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 Using Wire Cutter

   Courtesy of HYUNDAI MOTOR AMERICA
   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 Injector Sealing Surface Using Brass Wire Brush

   Courtesy of HYUNDAI MOTOR AMERICA
   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 Combustion Seal

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   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 Downward Near Bottom

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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: Pressing Seal Over Injector Using SST (09353-2B000)

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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: Inspecting Seal Damage

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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 Tool For Reducing Size Of Seal

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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 re-sizing of the seal.

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

   Fig 9: Twisting While 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: Identifying 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 Seal Stepped Rubber Side

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13. The flat washer side of the seal goes towards the head.
    Fig 13: Identifying Seal Flat Washer Side

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