Oil Squirters
Oil squirters: one of those things that isn't talked about much. Those who've been around engines a while know them well, but for someone new like me, they're simple and elegent. If you break one on the 1Z a replacement is ~$50 from IDParts. They're made from a banjo bolt with a valve of sorts that looks to be made from a ball bearing and a spring. This holds down what is basically a slightly oversized square nut with an corner cut off and a small metal pipe/nozzle press fitted in.
These guys are setup to spray oil at the bottom of the 1Z piston that has no oil galley and the oil will just slingshot around the underside of the piston. However, the nozzle needs to be delicately bent a few times in order to clear the fill hole on the new pistons if you're not putting 1Z pistons back in your TDI.
Stock Orientation:
I tried a coule different ways to hold onto the nozzles body (square nut) and bend the nozzle. I ended up using some tissue or paper and covered both sides of the nut with it and put it inside the jaws of an adjustable wrench. With it's weight and handle, it was the best anchor I had that didn't have teeth.
The easiest solution for bending the nozzle/pipette was the purchase of some brazz pipe; 2 sizes are needed with one at 3/16" and one at 1/8". I picked up 2, 1' sections of both pipe sizes for less than $5. The brass is rigid enough to bend the steel nozzle's end, but will not mar the surface. I had tried 8 mm wrenches, 4 & 5 mm, 1/4" drive sockets, but I needed deep throat variants but I know they'd mar or dent the nozzle.
Now if you go about this yourself, you may find that you can actually start closing down the opening of the nozzle due to how the brass pipe rests on the rest of the nozzle when you bend it. To solve that, I used my spike-on-a-stick tool from craftsman. It was in a toolset I have from a few years back and I just call it my shank; I've drawn blood a couple times with it unfortunately.
The shank is a rounded spike and is sharp enough and strong enough to use as a light pick, re-aim window washer jets, and for this use, re open up or round out the end out the nozzles of the oil squirters
Now, at first I thought that the squirters only needed a little rotation and outward bend so the stream of oil would hit the hole when the piston was close. However, I later decided to get a little more detailed and measured out the distance of the stroke, 95.5 mm, and move the pistons all of the way down the bore until it was at the end of it's stroke. For those who don't know, this is at a position that causes the piston's skirt to exit the cylinder bore, which is why the notch is present (duh!). So, I quickly found out that the nozzle needed to be bent/modded so it was parallel to, and cleared the oil galley hole because it actually sticks inside the piston.
As such, just aiming it at the hole won't work:
I'm sorry I don't have followup/final photos of the squirters clearing the entry holes, but I didn't want to clean the gloves or remove them and wash the powder off my hands to photograph things when I had momentum during reassembly. It took me about 8 minutes just to get those 5 photos after about 30 minutes trying to get lighting just so things could be seen clearly on camera.
