Unusual Problem With I30 Crdi, Won't rev passed 3000rpm Options

[tjaliwalpa]

Hi John (and other interested owners),

Phoned the dealer today to see if there was any news about a solution to the problem I am experiencing with rev limit. The service manager received a package yesterday which he had not opened yet as he was away yesterday.

It contained a fuel filter replacement.

Hyundai Believes Solution Found
Apparently the fuel filter has been known to develop air bubbles of sufficent size and number that can effect the pressure in the common rail and therefore not allowing the engine to rev out passed 2950 (approx.).

The replacement filter is designed to reduce the number and size of the air bubbles passing through to the rail and therefore eliminating the problem.

My suggestion is that owners who experience this henomenon (lack of revs) should contact their service centre immediately.

If OURI-30 should experience further rev limit problems (remember it has happened 3 times in 6000k), I shall report the issue in this thread (plus inform the service manager).

I'm off to the Hyundau dealer's service centre now. It is said to be a 0.6 hr replacement.

Full marks to Hyundai Australia if this is indeed the answer to the problem.

Bob

[dazzling_darryl]

Hi Bob,

Thanks for the update, If it fixes the problem hopefully Hyundai will offer to replace all diesel fuel filters free of charge at the next service (and pigs might fly) :460: Closest I could get to a flying pig....

Cheers,

Dazz

[Tony Marriott]

Hopefully the fuel filter replacement is the fix.
I just picked up my car from the special service. Hyundai invited me to come in and get the fuel filter replaced. I will keep the forum (and Hyundai) posted if any further rev limit problem occurs.
Tony

[tjaliwalpa]

Could we be the guineapigs Tony?

I got to see the replacement part. Wish I'd asked if I could take a picture of it. Anyway, I have done the next best thing. I took off the top plastic engine cover and got as good a picture of the fuel filter unit as I could. It is right back against the firewall and the rightside (facing the engine. The filter cylinder sits down inside a black sleeve (the main cylinder of the filter is silver). There two sensors with wireling looms on either side at the top and a sensor at the bottom (assume this is the water sensor).

So below you will find three photos, One is a closeup of the filter assembly and the other two of the engine minus the plastic cover as I thought some of you might be interested in seeing what's under there. You can clearly pick out all the fuel plumbing, including the common rail.

Enjoy!

Bob

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[dazzling_darryl]

Hi Tony & Bob (Thanks for the photos Bob)

Apparently the cover is to restrict access to components that are not user serviceable but it also makes the motor look a whole lot nicer...as well.

Very interesting (as they used to say on Rowan and Martins Laugh in) Now that shows my age...

Cheers,

Dazz

[Shambles]

So below you will find three photos

Eeeh - looks just like mine :thumbsup:

Thanks for the info Bob

[Lakes]

Thanks Bob for the update, very intersting, i like looking at the motor better than the plastic cover as i like to see whats going on. but true the covers clean the look up. how many bolts hold the cover on Bob?
John
PS forgot to add i think the air intake looks really good, that can help too

This post has been edited by Lakes: Apr 22 2008, 02:42 AM

[tjaliwalpa]

John,

There are 2 bolts (10mm socket needed) at the front of the cover. Take them out and lift the cover off. There are 2 rubber dampers/grommets under the cover that sit on 2 pegs (for want of a better word). If you look carefully, you will see the pegs at the back of the cam cover - they have a rubber O-ring near the top. Lift the cover up and it will pop off these pegs. Simple.

I think the cover has several functions. Yes, it makes the motor look cleaner and robust, but it also acts as a heat shield plus I guess it hides the components from careless owners who fiddle. Not me, I never fiddle with things I don't understand. (Don't tell the other half that, she'd not believe you. Double meaning there -somewhere.)

Bob

[Lakes]

John,

There are 2 bolts (10mm socket needed) at the front of the cover.  Take them out and lift the cover off.  There are 2 rubber dampers/grommets under the cover that sit on 2 pegs (for want of a better word).  If you look carefully, you will see the pegs at the back of the cam cover - they have a rubber O-ring near the top.  Lift the cover up and it will pop off these pegs.  Simple.

I think the cover has several functions.  Yes, it makes the motor look cleaner and robust, but it also acts as a heat shield plus I guess it hides the components from careless owners who fiddle.  Not me, I never fiddle with things I don't understand.  (Don't tell the other half that, she'd not believe you.  Double meaning there -somewhere.)

Bob
[right][snapback]155048[/snapback][/right]

Thanks for the Tip Bob, always good to know those things just in case. is that Fuel Filter they replaced, a service item? like is it a disposible filter? hard to see in the pic it is smaller than i would have thought but the new Comon Rail Diesel's filters look different to the old diesels. the new glow plugs also work a lot faster than the old style glow plugs, think they only take a few seconds to warm up.

John

[tjaliwalpa]

John,

Only the top of the fuel filter unit is visible in the photo. The canaster or casing is below it. My estimate of the size of the canaster is 8cm diameter and 12cm long.

No, the fuel filter unit that was replaced is not a servisible item. I would imagine that it would be a very expensive item. I suspect that the element inside the unit is replaced as part of the service shedule.

ALERT TO ALL i30 OWNERS
If you experience the problem Tony and I have experienced (motor will not rev passed 2950rpm), immediately let your service manager know.

Remember, if you stop, turn off motor and restart, the problem is likely to be rectified. This is only a temporary solution, and further instances are likely to occur.

Bob

This post has been edited by tjaliwalpa: Apr 22 2008, 03:50 AM

[Lakes]

John,

Only the top of the fuel filter unit is visible in the photo.  The canaster or casing is below it.  My estimate of the size of the canaster is 8cm diameter and 12cm long.

No, the fuel filter unit that was replaced is not a servisible item.  I would imagine that it would be a very expensive item.  I suspect that the element inside the unit is replaced as part of the service shedule.

ALERT TO ALL i30 OWNERS
If you experience the problem Tony and I have experienced (motor will not rev passed 2950rpm), immediately let your service manager know. 

Remember, if you stop, turn off motor and restart, the problem is likely to be rectified.  This is only a temporary solution, and further instances are likely to occur.

Bob
[right][snapback]155058[/snapback][/right]

Thanks Bob, good advice, i would say some time in the near future they will all have the same as you have. well done Hyundai! it is not often you see a manufacturer solve a problem that quick and repace a part to fix it, most just try to ignore problems like that. let us know if car performs any better too.
John

[eye30]

Found this posting on a Kia Cee'd forum which might help at least point to possible causes and fixes. You can them go to your dealer and ask the question "could it be ...................................... ?"

Cee'd and i30 are the same platform and if you look under the bonnet you'll find both Hyundai and Kia stamped on the bits and pieces.

There are 219 postings.

http://www.kia-forums.com/kia-ceed-forum/4...ine-hiccup.html

[tjaliwalpa]

eye30,

Since the replacement of the fuel filter unit, I have not had any issues - the problem has not resurfaced. The other i30 owner in Sydney that I corresponded with had the same part replaced and I assume he has not had the issue resurface again as we said we'd keep in touch about any further problems.

Have reead some of the stuff on the Kia forum, but it in no way resembles the issue I once had before the fuel filter unit replacement.

Thanks anyway,
Bob

[Tony Marriott]

Hi there,
I have read the Kia forum, and this does not sound like the problem we had in the i30. Since the fuel filter was replaced I have had a perfectly good experience in my i30. I would like to congratulate Hyundai on its response and fix.
Tony

[chb]

A question for you guys who encountered this problem and had to take it into service multiple times. Did you get charged a $44 service fee? This guy from the service department wants to charge me for bringing in my car for a check on the horn. According to him, if they don't find the problem then i'll have to pay and if they find it then its free.

I told'em to get fooked! (in a nicer way heh)

[Tony Marriott]

I took the car in once only, for the 1000k free service. I told them about the problem, but they did not know the answer. They told me to bring it in if it happens again. After a few weeks they rang me and asked me to bring it in for a special ervice to fix the issue. Great customer service, and they did not charge me a cent.

[tjaliwalpa]

There was no charge, nor should there be. My dealer believed me when I informed them prior to the 1000k service. They contacted Hyundai who told them to run some tests on the fuel system. The dealer collected our car from my wife's worksite, some 70km one way from the dealer and left her a loan car for the day. The car was returned later that day, cleaned and detailed.

Next thing I heard via this forum was that Tony's car had a new part fitted to solve the problem and then a week or so later my dealer asked me to bring in the car for the same part to be fitted. I was on holidays and only to glad to take it in. Again, cleaned and detailed when I picked it up.

Great work Hyundai!

Bob

This post has been edited by tjaliwalpa: May 19 2008, 04:15 AM

[chb]

brilliant!
great tales of customer service....always good to hear and long may it continue...

well i have my issue sorted, i rang back to change the service date and at the same time asked to speak to a service manager and for some reason he decided to add in a note saying my service/check up will be free onto the system ;) ;) ;)

[shari]

Hi Bob, I bought an I30 CRDI automatic in July last year. I didn't have any problems until we began to get hot weather. I started noticing the problems when I was sitting in bumper to bumper traffic on the freeway, when it's is over 30 degrees and the car had been running for over 30 minutes, I first noticed that as soon as I took my foot off the accelarator that the car would pull back, and then when the traffic was speeding up my car would rev between 3-4 when it was only going about 30-40 klms and then when I'd be trying to go up to 100kms it would rev high and not want to go above 60kms. I also noticed that the brakes felt heavy and when I managed to get off the freeway the brakes would make a metal grinding noise. After the 2nd occurance smoke was coming out of the engine and I got it towed to the nearest service centre. They then replaced the fuel filter and told me that they were having some problems with a few of the fuel filters.

The problem is it is still happening, I left it with the mechanics for a week and they said it didn't happen to them, however 2 days later coming home from work it happened again. I drove it straight to the mechanics (but by the time I got there it stopped and there was no code for them to capture)

This is driving me and everyone else crazy they think I'm the only person who has this problem, but looking at your posts I think we are having a similiar issue.

I look forward to hearing if you get the problem solved.

[Shambles]

shari..

Bob, amongst many others, now frequents the dedicated owners club which can be found at www.i30ownersclub.com

Try posting there too (IMG:style_emoticons/default/smile.gif)

Good luck