Hatterasguy - yeah, I only run D2 that I buy from the local high-volume truck stop. So I doubt it's a fuelling issue. I'll go for the plugs and reaming first, then report back. My expectation is that should clear up at least 90% of what's going on here.

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1984 300D Turbo, 326000 Km, Thistle Green Metallic

The issue with carbon build up and poorer starting is the glow plug body becomes mechanically connected to the cylinder head for the length of the plug "shaft." The carbon is a very good conductor of heat, so some of the glow plug tip heat is carried away, into the cylinder head and prechamber walls. Carbon is also a reasonable conductor of current. A carbon path from the tip to the wall may introduce a parallel path for current that will also reduce the tip temperature. Reaming removes the excess carbon build up.

Drive it like you stole it on a regular basis and the carbon build up problem is also relieved. Lots of stop and go, idling, etc. does just the opposite - packs the carbon into crevices. Take a cruise to Whistler when the traffic isn't bad - that road is being widened to make it easier for the Olympic crowds, but it still has a few hills that should get you to wide open throttle for a few minutes straight. Not many places where you can run WOT on the highways as I recall - too much traffic - but that will do too. The emphasis is on dumping lots of fuel at high rpm, to get the highest temperatures and pressures.

You might try the "Italian tuneup" before you start digging into the engine. These engines respond well to hard running and get wheezy on stop and go city stuff. Jim

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Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

If you are going to get your injectors done, NW fuel Injection Service in Surrey does a great job. I brought in my old injectors and my own Bosio nozzles. I would probably go with the Monarks though. Not that I'm unhappy with the Bosios, but the Monarks are cheaper and I have not heard one complaint about them on this forum.

NW could only get Bosch nozzles and couldn't be sure they weren't made in India. I could get the Bosios cheaper too.

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1985 300SD