Engine Replacement Instructions For DTC P1326 Pi2106Y/Z (PI2106Y/Z)

ENGINE REPLACEMENT INSTRUCTIONS FOR DTC P1326 PI2106Y/Z

SERVICE CAMPAIGN BULLETIN

SERVICE INFORMATION

This bulletin provides information related to the Technical Service Bulletin previously published (PI2106) titled "Nu 2.0L GDI - Knock Sensor Detection System ECU Logic Improvement". Specifically, this bulletin provides instructions on which procedures to follow if, after installation of the KSDS, any one of the subject vehicles below return to the dealer with Diagnostic Trouble Code (DTC) P1326 (Knock Signal Range/Performance).

Model List: 

MY	Model	Engine	Production Date
2017-2018	Forte (YD, YDm)	Nu 2.0L GDI	May 19, 2016 to May 7, 2018

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 pages 2-4, then follow the appropriate procedure as outlined in this bulletin  . Before conducting the procedure, verify the vehicle is included in the list of affected VINs.

A Vehicle Diagnosis Number (VDN)  must be created with or without DTC P1326, after scanning for DTCs, prior to performing PI2106Y/Z. If a VDN is not created, Warranty claim submission issues WILL occur. 

MAIN FLOWCHART

Follow the applicable flowchart upon documenting customer complaint for one (1) of the three (3) following concerns from Main Flowchart: 

1. DTC P1326 Stored... (Page 4)
2. ENGINE NOISE... (Page 5)
3. ENGINE, NO CRANK... (Page 6)

OIL CONDITION AND OIL LEVEL INSPECTION: (MAIN FLOWCHART)

1. Start video showing vehicle and move in towards the dash VIN tag.
2. Measure and record oil dip stick level.
3. Note oil dip stick reading on the RO.
4. Take a picture of the oil reading on dipstick.

   Inspect the inner/bottom of the oil cap and

5. inside oil filler opening.

   Take a picture of both  , the bottom of the oil

6. cap and oil filler opening.

   Record/Note findings:  No oil, oil sludge, varnish, burnt oil smell condition(s) found.

   NOTE: If NO oil is registered on the dipstick, or oil lacquering, oil sludge and/or oil varnish is present (NG), then the engine is therefore suspect to maintenance neglect. Review of the vehicle's maintenance history is required.
   If suspect  , proceed to the 'Oil Level Measurement' instructions below and submit with the Techline case. 

OIL LEVEL MEASUREMENT: (MAIN FLOWCHART → PWA REQUEST) NO OIL READING ON DIPSTICK

1. Remove oil filler cap, remove oil drain plug and drain oil into the measuring container SST067BUCK and check oil level.
2. Record oil level reading on the RO.
3. Take photo of the drained oil container  using KDS and attach to warranty claim PWA request  .

A. DTC P1326 Stored 

Create PI2106Y Claim - No Techline PWA Required 

KNOCK SENSOR REPLACEMENT PROCEDURE

1. Replace the knock sensor by referring to the "Engine Control/Fuel System → Engine Control System → Knock Sensor → Repair procedures" chapter in the applicable Shop Manual on KGIS.

B. Engine Noise 

Techline PWA Required; Diagnosis Only Campaign Possible 

C. Engine No Crank 

Techline PWA Required; Diagnosis Only Campaign Possible 

ENGINE REPLACEMENT PROCEDURE

1. Replace the engine assembly by referring to the "Engine Mechanical System → Engine And Transaxle Assembly → Engine And 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. Install all removed components from the old engine block onto the new engine block utilizing all parts from Service Kit(s)  .
   NOTE: Refer to TSB ENG083  for gasoline direct injection (GDI) specific information, including related warnings and cautions for handling high fuel pressure system components and combustion seals must be compressed after installation and before attempting to install into the cylinder head. Use SST 09353 2B000.
4. Reinstall the assembled engine and transmission/transaxle into the vehicle.

   Be sure to:

   • Fill crankcase with 5W-30 oil (refer to KGIS for oil fill level requirements)
   • Recommended Product: QUARTZ 9000 FUTURE FGC 5W-30 Full Synthetic  SN PLUS, QUARTZ 9000 FUTURE XT 5W30 Full Synthetic  SN PLUS,

     Mobil Super Synthetic 5W30 or above.

     If not available, use other brand 5W30 and Full Synthetic  type with API SN/SN+/SP, ILSAC GF4/GF5 or higher service grade.

   • Fill and bleed the cooling system with 50/50 coolant or mixture appropriate for area.
   • Pressurize the fuel system before starting the vehicle.
   • Reset engine adaptive values and perform steering angle sensor calibration.
5. Confirm that the Rom ID is up-to-date. If not, reflash the ECU to the latest ROM ID available. Refer to PI2106 - Knock Sensor Detection System ECU Logic Improvement.
6. Verify proper operation of the vehicle with road test, and with the engine ON (running), erase any stored DTCs  (e.g., EPS, ESC, and TPMS) that may have been set by this procedure. Verify no leaks exist and ensure engine oil and coolant are at their proper level.

   If any DTCs are still active, follow any related diagnosis and repair as needed.

AFFECTED VEHICLE RANGE

Model	Production Date Range
Forte (YD, YDm)	May 19, 2016 to May 7, 2018

REQUIRED TOOL

Tool Name	Tool Part No.	Figure	Comments
Torque Wrench Socket	09314 3Q100		Refer to TSB ENG083  for detailed usage instructions
Injector Combustion Seal Ring Installer	09353 2B000
Click-Type or Electronic Torque Wrench	N/A		Locally Sourced
Bearing Clearance Tester Kit	KQ231 2T110QQK		Auto-shipped to Dealers For troubleshooting assistance contact the GITA Support Line at: (888) 542-4371.  For replacement parts, contact Snap-On Tools at: (888) 542-1011.

REQUIRED PARTS

Part Name	MY	Model	Part Number	Figure
Engine Long Block (Nu 2.0L GDI)	17-18MY	YD	21101 2EG12FFFR
		YDm	21101 2EG17FFFR

SERVICE KITS

Models	Part Name	Engine	Part Number	Figure
YD/YDm	Service Kit	2.0L GDI	21111 2EG01FFF
	Fuel Tube		35305 2E510FFF
	Knock Sensor		39250 2E000	N/A

WARRANTY CLAIM INFORMATION FOR

PI2106 Y1  , PI2106 Z1  and PI210S  (DIAGNOSIS ONLY CLAIMS):

Flow Chart Symptom #A	Diagnostics	Repairs
PI2106Y  DTC P1326 (No TL PWA Required)	BCT Pass	R & R Knock Sensor
		ECU Upgrade
	BCT No Pass	Engine R & R
		Engine R & R + ECU Software Update
Flow Chart Symptom #B	Diagnostics	Repairs
PI2106Z  Engine Noise (TL PWA Required  )	Check Oil + BCT Pass	Inspection + Noise Check (N) (PI210S Claim)  Repairs under normal warranty coverage MAY apply. Separate TL PWA case required
		Noise Check + TL PWA + Engine R & R
		Noise Check + TL PWA + Engine R & R + ECU Software Update
	Check Oil + BCT No Pass	Engine R & R with TL PWA
		Engine R & R with TL PWA + ECU Software Update
Flow Chart Symptom #C	Diagnostics	Repairs
PI2106Z  Engine No Crank (TL PWA Required  )	Check Oil Amount + Check Crank Rotation (+ 94lb.ft)	Inspection Only (PI210S Claim)  - Repairs under normal warranty coverage MAY apply - separate TL PWA case required)
	Check Oil Amount + Crank Rotation (- 94lb.ft) + BCT Pass	Diagnosis Only (PI210S Claim)  - Repairs under normal warranty coverage MAY apply - separate TL PWA case required)
	Check Oil Amount + Crank Rotation (-94lb.ft) + BCT No Pass	Engine R & R with TL PWA
		Engine R & R + ECU Software Update with TL PWA
	Check Oil Amount + Crank Rotation (+94lb.ft) (no BCT)	Engine R & R with TL PWA
		Engine R & R + ECU Software Update with TL PWA

APPENDIX 1 (TECHLINE PRIOR WORK AUTHORIZATION)

Inspection Type	Findings	Action
Oil Dipstick  Oil Filler Cap  Oil Filler Opening  NOTE: Using KDS, take (3) photos: Oil Dipstick Reading Inside Oil Filler Cap Inside Oil Filler Opening	Suspect Exceptional Neglect (NG)  Physical inspection of engine shows oil sludge/buildup/varnish.	Perform Oil Level Measurement  Dealers are to empty crankcase oil into a measuring container and record findings. NOTE: Take a photo of the oil level using KDS. Request Maintenance Records:  Customers may be required to provide Maintenance Records in the absence of  sufficient CP/Carfax data. Customers have 5 business days to respond to dealer's request for maintenance records (or to confirm that they are gathering records and/or need additional time), in which case customers will be permitted an additional 5 business days (10 days total) to produce records or  confirm they do not have records to provide.
	Oil level & Oil condition (OK)	KSDS Installed or DTC P1326 Stored?  Applicable Flowchart A, B or C.

Maintenance Record Request	Maintenance Record Results	Action
Kia is required to verify Oil change records from dealers, Carfax (or similar reputable 3 rd  . parties) but may also request maintenance records from the customer.	One oil change gap of greater than 14 months and/or 10,500 miles. Previous diagnosis of excessive oil consumption issues but the customer did not obtain a repair to address such issues within 30 days or 1,000 miles (whichever comes first), subsequent after a completed oil consumption testing and confirmed diagnosis. No "Exceptional Neglect" can apply to otherwise eligible engine failures that occur within a Class Vehicle's first 15,000 miles.	Exceptional Neglect Determined. Any repairs performed are the customer's responsibility or insurable extended warranty plan. Diagnosis Coverage Only.
	Maintenance Records Provided	Repair Assistance (RA)

APPENDIX 2 TECHLINE PRIOR WORK AUTHORIZATION (PWA)

Scenario	Description	Action Required
Flowchart A	DTC P1326 Stored	No TL PWA required.
Flowchart B	Engine Noise	TL PWA required for all dealers - Video of condition  Video requirement examples below are for illustration purposes, individual requirements will vary based upon the condition reported: Video should be continuous and show the VIN (most convenient VIN plate) and pan to show the engine condition. For engine seizures, attempt to turn over engine with torque wrench in video and exceeding 94 lb.ft. For hole in engine block, show hole in video For severe engine noise demonstrate severity of the noise without over accelerating (to RPM redline) the engine in video (Refer to APPENDIX 3 )
Flowchart C	Engine Seized Bearing Clearance Test or  No Test

VIDEO INSTRUCTIONS FOR SEIZED ENGINE INSPECTION: (FLOWCHART C)

Prepare the vehicle prior to the video by removing the spark plugs and drive belt as well as setting the torque wrench to 94 lb.ft. 

1. Start video showing the vehicle being worked on and move the camera in towards the dash VIN tag.
   NOTE: Continue filming video until step 7.
2. Show the removed spark plugs.
3. Show the empty spark plug holes from the engine.
4. Show the removed drive belt and attached torque wrench to crank bolt.
5. Show the engine being cranked and torque specification exceeding 94 lb.ft. torque.
6. Submit video with Techline PWA case.

APPENDIX 3 (VIDEO CAPTURE & UPLOAD)

The Chrome™ browser should be used to access the Techline portal. Follow the steps below to clear the default browser if it is other than Chrome™.

For KDS Tab 10.1 Tablets: 

1. Select "Settings" from the App Screen.
2. Select the "General" tab at the top.
3. Select "Default Applications".
4. If "Internet" is the default browser, select the CLEAR button.

   If "Chrome" is the default browser, further action is not required.

5. When opening the Techline portal, select "Chrome" and select Always".

For KDS Tab S2 Tablets: 

1. Select "Settings" from the App Screen.
2. Select "Applications".
3. Select "Default Applications".
4. Select "Browser app".
5. Ensure "Chrome" is selected.

ATTACHING VIDEO TO A TECHLINE CASE

1. Open K-Support in the device Chrome™ browser or select the "Techline" button on KDS home page.

   https://ksupport.kiausa.com 

2. Open your existing Techline case for the vehicle requiring a video capture by selecting the case number.
3. Select 'Attachment'  .
4. Select 'Add Files'  .
5. Select 'Camcorder'  and the video camera will open.
6. Start by recording the VIN. Ensure sun glare is not reflecting off windows or other objects.

   Without stopping the recording, capture the area of the vehicle displaying the issue. i.e.;

   • Engine Noise - record the engine.
   • Hole In Block - record the side of the engine with the damage.
   • Seized Engine - record a technician trying to turn the engine over with a torque wrench.
   NOTE: Ensure the video size is set to "Limit to email". Only record the VIN and the engine exhibiting the concern  . Any additional information will increase the size of the video and make it difficult to upload or download.
7. Stop the video when you captured what is needed. Select "OK" to use this capture or "RETRY" to capture the video again.
8. Ensure a description of the recording. For example, engine knock or smoke from exhaust.
9. Select 'Submit Case'  .
10. Select 'Yes'  when the confirmation message below appears.
    NOTE: Selecting anything other than "Yes" will not save the video capture.