i rebuilt my injectors on my77 300D , but didnt pop test them like i should i have.
I also noticed when it was running for the brief time that diesel fuel was leaking from one the prechambers so i think if tighten down that precollar and balance and pop test my injectors after im done buidling my pop test i should be fine. Anything i missed?

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1986 300SDL, 211K,Dealership serviced its whole life
1991 190E 2.6(120k)
1983 300D(300k)
1977 300D(211k)

I do not agree with all of the below article but there is a rason for all of the below suggestions.
How to Rebuild Injectors
vincewaldon.com - HOW-TO: Rebuild Diesel IDI Injectors

More likely the Diesel is leaking from between the Injector Nut and the upper part if the Injector.
Where the Injector Heat Shields replaced?

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84 300D, 82 Volvo 244Gl Diesel

i order the monarks from mercedes source and it came with heat sheilds in the kit. I followed the instructions, cleaned them, lapped them and torqued them to spec. after i got all the injectors to stop leaking at the halves i replaced some leaky fuel hoses, i bleed the the low and high system which took two battery recharges to get the air out of them.
the diesel giant write up for the nozzle replacement sucks leaves out important steps such as lapping and balancing and pop testing

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1986 300SDL, 211K,Dealership serviced its whole life
1991 190E 2.6(120k)
1983 300D(300k)
1977 300D(211k)

If it took 2 full battery charges to bleed your fuel system you have significant delivery system issues.

After my injectors were reinstalled, it took about 35/40 cranks to fully bleed the pressure side.

How do you bleed the return line if thats what you are referring to as 'the low' ?

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

i bled the low side with the primer pump and loosening the 19mm on the side of the fuel filter housing and the high side i bleed by cracking the lines one by one until fuel came out. the car ran decent before and had decent power but the some of the injectors were nailing bad and couldnt stand it anymore so i bought some monarks and put them without pop testing them like i should have.just wanted to see if the diesel giant article was any good, guess not.

gonna pop test them with my home made tester after i work out the bugs in it to see what pressues they are opening at.

I hope its not the injection pump, previous owner replaced it 6k miles ago with a good used one. I have an extra injection pump but not looking foward to that job if it comes to that

gonna check my fuel delievry pump noticed a leak at it today.

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1986 300SDL, 211K,Dealership serviced its whole life
1991 190E 2.6(120k)
1983 300D(300k)
1977 300D(211k)

If the Extra Fuel Injection Pump has a Fuel Supply/Lift Pump you might try swapping that.
But, that would mean an un-know Hand Primer that may or may not have an Air Leak.

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84 300D, 82 Volvo 244Gl Diesel

I am also installing Monarks on my '81 240D. But I followed the instructions from Mercedes Source and when I got to testing the last injector- it popped at 250# above the rest. I am going in today to pick up some different shims to lower the pressure. To make things more interesting, I had previously gotten some injectors from a Pick n Pull. All the installed shims were identical, but I tried getting this one to pop lower by exchanging the guts. Still popped at 2000#. Hmmm... maybe previous wrenching on my car and the one in the Pick n Pull led to some turbo version parts installed in both cars-which would cause performance issues, I would think. Which may be part of the reason my car sounded like a bag of ball pein hammer heads in a washing machine. Which may be what the car in the junk yard sounded like.
Bottom line- All the first 3 injectors after being thoroughly cleaned, lapped, and reassembled with Monarks popped at 1750#. I can live with that. Injector #4 popped at 2000#, and had I not pop tested, I would have installed them and wondered why there were still ball pein hammer heads in the engine. I am glad I went through the trouble and expense.
Well worth it.

I get to do the same on my daughter's 300TD in the next month or so...

snapped_bolt

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'81 240D For now, a good place to borrow new parts
'80 300TD Probably will be put back into service!
'79 240D BACK IN SERVICE SINCE 09/16; limited use, oil leak. Guide pin r/sealed/replaced. Still a leak. Front crank seal....

You can Measure the thickness of the Shim. Sand it down by hand a little. Measure it again and install it.
See how much lower the pop pressure is. After that you have a formula as to how much material removal equals X amount of Pressure difference on that particular Injector.

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84 300D, 82 Volvo 244Gl Diesel

got my day off tomorrow so im gonna try to wrap up the pop tester. I took care of some leaks today, bleed it out in a out in 15 minutes and when it ran had lots of smoke and noticed 3 of my prechambers were leaking so maybe the collar nuts loosened when removing the injectors. The socket is on its way. ill tighten them down and see if that takes care of the leaks, if not ill have to do the prechambers. also noticed the injectors nailing which probally means they arent balanced.

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1986 300SDL, 211K,Dealership serviced its whole life
1991 190E 2.6(120k)
1983 300D(300k)
1977 300D(211k)

Low Compression from the loose Prechamber Retaining Ring/Collars can also cause nailing.

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84 300D, 82 Volvo 244Gl Diesel

got the car running and running well just some minor starting issues to take care of other than that running good

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1986 300SDL, 211K,Dealership serviced its whole life
1991 190E 2.6(120k)
1983 300D(300k)
1977 300D(211k)