I am in the process of replacing the injectors on my 240D with some fresh rebuilt injectors and I am running into a few problems. I cant figure out how to remove the heat sheilds from inside the pre chamber and the new injectors look different than the ones I have removed. Any suggestions?

People have used several mathods and I don't remember all of them.

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Also in you pic that does not look like the Heat Shields on My Car. I am gussing you from the pics you have the ones that are solid Metal Plates; if not that someone installed the shield upside down.

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84 300D, 82 Volvo 244Gl Diesel

Well I got the heat shields out without much fuss. The new shields do look much different than the ones I removed. I did also shine a flash light down in the pre chambers and everything looked kosher in there as far as I could see. I'm about to button everything back up but I am still concerned that the new injectors look different.

That looks as if there is no heat shield.

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I have just done mine on a '99
I used a magnetic pick-up device and slid them down a straw to have them land right side up. I have heard that needle nose pliers can be used, insert in hole and open with the jaws apart will also remove them.

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how do the new injectors look different ?

As for the heatshields/crush washers, the side with the groves or ridge is what you should be seeing. The side which is convex is down towards the ground. Hope that explanation helps or not too confusing.

Ok ... I see what you're talking about the injectors looking different. There are two styles. The ones with the longer bottom part and the ones with the longer upper part. They are same other than styles. They are the same height. I do not believe I have ever seen BAR 115 injectors which have the longer bottom part. Would you mind checking to see if your old injectors were BAR 115 ??

I noticed the same thing about my reman injectors vs. the old ones ... as far as I could tell from punching the numbers into Google, it's just a matter of there being multiple nozzle holders that can be used. They are the same height, same threads and have the same nozzles (115 bar).
Hopefully you have better luck with your remans than I did ...

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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 I got the new ones in and they seem to be working great. I had a few leaks which I seem to have fixed. The car runs much smoother with the new injectors.

I did some digging back in the archives and determined that I had the old style heat washers and I don't think the injectors had ever been out in 36 years. There was a bit of carbon build up on the old injectors and the washers but after cleaning the pre chambers I seem to have a good seal since my leaks were from the hard lines not being tight enough.

How do I determine the pressure of the old injectors?

You can mix the 2 styles of Injectors on the same Engine as long as they are Set at the same opening Pressure.

However, the internal parts of the Injectors are different as well. If you are rebuilding the Injectors yourself you need to keep the parts of the different types of Injectors segregated from the other types.

It is a good idea to do that anyway even if you have all the same type of Injector as it makes setting the Opening/Pop Pressure easier.

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84 300D, 82 Volvo 244Gl Diesel

Well I went out to try to start the car in sub freezing temperatures and it was covered in snow. 5 second glow time and the car fired right up at a very smooth idle. Very happy with the injectors from greazzer. If anyone ever needs some he is great!

If you don't want them back, I will be happy to check them for you.

Thank you Sir !

You need a Diesel Nozzle/Pop Tester to check the opening pressure if the Injectors.
It is also the best thing to see if the Nozzles are worn out.

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84 300D, 82 Volvo 244Gl Diesel