[R2D2]

Originally Posted by arjunrudra

This is getting very frustrating. This morning when I was finally able to get to a senior one Mrs. Hemalatha she said the service head is in a meeting and she will call back In 2 hrs. The call never came. Suggestions to get their attention ?

If you have a Twitter and a FB account please use those to get their attention. Include Hyundai Global in that post. Make sure you upload some of the photos too. That should get their attention. Also, provide a link to this thread on T-BHP just in case someone wants additional information.

[aaggoswami]

Originally Posted by vishy76

A blocked oil jet explains why only one cylinder threw a rod and why the low oil pressure light never came on. What blocked the jet remains a mystery.

Originally Posted by Jeroen

As I mentioned before, I would really urge them to check all the oil canals and the oil jet as mentioned by Vishy76. And get them to warrant the repair and part in writing.

Originally Posted by R2D2

a) How did the lubrication gallery get blocked when the car has been experiencing regular oil changes? There is minimal sludge formation in the engine.
d) Overload of the engine due to an AT? Then the engine and/or the gearbox combination are not really suited for this car.

Something new to learn here for me. But I still cant digest a blocked oil gallery resulted into conrod breaking block without any symptoms ? Like some indication such as rise in temperature, or even a slight loss of performance ? All of a sudden such a catastrophic failure can happen (this is a huge unpleasant surprise) ? The blockage of oil gallery must be gradual and given our some hint. The engine looks clean, I have seen a few engines with sludge formation when I visit FNG. This engine has nothing of that sort. Engine overload in AT is just a blame game to support their theory of wear and tear.

My experience with Hyundai after sales support has been terrible. They spoke something else on phone, wrote something else. They were bit rude too when they realized I am not buying their theories. Try Facebook as mentioned by R2D2. Also, try to cover everything in email, they have a habit of pushing something else in writing over any verbal commitment.

[R2D2]

Originally Posted by aaggoswami

Something new to learn here for me. But I still cant digest a blocked oil gallery resulted into conrod breaking block without any symptoms ? Like some indication such as rise in temperature, or even a slight loss of performance ? All of a sudden such a catastrophic failure can happen (this is a huge unpleasant surprise) ? The blockage of oil gallery must be gradual and given our some hint. The engine looks clean, I have seen a few engines with sludge formation when I visit FNG. This engine has nothing of that sort. Engine overload in AT is just a blame game to support their theory of wear and tear.

There was metal to metal contact on the big end bearings and the crank, IIRC in 2 cylinders. Very clearly a lube failure. Why? I don't know.

The ASC says its oil blockage! How?! The engine is so clean! Check the valve train and other parts. They look as if they are <10000 km old and this motor has done 100K kms! At highway speeds lube failure can result in enough heat for the metal to fuse and this can result in compromised strength and eventually breakage. Imagine attempting to stop 1 out of 4 pistons at highway speeds. This is what probably happened here. The con rod broke off at the big end and knocked a hole in the crankcase. Hyundai should really take this case seriously.

[Jeroen]

Originally Posted by aaggoswami

The blockage of oil gallery must be gradual and given our some hint. The engine looks clean,

Actually, I am thinking it was not gradual at all. That engine does look clean. It’s more likely something small broke off or dislodged and blocked it. Something as simple as a broken washer could cause this.

You won’t notice one piston not getting lubrication all of sudden until it is too late. Any additional heat will be dissipated by the cooling system.
Might be useful to check the oil pump on damage too.

Jeroen

[Akshay6988]

Originally Posted by arjunrudra

Suggestions to get their attention ?

Comment the issue and link to this thread on their Instagram, facebook posts. Use strong words such as "pathetic service", "poor customer treatment" . They are very afraid of negative publicity. They'll connect with you immediately. I did this when they were delaying my creta delivery. Hope they honour the goodwill warranty as engine pistons are not "wear and tear" parts.

[sid_deb]

Originally Posted by Kosfactor

as we speak Toyota is under investigation for yet another recall - 1.9 million vehicles.

I have a simple point to make, Japanese cars are the most reliable globally. This is a perception seen across North America, UK and even Asia.

Statistically speaking, a survey done in UK revealed similar findings. Toyota, Lexus and Honda being 80%+ reliable while the Koreans (Hyundai/Kia) being around the 70% mark. Japanese cars will also fail, but are less likely to fail than others given it is their primary focus area. That said Honda is on a downward spiral and I won't be surprised when Korean twins overtake it in terms of reliability too.

https://www.carwow.co.uk/blog/most-a...rands-revealed

[Kosfactor]

Originally Posted by Akshay6988

Comment the issue and link to this thread on their Instagram, facebook posts. Use strong words such as "pathetic service", "poor customer treatment" . They are very afraid of negative publicity. They'll connect with you immediately. I did this when they were delaying my creta delivery. Hope they honour the goodwill warranty as engine pistons are not "wear and tear" parts.

I have posted it in Twitter on Hyundai India handle, lets see. I hope others too will do this.

[arjunrudra]

Originally Posted by Kosfactor

I have posted it in Twitter on Hyundai India handle, lets see. I hope others too will do this.

Thanks a lot, Kosfactor. Request other to help also.

For me apart from the breakdown and repair expenses, I have incurred an additional expense on 9K on towing expense + Taxi expense of 15k + Car Rental Expense of 10k + Flight tickets back home for 20K. Totaling: 54k

Its been quite stressful episode.

Originally Posted by Jeroen

Actually, I am thinking it was not gradual at all. That engine does look clean. It’s more likely something small broke off or dislodged and blocked it. Something as simple as a broken washer could cause this.

You won’t notice one piston not getting lubrication all of sudden until it is too late. Any additional heat will be dissipated by the cooling system.
Might be useful to check the oil pump on damage too.

Jeroen

That is very true it happened all of sudden without warning and we immediately came to a halt.

[vipul_singh]

If I were a betting man, I'd wager that this is another case of catastrophic failure caused by metal fatigue. There are a fair number of other incidents in Hyundai and Kia vehicles where a metal part has just sheared off without being severely stressed.

H/K should really look at their foundry processes, in my opinion.

[Jeroen]

Originally Posted by vipul_singh

If I were a betting man, I'd wager that this is another case of catastrophic failure caused by metal fatigue. There are a fair number of other incidents in Hyundai and Kia vehicles where a metal part has just sheared off without being severely stressed.

H/K should really look at their foundry processes, in my opinion.

I doubt it; I am not a metallurgist, maybe we have some specialist members?

From my (dated) knowledge and experience with metal fatigue:

Metal fatigue is the weakening of a material caused by cyclic loading. I am oversimplifying but statistically once a part has “survived” a certain number of these cycles, the likelihood of it failing due to fatigue reduces greatly. The number of cycles depends on many factors, but again oversimplifying, think of a relatively small number say a million or 10 million. Yes, in this context that is a small number. Every moving part of an engine will have gone way past million in a matter of hours/days of running.

Unless something else changes as well; major wear, or a completely different loading, the changes of parts breaking on car engine/suspension due to metal fatigue is very very small indeed.

Also, it is highly repeatable. If one part, see a piston rod fails, every piston rod produced in the same way will fail at a similar fashion.

Metal fatigue is first and foremost countered by proper design, secondly by applying the correct production techniques and thirdly by correct maintenance procedure.

Sometimes parts are designed to allow for a certain level of metal fatigue, which means actual cracks develop. E.g. the crankcase bed of large marine engine will always show fatigue cracks after a while. These are expected, and are monitored and measured at regular intervals.

However, our engines are designed in such a way that fatigue life is never an issue. If it is, it would be a huge issue, because as I mentioned all similar parts would be failing roughly at the same time.

Jeroen

[vipul_singh]

Originally Posted by Jeroen

Metal fatigue is the weakening of a material caused by cyclic loading. I am oversimplifying but statistically once a part has “survived” a certain number of these cycles, the likelihood of it failing due to fatigue reduces greatly. The number of cycles depends on many factors, but again oversimplifying, think of a relatively small number say a million or 10 million. Yes, in this context that is a small number. Every moving part of an engine will have gone way past million in a matter of hours/days of running.

Totally agree that we need a metallurgist here, with knowledge of the alloys used inside an engine. I was basing my comment on the fact that the damage due to impact is additive for certain materials (that is: damage accumulates over time).

But my top reason for wagering that this was caused by a sudden catastrophic metal component failure is that had it been a lubrication issue, the user would probably have noticed subtle changes in engine sound and performance (e.g. piston slap, rod knock or something). In this case, the car was fine one moment, and totally broken the next.

Also, as you said, metal fatigue is countered by correct design and production techniques. Based of sudden catastrophic material failures on H/K vehicles reported earlier on the forum, I would not be surprised if those things are not as perfect as we (the customers) would like them to be.

[Jeroen]

Originally Posted by vipul_singh

T
But my top reason for wagering that this was caused by a sudden catastrophic metal component failure is that had it been a lubrication issue, the user would probably have noticed subtle changes in engine sound and performance (e.g. piston slap, rod knock or something). In this case, the car was fine one moment, and totally broken the next.

Not necessarily, see my earlier post. I have had the odd engine throw a rod at me. Never knew what hit me, till it did.

Jeroen

[vishwasvr]

I know of one Hyundai i20 (2013 diesel, clocked around 1L Km if my memory serves me right) which had excess smoke from the exhaust and the car was sent to Hyundai ASC in Koramangala, Bangalore and they had quoted replacement of turbo. The customer refused to do it and the driver drove the car about 300m down the road and he heard the exact same noise. Loudish metallic noise and car stopped. They towed it back and they said engine had seized.

Long story short, customer raised a hue and cry, turns out, one of the mechanic had mixed up another i20 which had come in for engine work. He had opened the oil pan, strainer etc of this car and loosened a few bolts in the crankshaft area but forgot to torque it back to the spec (something to that effect, when the customer informed me). When the driver started the car, I guess one of the bolts came undone and the conrod hit the engine block.

Sadly, they did not agree to compensate and the customer who was not in a position to fight with them, got it repaired at an FNG.

[Taha Mir]

Hydrolock through water in fuel isn't possible as it'd trigger the water in fuel light on the dash. The car had been serviced recently and they drain water from the fuel filter at every service.(I hope) Plus the oil would've been a milkshake IF it had hyrdrolocked.

Do you idle the car before shutdown after a hard run?
Not doing that could potentially clog up arteries due to oil coking BUT that'd also cause turbo damage.

It's highly likely something went wrong during the service. Maybe they didn't change the oil filter. Maybe some bloke drained the oil and left for another job without adding oil? Then someone ran it without oil until they realized what happened.

I'd assume there was a mishap during the service until they prove otherwise. Ask for CCTV footage of the entire time your car was left at the workshop.

[arjunrudra]

Hi All,

Just an update. I got a call from the service area manager for KA state. A very nice gentleman called Nikhil had called. The only point of discussion was that cars are mechanical bits and it can fail. Probability was stated.

I have anyways asked for him to talk to his superiors and look at giving us a solid response.

So waiting on them. I wish they come clean and admit its their fault and do the needful. its only fair.

Thanks all for the support.

Hope they give a favorable response to re-instill some comfort and dependence on the Hyundai Brand for me and for others who are unnerved by this situation.