[Vwdiesel] Rebuilding injectors Vs. Replacing Injectors

[LBaird119 at aol.com]

In a message dated 2/9/2007 8:30:40 AM Pacific Standard Time, 
bryankwalton at machlink.com writes:

> I'd like to
> simply purchase new nozzles and rebuild the injectors myself.  Then,
> I'd just take the rebuilt injectors to be spray calibrated and pop
> tested.  But I've never done this before.  My question specifically is
> this: does there ever come a time when an injector should NOT be
> rebuilt?  In other words, do they eventually have to be replaced?
> 

  It's kind of a matter of what's your time worth?  For that 
year the nozzles are reasonable.  (later years my price is 
about the same for a nozzle as a complete, rebuilt injector!)
You have to disassemble, lap the bottom of the top half, and 
both sides of an intermediate piece with fine sandpaper a flat 
surface and oil.  Clean, clean, rinse and reassemble with dripping 
of diesel or WD-40.  Then you torque and hope all comes out right. 
Take it to a shop and have a few flushing pumps through it, 
check the pattern and pressure, set if needed and you're done.  
You'd save a LOT of time but spend about an additional $30 or 
so to just buy injectors and send in your cores.
  They don't always flush out the first time or seal up well and 
then it's back apart and try again.  Last leaking one I had I 
gave up and bought a rebuilt.  Two times of disassembly and 
I couldn't get it to seal up.  I have a tester so I can pressure 
them up too.  
 Bubbling around the outside of the injector is just the seal 
between the head and the injector shield.  I don't frankly see 
how it could ever NOT leak a little.  Nothing's really a "machined" 
looking surface other than where it meets the injector.
  Most of the time after lapping in the pieces your pressures 
will come out within spec, when using a new nozzle.  It's nearly 
never worth going back together with a used nozzle.
     Loren