement of the intercooler and the catalytic converter, it will lead to even more consumption of time. Instead, i would suggest you ask them for an additional warranty of 1 or 2 years after 5 years. This will just ease up the additional stress post the regular warranty. Please make sure an extended test drive of atleast 50-60 kms is taken with a technician and the service advisor. Most importantly, all the data with respect to the boost pressure and coolant temperature is logged during this TD.