Little update: Motivation has not been high but I managed to take it for a spin today, get it up to full operating temperature (it drives great, but definitely not a smooth idle) then do a compression test after removing the injectors. Since I had to take all the injectors out anyway, I figured, why not give this another try while I've got it running? I had to use a different combination of connectors from my HF set because the proper one was defective. If anything that could have led to a lower-than-actual reading. My numbers were:
1-320
2-320
3-340
4-340
That's pretty good, right? It may have cooled down some while I was trying to get everything apart and rigging the stop lever, etc. ... I think I was faster than last time, but I also did not have ambient temps on my side (it's below freezing).
Tomorrow the injectors will go back to the dealership and hopefully Bosch will send me a new set. The new set will go to the injection shop for pop testing before they go in the car.
Moving along ...

__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

If you have the HF kit and used the injector holes, you must use the injector adapter along with a collar and a copper washer (supplied in the kit).

Your numbers are good.

normal 350 to 435 psi
min 217 psi
max variation between cyl 43 psi

FSM says to take the compression with coolant temp at 176 F.

injector cap nut torque is only 18 ft lbs! They are often over tightened and "grooved" resulting in leaks.

__________________
85 300D turbo pristine w 157k when purchased 167,870 July 2025
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

It's running again!!! I had a hard time starting it, hopefully just because it wasn't quite bled. Bleeding took kind of long because it was 15 degrees out and the battery needed a lot of extra love and support to get through it.
So far, it sounds great and does not shake like before. I'm not going to celebrate quite yet because before the shaking was intermittent so I need a little more driving to judge. The only bad news so far is a couple fuel leaks I need to address: One braided return line (brand new) just really wants to leak. I have some extra so I'll replace it (again). Am I the only one who just has a bear of a time getting return lines on??? It feels like by now I've grated my fingerprints off doing it. Also, the fuel line nut on injector #1 leaks now ... it is tightened to spec, no harder, using a crow's foot. It is possible I overtightened it while doing all the bleeding. I have an extra set of fuel lines so ... ugh ... I'll replace that one. I really hope I didn't damage the threads on the injector.
At least I'm down to some more "normal" problems now.

__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Update: I replaced the leaking hard fuel line ... looks like it's still weeping a tiny bit (ugggghhhh). BUT, I was able to take it for a short drive. It drives great and the idle is night-and-day from what it was with the original injectors. It actually feels weird to sit in this car without being rocked out of my seat! I really hope this keeps up when I get it out for a full drive.
240DJan29 - YouTube

Next up: Fix the leaks. New tires. Renew registration (was hoping to get it in there before it expires the 31st but not quite going to be able to dodge that $10 late fee).

Edit: It wasn't the return line leaking, but that hard line as well. So two hard lines leaking, one of which I replaced with another and still leaks. Great.

__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Well ... today I test drove it all the way out of my neighborhood to the tire place three miles away, and got new tires (mine were almost 10 years old, on it since I bought it). I didn't see any leaks, so I took it to the DMV, about 20 miles away ... not only made it all the way there, but passed easily. Stopped by the MB dealer to pick up a part for my 300D, then drove all the way home in a downpour. Never felt so good being stuck in traffic in the rain. It's a world away from before, probably due to 1) the injectors and 2) fixing the lift pump, which was I guess the silver lining in my wild-goose chase.
There is some fuel on the injection pump and in a few crevasses, but I believe it is residual from the giant mess I made while bleeding it. Will clean it up and re-assess. But basically, the only glitch during my 50-mile drive this afternoon was when my knee jammed up while I was trying to work the clutch. Felt really good to drive it again; there were a lot of times last year I thought it would never go anywhere without being on a tow truck.
Thanks for all the help, guys, as usual.

__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Congrats for sticking with it and getting it done! So, no more bubbles? Were you able to finally determine the cause of the bubbles?

__________________
85 300D turbo pristine w 157k when purchased 167,870 July 2025
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

That's great news! I'm thinking you'll have these bled out in no time now, you're an expert!

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

Good news!

I was looking for a place to test my old injectors too. Where are they?

Hoffmann's Fuel Injection Service in Newark | Hoffmann's Fuel Injection Service (302) 834-3005 & 2676 Frazer Rd, Newark, DE 19702 | - Yahoo! US Local ... kind of tucked away off Frazer Rd. south of Rt. 40 ... I almost drove past it. There is a sign in the driveway but you have to look closely. Very nice guy ... they are a licensed Bosch dealer and rebuild injectors as well, so I will keep that in mind next time.
I actually heard of the shop from a guy I happened to start chatting with at the Royal Farms diesel pump ... nothing like old-fashioned word of mouth.

__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Oh... I could literally walk there from my house. I thought the name sounded familiar but I didn't realize I have passed it

With your phone's Google Maps set at my location., search for fuel injection. also search for diesel injection. In my area more diesel shops were found under fuel injection, but 1 was found only under diesel injection.

__________________
85 300D turbo pristine w 157k when purchased 167,870 July 2025
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

__________________
-Evan


Benz Fleet:
1968 UNIMOG 404.114
1998 E300
2008 E63


Non-Benz Fleet:
1992 Aerostar
1993 MR2
2000 F250

More good news: I think the first injector line is not leaking now ... I noticed the torque wrench had slipped down to 10 ft-lbs so (hopefully) it was just loose. I also replaced the other line and it's only weeping a little bit now, so maybe if I find another replacement line for that, I'll be good to go!
I'm calling it a night and celebrating just a little bit with something from Starbucks.

__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

It's not easy to use a torque wrench on the line nuts. I tighten them (by feel) just enough so they do not leak. Take the line off and look under a magnifier at the flared ends. If you see a groove there that is what's making it leak. You may be able to fix it by polishing that groove away with 400 grit wet/dry paper in a twisting motion.

__________________
85 300D turbo pristine w 157k when purchased 167,870 July 2025
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

On my (5 cyl) motor, I change 2 nozzles then start & run for 30 seconds or so, change 2 more, s&r, then the last one. Just a "few" extra seconds of cranking. On my 6.2 diesel blazer, I go 3, 3, & then 2. Works for me. -corne-

note - FWIW the wd-40 uses propane as propellant, this is what aids starting. If you dare, try using a propane torch (unlit, duh). I used to run several excavators which had 'deetroit diesels' for power. The all had cold climate starting aid units on 'em. They used standard disposable propane tanks. I've done my Blazer w/ the propane torch, never needed to with my MB.