PI1805YZ_TSB
Service Bulletin Details
Public Details for: PI1805YZ_TSB
Technical service bulletin: product improvement (pi1805y/z) - this bulletin provides information related to the technical service bulletin previously published in (pi1805) titled "knock sensor detection system - ecu logic improvement
- 2019 -
Models from 2019
2019 KIA OPTIMA |
2019 KIA SORENTO |
2019 KIA SPORTAGE |
GROUP MODEL Subsequent Repair Action 2019MY Optima (JFa), Sorento (UMa), and Sportage (QL) NUMBER DATE PI1805Y/Z January 2024 SUBSEQUENT REPAIR ACTION SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) This bulletin provides information related to the Technical Service Bulletin previously published in (PI1805) titled “Knock Sensor Detection System - ECU Logic Improvement” for certain 2019MY Optima (JFa), Sorento (UMa) and Sportage (QL) vehicles equipped with a 2.4L GDI or 2.0L T-GDI engine (Refer to page 9 for production dates). 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. Before conducting the procedure, verify the vehicle is included in the list of affected VINs. Refer to the flowcharts found on pages 2-6, then follow the appropriate procedure as outlined in this bulletin. Note: Certain limitations may apply to this Product Improvement Campaign coverage. Refer to Warranty Bulletin 2024-02 for more details. IMPORTANT A Vehicle Diagnosis Number (VDN) must be created with or without DTC P1326, after scanning for DTCs, prior to performing PI1805Y/Z. If a VDN is not created, Warranty claim submission issues WILL occur. NOTICE To assure complete customer satisfaction, always remember to refer to KDealer+ 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 17 ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) SUBJECT: Main Flowchart: Vehicle In Validate Warranty Confirm customer complaint as listed on the RO and note on the RO if vehicle was towed in. Oil Dipstick/Oil Cap & Oil Filler Opening Inspection Using KDS, record video and take (3) photos of: Oil Inspection (NG) 1. Oil Dipstick Reading 2. Inside Oil Filler Cap 3. Inside Oil Filler Opening Oil Inspection (OK) (Refer to Page 3 & Appendix 1 for Additional Instructions) Open Techline Repair Assistance (RA) Be prepared to submit all required documentation. (Refer to Appendix 1) KSDS Installed or DTC P1326 Stored Refer to the applicable Flowchart A,B or C (Per Appendix 2) Maintenance Verified OK Techline Verification of Proper Maintenance Per Appendix 1 Request Maintenance Records from Customer In Writing Receipt Due Within 10 Days NG No Repair Coverage Diagnosis Claim Only P180S Vehicle Out Follow the applicable flowchart upon documenting customer complaint for one (1) of the three (3) following concerns from Main Flowchart: A. DTC P1326 Stored… (Page 4) B. ENGINE NOISE… (Page 5) C. ENGINE, NO CRANK… (Page 6) Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI1805Y/Z Multiple Models January 2024 Page 3 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) Oil Condition and Oil Level Inspection: (Main Flowchart) 1. Start video showing vehicle and move in towards the dash VIN tag. 2. Measure and record oil dip stick level. 3. Note oil dip stick reading on the RO. 4. Take a picture of the oil reading on dipstick. 5. Inspect the inner/bottom of the oil cap and inside oil filler opening. Record/Note findings: Oil sludge, varnish, burnt oil smell condition(s) found. 6. Inspect the inner/bottom of the oil cap and inside oil filler opening. Record/Note findings: Oil sludge, varnish, burnt oil smell condition(s) found. 7. Take a picture of both, the bottom of the oil cap and oil filler opening. NOTICE If oil lacquering, oil sludge or oil varnish is present, then the engine is therefore suspect to maintenance neglect. Review of the vehicle's maintenance history is required. Oil Level Measurement: (Flowcharts B & C → PWA Request) 1. Remove oil filler cap, remove oil drain plug and drain oil into the measuring container SST067BUCK and check oil level. 2. Record oil level reading on the RO. 3. Take photo of the drained oil container using KDS and attach to warranty claim PWA request. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI1805Y/Z Multiple Models January 2024 Page 4 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) Flowcharts A/B/C: A. DTC P1326 STORED Create PI1805Y Claim – No Techline PWA Required From Main Flowchart (page 2) 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 8. 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. 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: PI1805Y/Z Multiple Models January 2024 Page 5 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) B. ENGINE NOISE Techline PWA Required; Diagnosis only Campaign Possible From Main Flowchart (page 2) Check oil level and document on the RO Full system DTC scan and generate VDN. Perform BCT PASS (OK) BCT Result NO PASS (NG) PWA PROCESS (Incl. Oil Level Measurement) 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 PI1805 (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, 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: PI1805Y/Z Multiple Models January 2024 Page 6 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) C. ENGINE NO CRANK Techline PWA Required; Diagnosis only Campaign Possible From Main Flowchart (page 2) 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 PI1805 Claim Oil level in the crankcase was less than 1 quart. Process Completed PWA PROCESS (Incl. Oil Level Measurement) NO PASS BCT Result PASS 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 PI1805 (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, 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: PI1805Y/Z Multiple Models January 2024 Page 7 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/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 the vehicle being worked on and move the camera in towards the dash VIN tag. Note: Continue filming video until step 7. 2. Show the removed spark plugs. 3. 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: PI1805Y/Z Multiple Models January 2024 Page 8 of 17 ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) SUBJECT: 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. 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 PI1805 – 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 Procedure: 1. Replace the knock sensor (A) by referring to the “Engine Control / Fuel System → Engine Control System → Knock Sensor (KS) → Repair Procedures” chapter in the applicable Shop Manual on KGIS. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI1805Y/Z Multiple Models January 2024 Page 9 of 17 ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) SUBJECT: AFFECTED VEHICLE RANGE: Model Production Date Rage Optima (JFa) May 21, 2018 to February 28, 2019 Sorento (UMa) January 22, 2018 to March 6, 2019 Sportage (QL) April 2, 2018 to January 14, 2019 REQUIRED TOOL: Tool Name Tool Part No. Torque Wrench Figure Comments 09314 3Q100 Socket Refer to TSB ENG083 for detailed usage instructions Injector Combustion 09353 2B000 Seal Ring Installer Click-Type or Electronic Torque N/A Locally Sourced Wrench Measuring Container Order replacements via SST067BUCK Snap On Business Solutions Auto-shipped to Dealers For troubleshooting assistance contact the GITA Support Line at: Bearing Clearance KQ231 2T110QQK Tester Kit (888) 542-4371. For replacement parts, contact Snap-On Tools at: (888) 542-1011. REQUIRED PARTS: Part Name MY Model 2019 Part Number 2.4L GDI 2.0L T-GDI QL 21101 2GK35QQKR 21101 2GK39QQKR 2019 UMa 21101 2GK33QQKR N/A 2019 JFa 21101 2GK34QQKR 21101 2GK32QQKR Figure Engine Long Block 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 10. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI1805Y/Z Multiple Models January 2024 Page 10 of 17 ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) SUBJECT: Models Part Name Engine 2.4L GDI UMa, QL, JFa Figure 21111 2GK51QQK Service Kit I 2.0L T-GDI UMa, QL, JFa Part Number 21111 2GK52QQK 2.4L GDI 21111 2GK71QQK 2.0L T-GDI 21111 2GK72QQK Service Kit II Drive Plate 2.4L GDI and Bolts 2.0L T-GDI All *Oil Cooler 23311 25050 2.4L GDI *25470 2G050QQK 2.0L T-GDI *25470 2G650QQK 2.4L GDI 39250 2G100 Tube Assembly All Knock Sensor N/A 2.0L T-GDI 39250 2G700 *Oil Cooler Tube assembly replacement is conditional, refer to instructions outlined in KGIS (if applicabale). Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI1805Y/Z Multiple Models January 2024 Page 11 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) WARRANTY CLAIM INFORMATION FOR: PI1805 Y1, PI1805 Z1 and PI180S (DIAGNOSIS ONLY CLAIMS): IMPORTANT REFER TO WARRANTY BULLETIN 2024-02 (PI1805Y, Z OR PI180S) FOR MODEL-SPECIFIC LABOR OPERATIONS AND TIMES, AS WELL AS SPECIFIC CLAIM SUBMISSION PROCEDURES. NOTE: SEE APPENDIX 1 & 2 ON PAGE 12 AND 13 FOR ADDITIONAL TECHLINE PWA INFORMATION REQUIRED. Flow Chart Symptom #A Diagnostics Repairs R&R Knock Sensor BCT Pass PI1805Y ECU Upgrade DTC P1326 Engine R&R (No TL PWA Required) 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 PI1805Z 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) Engine No Crank (TL PWA Required) Engine R&R with TL PWA Engine R&R with TL PWA + ECU Software Update Diagnostics Check Crank Rotation PI1805Z Noise Check + TL PWA + Engine R&R + BCT Pass Check Oil Amount + Repairs Inspection Only (PI180S Claim) – Repairs under normal warranty coverage MAY apply – separate TL PWA case required) Diagnosis Only (PI180S 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 Note: Photo requirement for Warranty Claim submission as outlined in TSB PI1805: Separate photos of the oil dipstick reading, oil filler cap, oil filter opening must be attached to the claim using Warranty Claim Attachment type ‘XX - Other’. Failure to provide the required photos may result in claim rejection or chargeback. Refer to Warranty Bulletin 2024-02 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: PI1805Y/Z Multiple Models January 2024 Page 12 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) Appendix 1 (Techline Prior Work Authorization) Inspection Type Findings Action 1. Perform Oil Level Measurement Dealers are to empty crankcase oil into a measuring container and record findings. Note: Take a photo of the oil level using KDS. 2. Oil Dipstick Oil Filler Cap Oil Filler Opening Suspect Exceptional Neglect (NG) • Physical inspection of engine shows oil sludge/buildup/varnish. Request Maintenance Records: Customers may be required to provide Maintenance Records in the absence of sufficient CP/Carfax data. Customers have 5 business days to respond to dealer’s request for maintenance records (or to confirm that they are gathering records and/or Note: Using KDS, take (3) photos: need additional time), in which case customers 1. Oil Dipstick Reading will be permitted an additional 5 business days 2. Inside Oil Filler Cap (10 days total) to produce records or confirm 3. Inside Oil Filler Opening they do not have records to provide. Oil level & Oil condition (OK) KSDS Installed or DTC P1326 Stored? Applicable Flowchart A, B or C. Note: Customers who perform their own maintenance may provide a service record log along with receipts for the purchase of oil filter and engine oil. Maintenance Record Maintenance Record Request Results • Action One oil change gap of greater than 14 months and/or 10,500 miles. • consumption issues but the customer Kia is required to verify did not obtain a repair to address Oil change records from dealers, Carfax (or similar reputable maintenance records from the customer. Any repairs performed are the miles (whichever comes first), customer’s responsibility or insurable subsequent after a completed oil extended warranty plan. diagnosis. • Exceptional Neglect Determined. such issues within 30 days or 1,000 consumption testing and confirmed 3rd. parties) but may also request Previous diagnosis of excessive oil No “Exceptional Neglect” can apply to Diagnosis Coverage Only. otherwise eligible engine failures that occur within a Class Vehicle’s first 15,000 miles. Maintenance Records Provided Repair Assistance (RA) Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI1805Y/Z Multiple Models January 2024 Page 13 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) Appendix 2 Techline Prior Work Authorization (PWA) Scenario Description Flowchart A DTC P1326 Stored Action Required No TL PWA required. TL PWA required for all dealers – Video of condition Flowchart B Engine Noise Video requirement examples below are for illustration purposes, individual requirements will vary based upon the condition reported: • Video should be continuous and show the VIN (most convenient VIN plate) and pan to show the engine condition. Engine Seized Flowchart C Bearing Clearance Test or No Test • 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 (Refer to Appendix 3) 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. NOTICE VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference PI1805* when accessing the KDealer+ system. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI1805Y/Z Multiple Models January 2024 Page 14 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) Appendix 3 (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: PI1805Y/Z Multiple Models January 2024 Page 15 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/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: PI1805Y/Z Multiple Models January 2024 Page 16 of 17 SUBJECT: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/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”. 5. Select “Camcorder” and the video camera will open. Printed TSB copy is for reference only; information may be updated at any time. Always refer to KGIS for the latest information. TSB: PI1805Y/Z Multiple Models January 2024 Page 17 of 17 ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1805Y/Z) SUBJECT: 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 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”. 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: PI1805Y/Z Multiple Models January 2024