Recheck this on the internet. 1 bar= 14.5 psi.

I am the one that said where I worked in a fuel injection shop they used 500 grit.
I personally used 600 grit when I rebuilt my injectors as that is what was available on ebay at a decent price. I used a plate of glass as a lapping plate. (Later I bought a real lapping plate but have not needed to use it.)

You can get the lapping compound on eBay, I believe what I bought was aluminum oxide. People that polish Rocks as a hobby use it.

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84 300D, 82 Volvo 244Gl Diesel

FWIW I have been told by a very experienced MB mechanic that the 135 bar injectors were used on NA engines too, it's just that the turbo engines took over in USA with them so folks over there assume NA engines stuck with 115 bar ones.

__________________
1978 300D, 373,000km 617.912, 711.113 5 speed, 7.5mm superpump, HX30W turbo...many, many years in the making....
1977 280> 300D - 500,000km+ (to be sold...)
1984 240TD>300TD 121,000 miles, *gone*
1977 250 parts car
1988 Toyota Corona 2.0D *gone*
1975 FJ45>HJ45
1981 200>240D (to be sold...)
1999 Hyundai Lantra 1.6 *gone*
1980s Lansing Bagnall FOER 5.2 Forklift (the Mk2 engine hoist)
2001 Holden Rodeo 4JB1T 2WD

McMaster-Carr
404-346-7000
404-349-9091 (fax)
atl.sales@mcmaster.com
Receipt
Billed to

Mcmasters-Carr

Line Product Ordered Shipped Balance Price Total
1 98055A105 Spring Steel Round Shim, 0.1MM Thick, 6MM ID, 12MM OD, Packs of 50 1
Pack
1 0 5.69
Per Pack
5.69

2 98055A106 Spring Steel Round Shim, 0.2MM Thick, 6MM ID, 12MM OD, Packs of 50 1
Pack
1 0 5.17
Per Pack
5.17

3 98055A107 Spring Steel Round Shim, 0.3MM Thick, 6MM ID, 12MM OD, Packs of 50 1
Pack
1 0 5.86
Per Pack
5.86

__________________
84 300SD
85 380SE
83 528e
95 318ic

It would be nice if there was some printed material to back that up. After all the Mercedes Service Manual has NA and Turboed Engines and as far as I know it lists the opening pressres as being different.

I believe that difference in opening pressures is also the same if you look and other makes like VW and Volvo diesels comparing the turboed to NA Engines.

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84 300D, 82 Volvo 244Gl Diesel

Clemson the shims you got from mcmaster were 12 mm o.d. the shims hunter recommended were 11.4 o.d. yes will the ones you got fit? Did anyone use these shims from mcmaster yet? I want to do my soon and want to have the parts on hand before starting.

If I'm not mistaken Bill installed those shims years ago.

So, how bout it, Bill?

"BillGrissom BillGrissom is offline
Registered User

Join Date: Aug 2010
Location: Sacramento, CA
Posts: 1,252
1950 psig. Best they can probably be trimmed is +/-50 psig.
Lookup my post. I gave McMaster-Carr PN's for steel shim washers that worked for me. As I recall, 0.1 mm shim gave a 100 psi increase. I never lapped the parts and never had leaks (both cars).

I suspect that spray pattern and lack of dribbling is more important than pop pressure. I say this because I found 3 of 5 injectors in my 1984 300D popped at 1600 psig and were for a non-turbo engine, yet changing them made no noticeable difference.

Fuel seems to make a big difference. I run Diesel HPR (only in CA) and when idling at a stoplight, the other cars can barely tell I have a diesel, with their windows down. It sounds as quiet as the newer M-B CDI diesels."
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Let me know if you want a handful of those. I have fifty of each of those three items.

Dan

__________________
84 300SD
85 380SE
83 528e
95 318ic

Clemson 88 I pm'd you on the shims. Don

Sure, just search for my post of several years ago (searching from Google works better for me). As I recall, I only used one 0.1 mm shim, and only in a few injectors to tweak the pop pressure up ~100 psi. I have probably pop-tested 3 sets so far, for my cars only. See my post on my pop-tester w/ electronic recording. I recall the M-C shims are slightly smaller OD than the spring, but will still touch it everywhere if offset, and sounds like even larger OD than the "correct" shims.

I may re-pop some in 5 years or so, which might tell if the shims wore, so wait for that if really concerned. Otherwise, not risking much if you buy a few bags from M-C, and probably only need the thinnest ones they carry.

And don't PM me asking to buy some of mine (like one guy). Too much trouble to dig the stuff up and mailing would cost as much anyway. M-C takes a credit card, and you can find much stuff there for your other projects. Note they carry the special 6 mm adapter fitting you need to connect a home-made pop-tester to a M-B fuel tube (don't PM me for the PN, lookup my post).

__________________
1984 & 1985 CA 300D's
1964 & 65 Mopar's - Valiant, Dart, Newport
1996 & 2002 Chrysler minivans

Thanks, Bill.

I posted my order from Mc-Carr above. I'm good and it's good to know that those shims worked. I'm sure many of the members here will purchase those instead of those sold by Diesel Gnat.

__________________
84 300SD
85 380SE
83 528e
95 318ic

Hi,
My name is David, from France and new to this forum.

WHUNTER mentionned 11,4mm shims diameter for Bosch injectors but when I contacted Mercedesource, they only sell 11,5mm shims, 0,1mm larger...

I need some 11,4 shims for my Lucas injectors on a Renault Clio. And I can't find any, only 11,5mm...

Can I have some advices ?
Thank you

Shim : https://photos.app.goo.gl/86H9SOJiz64t9YDk2

I was unable to find injector shims for my 1995 e300. The shims are good for 1995 - 1997 injectors.
Well I bought a die and some shim stock and made my own.
I'm wondering if anyone else has had trouble locating these shims.
I called a local diesel injection shop and Bosch sells the shims but you must buy 10 of each size. The sizes run something like 8.1 mm, 8.2 mm, 8.3 mm and so on. They run like $5.00 each.
I didn't want to go this route. So I bought a die to produce a shim of .375 od and .125 Id in the following sizes .0035, .005, .006, .007, .009 inches.
My local diesel injection shop manager said that every .1 mm gains approximately 100 psi. .1 mm is approximately .004 inches. All my injectors were 200 psi low. So I needed approximately .008 to get to 1668 psi. Keep in mind that a little tweeting is required to get the desired setting.
PM me if anyone is interested in some shims.
Like I said... these are almost impossible to find. I did hear that the shims were a dealer only part but the dealer doesn't sell them anymore.
Roddy



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So I found out that the 98 - 99 e300 use the same injector but the pop pressure for the turbo engines is 135 bar or 1958 psi.
So the shims will work for 95 through 99 mercedes e300.
Roddy

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I just finished
adjusting my 1995 e300 injectors. Found out that for every. 001 the pressure goes up 40 psi. All my injectors were 200 psi low so I used .005 inch shims and got to around 1668 psi or 115 bar.
At first I put in a .009 shim and got around 1950 psi.
I wasn't expecting that because I've been told that every. 004 would increase the pressure by 100 psi. That equals 25 psi per .001 shim. That is a figure that works on the 617 engines. While the 606 engine injectors respond quite differently. For every. 001 the pressure increases 40 psi. So when I bought my shim stock I bought shims in excess of .005. I now know to buy much thinner shims for the 606 injectors.
Roddy

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Just got my e300 running again. Cranked it two times with the fuel feed opened up all the way and noticed a bit of fuel on the injector line going to the injectors. Tightened the injection lines and it started right up.
My car used to smoke a bit but that has stopped. The engine is more responsive and starts better.
I did re time the injection pump to 13.5 after top dead center. Seems to have made a slight difference. Idle is nice and smooth.
Roddy

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Not injector related but since I adjusted the injectors pop pressure the return line going from number 1 injector to the main fuel filter keeps popping off and spraying fuel everywhere. I made a note on another thread. Bottom line the 1 way valve going from the main fuel filter to the hard line return line was installed backwards. I blew some compressed air through the hose connected to the hard return line and heard a bubbling sound coming from the fuel tank. Took the fuel cap off first. That told me there wasn't a blockage down stream. Just in case this happens to anyone else.
Very hard to believe someone would install a 1 way valve backwards.


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