Repair procedures: Replacement

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

1. Remove the combustion seal (A) with a wire cutter.
   Fig 1: Identifying Combustion Seal

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   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 using a clean cloth.

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

   Fig 2: Removing Injector Sealing Surface Coking Using Brass-Wire Brush

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   CAUTION: The surfaces of the new sealing ring must be clean and free of grease.
3. Place the combustion seal on the cone and pull downward on the seal as indicated in the photo.
   Fig 3: Pulling Combustion Seal Downward On Cone

   Courtesy of KIA MOTORS AMERICA, INC.
   NOTE: Your fingers will work better for installing the Combustion Seal over the cone.
4. Pull the seal downward until it is near the bottom of the cone as shown in the photo.
   Fig 4: Pulling Combustion Seal To Bottom Of Cone

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5. Place the cone (with seal) on the end of the injector.

   Place the sizing tool (SST No.: 09353-2B000) over the cone. Make sure the tool flange is toward the seal as shown.

   Press down on the tool to work the seal over the injector and into the groove.

   Fig 5: Installing Combustion Seal On Injector And Grooves Using Tool

   Courtesy of KIA MOTORS AMERICA, INC.
6. Because the seal will stretch as it goes over the end of the injector, it will be a bit oversized after installation.

   By letting the injector and seal set for a few minutes, the seal may reduce in size.

   Inspect the seal for damage before continuing.

   Fig 6: Checking Combustion Seal For Damages

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7. Place the resizing tool (flange up) over the seal. Twist the tool slightly while pushing down over the seal. This should reduce the size of the seal.
   Fig 7: Reducing Combustion Seal Size Using Tool

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   CAUTION: Be careful not to apply engine oil on the combustion seal ring.
8. Place injector into the head as shown.
   Fig 8: Placing Injector Into Head

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9. Twist slightly while pressing the injector into position in the head.

   This should complete the resizing of the seal.

   Remove the injector and inspect the seal before completing the injector installation process.

   Fig 9: Pressing Injector Into Head Position

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10. If the injector comes with a protective steel washer held in place by a spring clip; both will have to be removed before installation.
    Fig 10: Removing Spring Clip And Steel Washer

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11. Install the Washer Seal onto injector with the rubber side (stepped) toward the injector.
    Fig 11: Installing Washer Seal Onto Injector

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12. The stepped rubber side of the seal goes towards the injector.
    Fig 12: Identifying Stepped Rubber Side Of Seal

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13. The flat washer side of the seal goes towards the head.

Fig 13: Identifying Flat Washer Side Of Seal

Courtesy of KIA MOTORS AMERICA, INC.