GROUP
Product Improvement

MODEL
See Model List
on Page 1

NUMBER
PI1803Y/Z (Rev 6, 12/23/2021)

DATE
March 2020

PRODUCT IMPROVEMENT CAMPAIGN
ENGINE REPLACEMENT INSTRUCTIONS
FOR DTC P1326 (PI1803Y/Z)

SUBJECT:

 NOTICE
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
PI1803 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).

Model List:
Year
2011-2013
2014
2011-2013
2012-2014

Model
Optima (QF/TF)
Optima (QF)
Sportage (SL)
Sorento (XMa)

Engine
2.4L & 2.0L T-GDI
2.4L & 2.0L T-GDI
2.0L T-GDI
2.4L GDI

Production Date
8/12/10 – 9/27/13
8/28/13 – 5/15/14
12/30/10 – 8/30/13
4/19/11 – 2/10/14

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 page 2, then follow the appropriate
procedure as outlined in this bulletin.
A Vehicle Diagnosis Number (VDN) must be created with or without DTC P1326 after scanning
for DTCs, prior to performing PI1803Y/Z. If a VDN is not created, Warranty claim submission
issues WILL occur.
Before conducting the procedure, verify the vehicle is included in the list of affected VINs.

 NOTICE
To ensure 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.

Printed TSB copy is for reference only; information may be updated at any time.
Always refer to KGIS for the latest information.
Circulate To:

X General Manager


X Service Advisors


X Technicians


X Service Manager


X Parts Manager


X Body Shop Manager 
X Fleet Repair


Page 2 of 25
SUBJECT:

ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/Z)

Main Flowchart:
Vehicle In
Validate Warranty
Confirm customer complaint as listed on

the RO and if vehicle was towed in.

1. Full system DTC scan and
generate VDN
2. Save Freeze frame Data

Drain Engine Oil If less than 1.38Qt. (1.3L)
1. Document the measurement in the repair
order.
2. Take a photo of the drained oil container
and attach to the warranty claim.

NO

Oil showing on dipstick?

YES

Refer to the Applicable Flowchart A, B, or C.

Follow the applicable Main Flowchart below upon documenting customer complaint. Then follow the
corresponding flowchart for one (1) of the three (3) following concerns:
A.

DTC P1326 Stored… (Page 3) – NO Engine Noise

B.

ENGINE NOISE… (Page 4)

C.

ENGINE, NO CRANK… (Page 5)

Note: If SC147 has not been completed,
refer to TSB SC147 repair procedures
before performing PI1803Y/Z.

 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.

Note: If any concerns arise during/after completing the flowchart(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: PI1803Y/Z (Rev 6) Multiple Models March 2020

Page 3 of 25
SUBJECT:

ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/Z)

Flowcharts:

A. DTC P1326 Stored
Create PI1803Y Claim – No PWA Required (Pass/No Pass result)
Create PI1803Z Claim - PWA Required (No BCT result)

Note: If any concerns arise during/after completing the flowchart(s), open a Techline case online.

1. Full system DTC scan and
generate VDN
2. Save Freeze frame Data

Perform BCT

NO BCT

BCT Result

PWA
Process

NO PASS
(NG)
PASS
(OK)

Repair Completed

Replace
Knock Sensor
Page 18

No

KSDS Software
Update available

Check for updated
software

Replace
Engine

Yes
KDS Software
Update

Yes

Refer to PI1803
(As Applicable)

KSDS Software
Update available

Check for updated
software

No

Note: If any concerns arise during/after completing the flowchart(s) or NO BCT result, 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: PI1803Y/Z (Rev 6) Multiple Models March 2020

Page 4 of 25
SUBJECT:

ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/Z)
B. Engine Noise
Techline PWA Required; Diagnosis only Campaign Possible

Note: If any concerns arise during/after completing the flowchart(s), open a Techline case online.

Full system DTC scan
and generate VDN.

Perform BCT

BCT Result

PASS / NO BCT

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 PI1803
(As Applicable)

PI180S

KDS Software
Update

 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: PI1803Y/Z (Rev 6) Multiple Models March 2020

Page 5 of 25
SUBJECT:

ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/Z)
C. Engine No Crank
Techline PWA Required; Diagnosis only Campaign Possible

Note: If any concerns arise during/after completing the flowchart(s), open a Techline case online.

Remove engine
drive belt and spark
plugs

Full system DTC scan
and generate VDN

Document engine
rotational torque
VIDEO

Check Max.
Torque Value
(94 lb.ft.)

Under
94 lb.ft.

Perform BCT

Over
94 lb.ft.

Replace Engine
Create
PI1803"Z Claim

YES

PWA
Process
(Connecting Rod
Bearing Related)

NO PASS
NO BCT

BCT Result

NO

Process
Completed

No

KSDS Software
update available

Yes

PASS

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

Refer to PI1803
(As Applicable)

PI180S

KDS Software
Update

 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: PI1803Y/Z (Rev 6) Multiple Models March 2020

Page 6 of 25
SUBJECT:

ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/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: PI1803Y/Z (Rev 6) Multiple Models March 2020

Page 7 of 25
SUBJECT:

ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/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 high
pressure 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: PI1803Y/Z (Rev 6) Multiple Models March 2020

Page 8 of 25
SUBJECT:

ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 (PI1803Y/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

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