This is not an uncommon thing with some Hyundai models of this vintage. Because of either poor design or materials, some Hyundai engines wear faster than they should. The first signs are rough running, noisy operation and oil consumption. On that basis, I reckon you may have one of those affected engines. That’s supported by the borescope examination that showed wear and the fact that the engine needed two litres of oil to bring it back to a normal level.

It's a fair bet the 1000km monitoring will show the engine has a thirst for oil, at which point it probably needs to be either replaced or rebuilt. My experience suggests that Hyundai is taking this seriously and is replacing engines under warranty with an improved unit that should last much better.

Give the dealership every chance to figure out what’s actually happening under the bonnet and then the time to make it right. You now have what’s called a pre-existing issue, so even if the warranty runs out, Hyundai knows the problem occurred while still within the warranty period. If your case is denied, then it’s time to contact Hyundai Australia’s customer service department and then, if you still don’t have any luck the ACCC which administers Australian Consumer Law and will be well versed with this issue.

The first thing to check here is what’s called the clock spring. This is an electrical connector inside the steering wheel that allows the wheel to be turned to full lock and back while still allowing for electrical contact between the airbag and the rest of the car.

If this spring fails, the connection between the airbag and the systems that would trigger it in a crash are lost. Which means that in a big enough collision, the airbag would not fire and protect the driver.

Clock spring replacement is relatively simple but it’s still a job best left to the pros, as any time you’re messing with an airbag, you’re playing with a fairly violent explosive component. Get it wrong and accidentally fire the airbag, and you could be seriously injured.

I’ll assume it’s a Hyundai dealership that wants to charge you to assess the car. And I hear what you’re saying about the car’s service history and the fact that some of these engines have been fixed by Hyundai because they were faulty from new. So, the best advice is to forget about the dealership and go straight to Hyundai’s customer service department at head office.

That cuts out the middle man at the dealership and should get you in touch with somebody who knows whether your car was one of the affected ones or whether you’ve just been unlucky in this instance. My experience has been that Hyundai takes this stuff very seriously and has helped other owners in the past. However, your case will still be assessed according to the service history and how many kilometres the car has covered.