Re: Hyundai Elite i20 : Official Review To AC or Not AC
I had my elite i20 CRDI Sportz O since August 2014. So far, I have never had any major issues other than the occasional left pulling and multiple failures of key-less entry sensor on door handle and electric boot latch release. Everything was going normal, while I raked up 50000 km in 3 years. All the services were done as recommended on the right km limit from Hyundai ASS.
Trouble started with my AC in July 2017, when the usual 24 deg in ACC was found not cooling the car enough. I also started to notice a small hissing sound every morning when I turned on the ACC. My wife also started to complain of foul smells every time the AC started and all inside the Car. So I took the car to Popular Hyundai Kochi, to check the ACC. I had tried the built in troubleshooting method for the ACC, and no error codes were present. They did a quick check and checking the AC gas pressure revealed that it was around 100. I was informed that it should be around 450-500 by the SA. So, there was a gas leak. Thus began my leak finding odyssey with the car.
Hyundai, somehow has outsourced every work related to ACC to a third party vendor and the moment my SA called up the vendor, he mentioned that the expansion valve "is" faulty and he is 100% sure of it. Thankfully, I had the extended warranty to my aid. So he came in next day, replaced the valve and topped up the gas. I was charged around 800rs for the AC gas which I happily paid thinking that was the end of it. I never knew that it was just the beginning.
Within few days, the hissing sound was back, and the cooling started to degrade, again. It was august 2017, and i went back to the same SVC. The whole process repeated and the vendor comes in again, does "troubleshooting" and declares that the compressor is dead. In this whole process, he had let out what ever gas was left in the system. So, I was informed that the order for a new compressor has been placed and I can expect the part in a week. Again, thanks god for making me extend the warranty. The compressor alone costs around 20k. On the downside, there I was left with no AC in the car for a week. The SVC called after a week to let me know that the compressor was there and I took the car there to get it changed. They changed the compressor and refilled gas and added new oil to the line. Thankfully, this time I was not charged for the gas, but was only charged for some O rings, seals and some other small things, bill was under 100rs.
I was happy, though I had to suffer for a few months, I now had a brand new compressor. The cooling was back to normal. Again, I thought it to be the end of that. 6 months later, I was back to square one. There was a loud hissing sound every time ACC started, there was always a foul smell inside the car, and absolutely no cooling. This time, was frustrated so much that I went to as SVC (VTJ Hyundai) who was quite far from my house, but had a better reputation at solving issues. I mentioned all the problems to the SA, who listened patiently to my ordeal. First thing done was a leak test using nitrogen, which I had to pay for. The test took a whole day, and by evening, he confirmed that there is no large scale leak which means all the lines are good. Since I had already changed the expansion valve and compressor, and the condenser had no visual indication of a leak, he pointed that the only other place where gas could leak is from the evaporator coil inside the Car. Given the foul smell inside the car, he confirmed that would be the case. They had the part in stock, they had the AC gas recovery/ refill machines and the staff who can do all this work.
Now, all that we had to do was to change the evaporator coil. Simple???? ohhh noooo. Hyundai, for unknown reasons, have placed the evaporator coil deep inside the dashboard. So all they had to do was to remove the steering wheel, remove lots and lots of trim in and around the dashboard, and then remove lots and lots and lots of plastic screws, fasteners, wiring harnesses, clips, clamps, and electrical stuff and finally pull out the entire dishoard!. The work started and by evening, they were able to pull out the evaporator coil. It’s a fairly large coil to be honest, almost twice the size of coils I have seen in Wagon R. Near the middle of the coil, there was a place where lot of oil, dust and debris was stuck on and voila, that was our leak all this time. All the other parts changed, did nothing to fix this. It was a nightmare for me to watch and I really do appreciate the service team who had the patience to do all this, pull out the coil, replace it, check for leaks, and then put back the whole thing. The refit of things were done the next day and by next day evening, they filled up gas and oil into the system. Again, extended warranty to the rescue!. Though I had to pay the full cost of gas and oil, around 1300 rs.
And the reason for the leak or theory of the leak as per my last SA:
I use the car for long highway runs on the weekend only. That’s a 5 hour one way trip with one stop in between. City use is limited to 20-30 km max every week. Most of the time, I keep the ACC on external air mode as on long rides. Whenever I had kept it in recirculation mode, by the end of the trip, my wife and I both had headaches. So to have fresh air inside the car, except for city drives or on traffic blocks, the car would be running mostly on external air. Now, as per the SA this is not that good for the evaporator coil because of the following reasons:
1. External air means more humidity and more water content the evaporator coil.
2. External air will have dust which can accumulate on time, especially if the moisture content is high.
3. Switching between external air and re circulation mode repeatedly puts more stress on the coil owing to rapidly changing temp of incoming air.
4. Dust combined with moisture is like cancer for Aluminum based coils. It degrades and corrodes the coils easily.
After all this, my car had a whole new ACC system, everything was brand new. But the pain I had to go through, running from SVC to SVC once in every couple of months for the last 8 months cannot be justified.
Lessons learned:
1. Finding a leak in ACC, most of the time is a difficult and time taking trial and error process.
2. If it smells inside your car and there is a leak in AC gas, mostly it would be the evaporator coil.
3. Always take extended warranty, no matter how much you have to pay, its always worth it. (I had to pay around 19000 rs for extended warranty).
4. Try to run the car ACC mostly on recirculation mode, unless you are on long drives or there are more people on board.
Last edited by ps_abhijith : 16th June 2018 at 22:34.
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