Bubbles around glowplug

[Quantum-man]

Having not been reset, that heat shield will not be sealing onto the injector.Look up my research into shield reuse. The damage around the outer ring will allow diesel fumes to pass across to the threads. Fuel may be getting trapped in this gap and then dripping out at the wrong time. I suspect stray drip of an injector though.

Overtorquiing the injector into the head in an attempt to stop injector to head leaks, [which you don't mention] could damage the head boss under the heatshield, but will not affect the spray pattern.
After dismantling the injector bodies, be it for cleaning or nozzle replacement,this can affect spray patterns if over tightening of the body occurs in an attempt to prevent seepage between the two halves of the body.
What happens is that the tubular nozzle part actually distorts and creates sticky needles.

Nozzles often perform better after a break-in period. Quite possible that the lower quality of post warranty replacement nozzles result in greater leakoff spillage, compared with original OEM stuff . This leads to differing injection quantities, even if the break pressures are set the same, so replacement injectors may be less perfectly matched than you think. Only sure thing is to select best four out of six for example, and matched by timed leakage whilst measuring their break pressures.Or colect individual spillages whilst engine running.

Don't worry about the grease issue; almost impossible to block the injector lines due to immense pressure buildup.

[Flynn]

Okay so ruling out the injector lines, that leaves two distinct possibilities; the injectors are buggered up some how (BOTH sets); or the copper heatshield is indeed causing an issue. If it is the heatshield I'll ask around some garages to see if they will handle it (unlikely unless they are specialists) or attempt it myself if I have to (I have visions of the screw used to pull the washer falling into the injection port). But without eliminating one of the two possibilities further discussion is pointless, so I'll see what I can do and report back.

[Quantum-man]

Using a screw that actually screws into the shield wont fall through. A coach bolt should fit tight enough to rock it loose. Make a sliding hammer, if neccessary. Even I conceed that that shield needs replacing, and that's some admission for me LOL.
Remember, its probably only one injector giving you that puff, otherwise engine would be shaking itself out of it's mountings

[Flynn]

Dare I say, it does actually shake very violently when the idle goes under about 1100 RPM. Do you propose to use a large bolt that threads into the inner circumference of the shield?

[Quantum-man]

The coach bolt should indeed grab thart inner part of the heatshield and not go in more than a cm. Removing the glow plug will stop you levering against that. It should rock loose. Sliding the side of a hammer up the stem of the bolt may help, or a ring spanner underneath the bolt head and tapped etc

We'll get back to the poor idling when you have eliminated this shield issue...

[Flynn]

Your wisdom quickly if I may. I went to a large hardware store and could not find a bolt big enough to fit the washer. I was wondering if this tool might work:

http://www.lasertools.co.uk/items/pdf/P ... ctions.pdf

But it looks like it's made for small DI injectors and might not be big enough for IDI injectors. In the meantime I propose to have another attempt at "cutting" the washer with a narrow chisel instead of my previous attempt with a screwdriver.

[82vdub]

I think it's for the smaller injectors as you suspect. You haven't tried the large threaded shaft into the old heat shield to try to get it out?

[Flynn]

That's the very thing I am having trouble finding though. I have a spare washer that I have taken to the hardware store to look for a bolt that would fit but the biggest screw I could find was way too small in diameter. I have bought some spray on oven cleaner which I hope will help but I can't see it making much difference, we shall see. I did find a paste oven cleaner but I decided the spray on one would be easier in the absence of a foam one.

[Quantum-man]

I should have said coach screw

I'd be so careful 'beefing up' the hitting downwards onto that shield. There are one or 2 heads out there that have missing pieces of ledge, making injector sealing a bit of a nightmare. Not sure how the damage has been done, but you certainly don't want to become a member

Stuff some cottonwool down through the shield hole if you are going to spray the cleaner down the hole.

Even a wood screw that was a little small diameter wise would probably work if you kept snatching at the shield

[Fatmobile]

Yeah, the chisel slamming downward into the shield is a bad idea. It could easily break or scratch the area under the shield.

I always thread a wood screw into the shield and pull it out.

Sooo didn't even try cranking it with the injector out?

[Flynn]

How would that work though? I guess there's nothing to lose from trying it at least.

[Fatmobile]

I've had to use a block of wood to pry against and use a claw hammer to pull the screw/shield out.

[Flynn]

Right, a suitable bolt has been found. It fits into the spare washer that I have, with a good degree of tightness:

However, my concerns are that the inside of the washer will just shear off and therefore I will be back to square one. I plan to screw the bolt in when warm and then wait for the engine to cool off before trying to remove the washer, but I'm not gonna get my hopes up.

[TylerDurden]

This is alien to me...

Copper washers between the heat shield and injector?

Seems that configuration would defeat the seal formed by the heatshield near the pintle, causing all manner of problems.

[Quantum-man]

Right, a suitable bolt has been found. It fits into the spare washer that I have, with a good degree of tightness:

However, my concerns are that the inside of the washer will just shear off and therefore I will be back to square one. I plan to screw the bolt in when warm and then wait for the engine to cool off before trying to remove the washer, but I'm not gonna get my hopes up.

That style washer has no business being in your engine and comes from this style of injector for some Peugeot/Citroen stuff in the link below

There could be a lake of fuel behind your heatshields if there is a spacing washer behind each injector . PULL ALL the injectors and remove your additional plain washers... Just goes to show just how tolerant these engines are

http://www.ebay.co.uk/itm/Peugeot-106-3 ... 4aba5646d5