PI2102YZ_TSB

GROUP
MODEL
Subsequent Repair Action
2010-2011MY
Forte & Forte Koup
(TD)
w/2.4L MPI
NUMBER
DATE
PI2102Y/Z
May 2022
SUBSEQUENT REPAIR ACTION
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS
FOR DTC P1326 (PI2102Y/Z)
This bulletin provides information related to the Technical Service Bulletin previously published in (PI2102)
titled “Knock Sensor Detection System - ECU Logic Improvement” for 2010-2011MY Forte and Forte Koup (TD)
vehicles equipped with Theta 2.4L MPI engine, produced from February 24, 2009 through May 31, 2011.
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).
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.
Before conducting the procedure, verify the vehicle is included in the list of affected VINs.
A Vehicle Diagnosis Number (VDN) must be created with or without DTC P1326, after scanning for DTCs, prior
to performing PI2102Y/Z. If a VDN is not created, Warranty claim submission issues WILL occur.
 NOTICE
To assure 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.
A printed copy is for reference only; publication information can be updated at any time.
Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical
publications are listed in ‘Service Releases’ and has the latest service information that has been released.
Page 2 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
Flowcharts 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, always follow the BCT procedure instructions outlined in KDS. You
may also refer to SST067 for BCT Procedure/Calibration information.
A. DTC P1326 STORED
Create PI2102Y 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: PI2102Y/Z Forte (TD) May 2022
Page 3 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/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
Diagnosis coverage
only; any required
repairs are to be
completed using
normal service
procedures.
Do Not Submit as a
Campaign Claim.
Check updated
software
Yes
Refer to PI2102
(As Applicable)
PI210S
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, always follow the BCT procedure instructions outlined in KDS. You
may also refer to SST067 for BCT Procedure/Calibration information.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI2102Y/Z Forte (TD) May 2022
Page 4 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/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
PI2102 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
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
Yes
Refer to PI2102
(As Applicable)
PI210S
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, always follow the BCT procedure instructions outlined in KDS. You
may also refer to SST067 for BCT Procedure/Calibration information.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI2102Y/Z Forte (TD) May 2022
Page 5 of 18
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
SUBJECT:
Engine Replacement Procedure:
1.
Replace 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.
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.
Install all removed components from the old engine block onto the new engine block utilizing all parts
from Service Kit(s).
5.
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.
6.
•
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.
Confirm that the Rom ID is up-to-date. If not, reflash the ECU to the latest ROM ID available. Refer to
PI2102 – 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: PI2102Y/Z Forte (TD) May 2022
Page 6 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
AFFECTED VEHICLE RANGE:
Model
Production Date Rage
Forte and Forte Koup (TD)
February 24, 2009 To May 31, 2011
REQUIRED TOOL:
Tool Name
Tool Part No.
Figure
Comments
Click-Type or
Electronic Torque
N/A
Locally Sourced
Wrench
Auto-shipped to Dealers
For troubleshooting
assistance contact the
Bearing Clearance
Tester Kit
GITA Support Line at:
KQ231 2T110QQK
(888) 542-4371.
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: PI2102Y/Z Forte (TD) May 2022
Page 7 of 18
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
SUBJECT:
REQUIRED PARTS:
Part
Name
MY
Model
10-11MY
TD
Part Number
Figure
Theta 2.4L MPI
Engine
Long
21101 2G402FFF
Block
Service Kit (Theta 2.4L MPI):
Models
Part Name
Engine
Service Kit
TD
Flywheel Bolt
Knock Sensor
Part Number
Figure
21111 2G4S2FFF
23231 25200FFF
M/T *Do Not reuse bolts. (Qty. 7)
23311 25050
A/T *Do Not reuse bolts. (Qty. 7)
39250 2G700
N/A
2.4L MPI
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI2102Y/Z Forte (TD) May 2022
Page 8 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
WARRANTY INFORMATION – Flowchart “A” for DTC P1326 STORED:
N Code: N99 C Code: C99
Model
Claim
Causal
Type
P/N
Qty.
Repair
Labor Op
Description
Code
OP
Time
DTC P1326 + BCT (PASS) +
Knock Sensor R&R
212017C1
(PI2102Y)
1.0
M/H
DTC P1326 + BCT (PASS) + ECU
Software Update
TD
(PI2102Y)
(1011MY)
Theta
212017C2
R
23060
2G400
0
0.8
M/H
DTC P1326 + BCT (NO PASS) +
Engine R&R
2.4L
212017C3
(PI2102Y)
MPI
5.6
M/H
Replacement
P/N
39250 2G700
1
N/A
0
21101 2G402FFF
and
21111 2G4S2FFF
and
23231 25200FFF
DTC P1326 + BCT (NO PASS) +
Engine R&R + ECU Software
Update
212017C4
5.8
M/H
(PI2102Y)
Qty.
1
or
23311 25050
(Requires Qty.7)
WARRANTY INFORMATION – Flowchart ”B” for Engine Noise:
N Code: N99 C Code: C99
Model
Claim
Causal
Type
P/N
Qty.
Repair
Labor Op
Description
Code
OP
Time
Check Oil + BCT (PASS) +
Check Engine Noise
212017C5
(PI210S)
0.8
M/H
Check Oil + BCT (NO PASS) +
TL PWA for Engine R&R
(PI2102Z)
TD
(1011MY)
Theta
212017C6
R
2G400
TL PWA for Engine R&R +
0
Software Update
P/N
Diagnosis Only
21101 2G402FFF
212017C7
5.8
and
M/H
21111 2G4S2FFF
(PI2102Z)
and
MPI
Check Oil + BCT (PASS) +
23231 25200FFF
Engine R&R
212017C8
5.6
or
M/H
23311 25050
(Requires Qty.7)
(PI2102Z)
Check Oil + BCT (PASS) +
Check for Noise + TL PWA for
Engine R&R + ECU S/W Update
212017C9
5.8
M/H
(PI2102Z)
NOTE: Refer to Warranty Bulletin 2022-20 for details regarding coolant and substitute transportation
reimbursement requirements.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI2102Y/Z Forte (TD) May 2022
0
5.6
2.4L
Check for Noise + TL PWA
Qty.
M/H
Check Oil + BCT (NO PASS) +
23060
Replacement
1
Page 9 of 18
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
SUBJECT:
WARRANTY INFORMATION – FLOWCHART ”C” for Engine Noise:
N Code: N99 C Code: C99
Model
Claim
Causal
Type
P/N
Qty.
Repair
Labor Op
Description
Code
Check Oil + Rotate Crank
(PI210S)
212017CA
Check Oil + Rotate Crank
(Pass) + BCT (Pass)
212017CB
(PI210S)
OP
Time
0.5
M/H
1.1
M/H
Replacement
P/N
Qty.
Diagnosis Only
0
Diagnosis Only
0
Check Oil + Rotate Crank
(Pass) + BCT (NO Pass) +
TD
TL PWA for Engine R&R
(10-
(PI2102Z)
11MY)
Theta
R
2.4L
23060
2G400
MPI
212017CC
6.1
M/H
Check Oil + Rotate Crank
0
21101 2G402FFF
(Pass) + BCT (NO Pass) +
TL PWA for Engine R&R +
212017CD
Software Update
6.3
and
M/H
21111 2G4S2FFF
and
(PI2102Z)
23231 25200FFF
Check Oil + No Crank + TL
PWA for Engine R&R
212017CE
(PI2102Z)
6.7
M/H
1
or
23311 25050
(Requires Qty.7)
Check Oil + No Crank + TL
PWA for Engine R&R +
Software Update
212017CF
6.9
M/H
(PI2102Z)
NOTE: Refer to Warranty Bulletin 2022-20 for details regarding coolant and substitute transportation
reimbursement requirements.
 NOTICE
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference
PI2102* 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: PI2102Y/Z Forte (TD) May 2022
Page 10 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
WARRANTY CLAIM INFORMATION FOR:
PI2102 Y1, PI2102 Z1 and PI210S (DIAGNOSIS ONLY CLAIMS):
 IMPORTANT
REFER TO WARRANTY BULLETIN 2022-20 (PI2102Y, Z OR PI210S) FOR MODEL-SPECIFIC
LABOR OPERATIONS AND TIMES, AS WELL AS SPECIFIC CLAIM SUBMISSION
PROCEDURES. NOTE: SEE APPENDIX 1 & 2 ON PAGE 11 AND 14 FOR ADDITIONAL
TECHLINE PWA INFORMATION REQUIRED.
Flow Chart Symptom #A
Diagnostics
Repairs
R&R Knock Sensor
BCT Pass
PI2102Y
ECU Upgrade
DTC P1326
(No TL PWA Required)
Engine R&R
BCT No Pass
Engine R&R + ECU Software Update
Flow Chart Symptom #B
Diagnostics
Repairs
Inspection + Noise Check (N) (PI210S Claim)
Repairs under normal warranty coverage MAY apply.
Separate TL PWA case required
PI2102Z
Check Oil + BCT Pass
Engine Noise
Noise Check + TL PWA + Engine R&R
(TL PWA Required)
+ ECU Software Update
Check Oil + BCT
No Pass
Flow Chart Symptom #C
Check Oil Amount +
(+ 94lb.ft)
Check Oil Amount +
Crank Rotation (- 94lb.ft)
PI2102Z
(TL PWA Required)
Engine R&R with TL PWA
Engine R&R with TL PWA + ECU Software Update
Diagnostics
Check Crank Rotation
Engine No Crank
Noise Check + TL PWA + Engine R&R
+ BCT Pass
Check Oil Amount +
Repairs
Inspection Only (PI210S Claim) – Repairs under
normal warranty coverage MAY apply – separate TL
PWA case required)
Diagnosis Only (PI210S Claim) – Repairs under
normal warranty coverage MAY apply – separate TL
PWA case required)
Engine R&R with TL PWA
Crank Rotation (-94lb.ft)
+ BCT No Pass
Check Oil Amount +
Engine R&R + ECU Software Update with TL PWA
Engine R&R with TL PWA
Crank Rotation (+94lb.ft)
(no BCT)
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: PI2102Y/Z Forte (TD) May 2022
Page 11 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/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
Engine Seized
Flowchart C
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: PI2102Y/Z Forte (TD) May 2022
Page 12 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/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 dash VIN tag.
2.
Show the removed spark plugs.
3.
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: PI2102Y/Z Forte (TD) May 2022
Page 13 of 18
SUBJECT:
5.
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
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: PI2102Y/Z Forte (TD) May 2022
Page 14 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/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: PI2102Y/Z Forte (TD) May 2022
Page 15 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/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: PI2102Y/Z Forte (TD) May 2022
Page 16 of 18
SUBJECT:
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/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”.
4.
Select “Add Files”.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI2102Y/Z Forte (TD) May 2022
Page 17 of 18
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
SUBJECT:
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.
8.
Ensure a description of the recording. For
example, engine knock or smoke from
exhaust.
9.
Select “Submit Case”.
Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information.
TSB: PI2102Y/Z Forte (TD) May 2022
Page 18 of 18
SUBJECT:
10.
ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI2102Y/Z)
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: PI2102Y/Z Forte (TD) May 2022