[Vwdiesel] Rebuilding injectors

[Libbybapa at wmconnect.com]

Today I also rebuilt a set of injectors for the Q TD.  I thought I would 
share a few things in that regard.  I found that a couple of the injectors in the 
last set I rebuilt weeped slightly.  I previously have hand lapped the top 
half of the injectors where they meet.  The problem is due IMO to the inabilty to 
keep the injector perfectly perpindicular to the sandpaper while lapping.  My 
solution was to use a planed 1 1/2" thick piece of oak to make a jig to hold 
the injector perpindicular.  I drilled a stepped hole into the oak to fit the 
injector body snugly.  That was placed on top of the paper on top of the flat 
and the injector body was rotated within in.  I could tell that the set had 
been rebuilt previously and a couple of the faces were at a slight angle and 
probably would have weeped.  I will create a "handle" to fit over the injector 
body to save my sore fingers next time.
A while back I purchased a 10" diameter 3,000 psi gauge.  It registers in 10 
psi increments.  I have found that sanding the mating face of the top half of 
the injector raises the breaking pressure and sanding the spring lowers it.  I 
was able to adjust the breaking pressures of the four injectors to within 10 
psi of each other.  Prior to adjustment, with new nozzles, the injectors 
varied 80 psi between the four, but all fell within the low and high specs in 
Bentley.
I will also add a fairly powerful exhaust fan for next time.
  
Andrew