[Vwdiesel] Injector testing/new nozzles

[LBaird119 at aol.com]

> For those who have done this before, what is the consensus with injector 
> nozzle replacement? Can I just install new nozzles &heat shields and 
> leave it at the that? Or is testing the break pressure, etc. necessary? ie: 
> do 
> the springs and shims wear over time so that break pressures drop, even 
> with new nozzles? 
> Those who have tested pressures: how often are worn injectors still out of 
> spec with new nozzles?
> 

  The biggest thing about testing them is to "clear" them out and 
get a good spray.  It usually seems to take a couple, fast, way 
over the top gushes from the tester to get a good pattern.  I suppose 
they'd clear in the car too.
  When you do new nozzles you nearly always need a little #400 
wet/dry sandpaper, oil and a flat surface like a drill press table or 
a piece of glass.  The upper body, and both sides of the intermediate 
piece need "ground" smooth again.  There will be ridges showing on 
the upper body and the smoothest side of the intermediate piece.  You 
need to sand off 90% of those ridges and make sure the double 
ringed sided of the intermediate piece is flat and smooth as well.  
Rinse everything in diesel, brakleen or WD-40 and make sure you 
have diesel, atf or at least WD saturating the nozzle's pintle and 
hole.
  I brakleen and blow off the body halves and use a dab of antisieze
on the threads, well above the mating surface.
  The little that you sand off nearly always puts the break pressure 
right in the "new" specs.  :-)
     Loren