Fuel Dist. Rebuild

[quk@isham-research.demon.co.uk (Phil Payne)]

In message <3443C398.3D29@ast.lmco.com> russ southerlin writes:

> I think I saw in the archives where back in Aug. you were trying to come
> up with parts and procedure for rebuilding fuel distribotors. Well I did
> the dumb thing of taking mine apart (thought it was contaminated) and
> now it is leaking. Any help would be appreciated.

This has so far been a long learning curve, and we're not done yet.

1) _EVERYTHING_ must be scrupulously clean.  I mean CLEAN.  Fibres from
   paper tissues are enough to cause leaks.

2) Clean, clean, clean and dry everything.  Remove all traces of coating
   from the diaphragm and the metal faces.  It usually takes us about an
   hour to prepare a head for resealing.

3) Orient the diaphragm.  There's a tiny (almost invisible) hole in it
   that forces orientation - there's only one correct orientation.

4) Seating the plunger housing requires six fingers - hence the joke around
   here that a fellow motorist with a single finger extended is merely offering
   to help.  Alternatively, the six tiny O-rings can be held in place by a
   very small, wide rubber band.

5) The sealant we have found to work is Loctite 54266.  It's a thin reddish
   liquid.  Method of application is with a fine (artist's) paintbrush to both
   of the casting faces.

6) The screws that hold the thing together should be tightened crosswise in
   stages to 6.5 lb ft.

7) Loctite 54266 takes 24 hours to cure, but we've used heads that have been
   together only a couple of hours without problems.

Yes, we can now get as many spares as we need, but the lead time is several
weeks.  We have another workshop session planned for this coming Sunday
evening.

--
 Phil Payne
 Committee Member, UK Audi [ur-]quattro Owners Club