PI1802YZ_TSB_R4

GROUP
Product Improvement
MODEL
See Model List
on Page 1
NUMBER
PI1802Y/Z (Rev 4, 11/12/2020)
DATE
March 2020
PRODUCT IMPROVEMENT CAMPAIGN
ENGINE REPLACEMENT INSTRUCTIONS
FOR DTC P1326 (PI1802Y/Z)
SUBJECT:
 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 related to the Technical Service Bulletin previously published in
July 2018 (PI1802 Rev 10, 03/16/2020) titled “Knock Sensor Detection System - ECU Logic
Improvement” equipped w/THETA II engine. Specifically, this bulletin provides instructions on which
procedures to follow if, after installation of the KSDS, any one of the subject vehicles below returns
to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).
Model List:
Year
Model
Engine
Production Date
2014
2015-2018
2014-2018
2015-2018
Optima (TF)
Optima (TF/QF/JF/JFa)
Sportage (SL/QL)
Sorento (XMa/UMa)
2.4L GDI
2.4L & 2.0L T-GDI
2.4L & 2.0L T-GDI
2.4L & 2.0L T-GDI
8/29/13 – 4/25/14
4/16/14 – 7/11/18
9/30/13 – 4/5/18
1/3/14 – 3/7/18
If DTC P1326 is present, first perform the bearing clearance inspection with the Engine Bearing
Clearance Tester device (SST KQ231-2T110QQK). This device checks the rod bearing clearance
by placing air and vacuum into the cylinder block. Measure the bearing clearance and follow the
instructions in this bulletin. Refer to the flow chart found on page 2, then follow the appropriate
procedure as outlined in this bulletin.
A Vehicle Diagnosis Number (VDN) must be created with or without DTC P1326 after scanning
for DTCs, prior to performing PI1802Y/Z. If a VDN is not created, Warranty claim submission
issues WILL occur.
Before conducting the procedure, verify the vehicle is included in the list of affected VINs.
 NOTICE
To ensure complete customer satisfaction, always remember to refer to WebDCS Warranty
Coverage (validation) Inquiry Screen (Service → Warranty Coverage → Warranty Coverage
Inquiry) for a list of any additional campaigns that may need to be performed on the vehicle
before returning it to the customer.
Printed TSB copy is for reference only; information may be updated at any time.
Always refer to KGIS for the latest information.
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 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Flowcharts A, B and C:
Follow the applicable flowchart upon documenting customer complaint for one (1) of the
three (3) following concerns:
A. DTC P1326 Stored… (Page 2)
B. ENGINE NOISE… (Page 3)
C. ENGINE, NO CRANK… (Page 4)
A. DTC P1326 STORED
Create PI1802Y Claim – No Techline PWA Required
Confirm customer complaint
as listed in the RO and if
vehicle was towed in.
Check oil level and
document on the RO
1. Full system DTC scan and
generate VDN
2. Save Freeze frame Data
Perform BCT
BCT Result
PASS
(OK)
Repair Completed
Replace
Knock Sensor
Page 18
No
KSDS Software
Update available
NO PASS
(NG)
Check for updated
software
Yes
KDS Software
Update
Yes
Replace
Engine
KSDS Software
Update available
Check for updated
software
No
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 3 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
B. ENGINE NOISE
Techline PWA Required; Diagnosis only Campaign Possible
Confirm customer complaint
as listed in the RO and if
vehicle was towed in.
Check oil level and
document on the RO
Full system DTC scan
and generate VDN.
Perform BCT
BCT Result
PASS
NO PASS
(NG)
Replace Engine
PWA
Process
Yes
Connecting rod
bearing noise
No
Process Completed
No
Software update
available
Check updated
software
Diagnosis coverage
only; any required
repairs are to be
completed using
normal service
procedures.
Do Not Submit as a
Campaign Claim.
Yes
PI180S
KDS Software
Update
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 4 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
C. ENGINE NO CRANK
Techline PWA Required; Diagnosis only Campaign Possible
Confirm customer
complaint as listed in the
RO and if vehicle was
towed in.
Measure the
remaining oil in the
crankcase.
There must be at
least 1 quart
remaining in the
crankcase.
Full system DTC scan
and generate VDN
Remove engine
drive belt and spark
plugs
Document engine
rotational torque
VIDEO
Check Max.
Torque Value
(94 lb.ft.)
Under
94 lb.ft.
Perform BCT
Over
94 lb.ft.
See Appendix 1
on page 25.
Replace Engine
Create
PI180X Z Claim
Oil level in the
crankcase was
less than 1 liter.
PWA
Process
NO PASS
BCT Result
PASS
Process
Completed
No
KSDS Software
update available
Check for updated
software
Diagnosis coverage
only; any required
repairs are to be
completed using
normal service
procedures.
Do Not Submit as a
Campaign Claim.
Yes
PI180S
KDS Software
Update
Note: If any concerns arise after completing the flow chart(s), open a Techline case online.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 5 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Bearing Clearance Inspection Procedure:
1.
Open the hood and remove the engine
cover.
Bearing Clearance Test
Video
 IMPORTANT
Have the SST Engine Bearing
Clearance kit ready. Place it on a
table/cart next to the vehicle and
use a fender cover.
2.
For troubleshooting assistance, contact
the GITA Support Line at: (888) 542-4371.
Remove the four (4) spark plugs (A) by
referring to the “Maintenance → Power
Train → Spark Plug → Repair procedures
(Replacement)” in the applicable Shop
Manual on KGIS.
Tightening torque for Spark Plugs:
10.9 – 18.0 lb.ft (14.7 – 24.5 N.m,
1.5 – 2.5 kgf.m)
3a. Using KDS, connect the VCI-II to the
vehicle’s OBD-II port.
3b. Turn the ignition to ‘ON’.
3c. On the KDS screen, select ‘Special
Inspection’ on the bottom tab of the
Home screen.
3d. Select the applicable vehicle model/year.
The VIN is recognized automatically and
will populate the ‘Model’ and ‘Year’.
4a. Enter the vehicle information: the vehicle
mileage and RO number.
4b. Select ‘Verify’ to confirm the automatically
detected VIN.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 6 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
5a. Under “Setting Event”, select ‘Bearing
Clearance Measurement’ and then
select ‘Next’.
5b. Turn the ignition to ‘OFF’ and remove the
VCI-II after verifying the VIN on KDS.
CAUTION
DO NOT attempt to start the
engine at any time as damage to
the SST and/or engine may
occur.
6.
STOP on this screen, proceed to step 7
first before continuing to KDS.
 IMPORTANT
DO NOT select ‘Next’ at this time.
Proceed to steps 7 – 9 first and
continue with KDS as instructed
after
installing
the
SST
components.
7.
STOP
Install the Dial Gauge fully into the Probe
Rod and secure together by hand
tightening the locking wingnut.
Be sure to
completely insert
the gauge into
the probe rod as
shown.
8.
Carefully, insert the assembled SST
Probe Rod and Dial Gauge into the
Cylinder 1 spark plug hole and carefully
turn the SST Crankshaft Rotator by hand
clockwise until hand tight.
CAUTION
Damage to cylinder head can
occur if spark plug hole is crossthreaded. DO NOT use a wrench
to tighten the SST rod.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 7 of 32
SUBJECT:
9.
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Turn the Dial Gauge ‘ON’ by pressing the
‘SET’ button.
Reset the Bluetooth connection by
pressing both the ‘MODE’ and ‘SET’
buttons simultaneously and holding for
two (2) seconds.
•
BLUETOOTH
PAIRING
MODE
SET
Bluetooth icon will blink to indicate
pairing mode
10. Using the KDS, select ‘Next’ on the
screen to proceed and begin Top Dead
Center (TDC) setup on the KDS.
 NOTICE
Follow the test procedure and
sequence as outlined in this
bulletin. DO NOT skip any steps.
11. Pair the Dial Gauge Bluetooth by
selecting the device displayed on the
screen. Device name is SY303.
 IMPORTANT
If the KDS is unable to locate the
Dial Indicator Bluetooth device,
select ‘Previous’ and repeat
steps 9 - 10. Ensure no other
Bluetooth devices are near the
KDS and Dial Gauge.
12. Once the Dial Gauge is paired to the KDS,
the shown screen will appear instructing
to insert probe rod into Cylinder 1.
 NOTICE
Refer to ‘NOTICE’ Box
If the probe rod is already
inserted into Cylinder 1 from
step 8, disregard this message.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 8 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
13. Insert the SST Crankshaft Rotator and
turn the crankshaft clockwise as
instructed on the KDS screen.
 NOTICE
Removal of inner wheel liner and
the use of general tools may be
required to access and rotate the
crank bolt on some 2.0L T-GDI
engine models.
14. Initially, the “Value” ‘Max’ reading may
not register when rotating crankshaft.
Continue to rotate the crankshaft slowly.
 IMPORTANT
Monitor the displayed reading on
the KDS screen/gauge. Turn the
crankshaft slowly as the value
starts to increase.
15. Once the ‘Max’ value is reached (sample
shows Max: 2.86mm), continue to turn
just past the ‘Max’ value reading and
STOP rotating the crankshaft (sample
shows 2.850mm value decreasing).
Note: The KDS may prompt to rotate the
crankshaft ‘counterclockwise’ if needed.
Select ‘Next’.
16. If TDC setup is completed successfully:
•
DO NOT turn the crankshaft rotator.
•
DO NOT select Start at this time.
STOP on this screen, proceed to step 17
to setup and connect the Engine Bearing
Clearance Tester before continuing to the
KDS.
STOP
X
 NOTICE
If TDC is NOT found, the KDS may display a message that the cylinder was on
the exhaust stroke. If so, repeat steps 13-16.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 9 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
17. Prepare to setup the Engine Bearing
Clearance Tester and components.
 IMPORTANT
DO NOT place the SST box over any paper work (ex. RO) as there is a water drain
hole located underneath the box. Ensure that the compressed air supply
provides consistent adequate air pressure. DO NOT use a portable compressor.
Always handle the SST box with care, DO NOT hit, drop, and expose to high heat
sources or moisture. Do not remove the cover (unless calibration is necessary).
Connect the following three (3) items to
the SST Bearing Tester Box:
1. Power Cable (12V)
2. Air Compressor Hose
3. Test Hose
1
Note: The 12V power cable has red (+)
and black (-) connector clamp ends.
18. Turn the Bearing Clearance Tester power
switch to the ‘ON’ position. Gauges
should read as follow:
AP (Pressure) Gauge: (0.1 ~ .011MPa)
VC (Vacuum) Gauge: (-73 ~ -83kPa)
3. Test Hose
ON/OFF
Switch
2. Compressor Air
1. Power Cable
If the gauges do not read within
specification, calibration of the SST box is
required. Refer to TSB SST067 for details.
19. Carefully, insert and connect the other
end of the Test Hose to the Probe Rod
fitting.
 IMPORTANT
DO NOT touch or turn the Crank
Rotator in any direction until
instructed to do so on the KDS.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 10 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
20. Select ‘Start’.
 NOTICE
The procedure outlined in this
bulletin follows the engine’s
firing order sequence (1, 3, 4, 2).
1
2
3
4
21. Locate the ‘AP/VC’ switch on top of the
Bearing Clearance Tester Box and switch
it to the ‘AP’ position. Select ‘Next’ to
begin Cylinder 1 bearing clearance test.
Pressure
Vacuum
 NOTICE
The toggle switch has a 3-way
operation. The center is neutral.
Always toggle past neutral.
 IMPORTANT
DO NOT touch or turn the
Crankshaft Rotator in any
direction until instructed to do
so via KDS. DO NOT touch the
clearance gauge, if touched, an
error may occur.
22. The KDS screen will prompt to change the
‘AP/VC’ switch to the ‘VC’ position.
Select ‘Next’ to complete. There are three
(3x) rounds per cylinder to complete.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 11 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
23. Once Cylinder 1 test is completed, the
KDS will prompt to take a picture of the
tested cylinder. Select ‘Take a picture’.
24. Carefully remove the Test Hose and the
Probe Rod from Cylinder 1.
The KDS will request to insert the Probe
Rod into Cylinder 3 and prompt to find
TDC again. Repeat steps 13-16.
Repeat steps 19-23 to test Cylinder 3 and
switching from ‘AP → VC’ and take
cylinder photo.
25. Carefully remove the Test Hose and the
Probe Rod from Cylinder 3.
The KDS will request to insert the Probe
Rod into Cylinder 4 and prompt to find
TDC again. Repeat steps 13-16.
Repeat steps 19-23 to test Cylinder 4 and
switching from ‘AP → VC’ and take
cylinder photo.
26. Carefully remove the Test Hose and the
Probe Rod from Cylinder 4.
The KDS will request to insert the Probe
Rod into Cylinder 2 and prompt to find
TDC again. Repeat steps 13-16.
Repeat steps 19-23 to test Cylinder 2 and
switching from ‘AP → VC’ and take
cylinder photo.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 12 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
27. After completing the test of all four (4)
cylinders, the KDS will prompt to check
the crankcase oil level and to select the
appropriate check box on the screen.
Select ‘Next’.
28. If the test result displays “PASS”, capture
the screen image/screenshot for record
keeping.
Select ‘Finish’.
•
Re-install all removed parts in the
reverse order of removal
•
No further action is required
If the test result displays “NO PASS”,
capture the screen image/screenshot for
record keeping. Then proceed to replace
the engine assembly per the instructions.
Select ‘Finish’.
•
Proceed to page 13 to replace the
engine assembly as outlined in this
bulletin
 IMPORTANT
Save a copy of the screenshot for
your records. It may be required
to submit with a PWA (See
Appendix 1 & 2 on page 25 and
28). Attach to the RO hard copy.
 NOTICE
If the KDS is not connected to the internet, up to five (5) results will stay pending
in the queue until the KDS is reconnected with the “Special Inspection”
application open, before a sixth (6th) test can be conducted.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 13 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Engine Replacement Procedure:
1.
Remove the engine assembly by referring
to the “Engine and Transmission
(Transaxle) Assembly → Engine and
Transmission (Transaxle) Assembly →
Repair procedures” chapter in the
applicable Shop Manual on KGIS.
Refer to TSB ENG190 for information
regarding engine replacement practices.
2.
After removal of the engine from the vehicle, remove all components that will need to be
transferred by referring to the applicable Shop Manual on KGIS.
3.
Place the new engine block on an engine stand.
4.
Install all removed components from the old engine block onto the new engine block
utilizing all parts from Service Kit I and II. Be advised of the following notes.
Tightening torque for Knock Sensor:
13.7 – 17.4 lb.ft (18.6 – 23.5 N.m, 1.9 – 2.4 kgf.m)
Notes:
High Pressure Pump & Roller Tappet:
• Refer to TSB ENG083 for special
attention and handling procedures of
GDI-specific components.
• When installing the high pressure
pump and roller tappet onto the new
engine, apply engine oil to the roller
tappet, and O-rings of the high
pressure pump.
Tightening torques of pump bolts:
9.4 – 10.9 lb.ft (12.8 – 14.7 N.m,
1.3 – 1.5 kgf.m)
Tightening torques of pipe flare nut:
19.5 – 23.9 lb.ft (26.5 – 32.4 N.m,
2.7 – 3.3 kgf.m)
 NOTICE
Refer to TSB ENG083 for gasoline direct injection (GDI) specific information, including
related warnings and cautions for handling high fuel pressure system components.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 14 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
High Pressure Fuel Pipe:
1. Properly position the new fuel pipe (A)
and then hand-tighten both flare nuts
(B).
B
A
2. Install the pipe retaining bracket and
bolt (C) and torque to specifications.
 NOTICE
If the bracket and bolt are
missing, order and install a new
bracket and bolt.
C
Tightening torque (bracket bolt):
5.8 – 8.7 lb.ft (7.8 –11.8 N.m,
0.8 – 1.2 kgf.m)
3. Using a click-type/electronic torque
wrench and SST 09314-3Q100,
torque both flare nuts (B) to
specifications.
B
Tightening torque (flare nuts):
19.5 – 23.9 lb.ft (26.5 – 32.4 N.m,
2.7 – 3.3 kgf.m)
Click here to see a video tutorial of high
pressure fuel pipe install (includes high
pressure pump install).
 IMPORTANT
The high-pressure fuel pipe
bracket and bolt must be
installed AND properly torqued
prior to torqueing the highpressure fuel pipe flare nuts.
B
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 15 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Delivery Pipe:
• Refer to TSB ENG083 for special
attention and handling procedures of
GDI-specific components.
• Prior to installing the delivery pipe, be
sure to replace all of the injector Orings and injector retainers.
• Prior to installing the delivery pipe,
apply engine oil to the injector O-rings.
• When installing the delivery pipe, use
caution not to damage the tip of the
injector.
• Be sure to replace the delivery pipe
retaining bolts and torque them in the
sequence shown.
Tightening torque of bolts:
13.7 – 17.4 lb.ft (18.6 – 23.5 N.m,
1.9 – 2.4 kgf.m)
32
22
1
 NOTICE
Combustion seals must be compressed after installation and before attempting to
install into the cylinder head. Use SST 09353 2B000 (refer to TSB ENG083).
Dipstick Tube & Dipstick:
• Prior to installing the new tube,
lubricate the o-ring located at the
bottom of the tube with engine oil.
• Install the red dipstick included in
Service Kit I.
Tightening torque of bolt:
5.8 – 8.7 lb.ft (7.8 – 11.8 N.m,
0.8 - 1.2 kgf.m)
Intake Manifold:
• Prior to installation, replace the intake
manifold gaskets.
• Torque bolts in the sequence shown.
Tightening torque of bolts:
13.7 – 17.4 lb.ft (18.6 – 23.5 N.m,
1.9 – 2.4 kgf.m)
22
42
32
12
52
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 16 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Exhaust Manifold:
• All engines supplied under this
Product Improvement Campaign have
the exhaust manifold studs configured
for SULEV engines.
• Using the pictures to the right, check
the exhaust manifold stud location and
quantity. Relocate as required for
ULEV engines and obtain one (1)
extra from the removed engine.
• Prior to installation, replace the
exhaust manifold gasket and front
muffler gasket.
• Torque nuts in the sequence shown.
SULEV (7 studs)
12
42
62
72
52
32
22
ULEV (8 studs)
22
52
42
62
32
82
72
12
Tightening torque of nuts:
36.2 – 39.7 lb.ft (49.0 – 53.9 N.m,
5.0 – 5.5 kgf.m)
*For 15MY Sorento (XMa) vehicles
only: check the underhood emissions
label and record whether the label
references ULEV or SULEV. This
information is needed to select/order
the correct replacement engine.
•
On Turbo engines, replace the
turbocharger oil feed line and gaskets.
Tightening torque of oil feed line bolt:
8.7 – 13.0 lb.ft (11.8 – 17.7 N.m,
1.2 – 1.8 kgf.m)
Tightening torque of oil feed line nuts:
5.8 – 8.7 lb.ft (7.8 – 11.8 N.m,
0.8 – 1.2 kgf.m)
Tightening torque of oil drain line nuts
and bolts:
5.8 – 8.7 lb.ft (7.8 – 11.8 N.m,
0.8 – 1.2 kgf.m)
12
92
42
62
52
72
32
82
22
•
Torque exhaust manifold nuts in the
sequence shown.
Tightening torque of nuts:
36.2 – 39.7 lb.ft (49.0 – 53.9 N.m,
5.0 – 5.5 kgf.m)
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 17 of 32
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
SUBJECT:
Oil Cooler Tube Assembly:
New engines may be supplied with a
different oil cooler. Use steps below to
determine the need for a replacement oil
cooler tube assembly.
•
•
•
If the new engine’s (bigger) oil cooler
(A) does not match the old engine’s
(smaller) oil cooler (B), replace the oil
cooler tube assembly with the
improved part. See parts table on
page 23.
If the new engine’s (bigger) oil cooler
(A) matches the old engine’s (bigger)
oil cooler (A), reuse the old engine’s oil
cooler tube assembly.
If the new engine’s (smaller) oil cooler
(B) matches the old engine’s (smaller)
oil cooler (B), reuse the old engine’s oil
cooler tube assembly.
A
B
Drive Plate Bolts:
•
Replace all seven (7) drive plate (AT)
bolts.
Tightening torque of nuts:
86.8 – 93.9 lb.ft (117.7 – 125.5 N.m,
12.0 – 13.0 kgf.m)
Drive Plate Bolt (A/T)
Torque Converter
•
If the torque converter has moved
from the fully inserted position,
carefully push inward while rotating
the torque converter until it is
recessed approximately 9/16 – 5/8”
(14 – 16mm) () into the transaxle
case when reinstalling the automatic
transaxle.

Not Fully Inserted

Fully Inserted
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 18 of 32
SUBJECT:
5.
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Reinstall the assembled engine and transmission/transaxle into the vehicle.
Be sure to:
•
•
•
•
•
Fill crankcase with 5W-30 oil (~5.8 quarts).
Recommended Product: QUARTZ 9000 FUTURE FGC 5W-30 Full Synthetic SN
PLUS, QUARTZ 9000 FUTURE XT 5W30 Full Synthetic SN PLUS,
Mobil Super Synthetic 5W30 or above.
If not available, use other brand 5W30 and Full Synthetic type with API SN/SN+/SP,
ILSAC GF4/GF5 or higher service grade.
Fill and bleed the cooling system with 50/50 coolant or mixture appropriate for area.
Pressurize the fuel system before starting the vehicle.
Reset engine adaptive values and perform steering angle sensor calibration.
Refer to TSB ENG190 for information regarding engine replacement practices.
6.
Confirm that the ROM ID is up-to-date. If not, reflash the ECU to the latest ROM ID
available. Refer to PI1802 – Knock Sensor Detection System ECU Logic Improvement
7.
Verify proper operation of the vehicle with road test, and with the engine ON (running),
erase any stored DTCs (e.g., EPS, ESC, and TPMS) that may have been set by this
procedure. Verify no leaks exist and ensure engine oil and coolant are at their proper
level.
If any DTCs are still active, follow any related diagnosis and repair as needed.
Knock Sensor Replacement:
1.
Ensure the ignition is ‘OFF’.
2.
Disconnect
terminal.
the
3.
Disconnect
connector.
the
4.
Remove the intake manifold by referring
to the “Engine Mechanical System →
Intake Manifold → Repair Procedure”
chapter in the applicable Shop Manual on
KGIS.
5.
Loosen the knock sensor (A) retaining
bolt (B) and replace the knock sensor.
battery negative
knock
sensor
(-)
(A)
Torque Specification for bolt (B):
13.7 – 17.4 lb. ft. (18.6 - 23.5 N.m,
1.9 - 2.4 kgf.m)
Reinstall all removed parts in the reverse
order of removal and confirm normal
engine operation and no DTC’s.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 19 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Additional Instructions for AWD (XMa) 2.4L models:
1.
Remove the right front drive axle (A) by
detaching the brake line and ABS retainer
brackets (B) from the strut housing and
knuckle
then
remove
the
two
knuckle/strut retaining bolts (C).
B
C
2.
A
Remove the five (5) transfer case
retaining bolts (D).
Note: Three (3) located on the bottom.
D
Refer to the chapter in the applicable
Shop Manual on KGIS for torque
specifications.
Note: Two (2) located on the top.
3.
D
Remove the two (2) drive axle bracket
retaining bolts (E).
E
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 20 of 32
SUBJECT:
4.
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Using a pry bar and rubber hammer,
strike the axle where shown to release
the right front drive axle (A).
Remove the right front drive axle (A) and
set aside.
5.
A
Remove the four (4) rear driveshaft
retaining bolts (F).
F
6.
Move the transfer case to the right for
additional room to allow engine removal.
Additional Instructions for AWD (SL) 2.0L-T models:
1.
Remove the two (2) bottom damper
retaining bolts (A).
A
2.
Remove the five (5) transfer case
retaining bolts (B).
Note: Two (2) located on the top.
B
Refer to the chapter in the applicable
Shop Manual on KGIS for torque
specifications.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 21 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Note: One (1) located on the bottom left.
B
Note: Two (2) located on the bottom right.
B
3.
Remove the two (2) drive axle bracket
retaining bolts (C).
C
4.
5.
Remove the four (4) rear driveshaft
retaining bolts (D).
D
Move the transfer case to the right for
additional room to allow engine removal.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 22 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
AFFECTED VEHICLE RANGE:
Model
14MY Optima (TF)
15-18MY Optima (TF/QF/JF/JFa)
14-18MY Sportage (SL/QL)
15-18MY Sorento (XMa/UMa)
Production Date Range
August 29, 2013 through April 25, 2014
April 16, 2014 through July 11, 2018
September 30, 2013 through April 5, 2018
January 3, 2014 through March 7, 2018
REQUIRED TOOL:
Tool Name
Tool Part No.
Figure
Comments
Torque Wrench
Socket
09314 3Q100
Injector Combustion
Seal Ring Installer
09353 2B000
Click-Type or
Electronic Torque
Wrench
N/A
Locally Sourced
KQ231 2T110QQK
Auto-shipped to Dealers
For troubleshooting
assistance, contact the
GITA Support Line at:
(888) 542-4371.
Refer to TSB ENG083 for
detailed usage instructions
Bearing Clearance
Tester Kit
For replacement parts,
contact Snap-On Tools at:
(888) 542-1011.
Will be auto-shipped to dealers at
end of December 2020.
Oil Measurement
Container
SST067BUCK
For replacement parts,
contact Snap-On Tools at:
(888) 542-1011.
REQUIRED PARTS:
Part
Name
MY
2.4L GDI
2.0L T-GDI
14-15
TF
21101 2GK06QQKR
N/A
14-16
SL
21101 2GK36QQKR
21101 2GK37QQKR
QF
21101 2GK06QQKR
21101 2GK08QQKR
XMa
ULEV &
SULEV
21101 2GK11QQKR
N/A
QL
21101 2GK35QQKR
21101 2GK39QQKR
15
Engine
Long
Block
Part Number
Model
17-18
16-17
21101 2GK31QQKR
UMa
18
16-18
Figure
21101 2GK32QQKR
21101 2GK33QQKR
JF, JFa
21101 2GK34QQKR
21101 2GK32QQKR
Note: You may receive an engine with a part number ending in “QQK” when a part number
ending in “QQKR” was ordered. Both part numbers are interchangeable and acceptable
in the warranty claim.
Continued on page 23.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 23 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Models
Part Name
Engine
Part Number
2.4L GDI
21111
2GK50QQK
2.0L T-GDI
21111
2GK60QQK
2.4L GDI
21111
2GK51QQK
2.0L T-GDI
21111
2GK52QQK
2.4L GDI and
2.0L T-GDI
21111 2GK70QQK
2.4L GDI
21111 2GK71QQK
2.0L T-GDI
21111 2GK72QQK
Drive Plate
Bolts
2.4L GDI and
2.0L T-GDI
23311 25050
Oil Cooler
Tube
Assembly
(replacement is
conditional,
refer to page 17)
2.4L GDI
25470 2G050QQK
2.0L T-GDI
25470 2G650QQK
2.0L-T
39250 2G700
Figure
TF, SL, QF,
XMa
Service Kit I
UMa, QL, JF, JFa
TF, SL,
QF, XMa
Service Kit II
UMa, QL,
JF, JFa
All
All
N/A
Knock Sensor
2.4L
39250 2G100
*Oil Cooler Tube assembly replacement is conditional, refer to page 17.
 NOTICE
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should
reference PI1802Y/Z* when accessing the WebDCS system.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 24 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
WARRANTY CLAIM INFORMATION FOR:
PI1802 Y1, PI1802 Z1 AND PI180S (DIAGNOSIS ONLY CLAIMS):
 IMPORTANT
REFER TO WARRANTY BULLETIN 2020-26 (PI1802Y, Z OR 180S) FOR MODEL-SPECIFIC
LABOR OPERATIONS AND TIMES, AS WELL AS SPECIFIC CLAIM SUBMISSION
PROCEDURES. NOTE: SEE APPENDIX 1 & 2 ON PAGE 25 AND 28 FOR ADDITIONAL
TECHLINE PWA INFORMATION REQUIRED.
Flow Chart Symptom #A
Diagnostics
Repairs
R&R Knock Sensor
PI1802Y
DTC P1326
(No TL PWA Required)
BCT Pass
ECU Upgrade
Engine R&R
BCT No Pass
Engine R&R + ECU Software Update
Flow Chart Symptom #B
Diagnostics
Repairs
Inspection + Noise Check (N) (PI180S Claim)
Repairs under normal warranty coverage MAY apply.
Separate TL PWA case required
Check Oil + BCT Pass
PI1802Z
Engine Noise
(TL PWA Required)
Noise Check + TL PWA + Engine R&R
+ ECU Software Update
Check Oil + BCT
No Pass
Flow Chart Symptom #C
PI1802Z
Engine No Crank
(TL PWA Required)
Noise Check + TL PWA + Engine R&R
Engine R&R with TL PWA
Engine R&R with TL PWA + ECU Software Update
Diagnostics
Repairs
Check Oil Amount +
Check Crank Rotation
(+ 94lb.ft)
Inspection Only (PI180S Claim) – Repairs under
normal warranty coverage MAY apply – separate TL
PWA case required)
Check Oil Amount +
Crank Rotation (- 94lb.ft)
+ BCT Pass
Diagnosis Only (PI180S Claim) – Repairs under
normal warranty coverage MAY apply – separate TL
PWA case required)
Check Oil Amount +
Crank Rotation (-94lb.ft)
+ BCT No Pass
Engine R&R with TL PWA
Check Oil Amount +
Crank Rotation (+94lb.ft)
(no BCT)
Engine R&R with TL PWA
Engine R&R + ECU Software Update with TL PWA
Engine R&R + ECU Software Update with TL PWA
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 25 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Appendix 1 (Techline Prior Work Authorization)
Scenario
Description
Flowchart A
DTC P1326 Stored
Action Required
TL PWA required for all dealers – Video of condition
Video requirement examples below are for illustration
purposes, individual requirements will vary based upon
the condition reported:
Flowchart B
Engine Noise
Flowchart C
Engine Seized
Bearing Clearance Test or
No Test
• Video should be continuous and show the VIN
(most convenient VIN plate) and pan to show the
engine condition.
• For engine seizures, attempt to turn over engine
with torque wrench in video and exceeding 94 lb.ft.
• For hole in engine block, show hole in video
• For severe engine noise demonstrate severity of the
noise without over accelerating (to RPM redline) the
engine in video
Note: Additional information may be requested by the Techline agent, including but not
limited to screenshot of the stored DTC(s), ROM ID and Bearing Clearance Test (BCT)
results.
Oil Level Check: (Applies to all Flowcharts B and C)
1. Measure and record oil dip stick level.
2.
Note oil dip stick reading on the RO.
Oil Level Measurement: (Flowchart C)
1. Remove oil filler cap, remove oil drain
plug and drain oil into the supplied
measuring container SST067BUCK
and check oil level.
2.
Record oil level reading.
3.
Take photo of the oil level using KDS.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 26 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Video Instructions for Seized Engine Inspection: (Flowchart C)
Prepare the vehicle prior to the video by removing the spark plugs and drive belt as well
as setting the torque wrench to 94 lb.ft.
1.
Start video showing vehicle and move
in towards the inside door VIN tag.
2.
Continue video and move to show the
dash VIN tag.
3.
Show the removed spark plugs.
4.
Show the empty spark plug holes from
the engine.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 27 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
5.
Show the removed drive belt and
attached torque wrench to crank bolt.
6.
Show the engine being cranked and
torque specification exceeding 94
lb.ft. torque.
7.
Submit video with Techline PWA
case.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 28 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Appendix 2 (Video Capture & Upload)
Note: Additional information required to open a Techline case including but not limited
to screenshot of the stored DTC(s), ROM ID and Bearing Clearance Test (BCT) results.
The Chrome™
browser should be used to access the Techline portal. Follow the steps
below to clear the default browser if it is other than Chrome™.
For KDS Tab 10.1 Tablets:
1. Select “Settings” from the App Screen.
2.
Select the “General” tab at the top.
3.
Select “Default Applications”.
4.
If “Internet” is the default browser, select
the CLEAR button.
If “Chrome” is the default browser, further
action is not required.
5.
When opening the Techline portal, select
“Chrome” and select Always”.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 29 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
For KDS Tab S2 Tablets:
1.
Select “Settings” from the App Screen.
2.
Select “Applications”.
3.
Select “Default Applications”.
4.
Select “Browser app”.
5.
Ensure “Chrome” is selected.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 30 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
Attaching Video to a Techline Case:
1.
Open K-Support in the device Chrome™
browser or select the “Techline” button on
KDS home page.
https://ksupport.kiausa.com
2.
Open your existing Techline case for the
vehicle requiring a video capture by
selecting the case number.
3.
Select “Attachment”.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 31 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
4.
Select “Add Files”.
5.
Select “Camcorder” and the video camera
will open.
6.
Start by recording the VIN. Ensure sun
glare is not reflecting off windows or other
objects.
Without stopping the recording, capture
the area of the vehicle displaying the
issue. i.e.;
•
Engine Noise – record the engine.
•
Hole In Block – record the side of the
engine with the damage.
•
Seized Engine – record a technician
trying to turn the engine over with a
breaker bar.
 NOTICE
NOTE: Ensure the video size is set to “Limit to email”. Only record the VIN and
the engine exhibiting the concern. Any additional information will increase the size
of the video and make it difficult to upload or download.
7.
Stop the video when you captured what is
needed. Select “OK” to use this capture or
“RETRY” to capture the video again.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020
Page 32 of 32
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z)
8.
Ensure a description of the recording. For
example, engine knock or smoke from
exhaust.
9.
Select “Submit Case”.
10.
Select “Yes” when the confirmation
message below appears.
Note: Selecting anything other than
“Yes” will not save the video capture.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI1802Y/Z (Rev 4) Multiple Models March 2020