Campaign SA092 - Abnormal Hydraulic Lash Adjuster Noise
NUMBER 106GROUP Engine
DATE October 2011
MODEL 2012MY Soul (AM)
SUBJECT:
SERVICE ACTION: SOUL 2.0L ENGINE HLA INSPECTION AND REPLACEMENT (SA092)
This bulletin provides information relating to Some SOUL vehicles produced from June 30, 2011 to Aug. 29, 2011 with 2.0L Nu engine and that might exhibit and abnormal noise emanating from the HLAa (Hydraulic Lash Adjuster) due to lack of oil supply. To inspect for affected HLAs, remove the cylinder head valve cover and check if engine oil is flowing from the HLAs while cranking engine. If not, replace the affected HLA(s) with improved parts following the Service Procedure below. Minimize engine runtime prior to repair to avoid potential engine damage.
*NOTICE
A Service Action is a repair program without customer notification that is performed during the warranty period. Any dealer requesting to perform this repair outside the warranty period will require DPSM approval.
Repair status for a VIN is provided on WebDCS (Service > Warranty Coverage > Warranty Coverage Inquiry > Campaign Information). Not completed Recall / Service Action reports are available on WebDCS (Consumer Affairs > Not Completed Recall > Recall VIN > Select Report), which includes a list of affected vehicles.
The issue number is SA092.
HLA Inspection Procedure:
1. Place the ignition switch in the OFF position and open hood.
CAUTION
Make sure engine has cooled enough before working on it.
2. Disconnect CMPS (Camshaft Position Sensor) wiring connectors (A and B) as indicated by the arrows.
A: Exhaust CMPS connector
B: Intake CMPS connector
3. Disconnect the breather hose (C).
Disconnect the PCV (Positive crankcase ventilation) hose (D).
Disconnect the ignition coil connectors (E: 4EA).
4. Remove the ignition coils (F).
Tightening Torque: 7.2 - 8.7 lb-ft (9.8 - 11.8 Nm)
*NOTICE
Engine shown removed for clarification purposes only.
5. Remove the cylinder head cover (G).
*NOTICE
When reinstalling cylinder head cover bolts, tighten them in the sequence shown in the illustration above.
6. Tightening torque:
1st step: 3 - 4.3 lb-ft (4 - 5.9 Nm)
2nd step: 6 - 7.2 lb-ft (8 - 9.8 Nm)
7. Ask an assistant to crank the engine (ensuring that the battery is fully charged). Check each of 16 HLAs (circled in illustration above) for oil flow. Oil should be directed at the camshaft lobe in a steady and narrow stream, as shown in detail pictures below.
CAUTION
DO NOT crank the engine any longer than 30 seconds in a single instance. It may cause starter motor damage.
8. If one or more HLAs do not show oil flow, then request repair parts by opening a Techline case via the web and indicating the quantity of HLA replacements required.
If engine oil is flowing normally from all 16 HLAs, no further repair action will be required. Complete the procedure and reinstall all removed components in reverse order of removal.
HLA Replacement Procedure:
1. Set engine to TDC, ensuring that the TDC marks on the intake and exhaust gears are aligned.
2. Remove the camshaft bearing caps.
3. While applying a pry bar against the timing chain tensioner arm and lifting each camshaft (as shown above), remove all 16 swing arms and HLAs. Important: remove ALL 16 HLAs, regardless of the number of affected HLAs.
a. The HLAs farther from the CVVTs can be removed by hand.
b. The HLAs nearer to the CVVTs can be removed by disconnecting the HLAs from the swing arms and clips by using a trim removal tool (as shown above), and removing both pieces from the engine head.
4. Disconnect any remaining HLAs from swing arms (shown above).
5. Replace affected HLAs with new parts. Retain old/removed parts for possible DPSM inspection.
6. Drain oil from all 16 HLAs (including new parts) by inserting a pin into the top of each HLA and turning it upside-down until it can be compressed by hand as shown.
7. Reconnect the HLA to swing arms in the reverse order of disconnect procedure, either outside of engine or in engine, as per instructions 3 (a) and (b) above.
8. Reinstall camshaft bearing caps and torque to specs in the following sequence in several passes.
Tightening Torque Specs:
M6 bolts: 8.7 - 10.1 lb-ft (11.8 - 13.7 Nm)
M8 bolts: 13.7 - 16.6 lb-ft (18.6 - 22.6 Nm)
9. Turn the crankshaft clockwise for two revolutions, and check & ensure that the TDC marks are still aligned.
10. Reinstall the valve cover, and then torque the bolts in two steps in the sequence shown above.
Tightening Torque Specs:
1st step: 3 - 4.3 lb-ft (4 - 5.9 Nm)
2nd step: 6 - 7.2 lb-ft (8 - 9.8 Nm)
11. Reconnect CMPS, breather hose, PCV hose, and install ignition coils and connectors.
12. Run engine for 5 minutes at low to medium RPM to ensure oil flow to the HLAs. At this time any "top end" noise should dissipate.
AFFECTED PRODUCTION RANGE
REQUIRED PART
SERVICE ACTION WARRANTY CLAIM INFORMATION
*NOTICE
VIN inquiry data for this repair is provided for tracking purposes only. Kia retailers should reference SA092 when accessing the WebDCS system.