TSB-ENG159R1

GROUP
ENG
NUMBER
159 (Rev 1, 03/23/2017)
MODEL
2016MY
Optima (JF/JFa)
2017MY
Sportage (QL)
2016-2017MY
Sorento (UMa)
DATE
September 2016
TECHNICAL SERVICE BULLETIN
SUBJECT:
E-CVVT COVER AND MOTOR PLUG REPLACEMENT
 NOTICE
This bulletin has been revised to include additional information. New/revised
sections of this bulletin are indicated by a black bar in the margin area.
This bulletin provides information about the replacement of the E-CVVT cover and motor plug
on some 2016MY Optima (JF/JFa), produced from August 29, 2015 to June 14, 2016, 2017MY
Sportage (QL) vehicles, produced from December 10, 2015 to June 15, 2016, and 20162017MY Sorento (UMa), produced from October 27, 2014 to June 14, 2016, which may exhibit
a MIL ON with DTC P001000 and/or oil leakage in the E-CVVT motor plug of applicable vehicle
models equipped with 2.4L GDI or 2.0 T-GDI engines. Follow the procedure outlined in this
bulletin to replace the E-CVVT cover and motor plug to correct the concern.
P001000: ‘A(Intake)’ Camshaft Position Actuator Circuit (Bank 1)
File Under: 
Circulate To:
X General Manager

X Service Advisors

X Technicians

X Service Manager

X Parts Manager

X Body Shop Manager 
X Fleet Repair

Page 2 of 8
SUBJECT:
E-CVVT COVER AND MOTOR PLUG REPLACEMENT
Service Procedure:
1. Carefully place a jack at the bottom edge of the oil pan and support the engine for
removal of the engine mounts.
CAUTION
Place a wooden or rubber block between the oil pan and the jack to prevent
damaging the oil pan.
 NOTICE
Allow sufficient time for the oil to drain from behind the motor plug before
removal of the plug in step 7.
2.
Loosen three (3) engine mounting
support bracket retaining nuts (A) and
one (1) retaining bolt (B).
Tightening torque:
65.1 - 79.6 lb·ft (88. 3 - 107.9 Nm)
B
A
3.
Loose two (2) engine mounting bracket
retaining nuts (C) and two (2) retaining
bolts (D).
Tightening torque:
47.0 - 61.5 lb·ft (63.7 - 83.3 Nm)
D
C
TSB: ENG159 (Rev 1) Optima (JF/JFa), Sportage (QL), Sorento (UMa) September 2016
Page 3 of 8
SUBJECT:
4.
E-CVVT COVER AND MOTOR PLUG REPLACEMENT
Loosen six (6) engine support bracket
retaining bolts (E).
Tightening torque:
(A): 28.9 - 32.5 lb∙ft (39.2 - 44.1 Nm)
(B): 14.5 - 18.1 lb∙ft (19.6 - 24.5 Nm)
B
A
E
5.
Disconnect
the
connector (F).
E-CVVT
cover
F
6.
Loosen and remove the four (4) ECVVT cover retaining bolts (G) and
then remove the E-CVVT cover.
Remove the cover plug (H) using a
non-marring trim tool (this plug will be
reused).
G
H
Tightening torque:
7.2 - 8.7 lb∙ft (9.8 - 11.8 Nm)
CAUTION
G
Use a non-marring trim removal
tool (Such as Snap-on® Part
Number PBN5 or equivalent) to
avoid damaging the cover plug.
TSB: ENG159 (Rev 1) Optima (JF/JFa), Sportage (QL), Sorento (UMa) September 2016
Page 4 of 8
SUBJECT:
7.
E-CVVT COVER AND MOTOR PLUG REPLACEMENT
Remove the motor plug (I) by carefully
breaking the center with a straight pick.
 NOTICE
Wipe off any oil leakage when
removing the motor plug.
Cover the motor shaft inlet with
a clean shop towel.
8.
Using brake cleaner, spray directly on
the motor plug assembly seat inside
the motor shaft and clean. Spray brake
cleaner on a shop towel to wipe and
clean the commutators (K).
I
K
 NOTICE
Remove any residual oil or fluid
in the motor shaft to prevent
plug from becoming displaced.
 NOTICE
Protect
the
E-CVVT
as
necessary
to
prevent
oil
contamination when spraying
brake cleaner.
TSB: ENG159 (Rev 1) Optima (JF/JFa), Sportage (QL), Sorento (UMa) September 2016
J
Page 5 of 8
SUBJECT:
9.
E-CVVT COVER AND MOTOR PLUG REPLACEMENT
Apply oil to the oil seal lip of the new
E-CVVT cover and install the SST “B”
to the E-CVVT motor as shown.
 NOTICE
When installing the cover,
correctly insert the end of the
SST to the motor shaft as
shown below. Ensure that the
SST hole faces towards the
motor shaft.
CAUTION
Use caution not to fold the oil
seal when installing the cover.
SST INSERTED
INCORRECTLY
SST INSERTED
CORRECTLY
E-CVVT removed from vehicle
for demonstration only purposes.
10. Install the new E-CVVT cover and
perform initial tightening sequence of
the E-CVVT cover to the specified
torque in the sequence below.
L
1
Tightening torque:
8.4 – 16.8 in∙lb (1.0 - 2.0 Nm)
 NOTICE
Tighten the retaining bolts in this
sequence: 1 → 3 → 4 → 2
2
4
3
TSB: ENG159 (Rev 1) Optima (JF/JFa), Sportage (QL), Sorento (UMa) September 2016
Page 6 of 8
SUBJECT:
E-CVVT COVER AND MOTOR PLUG REPLACEMENT
11. Install the new motor plug (M) by using
the SST “A” of Required Tools.
 NOTICE
M
Insert the plug onto the SST and
then insert the SST into the ECVVT cover opening.
CAUTION
Do not apply impurities (oil,
cleaners) on the motor plug.
12. Remove the SST and perform final
tightening sequence of the E-CVVT
cover retaining bolts to the specified
torque in the sequence below.
1
Tightening torque:
7.2 - 8.7 lb∙ft (9.8 - 11.8 Nm)
 NOTICE
2
4
Tighten the retaining bolts in
this sequence: 1 → 3 → 4 → 2
3
13. Reinstall all removed components by
reversing the order of removal.
Start and run the engine to confirm
proper operation, no oil leakage, and
clear any related DTC(s).
 NOTICE
A video clip is available to aid technicians in completing this repair. Access the Tech
Videos in the Publication section of KGIS and look under Engine Mechanical System
for “[VID012]2016 Sorento (UMa), Optima (JFa), Sportage (QL) – E-CVVT Cover &
Motor Plug Installer”.
TSB: ENG159 (Rev 1) Optima (JF/JFa), Sportage (QL), Sorento (UMa) September 2016
Page 7 of 8
SUBJECT:
E-CVVT COVER AND MOTOR PLUG REPLACEMENT
AFFECTED VEHICLE RANGE:
Model
Production Date Range
Sorento (UMa)
From October 27, 2014 to June 14, 2016
Optima (JF, JFa)
From August 29, 2015 to June 14, 2016
Sportage (QL)
From December 10, 2015 to June 15, 2016
REQUIRED TOOLS:
Part
SST
Part
Number
A
Figure
B
09243
C1000
C
Remarks
A: E-CVVT
Plug Installer
N/A
B: E-CVVT
Cover Installer
A: E-CVVT
Plug Installer
SST
09243
C2000
B: E-CVVT
Cover Installer
C: Handle
Brake
Cleaner
UM040
CH018
Order through
Kia Chemicals
 NOTICE
SST 09243 C1000 or 09243 C2000 can be used for this repair.
TSB: ENG159 (Rev 1) Optima (JF/JFa), Sportage (QL), Sorento (UMa) September 2016
Page 8 of 8
E-CVVT COVER AND MOTOR PLUG REPLACEMENT
SUBJECT:
PARTS INFORMATION:
Part Number & Figure
Previous
New
Part Name
Remarks
Brown → Black
Motor Plug
24351 2GGA0
24351 2GGA1
Center boss height
tolerance changed
E-CVVT Cover
24360 2GGA0
24360 2GGB0
WARRANTY INFORMATION:
N CODE: E74 C CODE: ZZ2
Model
Claim
Type
Causal
P/N
Qty.
Repair
Description
Labor Op
Code
Op
Time
Replacement
P/N
Qty.
24360F01
0.7
M/H
0
(ENG 159)
E-CVVT Cover
& Motor Plug
Replacement
24351 2GGA1
24360 2GGB0
1
1
24360F02
0.8
M/H
24351 2GGA1
1
24360 2GGB0
1
QL, UMa
W
JF, JFa
24351
2GGA0
TSB: ENG159 (Rev 1) Optima (JF/JFa), Sportage (QL), Sorento (UMa) September 2016