Hello, gents.

I replaced my recently rebuilt, but worn injectors with newly equipped Bosios last weekend. Although worn, these old injectors gave a buttery smooth, yet torquey throttle response, were surprisingly quiiet, and fuel economy was approaching 30mpg.

The new injectors were professionally done by a certified Bosch shop and supposedly set to 120 bar.

I took it on a 110 mile shakedown run last weekend and the first few miles brought an embarassing cloud after cloud of black smoke under acceleration.

The black smoke eventually eased up a bit, but there's still some grey smoke even at idle.

They also make a fair amount of noise. If I close my eyes I'd think there's a Power Stroke Ford in my garage (no nailing, though).

Fuel economy has dropped to just over 26 mpg.

Is it possible that the shop incorrectly shimmed my injectors (set to pop higher and slightly retarding the delivery) or do new nozzles just require a few tanks to get dialed in?

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1974 240D "Boldie" 170K.- New timing chain/freshly rebuilt IP/replaced valve seals/injectors/upgraded stereo/new Bilsteins with Yokohamas/fresh paint and rocker panels plus lots of welds.

I don't have a manual that goes back to 1974 but for the later model 240Ds it has 115-123bar as the acceptable range for the Injector Pop Pressure with a New Nozzle in it. So they actually could have set the Opening/Pope Pressure a little Higher.
Where I used to work back in the 1970s we set them at 1800psi which is slightly higer than the max. And, I we never had costomer complaints about them.

Bosio Nozzles lack the hole drilled in the Pintle of the Stock Nozzles or the Facet that is on the Monark and later Bosch Nozzles that are there to deal with the idle Fuel that would quiet down the noise at idle.
And, people have said Bosio Nozzles make more noise.

Some have also said that there is a break in period where Injector Nozzles sort of seat in.

I don't recall anyone saying they had more smoke after installing new Nozzles.

It could be you should check the Valve Timing/Timing Chain Stretch and re-time the Fuel Injection Pump.

With out any hint of blaming them I would call the Fuel Injection Shop and state the facts and see what they have to say.
Don't tell them anything I said just see what they have to say.

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84 300D, 82 Volvo 244Gl Diesel

I just put in a set of new Bosch injectors (complete) about a month ago and experienced the same issue, noticeable smoke at idle and enough smoke at kick down it was visible in the rear-view in daylight.

As suggested above I double checked valve and injection timing and did an early valve adjustment, all to no avail.

I really had a hard time believing the whole "injector wear in" theory but after about 1K on the clock all is back to normal except less power than with the Monarks I replaced.

Please post back your impressions of the Bosios! I've really been thinking about trying them but haven't read any impressions from another 240D'er.

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'83 240D

Don't want to seal this thread but how about some infomation on why the Monark Injector Nozzles were changed and how many Miles they were in the Engine?

Also are you useing only Diesel Fuel?

I have Monark Nozzles on my Mercedes and even the Volvo Diesel for at least 4+ with no issues caused by them. But, I am a low Mileage Driver at maybe 5,000 miles per year on either Car so it is hard to evaluate them based on the low Mileage.

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84 300D, 82 Volvo 244Gl Diesel

I wasn't having any issues with the Monarks, had about 20K on them and was just curious as to an apples to apples comparison, new Monarks to new Bosch. The motor itself has about 75K on it.

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'83 240D

Thanks.

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84 300D, 82 Volvo 244Gl Diesel

I have rebuilt a bunch of injector sets for 240's and 300's (OM617.9XX engine) during the last year +. Bosio's are the high end and you pay for quality. Smoke the first minute or two maybe, but driving around for 2-3 miles, and you have cleared out the system of any air or whatever. After about 4-5 dozen of rebuilt sets, folks only point out how smooth the idle is, no smoke or a lot less, et cet. So, either they are not pop tested, not balanced correctly or something is up with the IP. Maybe something got in your fuel ?

I have a set of Bosio's in my '83, and they run clean as a whistle, whether idling or a cold start at 8*.

Interesting. Please keep us updated. I'm planning on doing these injectors soon.

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'83 300D - 261K | '97 Jetta - 209K | '63 Rivera - 22K | '86 C30 Dually - 105K

WTB: W123 Passenger doors - preferably Brown!

Do you know if your Fuel Injection Pump has a Pneumatic Governor.

If so there is some threads on Smoking and Vacuum leaks around one of the Shafts an the Diaphragm.

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84 300D, 82 Volvo 244Gl Diesel

Thanks for the tips, all.

My timing chain is newer, replaced about 3000 miles ago. The injection pump was rebuilt 2500 miles ago and I dialed in the timing to get 1 drop/second. That doesn't mean that it's shifted since but I doubt it's off my much, if any.

I'm waiting for a call back from the shop. After checking the receipt, I see a note: "adjusted to spec 140" Spec on NA cars is 115 :/

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1974 240D "Boldie" 170K.- New timing chain/freshly rebuilt IP/replaced valve seals/injectors/upgraded stereo/new Bilsteins with Yokohamas/fresh paint and rocker panels plus lots of welds.

Maybe the shop was not as professional as you thought.

If that is so 140bar is the high end of for a Turbo Engine.

When I looked up the spec for a 240D it was 115-123 bar with a new Injector nozzle.

What bar pressure do you remember is stamped on the upper Injector Body?
People and Bosch themselves mix the Injector Parts so that it is possible to make NA Injectors with Turbo Injector Parts.
When I did my first Injector Rebuild on the Mercedes I used extra Injector bodies I had from my Volvo and it has 137 bar on the Body but I set the Pop at 135 bar.
If I sent them to a shop they might set them at 137 bar because that is what is on the body.

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84 300D, 82 Volvo 244Gl Diesel