Any kind of inlet, except on-column, is sensitive to temperature, gas flow, liner geometry, liner packing, injection speed, pre- and post-injection needle dwell time, split ratio et etc etc. Indeed, the inlet is the weakest link by far in the whole GC chain.
Many (most ?) of the problems with inlets stem from flow disruption when a volatile solvent is injected into an inlet hot enough to evaporate heavy analytes - the usual 250 to 350 C split-splitless injection - or from analyte boiling point discrimination when the inlet is cooler - as with a PTV.
You are probably right about the needle discrimination - during injection at 60 C which is just above/below the BP of your solvent (depending with petroleum ether fraction you are using) you get an inconsistent evaporation / boiling of the sample in or on the needle, which gives eratic transfer of the analytes to the inlet.
With PAHs and pyrethroids in toluene I found that repeatability improved as the temperature of the Gerstel CIS3 PTV inlet during injection was lowered in 20 C steps from 120 C to 60 C - the same as you have found. A faster injection speed also helped - probably by squirting the sample out of and off the needle before it had time to evaporate. When I get a chance I want to follow up on this in more detail.
An alternative to lowering the inlet temperature would be to use a less volatile solvent - I start to think that using hexane, dichloromethane etc even with heavy analytes is GC folklore - does anyone know of any good literature on the influence of solvent BP on discrimination and repeatability for a given set of inlet conditions ??
All the best for 2007
Peter