Normally aspirated engines - 115 BAR (atm. absolute) The FSM I have does not state a variance for new or used, HOWEVER, I've found slight differences in the FSMs printed in English and German. (German lists 115 BAR, exactly with no values listed for new or old.)

Turbo charged engines (OM61X to OM60X) New = 135 to 145 BAR with no more than three bar variance for the WHOLE SET. This does not mean you can have the set from 132 to 148, it means the minimum for NEW nozzles is 135 and the rest can be NO HIGHER than 138 BAR. OR the MAX is 145 where the rest can be no lower than 142. *NB* of the hundreds of complete injectors I've seen from the Monark factory, they've been 140 EXACTLY (for turbo) and 115 EXACTLY for normally aspirated.

Used nozzles (for turbo) = 130 with good chatter and cone pattern. For anyone who has questions about this, I wholeheartedly recommend getting a factory manual or FSM CDs and read up from the source. You can't go wrong or worse, hurt your engine.

The rest is my personal opinion - not from a manual

If you have decided to service your own injectors, outstanding. IF your work area is not clean enough to assemble satellites or do surgery, it is NOT clean enough for proper, clean injector work. "Diesel911" and other members might say it in different ways but cleanliness can't be overstressed. If you have any doubt about local shops, BGKast (not sure if he still is), myself and a couple other members have serviced them successfully. Send us a PM if you need help.

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1987 300D (230,000 mi on a #14 head-watching the temp gauge and keeping the ghost in the machine)
Raleigh NC - Home of deep fried sushi!

That is not what the English version of the 617.95 Engine Manual says.

@tangofox: I was imprecise with my language. None of my rebuilt Monark nozzles tested over 1700 psi. They are all between mid-1600s and 1700, a spread of 3-4 bar. In driving these, they are very smooth, good idle, etc.

What do you consider an acceptable variance among injectors and what is your source?

Thanks,

Ken

Ya know,...............I bet he is selling those new pre-tested nozzels.

Saves all that time and trouble of shimming and Pop Testing .

JK JK JK.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

That is certainly within reason.

I have seen MB specs of both 3 bar and 5 bar, depending on application. In my opinion, 5 bar is too much spread. My person target is as close as possible, which is reasonably around two bar, given the variation in gauge behavior from one injector to the next.

In your case, a bit of shim lapping (on the higher pressure injectors) could have reduced your spread significantly.

What's the ISDN number of your manual and what does it say?

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1987 300D (230,000 mi on a #14 head-watching the temp gauge and keeping the ghost in the machine)
Raleigh NC - Home of deep fried sushi!

If you are happy with the Injectors they way they are no one can argue with that.

However, in the Fuel Injection Shop that I worked in back in the middles 1970s we always tried to balance a set of Injectors as close as we could within a resonable time to do the job.

This was done on all types of Injectors.

So balancing was considered important enough to expend the extra effort on.

Since time is money if it did not make any differance we would not have been so picky.

My other comment is that different Manuals not only sometimes give different information the sometimes give even the wrong information.
If I am keeping a vehicle I try to have at least 2 different companies manuals.
Since I have this Mercedes I have aquired 6 seperate Manuals for it; with the exception of the Mercedes Paper Mnuals and the CD set the rest are from different companies.

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84 300D, 82 Volvo 244Gl Diesel