3. Remove the 4 spark plugs.
Tightening Torque:
14.7 - 24.5 Nꞏm
(1.5 - 2.5 kgfꞏm, 10.9 - 18.0 Ibꞏft)

4. Insert the appropriate (use M12 for GDI and
Theta MPI Hybrid engines or M14 for all other
MPI engines) spark plug rod SST (A) into
Cylinder #1 spark plug hole and turn until hand
tight. Insert the clearance gauge SST into the
spark plug rod and tighten using the thumb
screw.

A

NOTICE
DO NOT connect the test air hose to the
clearance gauge at this time.

5. Connect the GDS to the vehicle and turn the
ignition ‘ON’.
6. Swipe up on the ‘More’ tab at the bottom of
the GDS home screen. Select the ‘Special
Inspection’ function.
7. Enter the vehicle info into the GDS as
prompted then select ‘Next’.

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8. 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.

NOTICE

E

If loose, apply Blue Loctite (or equivalent)
to the tip thread and retighten securely to
the gauge plunger.
9. Turn the ignition ‘OFF’ and remove the VCI.
10. 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.

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
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11. 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.)

IMPORTANT



For the step below, the engine must be rotated SLOWLY using the crank rotator SST.
o Abrupt or erratic movements may cause improper TDC setup and test errors.
Do NOT stop rotating the engine before reaching MAX TDC, especially during the
initial rotation towards TDC where the value may be at 0mm and change all the
sudden.
o Be sure to find TDC correctly by slowly and slightly nudging the engine a little
more to verify no change in value to confirm that the piston is at MAX TDC.

 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.
12. 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

13. 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.
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14. Connect the test hose (1) to the spark plug rod
SST and to the bearing tool SST.

15. 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.

16. Locate the AP/VC switch on the bearing
tool SST and switch it to the AP Position.
17. 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.
18. On the bearing tool SST, change the AP/VC
switch to the VC position when instructed by
the GDS.

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

20. 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.

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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.

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.

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4. 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.
5. (For GDI Engines Only) Follow the published procedure outlined in TSB 19-FL-001H to remove
and reinstall the GDI high pressure fuel system components (GDI High Pressure Pump, Fuel
Injectors, and Fuel Rail) from the existing engine to the new engine
!

CAUTION

Follow TSB 19-FL-001H carefully and replace the following newly supplied parts from the
Service Kits for GDI engines:
 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)
For all engines with Service Kits: (1) Exhaust Pipe Gasket is included. Install this new gasket
when attaching the front and center muffler assemblies together during the engine installation.

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

TSB #: 21-01-024H

NOTICE
Be sure to replace the following newly
supplied parts if the Service Kit is
applicable for the engine:
 Oil Level Rod & Oil Level Guide Assy.
 Intake Manifold Gasket(s)
 Exhaust Manifold Gasket
 Fuel Pipe Assembly

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NOTICE
(For Automatic Transmissions equipped w/ torque
converters only) 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.

9. Reinstall and connect the cooling system components.
 Fill the cooling system with 50/50 ~ 70/30 (Water/Anti-Freeze) coolant mixture.
10. Fill the engine crankcase:
a) Follow the specified engine oil capacity 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 5W-30 Full Synthetic type with API SN/SN+/SP, ILSAC GF4/GF5 or higher service
grade
11. Start the engine to warm it up and begin the cooling system air bleeding process.
 Check for any leaks during this time.
Optimum Engine Oil Fill Level
 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.
12. Refer to TSB 21-01-023H to update the Engine ECM if new software is available.
13. 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.)

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