KIA Remanufactured Engine Program (ENG042)

KIA REMANUFACTURED ENGINE PROGRAM

TECHNICAL SERVICE BULLETIN

SERVICE INFORMATION

This bulletin reintroduces the Kia Remanufactured Engine Program and related procedures. Effective May 2008, KMA is supplying remanufactured short and long block engines. Initial launch was the 3.5L Sigma engine only. The Remanufactured Engine Program has expanded to include additional engines, and more may be added in the future.

This TSB contains the following items and procedures:

• Engine Core Data Form (WRTY 135 May 2008)
• Diagnostic service procedures
• On-line Dealer Communications System (DCS) entry of diagnosis and core information for all Kia Remanufactured Engines. This process will be used to return ALL engines in the Reman Program, regardless of whether they are replaced by a new or remanufactured unit. Failure to return the engine core will forfeit the warranty claim. 

File Under: Engine 

EFFECTIVE VEHICLE INFORMATION

SEDONA - (GQ) 3.5L	RIO (BC) 1.5L	OPTIMA (MS) 2.4L	SEPHIA/SPECTRA (SD) 1.8L
SEDONA - (VQ) 3.8L	RIO (JB) 1.6L	OPTIMA (MS) 2.5L	SEPHIA/SPECTRA (LD) 2.0L
SORENTO - (BL) 3.3L	BORREGO (HM) 3.8L	OPTIMA (MS) 2.7L	SPORTAGE (AL) 2.0L
SORENTO - (BL) 3.5L	BORREGO (HM) 4.6L	OPTIMA (MG) 2.7L	SPORTAGE (KM) 2.0L
SORENTO - (BL) 3.8L	AMAN TI - (GH) 3.5L	SOUL - (AM) 2.0L	SPORTAGE (KM) 2.7L
RONDO (UN) 2.4L	AMAN TI - (GH) 3.8L	SOUL - (AM) 1.6L

PARTS INFORMATION

VEHICLE	ENGINE		PRODUCTION Y/M/D	OE PART NO.	REMAN PART NO.
	MODEL	PART TYPE
SEDONA	GQ 3.5 (SIGMA)	Long Block	20010430~20040415	21101 39B00	N/A (ORDER REMAN SHORT + NEW HEADS)
			20040415~20051101	21101 39B00A
		Short Block	20010430~20051101	21102 39B00	21102 39B00R
	VQ 3.8 (LA MBDA)	Long Block	20050901~	21101 3CC00	21101 3CC00R
		Short Block	20061104~	21102 3CA00	21102 3CA00R
SORENTO	BL 3.5 (SIGMA)	Long Block	20020601~20040415	21101 39E00	N/A (ORDER REMAN SHORT + NEW HEADS)
			20040415~20060612	21101 39E00A
		Short Block	20021030~20060612	21102 39B00	21102 39B00R
			20020601~20021030	21102 39C00
	BL 3.8 (LA MBDA)	Long Block	20060917~	105Y1 3CS00	105Y1 3CS00R
		Short Block	20060917~	21102 3CA00	21102 3CA00R
	BL 3.3 (LA MBDA)	Long Block	20060917~	132Y1 3CS00	132Y1 3CS00R
			20090202~	182Y1 3CH00
		Short Block	20060613~	21102 3CB00	21102 3CB00R
SEPHIA/SPECTRA	SD 1.8 (GT)	Long	20000115~20000518	K0AB9 02100	N/A
			20000518~20010514	K0AB9 02100A	N/A
			20010514~20020501	K0AB9 02100B	N/A
			20020201~20031130	KZ295 02100	N/A
		Short	20000115~20000518	K0AB9 02200	N/A
			20000518~20010514	K0AB9 02200A	N/A
			20010514~20031130	K0AB9 02200B	N/A
	LD 2.0 (BETA)	Long	20031201~20040825	21101 23P10	108Y1 23H00R
			20040825~20060927	KZ376 02100
			20060922~	108Y1 23H00
			20061201~	129Y1 23H00	129Y1 23H00R
		Short	20031201~20060927	21102 23J00	204Y2 23H00R
			20060922~	204Y2 23H00
RIO	BC 1.5 (GA)	Long	20000510~20020701	K0AB2 02100	N/A
		Short	20000510~20020701	K0AB7 02200	N/A
	BC 1.5 (GA)	Long	20020701~20050615	KZ308 02100	N/A
		Short	20020701~20050615	KZ312 02200	N/A
	JB 1.6 (AL PHA)	Long	20050523~	KZ412 02100	KZ412 02100R
		Short	20050523~	KZ387 02200	KZ387 02200R
SPORTAGE	AL 2.0	Long	19970503~20020930	0K01C 02000	N/A
			19970503~20020930	0K01B 02000	N/A
		Short	19970503~20020930	0K01C 02200	N/A
	KM 2.0 (BETA)	Long	20041025~	KZ358 02100	KZ358 02100R
		Short	20041025~	21102 23J00	204Y2 23H00R
			20060922~	204Y2 23H00
	KM 2.7 (DELTA)	Long	20041025~	21101 37P30	21101 37P30R
		Short	20041025~	21102 37G00	21102 37G00R
OPTIMA	MS 2.4 (SIRIUS)	Long	20001001~20050930	21101 38E01	N/A
		Short	20001001~20040701	21102 38C00	21102 38C01R
			20040607~20080519	21102 38C01
			20080519~	21102 38C01B	21102 38C01BR
	MG 2.4 (THETA)	Long	20051201~20061001	21101 25R00	123Y1 25H00R
			20061001~	123Y1 25H00
			20080801~	146Y1 2GH00	TBD
		Short	20051201~20061001	21102 25J00 *	212Y2 25H00BR + (SEE NOTE 1 BELOW)
			20051201~20061001	212Y2 25H00 *
			20061001~20070615	212Y2 25H00A
			20070615~	212Y2 25H00B	212Y2 25H00BR
			20080801~	226Y2 2GH00	TBD
	MS 2.5 (DELTA)	Long	20001001~20010601	21101 37A00/01	N/A
		Short	20001001~20010601	21102 37A00	N/A
	MS 2.7 (DELTA)	Long	20010601~20050930	21101 37G00	21101 37G00R
		Short	20010601~20050930	21102 37E00	21102 37E00R
	MG 2.7 (MU)	Long	20051201~20051201	21101 3EE00	165P1 3EA00R
			20051201~	165P1 3EA00	165P1 3EA00R
		Short	20051201~	21102 3EA00	21102 3EA00R
SOUL	AM 1.6 (GAMMA)	Long	20090115~	168Y1 2BH00	TBD
		Short	20090115~	239Y2 2BH00	TBD
	AM 1.6 (GAMMA)	Long	20090115~	164Y1 23H00	TBD
		Short	20090115~	236Y2 23H00	TBD
RONDO	UN 2.4 (THETA)	Long	20061030~	123Y1 25H00	123Y1 25H00R
			20080528~	146Y1 2GH00	TBD
		Short	20051201~20061001	212Y2 25H00	212Y2 25H00AR
			20061001~20070615	212Y2 25H00A
			20070615~	212Y2 25H00B	212Y2 25H00BR
			20070615~	226Y2 2GH00	TBD
	UN 2.7 (MU)	Long	20061030~	165P1 3EA00	165P1 3EA00R
		Short	20061030~	21102 3EA00	21102 3EA00R
BORREGO	HM 3.8 (LA MBDA)	Long	20080426~	125G1 3CU00	TBD
		Short	20080426~	214G2 3CU00	TBD
	HM 4.6 (TAU)	Long	20080426~	104K1 3FU00	TBD
		Short	20080426~	204K2 3FU00	TBD
AMANTI	GH 3.5 (SIGMA)	Long Block	20030929~20040415	21101 39C02	N/A (ORDER REMAN SHORT + NEW HEADS)
			20040415~20060630	21101 39C02A
		Short Block	20030929~20060630	21102 39B00	21102 39B00R
	GH 3.8 (LA MBDA)	Long Block	20061030~	21101 3CL00	21101 3CA00AR
			20061030~	21101 3CA00A
		Short Block	20061030~	21102 3CA00	21102 3CA00R

Notes to Parts Information: 

21102 25J00 * - Order 212Y2 25H00BR plus 21350 25003, 24420 25001, & 24431 25001.

212Y2 25H00 * - Order 212Y2 25H00BR plus 21350 25003, 24420 25001, & 24431 25001.

212Y2 25H00A * - Order 212Y2 25H00BR plus 21350 25003

Remarks: 

	Currently in the reman program
	No reman program is scheduled
	Same application as other vehicle model
	New part added or correction needed

Revised 3/20/2009 

SERVICE PROCEDURE

1. Open a repair order and with the customer, complete the top section of the Engine Core Data Form (WRTY 135 May 2008), available on KGIS or copy attached form)
2. Give the repair order and Engine Core Data Form to the technician to begin diagnosis of customer concern to determine if there is an internal problem requiring the installation of a remanufactured engine. The technician should follow the Kia Engine Diagnosis Flow Chart (attached to this TSB). Record the results on the Engine Core Data Form.
3. If it is determined that an engine assembly is necessary, send the RO and Engine Core Data Form to the Parts Department to order the correct remanufactured unit for the vehicle. Retain the RO and the Engine Core Data Form in Parts Department*. Upon receipt of the remanufactured unit, forward the engine assembly with the RO and Engine Core Data Form to the technician.
4. Complete all necessary fields on the Engine Core Data Form.
5. Completely drain the engine unit of engine oil and coolant prior to removing it from the vehicle.
6. Remove the Engine Assembly per the Service Manual.
7. Transfer all applicable accessories, A/C compressor, alternator, manifolds etc., as required. Install the remanufactured engine assembly according to the appropriate Service Manual instructions. Fill the remanufactured engine with the correct Kia specified engine oil and engine coolant.  Ordering information can be found in the Kdealer.net Parts, Programs & Incentives section.
   NOTE: Retain the reusable plastic shipping container and use it to return the removed engine unit to the Kia Remanufacturing Center. Failure to return the engine in the authorized shipping container may result in forfeiture of core credit.
   NOTE: When verifying the repair, especially when the engine has been replaced, it is critical the engine has the correct amount/viscosity of engine oil and the correct engine coolant.
   Confirm with the service information (KGIS) that:
   

   • The engine is at normal operating temperature,
   • The vehicle itself is level,
   • Engine Oil level is at the correct mark on the dip-stick (gauge) indicating engine is properly filled with engine oil.
   NOTE: Use of incorrect engine oil and coolant can result in damage to the engine, which is not covered by Warranty.
8. Enter all information into the DCS Dealer Parts Core Return Entry screens (see Parts Bulletin No: MI-0018) and print the Engine Core Return Form. Place the following documents into the plastic document bag, provided with the remanufactured engine assembly:
   • Kia Engine Core Return Form (Printed from DCS)
   • Kia Engine Core Data Form (WRTY 135 May 2008)
   • Copy of Repair Order (RO) with Technician's notes or invoice for over-the-counter sale
   • Securely close the bag and place inside of the engine shipping container. Tie the document bag to a hole on the engine case using a wire/tiewrap. Secure lid with retaining straps.
9. Arrange shipment of the removed engine in accordance with instructions provided in Parts Bulletin MI-0018.
   • When returning engines, only return either the short-block or long-block. If you ordered and are returning a short block, return the short block only and not the related parts with the short block, for example the cylinder heads, gaskets, etc.
   • Roadway Logistics will only pick up an assembled short block or assembled long block with related parts. Discard the related parts 30-days after FINAL claim payment notification shown on the Monthly Warranty Claim Statement.
   • Engine pick-ups can be arranged by contacting Roadway Logistics at 1-800-357-9199. If you have any questions please contact the Kia Warranty Helpdesk at 1-800-225-3217.
10. Applicable core reimbursement will be issued following receipt and inspection of core and Engine Core Return Form.
    NOTE: Disassemble only parts needed to swap from removed engine unit to installed remanufactured engine unit.
    NOTE: KMA may deny/charge back all or portions of the OEM or remanufactured engine claims and/or core credit if:
    Remanufactured or OEM engine is damaged due to:
    

    • Abused/Accident damage
    • Improper installation/removal
    • Improper packaging
    • Improper diagnosis
    • Parts missing and or damaged
    • No trouble found/incorrect diagnosis
    • Missing or incomplete Engine Core Data Form
    • RO missing
    • Engine Core Return Form missing
    NOTE: Lost Packaging - Including the Kia authorized Returnable Container - Call Parts Hotline at 800-542-5611.
    Engine Core Data Form (WRTY 135 May 2008) download via KGIS

CURRENT ENGINE MECHANICAL SYSTEM PUBLICATIONS

The table below lists the Service Publications applicable to diagnosis and repair of Engine-related conditions at time of publication. Refer to KGIS for the latest Engine related service publications.

TSB No.	Subject	Model	Group	Component
KT2008052101 (SC073)	Sorento (BL) 3.5L Induction Control Valve/Lower Induction Manifold	Sorento (BL) 2003-2005	Engine Mechanical	Induction Control Valve/Lower Induction Manifold
KT2007070901 (SC072)(Updated 2007-08-13)	Sorento (BL) Crankshaft Bolt Replacement	Sorento (BL) 2003-2004	Engine Mechanical	Crankshaft Pulley Bolt
KT2007073101 (Engine-034)	Sorento (BL) Coolant Reservoir Replacement	Sorento (BL) 2003-2005	Cooling System	Coolant Reservoir Tank

KIA ENGINE SERIAL NUMBER LOCATIONS

These examples show Kia Reman Engine Serial No. tag location. Refer to Kia's electronic service information for OEM serial number location.