I removed all 5 of my injectors a few days ago to swap in the Bosio nozzles which cured most of my shaking problem. Now I have a new problem, 1 injector is dry, 2 are leaking a bit and 2 are STREAMING out of the middle of the injector where the 2 pieces screw together. They were torqued to the spec of 70 NM and the second time they came out I torqued them down as tight as I could before I feared cracking them. No change at either point. I know its NOT the return lines. I'm about to do the red-neck method of sealing them with a bit of high temp silicone sealant (not really) but I'm not sure where to go about solving this now. I have 10 more heat shields and more return line on its way due here on Tuesday.

__________________
Adam Lumsden
(83) 300D
Vice-President of the MBCA International Stars Section

How do those two sections seal to each other??

I didn't see any crush washer........or similar........when DG took them apart.

It is quite simply a metal to metal seal. You need to take a piece of flat e.g. plate glass, and use progressive grits of sandpaper (grit up) to hand lap the sealing surfaces up to 600 grit. The surfaces to focus on are the mating surface of the top half, and the two sides of the spacer between the top half and the nozzle. You need to remove the grooves in the metal from the previous assembling. Now that you have torqued them together without doing that, you probably ought to reface the top of the nozzle as well, as it has probably deformed to the previous grooves somewhat. With each of the parts you need to be sure that the part is held flat against the paper. If it is tipped it will not seal well afterwards. Be sure to use a sanding technique so that any irregularities in the sandpaper will be dispersed across the sealing surface. Use wet/dry paper and lube it with wd40 or diesel. Be sure to clean all parts meticulously prior to reassembly. Hopefully you haven't damaged/warped anything permanently by overtorqueing. Good luck.

I thought this might be of help and interest:

http://www.vwdiesel.net/phpBB/viewtopic.php?t=2828&postdays=0&postorder=asc&start=0

And this too:

http://www.vwdiesel.net/phpBB/viewtopic.php?t=2674

Andrew