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I also feel that residual rubber particles remaining in the pump body from the deterioated o-rings is a contributing factor. You can have everything sparkling clean before removal and rinse the valve holder numerous times before reinstalling but will still have contaminated fuel that remains inside the lower portion of the valve.
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I agree. Short of dismantling the whole IP I think it's impossible to get it 100% clean after a delivery valve O-ring replacement. When you consider the secondary fuel filter is there to filter out exactly that sort of very fine grit it makes sense that there would be some impact related to it being downstream from the filter. Even cranking to clear out the injectors may not get it all.
A good way to know if this is a factor would be if someone had all their injectors rebuilt/replaced a few 100 miles after a delivery seal job. I assume you'd need some miles after the DV work to allow all the particles to clear out of the IP. Anyone out there done that? If so did the nailing get softer or stop after the injectors were replaced?