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 KIA MOTORS AMERICA, INC.

   NOTE: With a wire cutter, carefully grab and pull out the sealing ring into a small loop and then cut it out. Be careful not to damage the surface of the valve sleeve with the wire cutter.
2. Before reassembling the sealing ring, clean the groove with a clean cloth.

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

   Courtesy of KIA MOTORS AMERICA, INC.

   NOTE: 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 so as 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 KIA MOTORS AMERICA, INC.

   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.

   Courtesy of KIA MOTORS AMERICA, INC.

5. Pull the injector out of the sizing tool by turning it in the reverse direction of the press-in process.
   NOTE: 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 that the combustion seal (A) is correctly installed.

   Courtesy of KIA MOTORS AMERICA, INC.