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.