Engine - Remanufactured Engine Program
Model
Group
Engine Mechanical System(12)
Number
KT2009032501
Date: Friday, March 27, 2009
Area N. America
Subject
KIA Remanufactured Engine Program (Engine - 042)
Description
This bulletin introduces 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.
NOTICE:
This Technical Service Bulletin contains information related to Remanufactured Engine Program. Failure to comply with the instructions could result in charge back of all or portions of OEM or remanufactured engine claims and/or core credit.
Effective Vehicle Information
Parts Information
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 the form shown above)
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. 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.
NOTICE:
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 foreiture of core credit.
NOTICE:
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.
NOTICE
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. If you have any questions please contact the Kia Warranty Helpdesk.
10. Applicable core reimbursement will be issued following receipt and inspection of core and Engine Core Return Form.
NOTICE:
Disassemble only parts needed to swap from removed engine unit to installed remanufactured engine unit.
NOTICE:
KMA may deny/charge back all or portions of the OEM or remanufactured engine claims and/or core credit if:
^ Abused/Accident damage
^ Improper installation/removal
^ Improper packageing
^ 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
NOTICE:
Lost Packaging - Including the Kia authorized Returnable Container - call Parts Hotline.
Engine Core Data Form (WRTY 135 May 2008) download via KGIS
CURRENT ENGINE MECHANICAL SYSTEM PUBLICATIONS:
The table above 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.
KIA ENGINE SERIAL NUMBER LOCATIONS:
NOTICE:
Note: Record part number and serial number of both installed and removed units on Form (WRTY 135 May 2008) for ALL Engine replacements (new or remanufactured units).
These examples show Kia Reman Engine Serial No. tag location. Refer to Kia's electronic service information for OEM serial number location.