Howdy, all,

Yesterday I pulled 5 injectors from an OM617 turbo 300D to clean and install in my car, an 83 300SD. Before dis-assembly, I pop tested them and 4 out of the 5 were OK but not near perfect. One was a pisser and the other 4 I could get to pee before popping if I tried to. I disassembled them one-by-one and soaked them in lacquer thinner for a few hours. The pisser injector was very dirty and rusty inside. The others were dirty but not near as bad. I lapped the mating surfaces with 2000 grit sand paper after a bath in Diesel fuel and I also put Diesel fuel on the sand paper while lapping. I used a picture frame with a glass surface to tape down the sand paper.

After my cleaning, I noticed the injectors pissed a little more than before. I was hoping for the opposite effect. They all break around 1900 PSI and depending on how hard I push on the pop tester, they can pop well or they can piss. 2 out of 5 piss no matter what and the other 3 still piss before popping.

I torqued them down, upon reassembly to the equivalent of 75nm.

My engine idles quite roughly and has low power along with delayed response. If I floor it, I have to wait for the engine to catch up and even still, the power is not what I would expect. It picks up a bit of power once the turbo decides to boost.

I replaced my #5 injector with one of the better injectors I rebuilt, along with the crush washer and cleaning the pre-chamber seat. I notice a slightly less rough idle than before and slightly more seat of the pants power. The #5 injector I pulled was a pisser no matter what pop pressure I applied. #4 was about the same as the injectors I rebuilt, so I reinstalled it. I am still working on the other 3 injectors 1-3.

Any advice? Did I screw something up rebuilding the spare injectors?

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1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge