Yeah or interference fit, pressed in like you said. Then probably lapped. I don't have a granite flat surface at my shop for relapping.
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I finally found my reference material. After viewing THIS VID, I'm with you on the shims (Sorry, played with too many different systems over the years...;-).
What you are saying makes sense to me, IFF #1 and #3 shut off with the [air] plate all of the way up (and the CO screw backed out enough)...If #1 and #3 OK and are set up correctly (5.2mm to 5.3mm height), they should act normal.
"As the control plunger rises, and fuel flow into the differential-pressure valve increases, the fuel pressure deflects the diaphragm. This causes a proportional increase in the area of the fuel outlet to the injector and maintains the same pressure drop at the control-plunger slit. Even though there is more fuel flow through a more open slit, the differential between pressure inside the slit and pressure outside the slit is constant.It may seem, because the deflection of the diaphragm enlarges the outlet to the fuel injectors, that fuel metering is a
function of how close the diaphragm is to the outlet. But this is not the case. All fuel metering takes place at the control-plunger slits. The movement of the diaphragm acts only to maintain constant pressure drop-to eliminate pressure drop as a variant and maintain accurate metering to each injector, regardless of changing fuel flow rates."
(Bosch)
I'd suggest: open it up one more time, measure and record the stacked heights, and check if the nozzles are flush. That should tell you what is wrong here. If the nozzles are off, I'd just swap it out or send the whole thing off personally. (Not worth trying to get the precision required and risk leaks ect. concerning the nozzles.)
Probably would work if just milling a mill or two. But the surface grinder would give the best finish and maybe lapped on a surface block.
https://www.amazon.com/TTC-Thick-Gra...8128270&sr=8-4
I watched that video like 6 times.
Interestingly he never shows removing the shims or really says much about them. This was part of the reason that mine ended up all over the work bench and floor. I was using this video as my guide.
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Last night I took the FD apart one more time.
I couldn't find anything obvious wrong with it. Used a straight edge to check the depth of the nozzles. All of them appear to be exactly flush with the surface of the cover. The only thing I noticed was that the o ring on cylendar was damaged a bit. This seems to happen everytime even if we lube it before assembly. I don't see how this o ring being damaged would make only two ports feed too much fuel. Instead I would think if anything it would cause a fuel leak. Some of the o-rings on the slit ports look a bit funny, like they went in kind of dry. But non of them are ripped, or not over the little fuel ducts.
At this point I am throwing in the towel on this job. Attachment 67543Attachment 67544Attachment 67545
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