Yesterday I finally got around to installing my injectors fitted with Bosio nozzles. I have learned an incredible amount of information from this forum, so thanks to all that have responded to my posts.

First of all I would like to say what a difference these injectors make. To set the record straight my engine was running well before I did this. To date with the electric fan conversion, fully synthetic oil, Fitch fuel catalyst and K&N air filter I have averaged 29MPG combined city / highway mileage. It only made sense to me to go the extra mile and install these injectors fitted with the Bosios.

The actual process of removing the injectors was a bit tedious but not too difficult. I know some of you will chastise me for doing this..... I had to leave in 3 of the 4 heat shields. I tried and tried to get them out but only cylinder #1 came out. I didn't have the time to wrestle with the other 3 so I bit the bullet and went ahead and left them in place.

After removing the original injectors I noticed something peculiar. To my knowledge an OM616 comes with 115 bar injectors. The ones I removed were 135 bar. At this point I figured things could only improve due to having the wrong bar injectors installed. I was correct on this assumption because my engine runs much better. I understand this might be due to the new nozzles and the injectors being pop tested, but I'm guessing it's better to have the right injectors installed.

So now I'm going to do a sort of long term test on the potential fuel mileage increase. So far I'm super satisfied on the difference they make. The engine runs smoother, starts up faster, and has more pep than before. Not to mention it sounds quieter and has much less startup smoke. I recommend Bosio nozzles to anyone looking for a good upgrade to their Benz diesel.

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1977 Mercedes 240D... 4 speed manual... soon to be host to a lot of mods..

1984 Toyota 4x4.. Weber 32/36 DGEV carb, Offenhauser Dual Port intake manifold, TRD cam, MSD 6A ignition, MSD 8.5 wires, MSD Blaster coil, NWOR Tri-Y header, cat-back exhaust, NHK 3" lift springs, Black Magic electric fan, LC Engineering crank pulley,traction bars, LockRight locker, oil cooler, manual water temp gauge, oil temp gauge, vacuum gauge, and 394,000 miles on the clock with one motor change.

How long did it take you to complete the change?

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1996 E300 D
1992 300D
1990 Ford E-350 7.3 Diesel AKA "the Deep Fryer"

That valve cover looks sharp

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1979 240D- 316K miles - VGT Turbo, Intercooler, Stick Shift, Many Other Mods - Daily Driver

1982 300SD - 232K miles - Wife's Daily Driver

1986 560SL - Wife's red speed machine

The nozzle "holder" has little to do with the nozzle or pop pressure of the actual inj. It is simple a core that was likely rebuilt; do not automatically assume they were the wrong inj for your engine. Looking at teh nozzle and then confirming pressure setting is the only way to know for sure "what" application they were set up for.

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

A quick crank of the engine with the injectors out will usually blow out the old shields.

Sixto
87 300D

It took me a few hours to complete. The hardest part is getting the injector lines off. Plan on bustin up a few knuckles.

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1977 Mercedes 240D... 4 speed manual... soon to be host to a lot of mods..

1984 Toyota 4x4.. Weber 32/36 DGEV carb, Offenhauser Dual Port intake manifold, TRD cam, MSD 6A ignition, MSD 8.5 wires, MSD Blaster coil, NWOR Tri-Y header, cat-back exhaust, NHK 3" lift springs, Black Magic electric fan, LC Engineering crank pulley,traction bars, LockRight locker, oil cooler, manual water temp gauge, oil temp gauge, vacuum gauge, and 394,000 miles on the clock with one motor change.

I appreciate it It's a fairly simple job. All I did was clean the cover with paint thinner and a rag real well. Then I used a cordless drill with a wire brush attachment and went at it for about an hour. I then painted it with Duplicolor Detroit Diesel Alpine Green high temp engine paint. I used pretty much the whole can and that was good for 5 layers. The oil cap was shot with some generic black paint.

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1977 Mercedes 240D... 4 speed manual... soon to be host to a lot of mods..

1984 Toyota 4x4.. Weber 32/36 DGEV carb, Offenhauser Dual Port intake manifold, TRD cam, MSD 6A ignition, MSD 8.5 wires, MSD Blaster coil, NWOR Tri-Y header, cat-back exhaust, NHK 3" lift springs, Black Magic electric fan, LC Engineering crank pulley,traction bars, LockRight locker, oil cooler, manual water temp gauge, oil temp gauge, vacuum gauge, and 394,000 miles on the clock with one motor change.

Painting it DD green WILL make it leak oil, Detroit Diesel has proven that many times.

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Gone to the dark side

- Jeff