prompted then select ‘Next’.

TSB #: 20-01-004H-3

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9. Connect the GDS to the clearance gauge
SST (gauge) via Bluetooth:
 Press the “Set’ button (B) on the gauge
to turn it on.
 Press the “Set” (B) and “Mode” (C)
buttons at the same time for about 4 sec
until the “reset” message is displayed.
 Select the gauge in the list of devices on
the GDS. Select the ‘Refresh’ icon (D) if
the gauge doesn’t appear automatically.

D

NOTICE
C



If more than one device appears in
the list of devices, there is another
device in range. Move away from
the other device to pair the gauge.

B

Check that the ball point tip (E) of the
clearance gauge SST is securely installed to
the tool as shown. Do not continue if ball
point tip (E) is loose or missing.

10. Turn the ignition ‘OFF’ and remove the VCI.

E

11. Follow the instructions on the GDS to start the test and select ‘Next’.

NOTICE



For the following steps, the Crank Rotator Tool or a long handled wrench should
be used for moving the crankshaft slowly and precisely.
Ensure the test hose is disconnected from the clearance gauge when finding TDC
piston depth.

NOTICE
Please take note of the following crank/piston position definitions.

BTDC (Before Top Dead Center)

TDC (Top Dead Center)  Find TDC during the compression stroke.

ATDC (After Top Dead Center)
In the following steps, the TDC point for testing must be at MAX (piston height) value
minus 0.03mm as the crank has moved slightly into ATDC (from its TDC dwell point).


If TDC is difficult to find, refer to Shop Manual Section Location: Engine Mechanical System
> Timing System > Timing Chain

TSB #: 20-01-004H-3

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12. To find TDC compression (TDC), rotate the crankshaft with the crank rotator SST at least one
cycle (1/2 turn). (If the SST does not fit the specific vehicle type, remove the front passenger wheel
and wheel liner or underbody tray as needed to rotate the crankshaft using standard shop tools.)
 Monitor the piston height value on GDS screen
or the clearance gauge SST while rotating the
engine clockwise using the Crank Rotator Tool.
 Rotate the engine SLOWLY as the value
increases towards a MAX value. (BTDC 
TDC)
 When the value changes direction
(increasing/BTDC  TDC 
decreasing/ATDC), stop rotating the crank
when the piston height is at MAX value
minus 0.03mm.

NOTICE
The testing point is slightly towards ATDC
from TDC when the piston has moved
down 0.03mm from its highest position.
13. Select ‘Next’ when TDC is found.
 Ideal set point for testing from TDC is found
when the maximum value minus 0.03mm is
reached on the clearance gauge SST (F).
 The value is also displayed on the GDS.

F

14. Once the set point for bearing testing is found,
select ‘Start’ in the GDS screen and proceed
directly to the next step below.
 Do not turn the crank rotator SST until
instructed to do so.

NOTICE
The value at TDC varies depending on the
specific vehicle and engine type.

15. Connect the test hose (1) to the spark plug rod
SST and to the bearing tool SST.

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16. Connect the SST power cables to a fully
charged 12V battery or to an external AC/DC
power supply.
 Turn the bearing tool SST power switch
‘ON’.

NOTICE

*** Bearing Tool SST Power Check ***
a) Supply 12 volts (or an alternate external AC/DC 13.8 volt power supply with at least ~2
amp output) to the power cable (3) connected to the bearing tool SST.
b) Turn power switch to ON.
c) Toggle AP/VC transfer switch between AP VC.
 The solenoids should “click” while switching between AP/VC when the unit is ON.
 If the solenoids are not switching, then check the power cable or the power supply.

17. Locate the AP/VC switch on the bearing
tool SST and switch it to the AP Position.
18. Follow the instructions on the GDS to test
each cylinder. Cylinder #1 is checked first.
 The cylinders will be checked per the
engine firing order: #1→#3→#4→#2.
19. On the bearing tool SST, change the AP/VC
switch to the VC position when instructed by
the GDS.

NOTICE
If the bearing measurement value does
not change when the AP/VC is
switched or the “Unable to measure”
message appears on the GDS, rotate
the crankshaft further as the exhaust
valves could be open. Set the
crankshaft to TDC again (Step 11).
Ensure the test hose is disconnected
from the clearance gauge SST when
finding TDC.

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20. Continue following the instructions on the GDS to
complete the bearing inspection. Check the engine oil
level and select the level in the GDS.

21. If the test result is “PASS”:
a) Save a screenshot of the results screen.
 If there is audible engine noise:
 Refer to HTSS "Fix it Right“ under
symptom: “Engine NoiseUndetermined”
 Using STUI on the GDS, record and
submit a video of the engine noise 12 ft above the valve cover. Include the
VIN Plate (at windshield or on door
jamb) in the beginning of the video.
 Follow remainder of Flow Chart A to
complete the procedure.
 If there is no audible engine noise:
 Follow remainder of Flow Chart A to
complete the procedure.
b) Reinstall all components in the reverse order of removal.
c) Check for DTCs and perform the appropriate diagnostic service. Ensure no warning lights are
present to complete the procedure.
If the test result is “NO PASS”:
a) Save a screenshot of the results screen.
b) Submit PA for engine replacement approval.
c) Follow remainder of Flow Chart A and
Engine Replacement section of this TSB to
complete the service procedure.
d) Check for DTCs and perform the
appropriate diagnostic service. Ensure no
warning lights are present to complete the
procedure.

NOTICE
PA Approval is required for engine replacement. Submit PA and refer to the Dealer Best
Practices guide for the latest requirements for engine approval.
 Refer to Prior Approval Submission Documentation section at the last page of this TSB
for the itemized checklist.
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Engine Replacement:
1. Continue with engine replacement if necessary according to the Service Procedure Flowchart.
2. Follow the applicable shop manual to remove the engine from the vehicle. The specific method for
removal varies by model.
 Shop Manual Section Location: Engine Mechanical > Engine And Transaxle Assembly >
Engine And Transaxle Assembly > Repair Procedures

NOTICE
Record the audio station presets (XM, AM, FM, etc.) prior to disconnecting the battery.
3. Certain replacement engines must be prepared prior to installation. Some components from the
existing engine must be transferred to the new engine.

NOTICE
Take special care of the original engine parts that will be required for reinstallation on
to the replacement engine.
Transfer GDI High
Pressure Pump

(2.4L ULEV Only) Relocate/Transfer
Exhaust Studs Manifold Studs

Transfer Fuel
Injectors,
Rail, Knock
Sensor,
Harness

4. (For 2.4L with ULEV / FED emissions only) 2.4L replacement engines are produced with the
exhaust manifold studs configured for SULEV / CAL emissions package.
 Two exhaust studs must be relocated on the new engine and 1 exhaust stud must be
transferred from the old engine.
 Use a commercially available stud removal tool or use the double-nut technique to
complete this step.
SULEV /
CAL Spec

ULEV /
FED Spec

Exhaust Stud Position Relocation Information

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5. Remove and reinstall the engine knock sensor
from the old engine to the new engine.
Knock Sensor Fastener Tightening torque:
21Nm (15.5lb-ft)

NOTICE
Ensure the knock sensor is torqued to
specification using a torque wrench.
 Improper installation can result in DTC
codes.
6. If 21101-2GK70QQA engine is used:
 Install the oil filler cap from the old engine to the
new one.
 Install the drive plate/flywheel on the new engine
using new bolts (QTY 7).
 Drive Plate Tightening torque:
111.7 ~ 127.5 Nm (86.8 ~ 94.1 lb-ft)

7. Follow the published procedure outlined in TSB
19-FL-001H to remove and reinstall the following
GDI high pressure fuel system components from the
existing engine to the new engine:
 GDI High Pressure Pump
 Fuel Injectors (4)
 Fuel Rail
The corresponding Service Kits will supply the
required new parts per TSB 19-FL-001H to complete
the transfer of the above existing parts.

8. Install the new oil cooler hoses if applicable.
9. Reconnect and reinstall the engine front harness.

TSB #: 20-01-004H-3

!

CAUTION

Follow TSB 19-FL-001H carefully and
replace the following newly supplied parts
from the Service Kits:
 Mounting flange O-ring (for High
Pressure Pump)
 O-rings, Backup Rings, Washer Seals,
Combustion Seal Rings, and clips (for
Fuel Injectors)
 Fuel Pipe (between High Pressure
Pump and Fuel Rail)
In addition, the Service Kits include (1)
Exhaust Pipe Gasket. Install this new
gasket when attaching the front and center
muffler assemblies together during the
engine installation.

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10. Follow the published Service Information
from the applicable Shop Manual to reinstall the
Sub Engine Assembly.
Shop Manual Section Location: Engine
Mechanical > Engine And Transaxle Assembly >
Engine And Transaxle Assembly > Repair
Procedures

NOTICE
Be sure to replace the following newly
supplied parts from the Service Kit:
 Oil Level Rod & Oil Level Guide Assy.
 Intake Manifold Gaskets (4)
 Exhaust Manifold Gasket
 Fuel Pipe Assembly
 (2.0T Only) Turbo Oil Feed Hose & Pipe
 (2.0T Only) Turbo Oil Drain Gasket (2)
 (2.0T Only) Oil Drain Gasket
 (2.0T Only) Gasket (2)

NOTICE
If the torque converter has moved from the
fully inserted position, carefully push inward
and rotate the torque converter until the
converter is recessed approximately 5/16” 9/16” (8 -14 mm) into the transaxle case when
reinstalling the automatic transaxle.
Check the depth of the torque converter to
confirm it's fully installed in the transmission
otherwise the oil pump may be damaged
resulting in transmission failure.

11. Connect the (2) oil coolant hoses between
the oil cooler and the water temperature control
assembly.
 Fill the cooling system with 50/50 ~ 70/30
(Water/Anti-Freeze) coolant mixture.
12. Fill the engine crankcase:
a) Add 5.8 quarts for the initial dry fill of the engine.
b) With the fuel system disabled temporarily, crank the engine for several seconds to prime the
lubrication system prior to starting the engine.
 Recommended Oil Specifications:
o For all models excluding Veloster N (JSN):
 5W-30 Full Synthetic type with API SN/SN+/SP, ILSAC GF4/GF5 or higher
service grade
o For Veloster N (JSN):
 0W-30 (or 5W30 if not available) Full Synthetic type with SN/SN+/SP, ILSAC
GF4/5 or higher grade
13. Start the engine to warm it up and begin the
cooling system air bleeding process.
 Check for any leaks during this time.
 After the engine has warmed up to normal
operating temperature, turn the engine off,
wait a few minutes, and then adjust the
engine oil level to near the “F” mark as
shown.
TSB #: 20-01-004H-3

Optimum Engine Oil Fill Level

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14. Refer to Campaign 953 to update the Engine ECM if new software is available.
15. When all fluids have been fully filled and all work quality checks are completed:
a) Set the customer’s audio station presets.
b) Relearn the Steering Angle Sensor using the GDS.
c) Clear DTC P1326 with engine ON. P1326 may reset if it’s not cleared with the
engine running. Then check for other DTCs and perform the appropriate diagnostic
service. Ensure no warning lights are present.
d) Reset the engine adaptive values using the GDS.
e) Perform a short road test to confirm normal vehicle drivability.

NOTICE



Clear DTC P1326 with engine ON. P1326 may reset if not cleared with the
engine running.
Reset engine adaptive values.

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Prior Approval Submission Documentation:
 Refer to chart below for items needed for submissions based on condition.
 If current condition does not fall within the chart below, contact Techline.

**Proper Photos / Videos:
 VIN in view when photo is taken of the item in question. (Windshield or doorjamb VIN Plate)
o Exception: For oil Measurement photo, a Repair Order in photo will suffice.
 Photo taken with clear focus, showing the item being presented.
 BCT Connection Calibration Test - show connections and gauges clearly (up to two photos)
 Crank Rotation Video and Engine Noise Video - start at the Windshield VIN Plate and move to
the front of the engine showing no crankshaft movement or noise (as applicable) in a
continuous video beginning to end.
o ***Returned engines may be inspected by WTC for a seized condition***
Media Submission Process:
 All photos / videos will be submitted via Single Technician User Interface (STUI).
(See Page 4 of Tech Net Times Vol 30 Issue 7 for additional details.)
TSB #: 20-01-004H-3

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