Hyundai i40 sump full of diesel

ffocused

I bought the supposedly just serviced car in January and it has broken down twice since then.

1st time it emptied a full tank of diesel on the road on my 70km drive to work and died in work car park.
Turned out the fuel filter was knackered and also had a leak in pre heater seal which I had repaired in a garage beside my job.

I then got it serviced by my regular mechanic and he said it was fine and drove very well.

2 weeks ago I drove 2km to supermarket and on the way home it died again.
This time with a loud tapping sound from engine and smoke from exhaust.
Got it towed to my mechanic who checked it over.

Faulty Injectors suspected this time, but they are fine and i was told it is the ecu at fault, and they will contact main dealer when they open up again.

I was wondering if I could get the ecu repaired if it’s removed from the car in autokey or similar place that does ecu repair? or will I be at the mercy of a main dealer who will probably just recommend a new ecu.

punisher5112

How old is this car?

What's driving style and mileage done etc etc....

ffocused

punisher5112 wrote: »

How old is this car?

What's driving style and mileage done etc etc....

It’s a 132 with 82k miles.
I use it for M9 M7 commute to Dublin.

show me the money.1

Has it 7 year warranty?

punisher5112

7 year warranty still on it, I'd be getting onto Hyundai Ireland etc and getting it sorted, no way that should be happening.

bazz26

Hyundai warranty is 5 years.

ffocused

bazz26 wrote: »

Hyundai warranty is 5 years.

That’s correct, it was 5 years in 2013

punisher5112

Has it full service history from Hyundai?

ffocused

punisher5112 wrote: »

Has it full service history from Hyundai?

No, it came with no service book so unknown history.
I knew i was taking a risk when buying it.
Mileage was verified by Motorcheck as genuine, so I assumed (wrongly) that it could not have too much wrong with it as it drove very well initially.

Fabio

So is the sump full of diesel or is it the ECU???

ffocused

Fabio wrote: »

So is the sump full of diesel or is it the ECU???

I was told the ecu is sending too much diesel through the injectors and the sump is now full of diesel. This all happened over 3 weeks since it was serviced. Not sure where the oil went though.
The dipstick comes out with diesel up to about 10cm above the high oil mark.
I am not a mechanic, and this is my first (and last) diesel car in 20 years of driving so know very little about the workings of a diesel.
I went for diesel as it was my only option for a decent sized automatic.

Turbohymac

ECU sending too much diesel ...that's not possible it would in theory smoke badly and wouldn't run..especially if it has filled sump... as for warranty that's out the window unless it had previous full dealer service history...
Sounds like a lemon

punisher5112

Is the dpf causing it?

As trying to regen or its clogged....

colm_mcm

Isn’t there a good chance the engine is totally hooped now either way?

ffocused

Turbohymac wrote: »

ECU sending too much diesel ...that's not possible it would in theory smoke badly and wouldn't run..especially if it has filled sump... as for warranty that's out the window unless it had previous full dealer service history...
Sounds like a lemon

It is not running now, it was parked up for over a week when I went to shop and it never made it home.
It did smoke badly when it started making noise and then cut out.
Why do you say it’s not possible? Corrupt software can do many unexpected things.

ffocused

colm_mcm wrote: »

Isn’t there a good chance the engine is totally hooped now either way?

That’s what I’m afraid of, as the noise was not pleasant to say the least and engine would not turn over once it stalled.

colm_mcm

I’m not usually one to be all doom and gloom. I’d want to know about the engine itself before sinking money on parts.

Blueshoe

ffocused wrote: »

It is not running now, it was parked up for over a week when I went to shop and it never made it home.
It did smoke badly when it started making noise and then cut out.
Why do you say it’s not possible? Corrupt software can do many unexpected things.

It doesn't sound possible. The injectors nozzles only spray a very fine high pressure mist. A drive to the shop isn't going to fill the sump with fuel. The car would have stopped on the road immediately. It wouldn't have even started if that was the volume of fuel entering the combustion chambers.

Sounds like a dpf issue
You are lucky you didn't end up in a "runaway diesel" situation where you would have been powerless to stop the engine revving itself to death. Stalling in a high gear sometimes possible to counteract

CoBo55

Sorry to be so blunt about it but that engine is knackered. Cut your losses and buy a €1000 banger on DD to tide you over or until the i40 is paid for. Please don't start throwing money at it, it never ends well..

CoBo55

Blueshoe wrote: »

It doesn't sound possible. The injectors nozzles only spray a very fine high pressure mist. A drive to the shop isn't going to fill the sump with fuel. The car would have stopped on the road immediately. It wouldn't have even started if that was the volume of fuel entering the combustion chambers.

Sounds like a dpf issue
You are lucky you didn't end up in a "runaway diesel" situation where you would have been powerless to stop the engine revving itself to death. Stalling in a high gear sometimes possible to counteract

Long term dpf issue I'd imagine, if there's one there at all at this stage. Looks like the op is left holding the baby, I'd be putting her up for adoption...

ffocused

colm_mcm wrote: »

I’m not usually one to be all doom and gloom. I’d want to know about the engine itself before sinking money on parts.

That’s why I am asking the question as I don’t want to spend big money on a new ecu if it’s not the culprit at all.

I got the car recovered by insurance breakdown assist who got it to the garage and I only spoke to my mechanic for 2 minutes the following morning. The garage is closed and he only went in to take delivery the car and check it out.

He said injectors are fine, and it’s the ecu at fault and will contact Hyundai when they are open again. They may well say it can’t be the ecu too. He also said he has never seen an engine with so much diesel in it before. Dipstick comes out translucent grey and strong smell of diesel, so very little oil left in it 3 weeks after service.

Would a dpf fault cause an engine to fill with diesel?
It was not smoking before this happened and my driving would surely be enough for a natural dpf regen.

This is all I have to go on until they are open again.

zilog_jones

Blueshoe wrote: »

It doesn't sound possible. The injectors nozzles only spray a very fine high pressure mist. A drive to the shop isn't going to fill the sump with fuel. The car would have stopped on the road immediately. It wouldn't have even started if that was the volume of fuel entering the combustion chambers.

The oil dilution probably happened gradually over the weeks since the service. 10 cm over the max line on the dipstick could be a few litres of fuel. If they're doing a substantial commute it's very possible for that amount of fuel to go missing by incomplete combustion, blow-by or whatever.

What isn't clear to me is why exactly the ECU is being put at fault here, because "overfuelling = ECU must be broken" seems like an odd conclusion to make without knowing more specifically what's going on here. And as others have said, oil dilution could have already caused damage to the engine so doing anything could be a waste of money without knowing the current condition.

CoBo55

ffocused wrote: »

That’s why I am asking the question as I don’t want to spend big money on a new ecu if it’s not the culprit at all.

I got the car recovered by insurance breakdown assist who got it to the garage and I only spoke to my mechanic for 2 minutes the following morning. The garage is closed and he only went in to take delivery the car and check it out.

He said injectors are fine, and it’s the ecu at fault and will contact Hyundai when they are open again. They may well say it can’t be the ecu too. He also said he has never seen an engine with so much diesel in it before. Dipstick comes out translucent grey and strong smell of diesel, so very little oil left in it 3 weeks after service.

Would a dpf fault cause an engine to fill with diesel?
It was not smoking before this happened and my driving would surely be enough for a natural dpf regen.

This is all I have to go on until they are open again.

Even if it was an ECU fault that engine is ruined. Any warranty from your seller or was it a private sale?
Yes, continued attempts by the ECU to clear the dpf, with each attempt failing would cause the sump to fill with diesel.

ffocused

CoBo55 wrote: »

Even if it was an ECU fault that engine is ruined. Any warranty from your seller or was it a private sale?
Yes, continued attempts by the ECU to clear the dpf, with each attempt failing would cause the sump to fill with diesel.

Private sale, so no warranty. Thanks for clearing up the dpf question.

Toyotafanboi

Agree with the above. The engine is goosed in all likelihood.

This was popular in the i40's. Repeated failed regens diluting the engine oil with diesel and no alert system for the driver for failed regens or over full engine oil. The only way to cop it in advance would be to have been checking the oil level on the dipstick and seeing it going up not down, the dilution happens over a long-ish period of time.

I'd say the mechanic is blaming the ECU in a generic way of not getting into the technicalities of the failed regens.

If the engine is knocking and smoking, I wouldn't be holding out much hope for this being a cheap or easy fix.

A recon engine might be a good shout if the rest of the car isn't in too bad a shape. You'd get a good recon unit fitted with a warranty for under €2k I'd say. I know that's a chunk of cash but it might be better making a good car out of the i40 than on buying a tide me over banger.

Blueshoe

Toyotafanboi wrote: »

Agree with the above. The engine is goosed in all likelihood.

This was popular in the i40's. Repeated failed regens diluting the engine oil with diesel and no alert system for the driver for failed regens or over full engine oil. The only way to cop it in advance would be to have been checking the oil level on the dipstick and seeing it going up not down, the dilution happens over a long-ish period of time.

I'd say the mechanic is blaming the ECU in a generic way of not getting into the technicalities of the failed regens.

If the engine is knocking and smoking, I wouldn't be holding out much hope for this being a cheap or easy fix.

A recon engine might be a good shout if the rest of the car isn't in too bad a shape. You'd get a good recon unit fitted with a warranty for under €2k I'd say. I know that's a chunk of cash but it might be better making a good car out of the i40 than on buying a tide me over banger.

I agree with this. Those i40s are ten a penny and you should be able to source another engine handy enough. Something written off from the rear with low mileage. A headache at the minute but if you find the right one you might just get years out of it. Motorway driving too. Ideal.
Underlying cause needs to be found though first

PukkaStukka

Op, what was the fuel consumption like between the last service and the subsequent breakdown? Was there anything out of character with the engines performance in that time?

kalkat2002

Could be that this car was baddly remapped in order to de-fap,egr..so sump full of dieSel when regen failed..
Is just an idea...

ffocused

PukkaStukka wrote: »

Op, what was the fuel consumption like between the last service and the subsequent breakdown? Was there anything out of character with the engines performance in that time?

Computer was showing 45mpg, but I don’t think I was getting that I was only saving €10 a week over my old 2l petrol (that I thankfully kept) that did 30mpg. That’s driving 700km’s a week.

kalkat2002

Not sure on this model but some cars have on dipstick low,high and sometimes and extra mark on top for maximum allowed level and when it gets this level the oil should be changed

CoBo55

kalkat2002 wrote: »

Not sure on this model but some cars have on dipstick low,high and sometimes and extra mark on top for maximum allowed level and when it gets this level the oil should be changed

That's Mazda's party trick...

kalkat2002

CoBo55 wrote: »

That's Mazda's party trick...

U right,rgds

CoBo55

ffocused wrote: »

Computer was showing 45mpg, but I don’t think I was getting that I was only saving €10 a week over my old 2l petrol (that I thankfully kept) that did 30mpg. That’s driving 700km’s a week.

They're heavy on diesel anyway.

kalkat2002

Some related info here...

https://www.i30ownersclub.com/forum/index.php?topic=26053.0

CoBo55

Toyotafanboi wrote: »

Agree with the above. The engine is goosed in all likelihood.

This was popular in the i40's. Repeated failed regens diluting the engine oil with diesel and no alert system for the driver for failed regens or over full engine oil. The only way to cop it in advance would be to have been checking the oil level on the dipstick and seeing it going up not down, the dilution happens over a long-ish period of time.

I'd say the mechanic is blaming the ECU in a generic way of not getting into the technicalities of the failed regens.

If the engine is knocking and smoking, I wouldn't be holding out much hope for this being a cheap or easy fix.

A recon engine might be a good shout if the rest of the car isn't in too bad a shape. You'd get a good recon unit fitted with a warranty for under €2k I'd say. I know that's a chunk of cash but it might be better making a good car out of the i40 than on buying a tide me over banger.

Plus a dpf plus the failed sensor(s) that caused the problem in the first place, down time in the garage, fights with the mechanic because he's sick to death of you and your bloody car, in fact he doesn't seem to be that interested already, run Forrest run... Give her to the scrappy and get some sleep at night. Don't start on open wallet surgery.

Hellrazer

There was also a well known issue with the high pressure pump seal leaking and throwing loads of diesel into the oil. I suspect in this case that's what's happened.
Its usually very quick once the seal on the shaft goes.
I used to see loads of them when I was in hyundai and kia... Optima had the same problem.

I'd wager the seal went, threw a load of diesel into the oil and now as toyotafanboi says either the dpf is gone or maybe even the bottom end due to the oil loosing its lubricating properties by being diluted with diesel.

punisher5112

Eh hello, I said dpf before any peasants......


It's a crappy result though and such a modern car is really depressing, is this what we all have ahead of us that can't afford anything newer.....


I'd expect it from Mazda....

Hellrazer

punisher5112 wrote: »

Eh hello, I said dpf before any peasants......


It's a crappy result though and such a modern car is really depressing, is this what we all have ahead of us that can't afford anything newer.....


I'd expect it from Mazda....

I don't think it is dpf related. The dpf issue used to happen very gradually... Usually a lot longer than 3 weeks whereas the fuel pump seal was almost always in the space of 2 to 3 weeks.

punisher5112

Hellrazer wrote: »

I don't think it is dpf related. The dpf issue used to happen very gradually... Usually a lot longer than 3 weeks whereas the fuel pump seal was almost always in the space of 2 to 3 weeks.

But will the dpf not be taken a dive now too?

I'm no mechanic and not trying to be but just going from experience and from others....

Hopefully they can get sorted but obviously the knocking either way isn't good and anything I've heard like that went bang... Another great car for that is the insignia around 2009-2012 model.... Dirt

CoBo55

punisher5112 wrote: »

But will the dpf not be taken a dive now too?

I'm no mechanic and not trying to be but just going from experience and from others....

Hopefully they can get sorted but obviously the knocking either way isn't good and anything I've heard like that went bang... Another great car for that is the insignia around 2009-2012 model.... Dirt

Insignia failures has nothing to do with the dpf.

Hellrazer

punisher5112 wrote: »

But will the dpf not be taken a dive now too?

I'm no mechanic and not trying to be but just going from experience and from others....

Hopefully they can get sorted but obviously the knocking either way isn't good and anything I've heard like that went bang...

Id say the dpf is gone alright..but if its knocking and smokey that would be the least of my worries.

Another great car for that is the insignia around 2009-2012 model.... Dirt

Different issue. The oil pump seal goes on that model starving the engine of oil.

vandriver

ffocused wrote: »

Computer was showing 45mpg, but I don’t think I was getting that I was only saving €10 a week over my old 2l petrol (that I thankfully kept) that did 30mpg. That’s driving 700km’s a week.

My back of the envelope calculations make that about 32 mpg for the diesel.

punisher5112

CoBo55 wrote: »

Insignia failures has nothing to do with the dpf.

Yes I do know that, was just saying as in unreliable.... Engines blow....

selectamatic

Best option I'd be thinking would be get a 2nd hand engine fitted (supplied by a somewhat legitimate breakers i.e Traynors etc.)

Once this is fitted sell the car to recoup some costs and start again. Maybe a hybrid might offer you the best of both worlds, reliability and decent fuel economy.

Going the fully reconditioned route is dear but the price is justifiable if you end up with a reliable car however if things go wrong it's an awful lot more heartache.

monkeysnapper

My i40 story ..... if it's any use....who knows...

I bought mine private around a year and half ago ... and after a few days noticed it was smoking under load a good bit , I was kicking myslef for not getting car checked out...

Anyway I took it to mechanic and turned out dpf had been bored out and ecu remapped ... but that wasnt cause of smoke...
Mechanic said 2 of the injectors had extra washers that they shouldnt have had and was causing problem ...
No more smoke after that...
L
Car has run perfect ever since , NCT was due pretty much straight away and passed with all this ....

Anyway .... I dread to think what asshole did all that messing to car .... and I wonder were they trying to fix something they couldn't figure out...

CoBo55

selectamatic wrote: »

Best option I'd be thinking would be get a 2nd hand engine fitted (supplied by a somewhat legitimate breakers i.e Traynors etc.)

Once this is fitted sell the car to recoup some costs and start again. Maybe a hybrid might offer you the best of both worlds, reliability and decent fuel economy.

Going the fully reconditioned route is dear but the price is justifiable if you end up with a reliable car however if things go wrong it's an awful lot more heartache.

700km a week on motorways would be the worst driving from an economy point of view for a hybrid, they really make their savings in town driving.

selectamatic

CoBo55 wrote: »

700km a week on motorways would be the worst driving from an economy point of view for a hybrid, they really make their savings in town driving.

They will still achieve impressive mpg figures on motorway spins though especially newer hybrids. The Toyota hybrid system from 2016 onwards in particular.

A Hybrid was merely a suggestion I made giving reliability a consideration tbh too.

CoBo55

selectamatic wrote: »

They will still achieve impressive mpg figures on motorway spins though especially newer hybrids. The Toyota hybrid system from 2016 onwards in particular.

A Hybrid was merely a suggestion I made giving reliability a consideration tbh too.

Scaldy money though, I had notions of getting one last year but they’re just crazy money, the superb would drop into the 4’s on the op’s commute. There are plenty of reliable diesels out there, the VW 2 litre being probably one of the better ones, the 1.6 not so good but would thrive on the op’s commute.

punisher5112

Cheap fluence, megane or Laguna

CoBo55

punisher5112 wrote: »

Cheap fluence, megane or Laguna

Not a thing wrong with them in fairness the Laguna would be super comfortable for that commute.

punisher5112

CoBo55 wrote: »

Not a thing wrong with them in fairness the Laguna would be super comfortable for that commute.

I had to go for megane and would love the Laguna, super comfortable...

I hit my head getting in or out of the megane