Di injector blowby cure??

[Graniterodder]

Hi guys, looking for some knowledge on this..

Just built a TDi on a Bosch pumped motor and fitted 'new' 100bhp injectors as part of the build. They were bought from Merlin Diesel and labelled as Stanadyne, so they are not the cheap foreign ones.

The engine has now been fitted into my Mk1 as an upgrade from the old asthmatic 70bhp Di that was already in there.

The engine will start and idle but has no power due to blow back through the injector ports - smoke and black fuel spraying out everywhere.. I've recut the seal cups and ensured it's all torqued up correctly but still getting it??

The injectors slide into the ports easily - there's no interference or resistance..

Are they too thin to seal properly?
Have I missed something obvious when fitting them?
Is there something I can fit into the port to stop this??

Any help/advice/abuse welcome..

Cheers

Mark

[jay]

I assume you fitted the injector washers at the seat bit. think they are copper washers

[meerkatmag]

My di uses the older larger injectors and won't fit the pencil standyne style. Are you.sure you don't have one of the earlier heads that need the bigger injectors?

[Keef]

Are both of the sealing washers in place and did all the old ones come out with the old injectors?

injector.jpg