I am stuck with the new injector tips I bought from DG (should have bought Monarks) His instructions while good completely negate balancing and testing for correct pop pressure. Those of you who are running Bosios, did you pop test/balance or just install and what were the results? Thank you! At this point, I am ready to mail to Pacific Fuel Injection in SF for balancing and setting up correct pop pressure -

Regardless of the brand, you should pop test and balance them.

They are not bad. I've had them on the bench side by side with Monark and Bosch (India and France) nozzles. They tend to spray a slightly coarser cone of fuel but it's always consistent.

If you don't mind, let us know what Pacific Fuel injector quotes you.

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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!

I have to admit that I didn't pop test when I replaced my nozzles, however I used a set of NOS old off the shelf Bosch, made in germany nozzles, being very careful to clean well and not mix up any parts. Even laid parts all out one at a time correct side up. My car runs fine. That said, if I were to do it with Bosio, or Monarch, I'd certainly be sure to pop test. Someday I'll even pop test what I did, just out of curiousity. My car ran really well before and after. I only replaced the nozzles because I got a good deal on the nozzles and this forum opinion was that they were a wear item at over 100k. My wife's SD has225k on the same nozzles since new, and that car runs fine. IMHO I would NOT replace nozzles without a pop test again, even with NOS. Even in the case of my NOS nozzles, I still have a nagging curiousity about whether they are properly set.

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85 300TD FED-Daily
84 300SD-Wife's
86 XJS-Sunday
66 GMC-Work- Given to my stepson
83 BMW Airhead- Given to my stepson

will do - I sent Gus (Pacific Fuel Injection) some old injectors for testing and he was very reasonable. He has been around for years and sold me a rebuilt Kugelfischer injection pump for a BMW 2002 tii I owned 25 years ago. Good shop!

i bought the bosios from russ and just put them in. ive had no problems with them, although i plan to pop test them since i just built a pop tester.

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1981 300 SD 213k miles "Stock for now"
1999 Super Duty 7.3L 113k miles
1981 300 SD 180k miles "Heavily modified" SOLD

Great, do share your results with us. I feel, based upon what I have read that they need to be pop tested for balance and opening pressure -can't see how just assembling them per DG's instructions would give good results unless one were very lucky

One set of results are in no way an indication of what the results might be on a different set of injectors. In my experience, installing a new nozzle will bring an injector pop pressure into tolerance around half of the time. Those aren't very good odds. I don't think I have ever done a set of five where at least two didn't require adjustment.

That would be an accurate analysis of the situation.

Agreed - I am sending mine out this week -

In my prejudiced opinion the DG instructions are designed to sell Nozzles.

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84 300D, 82 Volvo 244Gl Diesel

Ya think? I think Russ should encourage pre testing before installation but that would sell fewer nozzles as you so accurately pointed out . . .

I just rebuilt 5 injectors with Monarks and did pop test them. Even though all I did was clean and swap nozzles, they all tested at about 1700 psi (a tad above 115 bar) give or take about 50 psi, so I felt that was close enough. I installed them and they run just fine.

So...maybe I am lucky to have not had to swap shims? Maybe Monarks are a different story from Bosios? Not sure.

Ken

Feelings aside, a range of 1650 to 1750 is not within specification.

If you look in your owners manual new injectors pop higher.How come rebuilt are so low.

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1999 w140, quit voting to old, and to old to fight, a god damned veteran

Good point, why is this?

The 617.95 engine manual does specify a higher pressure when installing new nozzles as opposed to reusing old nozzles. That would account for the normal drop in pressure that occurs with wear.