SUBSEQUENT REPAIR ACTION

Introduction

This bulletin provides information related to the Technical Service Bulletin previously published in (PI1805) titled “Knock Sensor Detection System - ECU Logic Improvement” for certain 2019MY Optima (JFa), Sorento (UMa) and Sportage (QL) vehicles equipped with a 2.4L GDI or 2.0L T-GDI engine (Refer to page 9 for production dates). 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).

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. Before conducting the procedure, verify the vehicle is included in the list of affected VINs.

Refer to the flowcharts found on pages 2-6, then follow the appropriate procedure as outlined in this bulletin.

Note: Certain limitations may apply to this Product Improvement Campaign coverage. Refer to Warranty Bulletin 2024-02 for more details.

Important Information & Notices

[IMPORTANT] A Vehicle Diagnosis Number (VDN) must be created with or without DTC P1326, after scanning for DTCs, prior to performing PI1805Y/Z. If a VDN is not created, Warranty claim submission issues WILL occur.

[NOTICE] To assure complete customer satisfaction, always remember to refer to KDealer+ 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.

A printed copy is for reference only; publication information can be updated at any time. Always refer to KGIS for the latest information. After logging in kdealer.com, the newest technical publications are listed in ‘Service Releases’ and has the latest service information that has been released.

Main Flowchart Overview

The main flowchart guides technicians through diagnosing and addressing DTC P1326. Key steps include:

• Vehicle In: Validate Warranty, Confirm customer complaint, note if vehicle was towed in.
• Oil Inspection: Perform oil dipstick, oil cap, and oil filler opening inspection. This involves recording video and taking photos of the dipstick reading, inside of the oil filler cap, and inside of the oil filler opening.
• KSDS Installed or DTC P1326 Stored: If the Knock Sensor Detection System (KSDS) is installed or DTC P1326 is stored, proceed to specific flowcharts (A, B, or C) as detailed in Appendix 2.
• Oil Inspection Results: If the oil inspection is 'OK', proceed to maintenance verification. If 'NG' (Not Good), open a Techline Repair Assistance (RA) case.
• Maintenance Verification: Verify proper maintenance per Appendix 1. This may involve requesting maintenance records from the customer.
• Repair Coverage: If maintenance is not verified or records are insufficient, the vehicle may fall under "No Repair Coverage Diagnosis Claim Only P180S".
• Vehicle Out: The final state if no repair is covered or the process is complete.

Technicians should follow the applicable flowchart based on the customer complaint:

• A. DTC P1326 Stored (Page 4)
• B. ENGINE NOISE (Page 5)
• C. ENGINE, NO CRANK (Page 6)

Oil Condition and Oil Level Inspection Details

This section outlines the procedure for inspecting oil condition and level:

1. Start video showing the 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.
5. Inspect the inner/bottom of the oil cap and inside oil filler opening. Record/Note findings: Oil sludge, varnish, burnt oil smell condition(s) found.
6. Inspect the inner/bottom of the oil cap and inside oil filler opening. Record/Note findings: Oil sludge, varnish, burnt oil smell condition(s) found.
7. Take a picture of both, the bottom of the oil cap and oil filler opening.

[NOTICE] If oil lacquering, oil sludge or oil varnish is present, then the engine is therefore suspect to maintenance neglect. Review of the vehicle's maintenance history is required.

Oil Level Measurement (Flowcharts B & C ➡️ PWA Request)

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.

Flowchart A: DTC P1326 STORED

Procedure: Create PI1805Y Claim – No Techline PWA Required

Steps:

1. Perform a full system DTC scan and generate a VDN.
2. Save Freeze frame Data.
3. Perform BCT (Bearing Clearance Test).
4. BCT Result: PASS (OK)
   • Check for updated software.
   • If KSDS Software Update is available, proceed to "Repair Completed".
   • If KSDS Software Update is not available, check for updated software and perform KDS Software Update.
5. BCT Result: NO PASS (NG)
   • Replace Engine.

[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.

Flowchart B: ENGINE NOISE

Procedure: Techline PWA Required; Diagnosis only Campaign Possible

Steps:

1. Check oil level and document on the RO.
2. Perform a full system DTC scan and generate VDN.
3. Perform BCT.
4. BCT Result: PASS (OK)
   • Proceed to PWA PROCESS (Incl. Oil Level Measurement).
   • If connecting rod bearing noise is confirmed, diagnosis coverage only applies; any required repairs are to be completed using normal service procedures. Do Not Submit as a Campaign Claim.
5. BCT Result: NO PASS (NG)
   • Replace Engine.
6. Check if a software update is available. If yes, check updated software and perform KDS Software Update. Refer to PI1805 (As Applicable).

[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.

Flowchart C: ENGINE NO CRANK

Procedure: Techline PWA Required; Diagnosis only Campaign Possible

Steps:

1. Measure the remaining oil in the crankcase. Ensure there is at least 1 quart remaining.
2. Perform a full system DTC scan and generate VDN.
3. Remove engine drive belt and spark plugs.
4. Document engine rotational torque [VIDEO].
5. Check Max. Torque Value (94 lb.ft.).
6. If Under 94 lb.ft.: Perform BCT. If BCT Result is NO PASS, proceed to PWA PROCESS (Incl. Oil Level Measurement) and then Engine R&R with TL PWA.
7. If Over 94 lb.ft.: Perform BCT. If BCT Result is PASS, proceed to Engine R&R + ECU Software Update with TL PWA.
8. If oil level in the crankcase was less than 1 quart, Replace Engine.

[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.

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.

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. Install all removed components from the old engine block onto the new engine block utilizing all parts from Service Kit(s).
4. Reinstall the assembled engine and transmission/transaxle into the vehicle.
5. 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.
6. Confirm that the Rom ID is up-to-date. If not, reflash the ECU to the latest ROM ID available. Refer to PI1805 – Knock Sensor Detection System ECU Logic Improvement.
7. 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.

Knock Sensor Replacement Procedure

1. Replace the knock sensor (A) by referring to the “Engine Control / Fuel System → Engine Control System → Knock Sensor (KS) → Repair Procedures” chapter in the applicable Shop Manual on KGIS.

Affected Vehicle Range

Required Tools

Required Parts

Note: You may receive an engine with a part number ending in “QQK” when a part number ending in “QQKR" was ordered. Both part numbers are interchangeable and acceptable in the warranty claim.

*Oil Cooler Tube assembly replacement is conditional, refer to instructions outlined in KGIS (if applicable).

Warranty Claim Information

Note: Photo requirement for Warranty Claim submission as outlined in TSB PI1805: Separate photos of the oil dipstick reading, oil filler cap, oil filter opening must be attached to the claim using Warranty Claim Attachment type 'XX - Other'. Failure to provide the required photos may result in claim rejection or chargeback. Refer to Warranty Bulletin 2024-02 for details regarding coolant and substitute transportation reimbursement requirements.

Appendix 1: Techline Prior Work Authorization

Inspection Type | Findings | Action

Note: Customers who perform their own maintenance may provide a service record log along with receipts for the purchase of oil filter and engine oil.

Maintenance Record Request | Maintenance Record Results | Action

Note: Using KDS, take (3) photos: 1. Oil Dipstick Reading 2. Inside Oil Filler Cap 3. Inside Oil Filler Opening.

Appendix 2: Techline Prior Work Authorization (PWA)

Note: Additional information may be requested by the Techline agent, including but not limited to screenshot of the stored DTC(s), ROM ID and Bearing Clearance Test (BCT) results.

[NOTICE] VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference PI1805* when accessing the KDealer+ system.

Appendix 3: Video Capture & Upload

Note: Additional information required to open a Techline case including but not limited to screenshot of the stored DTC(s), ROM ID and Bearing Clearance Test (BCT) results. The Chrome™ browser should be used to access the Techline portal.

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. (URL: 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 (e.g., Engine Noise - record engine; Hole In Block - record side of engine; Seized Engine - record technician trying to turn engine with torque wrench).

7. [NOTICE] 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.

8. Stop the video when you captured what is needed. Select “OK” to use this capture or "RETRY” to capture the video again.
9. Ensure a description of the recording (e.g., engine knock or smoke from exhaust).
10. Select "Submit Case".
11. Select "Yes" when the confirmation message appears. (Note: Selecting anything other than “Yes” will not save the video capture.)