I would like to show and get some feedback on the spray pattern I got after injector rebuild.
I have removed the injectors from my 85 300SD with 190k miles, I believe the injector nozzles were original (Bosch240). Testing showed high internal leak down, so I decided to rebuild them. Dissembled, lapped, cleaned, and reassembled with new monark 261 nozzles. All popped around 1950-1975 psi, internal leakage is good now, but I'm disappointed with the new nozzle spray pattern.

inj1 - heavy center droplets, not good, maybe acceptable
inj2- looks good
inj3 - asymmetrical, heavy droplet sideways, not acceptable
inj4 - looks good
inj5 - heavy droplets at the center, side spray, not acceptable

i have retested and captured the random sample of old 240 nozzle. Much narrower spray pattern, but good atomization and droplet distribution.

Questions
- Am I looking and evaluating the spray pattern correctly?
- What should I do with nozzle 1/3/5? Disassemble clean and retest? Send them back?
- Run them in the engine a bit then reevaluate?
- Any other suggestion?

Attached Thumbnails

   

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1985 300SD - very special CA edition