PI2002YZ_TSB
Service Bulletin Details
Public Details for: PI2002YZ_TSB
Technical service bulletin: engine replacement instructions for dtc P1326 (pi2002y/z) - this bulletin provides information related to the technical service bulletin previously published in january 2021 (pi2002a and pi2002b, august 2020) tit
- 2016 - 2015 - 2014 - 2013 - 2012 -
Models from 2016
2016 KIA SOUL |
Models from 2015
2015 KIA SOUL |
Models from 2014
2014 KIA SOUL |
Models from 2013
2013 KIA SOUL |
Models from 2012
2012 KIA SOUL |
GROUP Product Improvement MODEL See Model List on Page 1 NUMBER PI2002Y/Z DATE April 2021 PRODUCT IMPROVEMENT CAMPAIGN ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) SUBJECT: This bulletin provides information related to the Technical Service Bulletin previously published in January 2021 (PI2002A and PI2002B, August 2020) titled “Knock Sensor Detection System - ECU Logic Improvement”. Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below return to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance). Model List: Year Model Engine Production Date 2012-2013 Soul (AM) Gamma 1.6L GDI July 8, 2011 to October 2, 2013 2014-2016 Soul (PS) Gamma 1.6L GDI July 26, 2013 to August 11, 2016 2014-2016 Soul (PS) NU 2.0L GDI July 21, 2013 to August 11, 2016 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 pages 2-4, 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 PI2002Y/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 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) Flowchart(s) A/B/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) IMPORTANT Due to recent updates to KDS, the BCT procedure screenshots outlined in this bulletin may differ from current instructions outlined in KDS. Always follow the procedure in KDS to perform the BCT. This publication will be revised as new updates are provided. A. DTC P1326 STORED Create PI2002Y 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 Note: If any concerns arise during/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 3 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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) PWA Process Replace Engine Yes Connecting rod bearing noise No Process Completed No Software update available Yes KDS Software Update Diagnosis coverage only; any required repairs are to be completed using normal service procedures. Do Not Submit as a Campaign Claim. Check updated software Refer to PI2002A/B (As Applicable) PI180S Note: If any concerns arise during/after completing the flow chart(s), open a Techline case online. IMPORTANT Due to recent updates to KDS, the BCT procedure screenshots outlined in this bulletin may differ from current instructions outlined in KDS. Always follow the procedure in KDS to perform the BCT. This publication will be revised as new updates are provided. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 4 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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 __. Replace Engine Create PI2002 Claim Oil level in the crankcase was less than 1 quart. PWA Process NO PASS BCT Result PASS Process Completed No KSDS Software update available Yes Diagnosis coverage only; any required repairs are to be completed using normal service procedures. Do Not Submit as a Campaign Claim. Check for updated software Refer to PI2002A/B (As Applicable) PI180S KDS Software Update Note: If any concerns arise during/after completing the flow chart(s), open a Techline case online. IMPORTANT Due to recent updates to KDS, the BCT procedure screenshots outlined in this bulletin may differ from current instructions outlined in KDS. Always follow the procedure in KDS to perform the BCT. This publication will be revised as new updates are provided. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 5 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) ADDITION OF BLUE LOCTITE TO BCT MEASURING POINT This outline provides information regarding the application of Loctite® Threadlocker Blue 242 to the dial gauge ‘measuring point’ end included in the Engine Bearing Clearance Tester (BCT) kit SST KQ231 2T110QQK. This extra step helps reduce the possibility of the measuring point tip loosening on the dial gauge due to repeated use. If measuring tip comes loose, inaccurate BCT measuring readings will result. This tool remedy should only need to be performed once. Probe Rod Instructions: 1. Unscrew the ‘measuring point’ end (A) from the base of the dial gauge. 2. Apply one drop of blue Loctite® to the threaded end of the ‘measuring point’. 3. Reinstall the ‘measuring point’ end back onto the dial gauge finger tight. 4. Fully insert the dial gauge into the probe rod. 5. Secure the gauge to the probe rod by tightening the locking wing nut by hand. 6. Test gauge operation by pressing the lower bar of the probe rod inward and verify the gauge readings correspond with the movement of the lower bar. (BCT) Dial Gauge Measuring Point (A) Loctite® Threadlocker A For replacement parts, contact Snap-On Tools at (888) 542-1011. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 6 of 34 SUBJECT: 1. ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) 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. Use air gun to blow off any debris from the engine top area. 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: PI2002Y/Z Soul (AM, PS) April 2021 Page 7 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 8 of 34 SUBJECT: 9. ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 9 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 10 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 11 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 12 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 13 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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 14 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. 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: PI2002Y/Z Soul (AM, PS) April 2021 Page 14 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) Engine Replacement Procedure: 1. Remove the engine assembly by referring to the “Engine Mechanical System → Engine And Transmission (Transaxle) Assembly → Sub & Long Engine Assembly → Repair procedures” chapter in the applicable Shop Manual on KGIS. Refer to TSB ENG190 for information regarding engine replacement practices. Note: 1.6L Gamma Engine images shown for reference use only. 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 long 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(s). 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: PI2002Y/Z Soul (AM, PS) April 2021 Page 15 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) High Pressure Fuel Pipe: B 1. Properly position the new fuel pipe (A) and then hand-tighten both flare nuts (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 high pressure 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: PI2002Y/Z Soul (AM, PS) April 2021 Page 16 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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) 3 2 1 4 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. 12 32 42 22 Tightening torque of bolts: 13.7 – 17.4 lb.ft (18.6 – 23.5 N.m, 1.9 – 2.4 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: PI2002Y/Z Soul (AM, PS) April 2021 52 Page 17 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) Exhaust Manifold Protector: Tightening torques : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lbft) 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. • Refer to KGIS for torque sequence. Tightening torque of nuts: 36.2 – 39.7 lb.ft (49.0 – 53.9 N.m, 5.0 – 5.5 kgf.m) Re-use Drive Plate 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) Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 18 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) 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 Note: In the case of a seized engine (Crank Rotation – NG), the torque converter bolts can be removed by following below procedure. 1. Disassemble the transmission from the engine by loosening engine/transmission housing retaining bolts. 2. When disassembling the transmission from the engine, transmission will leaked. *Transmission oil needs to be suplemented. (Allowed capacity of mission oil is ‘Maximum 1L’.) 3. Insert a prye bar between drive plate & cylinder block. Push the prye bar to make space where spanner reaches to the torque converter bolts. To maintain the space, put the wedge as shown on the right photo. 4. By using spanner, loosen all torque converter bolts.. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 19 of 34 SUBJECT: 5. ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) Reinstall the assembled engine and transmission/transaxle into the vehicle. Be sure to: • • • • • Fill crankcase with 5W-30 oil (refer to KGIS for oil fill level requirements) 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 PI2002A/B – 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. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 20 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) AFFECTED VEHICLE RANGE: Model Soul (AM) Production Date Range July 8, 2011 to October 2, 2013 July 26, 2013 to August 11, 2016 July 21, 2013 to August 11, 2016 Soul (PS) REQUIRED TOOL: Tool Name Tool Part No. Torque Wrench Socket 09314 3Q100 Figure Comments Refer to TSB ENG083 for detailed usage instructions 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. Bearing Clearance Tester Kit For replacement parts, contact Snap-On Tools at: (888) 542-1011. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 21 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) REQUIRED PARTS: Part Name Engine Long Block Part Name Engine Long Block MY Part Number Model Gamma 1.6L GDI AM 21101 2BK01FFFR* AM (Soul Eco ISG Only) 21101 2BK02FFFR* 14-16MY PS 21101 2BK03FFFR* MY Model Figure 12-13MY Part Number Nu 2.0L GDI PS 21101 2EG01FFFR* PS (Soul Eco ISG Only) 21101 2EG02FFFR* Figure 14-16MY *Note: You may receive an engine with a part number ending in “FFF” when a part number ending in FFFR” was ordered. Both part numbers are interchangeable and acceptable in the warranty claim. Service Kits (Gamma 1.6L GDI): Models Part Name Engine Part Number Figure 21111 2BS01FFF Service Kit I 1.6L GDI Service Kit II 21112 2BS01FFF Fuel Tube 35305 2B000FFF AM, PS 1.6L GDI Knock Sensor 39250 2B000 N/A Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 22 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) Service Kit (Nu 2.0L GDI): Models Part Name Engine Service Kit PS Fuel Tube Part Number Figure 21111 2EG01FFF 2.0L GDI Knock Sensor 35305 2E510FFF 39250 2E000 N/A Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 23 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) WARRANTY INFORMATION – FLOWCHART “A” DTC P1326 STORED: N Code: N99 C Code: C99 Model AM (1213MY) Gamma 1.6L PS (1416MY) Gamma 1.6L PS (1416MY) Nu. 2.0L Claim Type R R R Causal P/N Qty. 0 0 0 Repair Description Labor Op Code OP Time Replacement P/N Qty. DTC P1326 + BCT (PASS) + Knock Sensor R&R (PI2002Y) 212221R5 1.5 M/H 39250 2B000 1 DTC P1326 + BCT (PASS) + ECU Software Update (PI2002Y) 212221R6 0.8 M/H N/A 0 DTC P1326 + BCT (NO PASS) + Engine R&R (PI2002Y) 212221R7 7.2 M/H 21101 2BK01FFFR or 21101 2BK02FFFR (Soul Eco ISG Only) 1 DTC P1326 + BCT (NO PASS) + Engine R&R + ECU Software Update (PI2002Y) 212221R8 7.4 M/H 35305 2B000FFF 21111 2BS01FFF 21112 2BS01FFF DTC P1326 + BCT (PASS) + Knock Sensor R&R (PI2002Y) 212221RH 1.5 M/H 39250 2B000 1 DTC P1326 + BCT (PASS) + ECU Software Update (PI2002Y) 212221RI 0.8 M/H N/A 0 DTC P1326 + BCT (NO PASS) + Engine R&R (PI2002Y) 212221RJ 7.2 M/H 21101 2BK03FFFR 35305 2B000FFF 21111 2BS01FFF 21112 2BS01FFF 1 DTC P1326 + BCT (NO PASS) + Engine R&R + ECU Software Update (PI2002Y) 212221RK 7.4 M/H DTC P1326 + BCT (PASS) + Knock Sensor R&R (PI2002Y) 212220R5 1.5 M/H 39250 2E000 1 DTC P1326 + BCT (PASS) + ECU Software Update (PI2002Y) 212220R6 0.8 M/H N/A 0 DTC P1326 + BCT (NO PASS) + Engine R&R (PI2002Y) 212220R7 7.2 M/H 21101 2EG01FFFR or 21101 2EG02FFFR (Soul Eco ISG Only) 1 DTC P1326 + BCT (NO PASS) + Engine R&R + ECU Software Update (PI2002Y) 212220R8 7.4 M/H 21111 2EG01FFF 35305 2E510FFF Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 24 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) WARRANTY INFORMATION – FLOWCHART ”B” ENGINE NOISE N Code: N99 C Code: C99 Model AM (1213MY) Gamma 1.6L PS (1416MY) Gamma 1.6L PS (1416MY) Nu. 2.0L Claim Type R R R Causal P/N Qty. Repair Description 0 Check Oil + BCT (PASS) + Check Engine Noise (PI180S) Check Oil + BCT (NO PASS) + TL PWA for Engine R&R (PI2002Z) Check Oil + BCT (NO PASS) + TL PWA for Engine R&R + Software Update (PI2002Z) Check Oil + BCT (PASS) + Check for Noise + TL PWA Engine R&R (PI2002Z) Check Oil + BCT (PASS) + Check for Noise + TL PWA for Engine R&R + ECU Software Update (PI2002Z) 0 0 Labor Op Code OP Time Replacement P/N Qty. 212221RP 0.8 M/H Diagnosis Only 0 212221R9 7.2 M/H 212221RA 7.4 M/H 21101 2BK01FFFR or 21101 2BK02FFFR (Soul Eco ISG Only) 1 212221RB 7.2 M/H 35305 2B000FFF 21111 2BS01FFF 21112 2BS01FFF 212221RC 7.4 M/H Check Oil + BCT (PASS) + Check Engine Noise (PI180S) 212221RQ 0.8 M/H Check Oil + BCT (NO PASS) + TL PWA for Engine R&R (PI2002Z) 212221RL 7.2 M/H 212221RM 7.4 M/H Check Oil + BCT (NO PASS) + TL PWA for Engine R&R + Software Update (PI2002Z) Check Oil + BCT (PASS) + Check for Noise + TL PWA Engine R&R (PI2002Z) Check Oil + BCT (PASS) + Check for Noise + TL PWA for Engine R&R + ECU Software Update (PI2002Z) 212221RN 7.2 M/H 212221RO 7.4 M/H Check Oil + BCT (PASS) + Check Engine Noise (PI180S) 212220RP 0.8 M/H Check Oil + BCT (NO PASS) + TL PWA for Engine R&R (PI2002Z) 212220R9 7.2 M/H 212220RA 7.4 M/H 212220RB 7.2 M/H 212220RC 7.4 M/H Check Oil + BCT (NO PASS) + TL PWA for Engine R&R + Software Update (PI2002Z) Check Oil + BCT (PASS) + Check for Noise + TL PWA Engine R&R (PI2002Z) Check Oil + BCT (PASS) + Check for Noise + TL PWA for Engine R&R + ECU Software Update (PI2002Z) Diagnosis Only 0 21101 2BK03FFFR 35305 2B000FFF 21111 2BS01FFF 21112 2BS01FFF 1 Diagnosis Only 0 21101 2EG01FFFR or 21101 2EG02FFFR (Soul Eco ISG Only) 1 21111 2EG01FFF 35305 2E510FFF Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 25 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) WARRANTY INFORMATION – FLOWCHART “C” (NO CRANK): N Code: N99 C Code: C99 Model AM (1213MY) Gamma 1.6L PS (1416MY) Gamma 1.6L PS (1416MY) Nu. 2.0L Claim Type R R R Causal P/N Qty. 0 0 0 Repair Description Check Oil + Rotate Crank (PI80S) Check Oil + Rotate Crank (Pass) + BCT (Pass) (PI180S) Check Oil + Rotate Crank (Pass) + BCT (NO Pass) + TL PWA for Engine R&R (PI2002Z) Check Oil + Rotate Crank (Pass) + BCT (NO Pass) + TL PWA for Engine R&R + Software Update (PI2002Z) Check Oil + No Crank + TL PWA for Engine R&R (PI2002Z) Check Oil + No Crank + TL PWA for Engine R&R + Software Update (PI2002Z) Check Oil + Rotate Crank (PI180S) Check Oil + Rotate Crank (Pass) + BCT (Pass) (PI180S) Check Oil + Rotate Crank (Pass) + BCT (NO Pass) + TL PWA for Engine R&R (PI2002Z) Check Oil + Rotate Crank (Pass) + BCT (NO Pass) + TL PWA for Engine R&R + Software Update (PI2002Z) Check Oil + No Crank + TL PWA for Engine R&R (PI2002Z) Check Oil + No Crank + TL PWA for Engine R&R + Software Update (PI2002Z) Check Oil + Rotate Crank (PI180S) Check Oil + Rotate Crank (Pass) + BCT (Pass) (PI180S) Check Oil + Rotate Crank (Pass) + BCT (NO Pass) + TL PWA for Engine R&R (PI2002Z) Check Oil + Rotate Crank (Pass) + BCT (NO Pass) + TL PWA for Engine R&R + Software Update (PI2002Z) Check Oil + No Crank + TL PWA for Engine R&R (PI2002Z) Check Oil + No Crank + TL PWA for Engine R&R + Software Update (PI2002Z) Labor Op Code OP Time Replacement P/N Qty. 212221RR 0.5 M/H Diagnosis Only 0 212221RS 1.1 M/H Diagnosis Only 0 212221R1 7.7 M/H 212221R2 7.9 M/H 21101 2BK01FFFR or 21101 2BK02FFFR (Soul Eco ISG Only) 1 35305 2B000FFF 21111 2BS01FFF 21112 2BS01FFF 212221R3 7.4 M/H 212221R4 7.6 M/H 212221RT 0.5 M/H Diagnosis Only 0 212221RU 1.1 M/H Diagnosis Only 0 212221RD 7.7 M/H 212221RE 7.9 M/H 21101 2BK03FFFR 35305 2B000FFF 21111 2BS01FFF 21112 2BS01FFF 1 212221RF 7.4 M/H 212221RG 7.6 M/H 212220RR 0.5 M/H Diagnosis Only 0 212220RS 1.1 M/H Diagnosis Only 0 212220R1 7.7 M/H 212220R2 7.9 M/H 21101 2EG01FFFR or 21101 2EG02FFFR (Soul Eco ISG Only) 1 212220R3 7.4 M/H 212220R4 7.6 M/H 21111 2EG01FFF 35305 2E510FFF Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 26 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) NOTE: Refer to Warranty Bulletin 2021-07 for details regarding coolant and substitute transportation reimbursement requirements. Use sublet code ‘X3’ with a maximum allowed amount of $19.80 for “ENGINE R&R” engine oil reimbursement. Dispose of old parts in accordance with local, state, and Federal regulations. NOTICE VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference PI12002* when accessing the WebDCS system. WARRANTY CLAIM INFORMATION FOR: PI2002 Y1, PI2002 Z1 AND PI180S (DIAGNOSIS ONLY CLAIMS): IMPORTANT REFER TO WARRANTY BULLETIN 2021-07 (PI2002Y, Z OR 180S) FOR MODEL-SPECIFIC LABOR OPERATIONS AND TIMES, AS WELL AS SPECIFIC CLAIM SUBMISSION PROCEDURES. NOTE: SEE APPENDIX 1 & 2 ON PAGE 27 AND 30 FOR ADDITIONAL TECHLINE PWA INFORMATION REQUIRED. Flow Chart Symptom #A Diagnostics Repairs R&R Knock Sensor BCT Pass PI2002Y DTC P1326 (No TL PWA Required) 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 PI2002Z Engine Noise (TL PWA Required) Noise Check + TL PWA + Engine R&R + ECU Software Update Check Oil + BCT No Pass Flow Chart Symptom #C PI2002Z 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) + BC T 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: PI2002Y/Z Soul (AM, PS) April 2021 Page 27 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 28 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI2002Y/Z Soul (AM, PS) April 2021 Page 29 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/Z) 4. Show the empty spark plug holes from the engine. 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: PI2002Y/Z Soul (AM, PS) April 2021 Page 30 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 31 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 32 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021 Page 33 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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 torque wrench. 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: PI2002Y/Z Soul (AM, PS) April 2021 Page 34 of 34 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2002Y/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: PI2002Y/Z Soul (AM, PS) April 2021