Bosio nozzle longevity question?
 

I was just wondering how many miles you guys got out of the Bosio injector nozzles & if anyone is doing rebuilds with them, my junk (probably India made) Bosch rebuilds are having leakage issues causing misfiring & difficult starting on a cold start, I just want to get something that will last a while (preferably longer that the 15K these did).

I replaced my most likely stock Bosch nozzles with the Bosio ones that Diesel giant sells. I have about 800-1000 miles on them so far and no problems. I think the motor starts a lot better with these vs. the Bosch but that is likely because they were original. At this point I would deffinatly buy them again. I will post if anything goes wrong. (doubtful)

Has anyone been running the Bosio nozzles on WVO as well? Problems?

I suppose a better question...
 

might be, "Who has the HIGHEST mileage Bosio Nozzles?"

The Bosio's are not as well done as the factory Bosch's. They lack a pre-ignition hole, or something to that effect which in theory causes a bit rougher idle and noise compared to a "proper" German set of new Bosch's. That said they are generally considered much better then the Indian Bosch's and they usually run much better then a worn set that was installed at the factory.

I am running SVO and very high-quality WVO in a single-tank system and have just installed the Bosio nozzles. I live in SoCal, and the weather has been in the 80's lately. I have an inline electric heater before the IP, a heated fuel filter, and injector line heaters from fattywagons...and that's it. No other conversion. I may add one final item in the course of this, be forewarned...I'm looking at an electric heater for the gas tank that will be powered by a small solar panel on the parcel shelf. I may also insulate the gas tank.

I'll tell you guys what, I'll be the guinea pig. I'll run my car on SVO/WVO only for the entire course of the hot season, no additives or cleaners in the fuel. I'll pull the first injector every 2k miles or so and will post a pic of in this thread. Here's the injector as it looks now. 179k miles on the car.

Bosio Nozzels
 

I tried the bosio nozzels for about 6000 miles. I'm running a turbocharged 77 240D at about 9 pounds of boost, so my experiance may not apply to an unmodified engine.

I set the nozzels up at 135 bar with my pop tester. The spray pattern looked good, so I stuck em in. At first, the engine sounded better, smoked less, started easier, and got better mileage. All miles are highway miles at 65 to 75 mph. The car is litterally started, driven 155 miles, shut down, started and driven 155 miles home. After about 3000 miles, the engine started nailing when it was cold. Not bad at first, but it got worse. By about 4000 miles the engine would nail when warm!

I ran some Power Service through it for a week to see if they would clean up, but the results were marginal. By now I had about 5500 miles on them, and the engine sounded horrible! Smoking, hard starting, and nailing.

At 6000 miles, I had had enough. I pulled the injectors and re- pop tested them. The pop pressure was fine, and they did not leak or ooze, but the spray pattern was CRAP! Most of the fuel seemed to spray out one side of the nozzle and formed course streamers rather than a fine mist.

I am not impressed by how quickly the spray pattern went to !@#%&!

Anyone want to buy a set of Slightly used Bosio nozzles? Cheep? Anybody?:D

I might have had better luck in an un modded engine, but I don't see how the turbo would affect the spray pattern.

Just my 425 cents!
Cheers, Chris

9lbs of boost on the stock fuel system???

Our '83 300SD has had them in for nearly a year now....and probably close to 15,000 miles....it idles a little rough (always has, even with the old injectors)...however, it has tremendous take-off power, and accelerates like mad with little to no smoke at all, gets 25-26mpgs....and startups are instant! The bosio's improved it significantly over the old Bosch nozzles. I am considering switching mine to Bosio's sometime soon.....

Spec is ~12 psi or so.

In Car and Driver, I read the boost pressure on a new E320 Bluetec is 29 psi!

Is there an OM 617 turbo in your 77 240D or is it a 616 with a turbo added?
115 bar is the setup for the 616. Perhaps you set the opening pressure too high for the fuel output from the injection pump on the 616, if you aren't running a swapped 617. Maybe this has something to do with it?

Bosio Nozzels
 

Hi all,
Regarding the turbo 240D. The engine is a 616 four cylinder with a Garret/ Air Research T3 turbo added. No the fuel system is Not stock! It will smoke with only 5 pounds of boost at full throttle, but at 8 to 9 pounds it runs clean
( and makes more power!:D ). I also run 3.07 gears and the large oil cooler from a 300TD which makes for a much happier engine at 75 MPH.

I realize that the Stock pop pressure for a 616 is 115 bar, but all of the turbos use 135 bar. The injectors I built are 135 bar turbo injectors. I did not shim the 115 bar injectors to 135 bar. I don't think you could. The 135 bar injectors use a much heavier spring and the piece that pushes on the back of the pintle is different too. Anyway, she runs like a scalded cat, which in 240D parlance means I can out drag a Yugo! I also don't have to get out and push on steep hills:grin:.

I don't know why the Bosio Nozzles went to poo so fast. What I can say is that they did, and ALL of them did. I tested all four, and the spray pattern was lousy on all four. The other thing is that the design is obsolete. The pilot injection hole on the Bosch nozzles has been universal in MB engines since what, the early 70s? If the Bosio Nozzles are so wonderful why don't they at least match stock Bosch nozzles in technical sophistication? I'm really tempted to fire up the lathe and try making my own!

Cheers, Chris

In my experience, there are a LOT of cruddy make nozzles out there, and HUGE numbers of cheap Chinese crap that wont last 10K miles...

There are even 'Counterfeit' make nozzles, which are 'reconditioned' Bosch/Delphi etc. types.

Having messed around for many years with Diesels, I will now Never use any other make other than Delphi or Bosch (France/Germany) made nozzles, which Must be in the original sealed makers carton.

Fortunately here in the UK, there are suppliers such as Merlin Diesel who will supply private individuals as well as Co's, and supply proper OEM nozzles at realistic prices...Around 15 dollars for a DNOSD240, as used in the OM-615/6/7

I had one bosio nozzle in my 240D single tank WVO car. After about 5000 miles I took it out and it was shot - not chattering, bad spray pattern. The pintle was stuck in the bore (I hope those are the right terms). I had to boil it in purple power and pull the heck out of it to get it out.

I didn't know if it was the nozzle or the WVO setup I have (starts on cold oil, but with injector line heaters) . So the jury is out. The rest of my nozzles were shot, so I put in 4 new ones and I'm going to see how they go. So far so good - but only about 600 miles so no real test there.

They seem to carbon up quickly - less than 1000 miles, but I don't know if that's normal or not for any injector or WVO setup.

Cephallus - yes, I'd love to see the injectors as time marches on.

Alastair - any idea where to get those french Bosch nozzles in the USA? And, do you know anything about the Elsbett nozzles for WVO? Sounds like you know about these things - what do you suggest for a WVO setup? I set my nozzles at 117bar after you posted about 123 bar being too high.

Interesting thread. I have 5 Bosios waiting in the wings that my PO gave me when I bought the car.

Where can I get the proper Bosch nozzles?