[narayans80]

Originally Posted by maximus_fiat

After clearing the error code and dpf regen, they returned the car asking me not to undertake any road trips in near future. They suspected that the issue will reoccur after some time.

I drive mainly on outer ring road (Hyderabad) and occasionally within city limits. My usage pattern should definitely clear out the DPF automatically.

What sort of nonsense advise is this? Isn't highway or Hyderabad ORR usage exactly what manual DPF regeneration is? 2000 rpm for 20 minutes.

Also the juddering symptoms and diagnosis are different, DPF regen in one and injector failure in another

I am suspecting bad fuel.

This is my guess too.

[maximus_fiat]

Originally Posted by narayans80

What sort of nonsense advise is this? Isn't highway or Hyderabad ORR usage exactly what manual DPF regeneration is? 2000 rpm for 20 minutes.

Also the juddering symptoms and diagnosis are different, DPF regen in one and injector failure in another

With BS6, diesel engines have become quite sensitive to fuel inputs. I never faced any issues with my Fiat Punto 1.3 multijet which served me well for 1.5 lakh kms and has seen a fair share of fuel outlets.

In my case the mechanics were not very sure on the actual cause of the issue. They cleared the error code but deep down they knew this issue will resurface. I was told that they will go for replacement if we get the error again. True to their belief, error occurred again. Since, it is under warranty they decided it to replace the entire catalytic converter unit. I opted for extended warranty at the time of purchase. Lets see how the car holds up.
Will be going for 2nd free service in a couple of weeks. It will be interesting to see the DPF levels.

[inwester]

I was having the same issue (Kia Carens Diesel AT) and when I first took the car to the service center they couldn't identify and replicate the issue because there was no error code/ check engine lights in the instrument panel. However, I had an accident and left the car in the shop for an extended time where they were able to replicate the issue. I did mention this thread and asked them to check the fuel injectors, but they said it was due to DPF and said they fixed it. I don't know how they fixed and what they replaced.

However, the car is still showing the same issues and my cousin who was driving the car stumbled upon this issue and he said the same thing.

What is the truth? Is it due to fuel injectors or catalytic converter?

[nagateja]

Similar issue on my Alcazar 1.5D AT. Initially service centre at Hyderabad (Lakshmi) failed to acknowledge my problem. Had a tough time convincing them.

I had to show them this thread and finally they atleast acknowledged after recording a horrible instance of judder on video. Initially they replaced ECM and Console (don't know how exactly they arrived at that diagnosis). They claimed to have no problems after checking for 200+ kms.

Car comes home, 2 days later issue is back. Sent the car back. Now replaced Torque converter.
They told me that they had no problems after testing for 150-200kms. Got the car back.

One week later issue is back. More than a month now and no solution. No CEL till now. Had a DPF regen notice in the console and I did it according to the service manual.

Went for a Highway drive of 500kms at mostly constant speeds above 80. While driving Back wierd that now I get the DPF regen required error again on console.

[Naetik30]

Originally Posted by inwester

What is the truth? Is it due to fuel injectors or catalytic converter?

My fuel injector was changed when my car was around 10000kms. It has hit 24000 now (around 6+ months) and no issues since then. So I am guessing the fuel injector change fixed the issue.

Originally Posted by nagateja

Similar issue on my Alcazar 1.5D AT.
Initially service centre at Hyderabad (Lakshmi) failed to acknowledge my problem. Had a tough time convincing them.

Pretty much the same issue on my Alcazar. It was very hard to reproduce when at the service center. And it was Lakshmi Hyundai as well. But had a service advisor that was willing to listen to me. Without the CEL glowing, it was initiially tough to convince them. But stay on point and ask them to replace the fuel injector. All the best.

[nagateja]

Originally Posted by Naetik30

...
Pretty much the same issue on my Alcazar. It was very hard to reproduce when at the service center. And it was Lakshmi Hyundai as well. But had a service advisor that was willing to listen to me. Without the CEL glowing, it was initiially tough to convince them. But stay on point and ask them to replace the fuel injector. All the best.

May I know which Laxmi Hyundai branch and if I can get the advisor or service manager involved in your case, that would be of great help.

[Naetik30]

Originally Posted by nagateja

May I know which Laxmi Hyundai branch and if I can get the advisor or service manager involved in your case, that would be of great help.

Sorry for late response. The branch is Lakshmi Hyundai Whitefield. Johnson and Mr. Chetan were involved with this case.

[nagateja]

Its a real late update and wanted to update anyways for the benefit of those having a similar issue.

After a 2-month long back and forth with the service centre, people from Chennai plant came with some fancy laptop gear and some cables connected to ECU via OBD. We had a very long run at multiple speeds at varying gear selections. Their software was plotting a detailed graph like an ECG showing millisecond responses to throttle inputs etc. (I guess it included the graphs of power/torque/speed/throttle input/braking etc)

Finally after a 100km drive, they dropped me back home and the team continued to drive on the Hyderabad ORR with all those sensors connected and collecting all the continuous real-time data for 6 hours.

1week after that, Hyundai has advised the Hyderabad service center to replace the entire ENGINE-TRANSMISSION along with associated peripherals.

Laxmi hyundai took 7 days to order required parts, 3 days to transplant my Alcazar's Heart and gave me back, all the while them offering me a 1.6D Auto Verna.

Finally, now the issue rests in peace. No more juddering again till now. Its been almost 6 months, issue-free.

Kudos to Laxmi Hyundai and the patient support especially the pressure on Hyundai from the Manager Mr. Sudheer and executive Mr. Ajith. He had even gone to an extent asking Hyundai, a new replacement vehicle on my behalf. And as a safety net, they have even offered me complimentary Extended service package.

[Naetik30]

Great to hear @nagateja. In cases of juddering the suspects in order (as per understanding) - fuel injectors, engine mounts, transmission and engine. Looks like in your case the worst case scenario came true. But happy to note they replaced the engine.

I hope you got your RC book updated too.