plunger fell out of fuel distributor

[kbendor]

I got a rebuilt fuel distributor from DMC about an year ago and I'm finally to then point when it's ready to be installed. I noticed that the plunger was stuck up in the fuel distributor so I used a q-tip and some acetone to try and get it loose. It did get loose but unfortunately, the plunger came all the way out and now it won't fit back in. Any suggestions?

-Ken

[dmc6960]

Its a micron-tolerance machine fit. It literally holds back the 80psi fuel with no extra seals, yet can slide in its housing (I may be wrong on this one as I've never had a distributor apart, perhaps there is an o-ring in there, but the tolerance for fit is still extremely tight). You need to get it perfectly aligned, then let it glide itself back in, don't force it. On the other hand, if it hit a hard floor like concrete when it fell out, it may have been deformed and will now never go back in.

[Delorean Industries]

If it hit anything hard when it fell out then you are definitely going to have an issue getting it back into place. What did it hit?

[David T]

The plunger is a very finely machined piece. If it struck and damaged an edge you may be able to carefully smooth the burr off with some croacus cloth. The plunger is fitted to the fuel regulator so if you damaged the plunger the mixture unit is junk, you cannot just buy a plunger.
David Teitelbaum