Repair Procedures: Replacement

The injector combustion seal should be replaced with a new one to prevent leakage after removing the injector.

1. Remove the combustion seal (A) with a wire cutter.

   Courtesy of HYUNDAI MOTOR AMERICA

   CAUTION:

   • Grip the sealing ring carefully, pull it to form a small loop and then cut it.
   • Be careful not to damage the surface of the valve sleeve with the wire cutter.
2. Before the assembly of the sealing ring the groove must be cleaned with a clean cloth.

   Any coking of the injector sealing surface must be carefully removed with a brass-wire brush.

   Courtesy of HYUNDAI MOTOR AMERICA

   CAUTION:

   • The surfaces of the new sealing ring must be clean and free of grease.
3. Place the seal installing guide (B) (SST No.: 09353-2B000) on the tip of the injector not to damage the injector tip (A).

   Push the sealing ring (C) with thumb and index finger over the conical assembly tool until it snaps into the groove.

   The complete assembly must not take longer than 2 to 3 seconds.

   Courtesy of HYUNDAI MOTOR AMERICA

   Courtesy of HYUNDAI MOTOR AMERICA

4. To measure the size of the sealing ring, the injector is first inserted into the sizing tool (A) (SST No.: 09353-2B000) and then pressed and at the same time rotated 180° into the sizing tool.

   Courtesy of HYUNDAI MOTOR AMERICA

5. Pull the injector out of the sizing tool by turning it in the reverse direction to the one used for the press-in process.
   CAUTION:

   • Check that the seal ring has not been damaged during assembly by the injector and that no circumferential scratches are present.
   • Do not reuse the combustion seal.
   • The seal must be completely free of grease and oil.
6. Check the combustion seal (A) installation.

   Courtesy of HYUNDAI MOTOR AMERICA