My 1984 300 Sd had an injectop knock. I replaced #5 injector and she ran fine for a couple hours. Now She runs like there is a real bad miss. No power at take off. Lots of smoke. Idle is extremely rough. Cracked all fuel lines at injectors. They all seem to be working. Not sure what to do next. I'm not a diesel mechanic. Nearest mercedes shop is 100 miles from me. Would appreciate any help. mm1_sw@yahoo.com or milehigh@commspeed.net

It will only run right if the injector nozzles are all of good quality and are properly balanced. Did you look down in the pre-chamber hole and make sure the little metal ball is still intact?

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-diesel is not just a fuel, its a way of life-
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Working on #5 you could have damaged the boost control hose coming out of the banjo bolt. I've seen them get brittle.

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1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

If it is the same Injector causing the problem maybe some dirt got into the Injector during the installation.

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84 300D, 82 Volvo 244Gl Diesel

Thought I had carbon. Should have blown out by now. Drove 150 - 200 miles since injector replacement. How do you balance injectors? Not sure what Banjo Bolt is?

A quick test is to inspect the area adjacent to make sure nothing was really disturbed. Then you could install the old injector temporarily and see if it gets back to normal with the injector knock.

You then know the new injector is faulty. Too coincidental to be much of anything else. You did put a new crush washer in when you changed the injector? For the test since the bad original injector will not be left in a new crush washer is not required. Could be as simple as the new injector is not closing off for one internal reason or another.

Banjo bolt is on back of intake manifold. Clear plastic hose (typically black inside) goes from the bolt to the overboost protection solenoid. It goes around the back of the engine near the firewall.

__________________
1977 300d 70k--sold 08
1985 300TD 185k+
1984 307d 126k--sold 8/03
1985 409d 65k--sold 06
1984 300SD 315k--daughter's car
1979 300SD 122k--sold 2/11
1999 Fuso FG Expedition Camper
1993 GMC Sierra 6.5 TD 4x4
1982 Bluebird Wanderlodge CAT 3208--Sold 2/13

Did try the old injector. Same results. Yet cracking the fuel line, I notice more of a miss. I did replace the crush ring when i installed the new injector. Looked for Banjo Bolt. Still can't find it.

Strong Nailing
Strong nailing

Injector stuff
Injector + Heat shield + Nozzle, Prechamber + Collar, and Nailing. LINK THREAD

Your Injectors are basically a spring loaded valve set to open at a certaing pressure. In order for your Engine to run smoothly the pressure they open at has to be within a certain range and the balancing part means they also have to have similar opening pressures when compared to each other.
You do this with a Diesel Nozzle Tester/Pop Tester.
Do a search on Pop Tester for mor info.

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84 300D, 82 Volvo 244Gl Diesel

Thank you for all the help. Think I'll start with having my injectors pop tested. I'll keep you informed.
Robert