What the FSM says about injector cleaning:

http://mercedes.thatchermathias.com/Index/617T/07MechElec.htm

Look at part 07.1-135

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1985 300D-189k The 'UD', Ivory and Pinkamino
1979 300D-211k Dark Gray, Parchment
A 1980 Harley-~166k and
A 1994 Ford diesel pickup-349k and
A 1990 gasser Volvo wagon-145k

Interestingly, FSM (07.1-232) "Reconditioning injectors" says only "Dress intermediate disc (33) on a surface plate." It says nothing about the surfaces that have to mate with the two sides of the intermediate disk; it says nothing about performing this operation wet or dry; it says nothing about flatness or smoothness requirements of this "surface plate." [Note that the spelling 'disc' is literally what is in FSM.]

Another interesting thing is that my copy of the FSM ("Service Manual / Diesel Engines 602, 603" S-2517-091 published by Mercedes-Benz of North America in 1991) has two sections numbered 07.1. One is for NA diesels and the other is for turbodiesels. The sections are mostly the same but the writing (or the translations) differ slightly in content and wording, not only for the obvious areas of difference between a normally-aspirated and turbocharged diesel engine, but for areas that should be identical, such as the injectors. On top of that, the page numbers are identical and you cannot immediately tell whether you are in the NA or turbo section unless you happen to spot the "turbodiesel" in the chapter title.

Thus, the NA version of 07.1 "Diesel Injection System" has a section 232 "Reconditioning injectors" while the turbo version of 07.1 "Diesel Injection System - Turbodiesel Engines" also has a section 232 "Reconditioning injectors (after testing) - Turbodiesel." The sections are similar but not identical, for example, the NA version has information on cleaning the little holes that some needles have in their tips but the turbo version does not. Does this mean that NA diesels have holes in their injector needles but turbodiesels do not? [FYI, about these needle holes, FSM says longditudinal bores are to be cleaned with a 0.18 mm needle while transverse bores are to be cleaned with a 0.35 mm needle.]

Pardon the digression, which I use as warning that you must be cautious accessing technical service information, even when your source is a factory manual. Continuing, the NA version of 07.1-232 on lapping the internal parts says "Polish intermediate plate (33) on both sides on the surface plate." Is there a difference between "dress" and "polish" or were the two different versions of section 0.7.1 simply subbed out to two different translators? Examination of a German version of the manual would be educational.

So there's nothing explicitly said in FSM about polishing too much off of the parts and changing the pop pressure. However, FSM covers its corporate tail by listing "test injector" as the very last item in the checklist.

Jeremy

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

No.

Anyone who thinks that you can reliably get away with cleaning nozzles and not testing them hasn't cleaned or tested many injectors.

Considering that the local diesel shop in my town charges $45 each [plus parts!] to clean, test, and adjust injectors, a tester would be a good investment.

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"Buster" in the '95

Our all-Diesel family
1996 E300D (W210) . .338,000 miles Wife's car
2005 E320 CDI . . 113,000 miles My car
Santa Rosa population 176,762 (2022)
Total. . . . . . . . . . . . 627,762
"Oh lord won't you buy me a Mercedes Benz."
-- Janis Joplin, October 1, 1970

I have been thinking to buy a mercedes source kit, what do you guys think?



This kit includes the following:

Bench mounted hand operated injector release and balance tester to 3000 psi
24 piece shim washer assortment that allows you to precisely adjust the injector release "pop" pressure
Special brass tools to help clean the carbon of the tips of your injectors
Pick tool to aid in removal of injector heat shield washers
Assortment of medium to super fine lapping paper to prevent injector fluid leaks
Nitrile gloves to save your hands
Bolts and nuts to mount tester to work bench
Complete step by step illustrated instruction manual.

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http://www.venganza.org/images/fsmrof.png

I only use B100 made out of recycled cooking oil under ASTM D6751 standards, from Sirona Biofuels in Oakland, CA. Currently $3.90 gal.

MANN/BOSCH filters.

Chevron Delo 400 15w40 or Castrol equivalent, planning to use Bio-Synthetic HD SHP Motor Oil
SAE 15W40 next.

When I took mine apart for cleaning and re-balanced them they needed chagnes to re-balance them.

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1991 350SD (updated rods)
Biodiesel B100 when I can find it.
Dino when really cold outside

This is what I have. It works great! I mounted the pump on a piece of steel plate bolted to a 8" x 16" x 2" piece of wood. I don't use biodiesel for the tester because I am worried about bacteria growing in the pop tester when it is not in use.

You really need to use a respirator and goggles when using the tester otherwise you will breathe a lot of diesel vapors and you might get some in your eyes.

There is also an injector cleaning kit you can get from them that is helpful.

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1991 350SD (updated rods)
Biodiesel B100 when I can find it.
Dino when really cold outside

Puts hair on your chest.

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RIP:
2011 E350 BlueTEC, Schwartz 81k (totaled by uninsured drunk driver)
1964 Unimog 404.1 (wrongfully towed by the city)
1994 E320, Brilliantsilber 208k (transmission shuffled off after sudden catastrophic fluid loss)
1982 300D, Silberblau under a blue repaint 256k (sold for parts)
1995 E320 Polarweiss, 131k (sold for parts)
1995 E300D Polarweiss, 287k (totaled by drunk driver)

Looks nice. Was kostet das? (What does it cost?)

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85 300D 75K Anthracite Grey 0-60 in 13 seconds **For Sale**
84 300D 333K Black (The Velveteen Rabbit) 0-60 in 14 seconds
00 Toyota Sienna 208K (Sold)
15 Subaru Outback 43K
11 Subaru Outback 67K
98 Ford Taurus 100K (Gertie - Was Grandma's - drove it to church and shopping - really) Daughter's car now.
30 Model A Ford 2 Door Sedan (Sold) 0-60 in . . . Never reached 60

Found it. $234.

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85 300D 75K Anthracite Grey 0-60 in 13 seconds **For Sale**
84 300D 333K Black (The Velveteen Rabbit) 0-60 in 14 seconds
00 Toyota Sienna 208K (Sold)
15 Subaru Outback 43K
11 Subaru Outback 67K
98 Ford Taurus 100K (Gertie - Was Grandma's - drove it to church and shopping - really) Daughter's car now.
30 Model A Ford 2 Door Sedan (Sold) 0-60 in . . . Never reached 60

Is it worth the price?

I guess I will test with the fuel I use, B100. I could run some LM purge after use if I'm nervous about the B100 monsters that can grow in it.

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http://www.venganza.org/images/fsmrof.png

I only use B100 made out of recycled cooking oil under ASTM D6751 standards, from Sirona Biofuels in Oakland, CA. Currently $3.90 gal.

MANN/BOSCH filters.

Chevron Delo 400 15w40 or Castrol equivalent, planning to use Bio-Synthetic HD SHP Motor Oil
SAE 15W40 next.

I recently purchased the kit and would recommend that people by an entire set of shims instead of the small kit. I ended up having to take one of the largest shims and filing it down a few thousandths in order to balance out my six injectors. The kit would be improved if it came with the cleaning kit that Mercedes source sells. I didn't by it and ended up needing a brass brush and they are hard to find. I did have a bronze brush that I use to clean my 12 gauge and that worked perfectly. One of my injectors had so much carbon on it it was very difficult to clean.

I cleaned out my injectors by running with high concentration Lucas fuel inj cleaners.
I messed her up when using filtered used motor oil!
Now i dont touch that stuff anymore.

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Thanks for DIY helped a lot. I did my OM606.962 and it is very similar.

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1999 W210 E300 Turbodiesel

A diesel shop rebuilt my original injectors for about $60/each with new 115bar BOSCH nozzles, and all were balanced within 1bar of each other.

Just another option if you're not in the tinkering, injecting yourself with diesel @ 115bar and special tool buying spirit.