Hyundai IX35 Engine Problems

When an engine blows thick white (or bluish-white) smoke, it’s often a sign of internal engine wear. Some Hyundai engines have had problems with major engine components developing premature wear and causing similar problems to the ones you’ve experienced. But some Hyundai engines of this era also suffered problems with the EGR valve (exhaust gas regulation, part of the emissions control system) and that could lead to similar problems.

The best advice is to have the vehicle inspected for internal wear or any other problems that could be causing the smoking under load situation. This is pretty back to basics stuff and would include a compression test and leak-down test and should be well within the capabilities of any decent workshop. From there, you can make a more informed decision on whether to spend the money to have the car fixed, or cut your losses and move on.

It's also worth mentioning that Hyundai has been very pro-active in helping out owners who have experienced premature engine-wear problems, but the age of your car plays against this. It would be worth contacting Hyundai’s customer service division, however.

If you're selling or trading-in the car, then a quality, tested second-hand engine from a wrecked iX35 is probably your best bet. This will be the cheaper option and even though you could spend a lot of money having the current engine reconditioned or a brand-new engine fitted, you'll find that won't affect the resale value as much as the extra outlay.

That said, it all depends on what's wrong with the current engine. If it's completely trashed, then a replacement is the go. But if your engine has simply stopped working for a potentially simple reason, then it might be worthwhile fixing it and maybe saving even more money. Either way, making your car a proper running vehicle again will definitely justify the cost as it's virtually worthless in a non-running state.

As for other brands of engines, the only viable choice is the same engine that make and model came with from the factory. Trying to fit anything else is a whole new car of very expensive worms.

If a timing belt breaks, one of two things are likely. Either the broken belt will allow the valves and pistons of the engine to collide, instantly turning the engine to scrap. (This is what happens in what's known as an interference engine design.)

The other alternative is that the belt snaps, but no intrinsic metallic parts collide (this is the case in a non-interference engine). If that's the case, the car won't run, but if a new belt is fitted and the engine retimed, it should work perfectly afterwards.

But even in an interference engine, if the tensioner gets slack but doesn't actually allow the timing belt to jump ship or break, then there's a chance that you've avoided a catastrophic failure. The bottom line is that if your engine suffered a problem with the timing belt, but works properly after being fixed, then all should be good in the long run.

I don't think anybody these days considers less than seven years and just over 100,000km to be the lifespan of a modern engine. Certainly not in a car serviced properly. And since this is a known problem with these engines, I think you have a very good case for Hyundai to at least help out with the repairs on a pro-rata basis.

Our experience lately has been that some Hyundai dealerships have been ignoring cases like these and not giving them the consideration they perhaps should be. In any case, any decision to help out with repairs must come from head office, so I'd forget about the dealership for now and go straight to the top. Hyundai Australia has a customer service division and that's who you need to be talking to. Approaching the ACCC should be your last resort, but at least give Hyundai the chance to do the right thing by a loyal customer.

Hyundai’s Theta 2 family of engines does, indeed, have a pretty chequered track record for reliability. But it’s important to note that the majority of vehicles affected have been US-market cars with engines built in a different factory to the cars supplied to Hyundai Australia. For the record, the North American cars in question experienced debris from the engine machining process blocking the oil passages inside the engine, leading to bearing failure. In some cases, the engine failure resulted in a roadside fire.

Even though our iX35s were built in South Korea rather than North America, there’s still a chance the same problem could crop up here given that engineering materials and techniques tend to be standardised across all factories in the name of efficiency.

As you point out, your car is now out of warranty, but I wouldn’t leave it at that. I’d be talking to Hyundai’s customer service department with a view to at least getting some assistance in having the car fixed if, indeed, it was a manufacturing fault that caused the engine failure. I’d also be pointing out that 80,000km is not a realistic life expectancy for a modern engine. To get anywhere with this approach, you’ll need to be able to show that the car has been serviced by the book and (probably) that the failure was due to a loss of oil pressure that led to bearing failure.

Anything can be made to work if you throw enough money at it, but the short answer, Bassel, is no. For the 2014 model year, Hyundai upgraded the petrol engines in the iX35, and the two-litre unit in your car received a direct-injection fuel system. While the basic engine architecture might be the same and the engine would probably physically bolt in, it’s almost certain that the computer in your car would be incapable of controlling the direct fuel-injection function. Your car is also probably missing components such as wiring, a high-pressure fuel pump and sensors required to make the newer engine operate.

You could also run afoul of the authorities because the earlier engine you want to use had a (slightly) higher tailpipe emissions rating. Our regulators take a fairly dim view of a vehicle being modified and going backwards on emissions.

Intermittent problems like yours are always hard to diagnose and fix because they rarely occur when the mechanic is present to observe them. It seems as though yours has gone into limp home mode after the computer detected a fault. The only course of action is persistence until the source of the problem shows up in a diagnostic check, or when the mechanic is there to witness it.

All non-commercial used cars sold in New South Wales are by law meant to have a warranty of 3 months/5000 km if they are less than 10 years old and have done less than 160,000 km. But even if it met those criteria you have had the car for six months and the warranty would have expired.

No, we haven't had any more reports of this issue, but it sounds serious. Hyundai has fixed your car before, so I would return it as you are doing and press on them the danger of the situation you found yourself in when it happened. Lemon laws where you could get a replacement car don't exist in Australia, and the consumer laws we do have are pathetic and few people have the fortitude it takes to pursue it to the end.

The 2.5-litre petrol engine in the CX-5 will give you the zip you want. If you need oomph for towing, go for the diesel.