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: Removing Combustion Seal

   Courtesy of KIA MOTORS AMERICA, INC.
   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: Cleaning Sealing Ring Groove

   Courtesy of KIA MOTORS AMERICA, INC.
   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 Downward On Seal

   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 displayed in the photo.
   Fig 4: Seal Near Bottom Of Cone

   Courtesy of KIA MOTORS AMERICA, INC.
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 displayed. Press down on the tool to work the seal over the injector and into the groove.
   Fig 5: Pressing Down On Tool To Work Seal Over Injector Into Groove

   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: Combustion Seal

   Courtesy of KIA MOTORS AMERICA, INC.
7. Place the re-sizing 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: Twisting Re-sizing Tool

   Courtesy of KIA MOTORS AMERICA, INC.
   CAUTION:

   Be careful not to apply engine oil on the combustion seal ring.

8. Place injector into the head as displayed.
   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 re-sizing of the seal. Remove the injector and inspect the seal before completing the injector installation process.
   Fig 9: Twisting & Pressing Injector

   Courtesy of KIA MOTORS AMERICA, INC.
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: Spring Clip & 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

    Courtesy of KIA MOTORS AMERICA, INC.
12. The stepped rubber side of the seal goes towards the injector.
    Fig 12: Stepped Rubber Side Of Seal

    Courtesy of KIA MOTORS AMERICA, INC.
13. The flat washer side of the seal goes towards the head.
    Fig 13: Flat Washer Side Of Seal

    Courtesy of KIA MOTORS AMERICA, INC.