Buying Bosio nozzles because your car has 100k+ or 200k+ mile on it is a waste of money.

Do yourself a favor and make yourself a pop tester.
http://www.peachparts.com/shopforum/search.php?searchid=1102093

Then you can test them whenever you want. I guarantee you you'll be taking them out, testing them and putting them right back in.

DAnny

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1984 300SD Turbo Diesel 150,000 miles

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I agree with what's been said about making sure your injection shop knows what it's doing. I have 2 diesel injection shops in my area and one of them has a moron working there. He insisted that anything within 14 bar is good enough when it comes to balancing the injectors. MB calls for a maximum difference of 5 bar. He also insisted that the injectors for the OM616/617 engines have no holes on the pintle. Wrong again. The other shop seems more knowledgeable but they're outrageously expensive, like $20 per injector just to test them for you, and they're pretty arrogant too. So I have my own injector tester that I bought on Ebay and that has more than paid for itself. I don't enjoy doing this work and it's stinky and tedious, but at least I know it's done right, though there's also the problem of lack of shims if the injectors need adjusting. Most likely though, you will not need to adjust the pop pressure and you just make sure each nozzle sprays a good mist without pissing or dripping and pops at approximately the right pressure. Recently a biodiesel station selling B99 opened up about 50 miles from here so I'm planning to get some not just for my cars but also for my injector tester to reduce the stink of diesel fumes from injector testing in my garage.

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2004 VW Jetta TDI (manual)

Past MB's: '96 E300D, '83 240D, '82 300D, '87 300D, '87 420SEL

take the injectors to shop they will pop test for free! well most do ,changing nozzles will not change pop pressure! its easy changing your nozzles 1/2 hr all six were done in mine that include two beers just make sure you put in new return lines and heat shields

That is not necessarily true. Machining tolerances on the height of the nozzle assembly can alter the pop pressure just like changing a shim. I'm sure the tolerances are tight, but you shouldn't just assume they are always correct.

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'83 240D with 617.952 and 2.88
'01 VW Beetle TDI
'05 Jeep Liberty CRD
'89 Toyota 4x4, needs 2L-T
'78 280Z with L28ET - 12.86@110
Oil Burner Kartel #35

http://i16.photobucket.com/albums/b1...oD/bioclip.jpg

I know a diesel mechanic who works on commercial ferries. He said they would pop test the injectors on 16 cylinder diesels all the time. He was also getting the ones in his MB pop tested.

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Scott
1982 Mercedes 240D, 4 speed, 275,000
1988 Porsche 944 Turbo S (70,000)
1987 Porsche 911 Coupe 109,000 (sold)
1998 Mercedes E300 TurboDiesel 147,000 (sold)
1985 Mercedes 300D 227,000 (totaled by inattentive driver with no insurance!)
1997 Mercedes E300 Diesel 236,000 (sold)
1995 Ducati 900SS (sold)
1987 VW Jetta GLI 157,000 (sold)
1986 Camaro 125,000 (sold - P.O.S.)
1977 Corvette L82 125,000 (sold)
1965 Pontiac GTO 15,000 restored (sold)

Having a shop pop and check the pattern of ANY injector only makes sense. Unless you have your own pop tester..... An injector that is not functioning correctly can cause many problems, some very expensive. Why would you not bother to check when its very inexpensive to do so?

Regarding the balancing of pop pressures. As long as the pop pressures are in the same ballpark and the patterns are good then the engine will run fine. If you really want to have your engine running as good as it possibly can, producing the maximum power, smoothest idle, etc. then pay the extra money and have the injectors balanced. A really good shop will get the injectors all within 2-3 bar. This is regularly done by the performance pickup crowd, that is the people with older IDI designs.

I wouldn't recommend that nozzles are just replaced for no reason. If you suspect that there is a problem or if the injectors have been removed for some reason then why not have them checked? If you need nozzles then why not have them setup correctly so they can perform at their best?

I had the 300D injectors tested at 165K and they were fine so I put them back in.

RT

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When all else fails, vote from the rooftops!
84' Mercedes Benz 300D Anthracite/black, 171K
03' Volkswagen Jetta TDI blue/black, 93K
93' Chevrolet C2500HD ExCab 6.5TD, Two-tone blue, 252K