[IndigoXLGrandDi]

Originally Posted by LONG_TOURER

After reviewing previous service records, it was discovered that during the 4th service, only 5.5L of Engine Oil were poured instead of the required 7.7L for the diesel variant. I didn’t budge much as the vehicle was functioning normally after the 6th service. After a little bit of research, I could find out that the 2.0L petrol engine of the Tucson requires only 5.5L of engine oil, while the diesel engine requires 7.7L of Engine Oil. It appeared that during the 4th service, Hyundai technicians mistakenly presumed the vehicle to be a petrol variant and added petrol engine oil in our diesel Tucson.

I don't think the Petrol Engine Oil is the culprit here as my brother still uses Shell Helix Ultra 5W40 SN Engine Oil in his i20 Diesel which was purchased in 2012.

It's the quantity 5.5Ltrs poured instead of 7.7Ltrs which could not provide enough protection to the engine. The Oil Sump was having @30% Less Engine Oil.

Also Mr. Long_Tourer, you did not update this thread on current status of the vehicle.

[Fastdriver]

This Hyundai ASC named Saraighat Hyundai (and other Hyundai ASCs should be) doesn't allow car owners to be present by the side of their cars in the workshop/service bay. Car owners had been forced to watch the service done on their cars from the customer seating lounge through glass with tinted film wrapped around which impairs visibility. They filled 3 litre engine oil in my i10 Kappa 2 Sportz instead of 3.5 litre which I came to know later. Irritated (as being a DIY enthusiast myself), I exchanged that car with the new Baleno Alpha MT 2022 and faced no such situations.

[GTE]

The problem will not be caused by the other oil used or the 5.5l filling it has to be something else.

[svsantosh]

Originally Posted by LONG_TOURER

...Upon inspection, it was discovered that the tappet cover was broken, resulting in engine oil spillage in the engine bay.

What is broken? This is blow by and engine is gone, period!

Smoke Emitting from the engine during the Trial run by Hyundai Technicians

Yes, google for diesel engine blowby gases. Causes are rings, cylinder, valves - some of these components are damaged permanently. Cannot be repaired back to factory condition ever again.

....eventually a technician diagnosed the issue, revealing that loosely mounted injectors had caused all four head gaskets to blow which led to breakage of the tappet cover breakage

Ok - now, How did this get missed here?

One Head has one head gasket (ok, dont get me started on OM502 Mercedes engine, there are very rare exceptions) - a V6 has 2 heads and 2 gaskets, V8 has 2 heads, 2 gaskets, W12 has 3 banks/3 gaskets, W16 has 4 & 4.

Since when did a Hyundai come with 4 head gaskets?

...which included opening the engine head.

Any pics of the piston head fouling with the valve? What is the condition of the head surface after machining? Was the timing components changed while engine rebuild. The repeated noise can be from head to timing. Get a compression test and post the results.

However, I was assured that the engine will be fitted to factory finish after the work was completed.

Biggest lie this year in your life, Long-Tourer.

Get a new engine, or junk the car, it will never ever come back to OEM condition.

CatCon, Turbo, Engine - either the car engine was a lemon to begin with, or it was abused (which you say no) with bad oil change cycles.

[starlord]

Originally Posted by true_sedan

You will be just facing a massive financial hit by selling the car. Instead replace the engine under warranty.

I’d agree, there is no problem which cannot be fixed with sufficient replacement of parts.
You’ve been patient enough, bear a little more and get all necessary repairs done and keep the car running.
Selling will only cause you losses on what is probably the fastest depreciating car in the Hyundai fleet, as you’d be looking to replace it with something similar.

[LONG_TOURER]

My sincere apologies for the delay in updating this thread. I have been swamped with personal matters and just haven't had the time to post. I'm sorry for keeping you all waiting.

After three months, from December 28, 2023, to March 24, 2024, I finally got my vehicle back from the workshop. I'm incredibly grateful to TeamBhp for bringing attention to my situation on this forum which increased visibility to a very large audience including officials of Hyundai Management. After my post got attention from various social media, a senior executive from Hyundai reached out to me. They assured me that my vehicle would be repaired as quickly as possible and that any pending spare parts would be sourced without further delay.

Here is a summary of the work done on my vehicle, along with the associated costs:

1) Air Cooler Gas: ₹487.28
2) Amaron Battery: ₹5,156.27 (The original OEM battery was weak and needed replacement)
3) Catalytic Converter: ₹2,41,308.60
4) Tappet Cover: ₹16,793
5) Engine Oil (BS6 Diesel): ₹2,882
6) Fuse (15A): ₹39
7) Head Gasket: ₹1,072
8) Nut & Rust Klene: ₹205
9) Oil Filter: ₹413
10) Timing Chain: ₹6,825
11) Turbo Charger: ₹1,00,045
The total cost for these parts amounts to ₹3,75,226, excluding GST. Labor costs are additional as well.

Wrong Engine Oil Episode

Regarding the confusion about pouring the wrong quantity of engine oil, where 5.5L was used instead of the recommended 7L, I reached out to the Hyundai service executive for clarification. They assured me that no such error had occurred and that the correct type and quantity of diesel engine oil had been added during the service. To further address my concern, they provided a screenshot from their internal portal confirming that 7.6L of engine oil had been used, not 5.5L as I was initially told verbally.

Given this new information, I'd like to sincerely apologise for any confusion caused by my earlier remarks about this engine oil mix-up.

If at all, the service center had poured 5.5L of engine oil instead of the recommended 7L, it is likely that the vehicle's instrument cluster would have displayed an error message showing low oil levels. However, I didn't experience any such warning, and the vehicle was operating normally. This further confirms that the right amount of oil was used during the service which actually justifies the assurance provided by the Hyundai service executive.It might just be a coincidence that the check engine light appeared shortly after the service.

I am however very happy to report that all related expenses were covered by Hyundai's warranty. The only expense that went out of my pocket was the battery replacement.


Expensive cost of Spares from Hyundai


The cost of spare parts for the Tucson is indeed quite high. As shown above, the total cost of parts alone exceeded 3.5 lakh INR, excluding labour charges. When you factor in labour costs and GST, the total expense could easily reach 5 lakh INR. It is worth noting that the catalytic converter had already been replaced once before, when the Odometer was around 25,000 km. This high cost of repairs and the repeated replacement of major components can be a concerning factor for Tucson owners and many other CKD based Hyundai products like Kona and Ioniq. Point to be noted here that the parts are mostly not readily available within the country. Heck, even there is a wait time for rear wiper as well.

Conclusion

The vehicle is driving smoothly now, and all the abnormal noises have been resolved. However, the Hyundai technicians forgot to install the battery cover after installing the new battery, raising concerns about their competency and sincerity of work. After reaching home, when I questioned them about it, they admitted having intentionally leaving the battery cover off because the new Amaron battery is smaller than the OEM ones that was resulting in extra space after the new battery installation. They assured me that the battery's voltage matches the OEM battery, so I shouldn't worry about electrical issues.

Since there's still one year left on the car's warranty and I have decided to keep the vehicle for the time being unless it starts acting up again. Although it is very concerning to see lack of competency from Hyundai technicians.

I once against request all the potential customers who are planning to buy any CKD Hyundai like Tucson, The Kona or the Ioniq to think twice before taking the plunge. I am sure there are better models from other brands that will give you a better product with better reliability. Now some photos after the vehicle delivery.

Near Deepor Beel, A Ramsaar site known for migratory Bird spotting in Assam


With BHPian ChiranjitP's Polo 1.5 TDi, he took a brief test drive of the vehicle after the repair and gave a green signal for the works carried out, an expert opinion is a must after such massive repair


The Hyundai Technicians did not install the battery cover citing the reasons stated above

[LONG_TOURER]

Appologies folks for taking so long for updating the thread.

[thanixravindran]

Isn't engine oil charged by the quantity filled? And is Hyundai adding 7.6L of engine oil but charging for only 5.5L of engine oil? Strange!

[svsantosh]

Originally Posted by LONG_TOURER

Here is a summary

3) Catalytic Converter: ₹2,41,308.60

Probably blow by gases clogged the catcon with oil and it got choked. It can be cleaned by wonder why they replaced it. Remember - the Cat Con was already replaced at 21k Kms. Wonder if this engine already had blowby at 20k kms.

4) Tappet Cover: ₹16,793

Again, Why? It is a non-critical plastic part and nothing wrong should happen here, what is broken, are they giving an answer?

10) Timing Chain: ₹6,825
11) Turbo Charger: ₹1,00,045

Timing chain alone cannot be changed. There are components that go along with it. Turbo change also an indication of oil seeping beyond the combustion chamber and/or turbo itself failing.

Anyways, the whole issue still has so many unanswered questions. It is purely your call to continue with this shoddy repair. Please consider selling off the car when it is still driveable. There is every chance of the issue coming up again, way too many loose ends here.

[SN88]

In my honest opinion and experience, almost all ASS of companies in India cause more problems than solutions. I have concluded that employees, mechanics working in ASS here are just too over worked and due to the "corporate culture" of a garage run by hundreds of persons the buck just keeps on passing. The guys in these service centers always seem busy, running around barely even listening to what customers have to say as they usually think they know it all.

A trusted stand-alone garage has given me much better peace of mind and I have stopped giving my cars to company service centers. My experience has been BAD with Honda, VW, GM(at that point). I have very similar sentiments from friends who go to other various service centers as well.

Better look out for a trusted garage and maintain cars there. If the car is in warranty then it is another issue.

[starlord]

Thanks for the update. Wishing you many more miles of travel in your refurbished vehicle.
I’d advise against selling it, if you are a value buyer. However if money is not a consideration and your time is more important then you are better off getting a fortuner.
IC engine cars have a long pedigree of reliability built in. Almost everything is replaceable and can keep the car running. As you reach the end of your warranty period you could seek out local garages that have specialisation in repairing luxury cars. They can bring down your cost of operations significantly.

[Livnletcarsliv]

Thank you for update.
But the work is not complete unless and until the RCA is done.
So if possible and if your willing, please do the analysis/study, understand and share the full story like
1. what went wrong?
2. why and how it went wrong?
3. what is the repercussion?
4. what have they done/how was it fixed?
5. how can it avoided in future/what is the guarantee that it cannot happen again?

This analysis and study will definitely help other users as well prospects to understand more and be prepared of what to expect. So please try to do it and share it.

[Joli]

Originally Posted by svsantosh

Timing chain alone cannot be changed. There are components that go along with it. Turbo change also an indication of oil seeping beyond the combustion chamber and/or turbo itself failing.

Was about to say this. The timing kit list is expansive and easily crosses 20k, if you include the water pump. This seems like a 'thukpatti' work. Anyways, any company ASS is mostly like this. As a recent owner of a Hyundai car and that too used, am wondering about the expenses that are coming my way.

[Chhanda Das]

Very sad to know about your ordeal but I am glad that it is over, hopefully. As an owner of a Creta since 2017, I would highly recommend you to get your hands on the service manual of your car especially if you want to keep it for a long period of time. And try to avoid the Hyundai authorized workshops for regular services unless absolutely necessary. Instead, a good friendly neighborhood garage may be more helpful.

Since you mentioned your location as CCU/GAU, here is some more information. The Hyundai service centre with the most knowledgeable personnel by far in entire Eastern India is the Mukesh Hyundai service centre in Kestopur in Kolkata. In fact, this service centre even has professors of its training college within its premises. So you might find consulting with them to be very beneficial if, God forbid, you face any further issues with your Tucson.

I couldn't help but notice the exorbitant prices. I mean if ₹39 for a fuse that costs ₹6-7 is any indication then they are really taking you for a ride which further emphasizes the need for you to find a good local aftermarket workshop. Consider the following : My Creta costs approximately ₹5000 for getting its regular annual service at any Hyundai authorized workshop but since we service it by ourselves at home the cost comes down to ₹1700-1800. In this regard, you might want to get the exact same parts from the original equipment manufacturers at cheaper rates instead of getting the more expensive Hyundai rebadged ones.

Another aspect that I am very concerned about is the battery. A smaller battery compared to the original one usually means that it can deliver lesser current than what the car manufacturer recommends. And that can put undue stress on various electrical/electronic components especially those that deal with starting the engine. Additionally, a smaller battery means that it would be charging with more current than what is recommended leading to its early failure. Also, a smaller battery usually has less reserve capacity which means that the other electrical/electronic components will not get adequate current at the recommended voltage and hence the alternator will have to work overtime to compensate. In summary, a 65 AH car battery is absolutely not the same as a 85 AH car battery even though their voltages may be the exact same. This battery saga alone is more than enough for me to concur with your initial assessment that they may not be qualified to work on your car. In fact, it may not be far from the truth to claim that they are not qualified to work on any car if they do not know something as basic as this about car batteries So please get it replaced as soon as possible.

Overall, I sincerely hope that your car is fixed now and I wish you many more miles of happy driving ahead.

P.S. : Deepor beelor osorot gaari tu bor dhunia laagise

[shiv11bhargava]

So happy to hear she's alright now! I have been following your thread carefully and this post brings me joy!
I do feel Hyundai India should be held responsible for all that happened.