NHTSA ID Number: 10183312
Manufacturer Communication Number: PI1802YZ_TSB_R4
TSB/Document Date: 2020-12-01
Summary
PRODUCT IMPROVEMENT CAMPAIGN: ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1802Y/Z) - 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).
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:
- 6X better wear protection on critical engine parts than...
- 1.3X better sludge protection than industry standards*
- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
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TSB/Document ID: PI1802YZ_TSB_R4
Replacement Service Bulletin Number:
MFR Communication Date: 2020-11-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
MFR Component System:
MFR Component Subsystem:
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