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.

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   CAUTION:

   • Lightly pinch the sealing ring into 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, clean the groove with a clean cloth.

   Any coking of the injector sealing surface must be carefully removed with a 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 seal installing guide (B) (09353-2B000) on the tip of the injector to prevent damaging 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 KIA MOTORS AMERICA, INC.

   Courtesy of KIA MOTORS AMERICA, INC.

4. To measure the size of the sealing ring, insert the injector into the sizing tool (A) (09353-2B000). Then, rotate it 180° while pressing it into the sizing tool.

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5. Pull the injector out of the sizing tool by turning it in the reverse direction of 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 KIA MOTORS AMERICA, INC.