[ttm_220d]

Engine Malfunction Warning came thrice in my New Kia Seltos Diesel




Prelude
I am writing this post as a follow up to my update to my new 2023 Kia Seltos Diesel GTX. As many of you know, I detailed my experiences in few of the posts before. I am writing this post to detail about an issue that has happened thrice now and want to know if other owners face the same.
For a quick upto speed- the car is a 2023 Seltos GTX Plus Diesel Automatic, purchased in end February 2024. It does an equal split of highway and city driving with fuel being filled from Shell or Indian Oil in Bengaluru. Car has now almost 7,500 KM on the odo.
Make no mistake, I have only positive things to say about this car apart from this one annoyance. The car has been a superb addition and has surpassed my expectations.

The issue
Around 5,000 KM on the ODO, the engine management warning had popped up on the dashboard. Immediately we took it to the dealership where they said it was due to carbon build up and after 30 or so minutes of ‘cleaning’ the carbon, the car was good to go.
It was all smooth sailing for another month or so, when this warning popped up again. We were a little perplexed at first because this is a car that does substantial amount of highway driving and fuel is filled from only reputable gas stations. The driver took the car to the service centre where they took almost two hours to clean the carbon and do a software update.
It seemed like everything was fine but this time, within two weeks of the visit, the warning popped up again. I had written an email to Kia India and Advaith Kia about this issue that is now a cause for worry. I took the car in on a Saturday where they took some time to diagnose this but basically performed the same ‘carbon clean up’ as well as software update. The service manager (who was very helpful, in fact all the Kia team were quite polite and helpful) told me that this issue is due to carbon build up. But to me, this warning is not the DPF warning but the engine warning light. From what I understood he has told me that if this issue persists, they will have to replace the catalytic converter. He also says the car is fine even with this warning on or the warning will disappear if you drive it for a long time.
There is also a tiny issue that has happened twice now where the one touch sunroof stops working and I have to reset the sunroof after watching online tutorials. Not sure if these are connected but its definitely another software bug.





My worries-
See as mentioned here and in my review, the car is absolutely superb, I really have no compplaints apart from this. Because the car is still new, and the team is supportive. But what happens when the warranty runs out? My other Diesel cars which are all 5 plus years old now still work rock solid. I am not sure if this is a Kia issue or a Diesel DPF issue that plagues all new cars. This is issue is something that doesn’t give me full peace of mind. It’s the one tiny obstacle prevcenting me from loving this car fully.
If anyone else has faced this issue or is facing this issue, please do let me know how you proceeded with this and how it was solved for you. So far I have full faith Kia will solve this issue (or maybe it has) and this issue won’t recur again but let’s see. Will update on the thread.

[tp_dominator]

I have a Seltos X-line Diesel purchased in Oct - 2023 and manufactured in Sep-2023. I too have got this engine management system warning twice while on roadtrips. My car is used for highways a lot and typical running involves 80% highway runs.

The first time it ocurred, the car was parked overnight and this was the warning that came up at first startup. I was perplexed as the car had run close to 8k kms till then with majority running on the highway. The previous day I had driven it close to 400 kms on the highway. I was in another city and was unable to take it to a dealer as I had about 750 kms to reach home. However, I stopped for breakfast some 2-3 kms later and the warning went away after the restart at the stop. Second time also stopping and restarting made the error go away.

Both times I wasn't in a position to take the car to the workshop and the warning went away anyway. However, seeing your post, god forbid if it happens again, I will definitely visit the workshop this time around. The car has currently run 18k kms. From what I got to know at the Kia workshop, the catalytic converter is actually problematic on the Seltos and replacing it solves such issues. However, the part is never readily available and wait times are closer to 4 months from the factory. Do update if they do a root cause analysis and you get to know what was causing this.

[maverickgenius]

I have had this twice in my Sonet GTX+ DCT. But mine is a petrol car so it can't be related to DPF or CatCon.

Originally Posted by maverickgenius

I'm facing this issue in my Sonet GTX+ 7DCT (petrol). The issue first occured two months ago. Kia service centre was unable to diagnose the cause even after keeping the car with them for a week. They cleared the error and gave it back.

It was fine for two months and yesterday, the same issue has re-occurred.

Any advice on what could be potential causes as Kia dealers seem to lack the expertise to work on this? Thanks!

[Bsilver]

Originally Posted by ttm_220d

But to me, this warning is not the DPF warning but the engine warning light. From what I understood he has told me that if this issue persists, they will have to replace the catalytic converter. He also says the car is fine even with this warning on or the warning will disappear if you drive it for a long time.

Catalytic converter being blocked on a less than a year old car seems to be very odd. The converter is designed to last for a very long time, and requires maintenance after say 6 years if you are constantly driving in city, or if you do a mix of highway then it would be around 10+ years. But in all, the converters are designed for a long term durability.
The check engine light says something is wrong with the engine, and it is not advisable to drive the vehicle until resolved. The technician should give this in writing if he claims that it is fine driving with the light on. The converter surely has a design flaw if it is failing at such an early stage. Please ask them for a scan of the vehicle.
Even if you continue to think it is of no problem as the car is driving fine, and then continue to drive, how will you get to know if any other problem with the engine occurs in the future?
The check engine is already lit up due to this thing, if in future if any sensors are throwing error, you may not even be able to recognize it due to the already lit engine light and may continue to drive causing more damage to the engine. So better to get this checked in order to avoid future mishaps with the engine. Hope you understand what I am trying to convey.

Happy Motoring!

[Bsilver]

Originally Posted by maverickgenius

I have had this twice in my Sonet GTX+ DCT. But mine is a petrol car so it can't be related to DPF or CatCon.

Petrols also come with Catalytic Converter though. If you are misinformed, catalytic converter is not only for diesels.

[ashtwinks]

Engine malfunction light comes up whenever there is sone sensor issue.. These sensors could be in the engine or in the ancillary systems likes breaks, filters, clutch, fuel pump etc..

Whenever the light comes up there is an error code generated..

Did your service station do a scan of your ECU.. Using a obd2 scanner.. (std equipment available at all service stations) this would have given out the exact cause..
In a 5k driven car it is unlikely a carbon sensor error that too when driven on highway

Few questions
1. Did you drive in rain water... The break sensors might have triggered it
2. Do you have rat infestation where you park your vehicle.. Some wires might have been bitten off
3. Who was driving..style of driving might give some hint at what was the issue..
4. What was the error code.. That will give exact location of the problem.. Insist this to be shared with you.. (else get to a local garage and ask them scan... it will not void your warranty, also you can buy a simple obd2 scanner and torque application on an android phone .. JIO also has one now.. Run the scan your self, it will the Give the error code.. You you can reset few errors but if they keep coming then need to get it sorted at the service station.)

DPF error comes much later in the desiel engine life.. Higher than 20k done.. That too if driven in low gear for long hours within the city at slow speeds.. Drive at high speed for sometime.. Heat up the parts with high gas flow.. It will cleanup in most case

Reepat errors and engine light needs attention and if your service station se ds you back by cleaning senror that to 2 times.. They are hiding something... Escalate the issue and ask them to fix.. Even if it means change of the engine..


Please visit a service station and get the scan report shared with you.. Get the root problem fixed, otherwise you will only see this error and spoil the ownership pleasure

[tsk1979]

Originally Posted by ttm_220d

. So far I have full faith Kia will solve this issue (or maybe it has) and this issue won’t recur again but let’s see. Will update on the thread.

If you want to get to the bottom of this, get an OBD reader and see what is the actual error code which happens. This will tell you if the dealership is just performing cleanup and clearing the error or getting to the root cause of the problem

[wadewilson]

Originally Posted by ttm_220d

Engine Malfunction Warning came thrice in my New Kia Seltos Diesel
Attachment 2643498

Hello, the same issue also occurs in our New Kia Seltos as well. I think I've had the issue pop up about 4-5 times as of now, but the CEL goes away on its own after a restart. The Service Centre also told me that Kia had issued a critical software update regarding the same and asked me to get it to the service centre to get the required update. I haven't had the time to drive 300kms (back and forth) to the nearest Kia service centre though.

I'm guessing that maybe there is an issue with the software's code in our cars which mistakenly reads the sensor's output as an engine malfunction (whether there is a malfunction or not) and perhaps the software update might help resolve the error in the code. Will update once I find the time to go the 300kms to the nearest KIA service centre.

[Adi_V4R]

Originally Posted by tp_dominator

I have a Seltos X-line Diesel purchased in Oct - 2023 and manufactured in Sep-2023. I too have got this engine management system warning twice while on roadtrips. My car is used for highways a lot and typical running involves 80% highway runs.

Hi there! While I cannot comment on the actual problem, I will say this - Take the Engine Management System warning report from the Vehicle Report section of the Kia Connect app with a pinch of salt. My Seltos's Report always shows that there is an issue with the oil filter even after reseting it a few times. This issue has persisted even after 3 oil filter + oil changes.

[svsantosh]

1) Get an inexpensive OBD scanner so you can learn yourself and also ask here with specific code related query.

2) Is it the manufacturers issue or the BS6 norms being so tight that DPF is born to fail?!

Another DPF/Regen sour experience looks like!

[Jay-Narula]

Originally Posted by ttm_220d

Engine Malfunction Warning came thrice in my New Kia Seltos Diesel

Hi
I would like to add an update on this topic

I bought A diesel Alcazar Automatic Prestige O in March 2023 now run 19600 km mix of highway and city, I gave my vehicle for the 20k service to the authorised service centre in July 24 also I had a small niggle of my Alcazar's main key fob not functioning, even after a battery change.

The service guys took my vehicle in, did the required service and updated the software, that is when the issues started, I took out my vehicle after a week during which it was parked at home. After a run of 50 odd km mixed on Delhi- Gurgaon highway and Delhi drive, I got the same message as yours on my system screen and app along with an engine management issue light.

Went right next day to the service centre and they did a Regen for the DPF FILTER ISSUE as per their software analysis, this time I parked at home for about a week or ten days and took it out for another Delhi Gurugram run, on my way had hardly run 37 kms when I got the same message, again went to the same service center, they scanned the vehicle and got an error code which when put in the system advised for the change of the whole catalytic converter assembly!.

unfortunately, it was not in stock at either the dealers end or Hyundai Chennai, and kept waiting for the part arrival for which the ETD was nearly a fortnight. After 20 odd days passed I asked the dealer to update me regarding the expected date of the parts' arrival, they said even Hyundai didn't have it and many other vehicles were in line (about 10) waiting for the same part. I waited another couple of days during all this wait my car was parked at home and I was using My 2018 Nexon diesel AMT extensively (will post my experience on that in some other thread.) and asked my service advisor for a Hyundai customer care email.

I wrote about the wait for the part and asked when was it going to be replaced. They didn't respond to my Email but sent the matter to the service centre guys who called me up assuring me that I was number 1 in the waiting list but they had no clue about the time for the arrival of the part. All through this ordeal, I was asked by the service guys to keep using the vehicle saying only a small drop in FE and pickup would be noticed and nothing more. I declined this advice and said I would wait and drive the vehicle only on replacement of the part.

After another 2-3 days I sent REMINDER 1 to Hyundai people saying that I would follow this up with appropriate authorities and asked for an extension of warranty on the time lapsed in getting my vehicle roadworthy and asked for damages and compensation for the ordeal and harassment. This somehow sent the backend teams into overdrive and I got a call from the dealer/service centre guys saying that they had arranged the part from some other Dealer in another city and would get it in 2 to 3 days.

Finally, the day arrived and it was replaced on the 17th of Aug. Now the car has run more than 150 km after the change and there has been no warning ⚠ light or error till now.

Keeping my fingers crossed that this was in the past and won't have to see this issue in the future.. Will update more in the future as and when I have anything to add.
Cheers

[sameerpatel90]

I must take this platform to inform not just Seltos but also, Carens has this concern. As far as the KIN is concerned, only an update along with cleaning of the intake & exhaust system is only advised.

Hope OE takes some serious call on this before the numbers sky rocket and satisfactions of its delighted customers plumet. I'm wondering are there any similar reporting in Hyundai service centres!?.

Please correct me if I'm wrong. In my new assignment with this brand, I believe the ECM is causing this clogging issue of DPF unit damaging beyond repair. So far the new facelift with addition of BSVI additive (adblue) none such issue is found.

[Bsilver]

Originally Posted by sameerpatel90

Please correct me if I'm wrong. In my new assignment with this brand, I believe the ECM is causing this clogging issue of DPF unit damaging beyond repair. So far the new facelift with addition of BSVI additive (adblue) none such issue is found.

We cannot directly say that the ECM is causing these problems. The ECU runs maps/tunes. The OE maps are tested rigorously before making them production, so that they can cater to the end user in various conditions. There should be some verifications in place in order to rule out design flaws in the Catalytic Converter. The best way to do this, if anyone has already replaced the Converter to a new one, you can break open the old one to check the actual condition of it. In the case of OP, the vehicle is relatively run less (comparing it to some vehicles who have run a lot and no converter issues), if you open up the converter, see how is the condition, if you find it to be heavily clogged up with soot, then you can tell that the map which the ECU is running is having too much of exhaust volume in it.
A little more technical way to put it across is, the more exhaust volume you flow as a byproduct in the initial revs, the more faster the turbine side will spool, providing a exponential kind of engine speed curve.
Now compare the same turbo (no changes made), if less exhaust volume is flowing, the turbine will spool gradually. Now why all of this?
More exhaust volumes can be produced by some unburned fuel, and the catalytic converter does the job of controlling this thing, and not letting it escape as a harmful gas.
But then if all this is not controlled perfectly, this means that there is more exhaust volume, leading to a more faster spool in the turbo, leading to a much more induced engine speed, which also will open the EGR valve, and this process will only increase until the redline, and it will end up in the converter, eventually blocking it.

But this can also be attributed to the fact that, if the vehicle is driven mostly in city, the EGR valve is closed as there is not much power requirement, but at the same time if the exhaust volumes are more, then it will directly go from the manifold-turbine to the catalytic converter, which is why the logic behind the city driven cars having blocked converters.
But OP drives as told primarily on highways, but nothing can be said until either the catalytic converter is either replaced or opened to inspect. If the replaced one also gets blocked, then there is something wrong with how the engine manages exhaust side, or there is a design flaw with the converter itself.

Hope this solves a few queries regarding the converter pertaining to the ECU.

Happy Motoring!

[Col Mehta]

Originally Posted by ttm_220d

Engine Malfunction Warning came thrice in my New Kia Seltos Diesel

So far I have full faith Kia will solve this issue (or maybe it has) and this issue won’t recur again but let’s see. Will update on the thread.

Originally Posted by wadewilson

Hello, the same issue also occurs in our New Kia Seltos as well. I think I've had the issue pop up about 4-5 times as of now, but the CEL goes away on its own after a restart. The Service Centre also told me that Kia had issued a critical software update regarding the same and asked me to get it to the service centre to get the required update. I haven't had the time to drive 300kms (back and forth) to the nearest Kia service centre though.

I'm guessing that maybe there is an issue with the software's code in our cars which mistakenly reads the sensor's output as an engine malfunction (whether there is a malfunction or not) and perhaps the software update might help resolve the error in the code. Will update once I find the time to go the 300kms to the nearest KIA service centre.

Hello,

Did you get a chance to gather any updates on the issue? Closing following this thread as our Seltos X line D AT will be delivered next month. Any pointers / updates/ development on the reported issue will be of a great help .

[wadewilson]

Originally Posted by Col Mehta

Hello,

Did you get a chance to gather any updates on the issue? Closing following this thread as our Seltos X line D AT will be delivered next month. Any pointers / updates/ development on the reported issue will be of a great help .

I got another call from the nearest Service Centre regarding this critical update - something related to ECM as per the SA. She said that Kia had highlighted the issue as very critical and that they would be bringing their technician to our town so that all the Kia Seltos Facelift owners can get their cars ECM updated. They're collecting information from the owners now and possible will come to my town by next Sunday.

Will update here after the ECM update has been installed.