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: Locating 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 assembling the sealing ring, the groove must be cleaned using a clean cloth.

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

   Fig 2: Removing Caulking From Injector

   Courtesy of KIA MOTORS AMERICA, INC.
   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.

   Fig 3: Pushing Seal Installing Guide

   Courtesy of KIA MOTORS AMERICA, INC.
   Fig 4: Pushing Sealing Ring

   Courtesy of KIA MOTORS AMERICA, INC.
4. To size the sealing ring the injector is first introduced into the sizing tool (A) (SST No.: 09353-2B000) and then pressed and at the same time rotated 180° into the sizing tool.
   Fig 5: Pressing Sizing Tool And Rotating At 180 Degree

   Courtesy of KIA MOTORS AMERICA, INC.
5. Pull the injector out of the sizing tool by turning it in the reverse direction to that used for the press-in process.
   CAUTION: Check that the seal ring has not been damaged during assembly to 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.

Fig 6: Locating Combustion Seal

Courtesy of KIA MOTORS AMERICA, INC.