I've located remanned Bosch, Delphi and Standard Motor (intermotor) injectors for sale for Mercedes 617 diesel engines on various websites. Obviously, it is easier to purchase off-the-shelf remanned injectors than to source parts then build and test your own. That said, I viewed with great interest the recent youtube video forum member Greazzer posted showing him building diesel injectors then pop testing them.

Question; where would one obtain the available parts/components to rebuild Bosch injectors? and....are said parts built with quality in mind?

Excluding shims and nozzles, the only other "wear" items are the springs and intermediate disc. If the disc does not have any indentation (the whole 'lapping' gimmick is just that ... you cannot sand down a disc that much) you can polish it with some 1000 grit. Springs should be OK as well as pressure pin. Keep in mind there are only 8 parts to an injector for a OM617 engine or similar application.

I posted PN's of metric shim washers I purchased from McMaster-Carr. I only used the thinnest ones (0.1 mm, recall) which gave ~100 psi increase in pop pressure. If your nozzles don't give a good spray pattern, I think you must buy new nozzles. Many posts and claims of bad ones from India (even w/ Bosch PN). I also posted PN's for fittings I used to plumb a Ford Rotunda PRV testing pump into a pop tester, and mine allows digital recording of pressure traces. In my experience, the pop pressure makes little difference in how the engine idles or runs, but just a one injector-set "data point".

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

Awhile back I purchased Monark nozzles and had them installed on Bosch bodies by a local diesel specialty shop. They nailed like the proverbial nail gun. I tried everything I knew to do to stop the nailing. No joy, so I ended up purchasing some Bosch injectors off Ebay.

Installed the Ebay Bosch injectors and the engine returned to sounding normal. That said, their spray patterns have not been checked with a pop tester; I feel the time has come to do something, either buy remanned or build my own.

I rebuilt my injectors, I found pictures and bought shim stock and made my own shims.

I also had the bright idea of trying a few chinese nozzles and just seeing how bad they are. they were so cheap I couldn't resist. (spoiler: they came back out, cheap as they may have been, they were not worth the money)

I combined several sets of used nozzles into one good set with a nice spray pattern and the car has never run so smooth.

They aren't that complicated, I even built my own pop-tester with a bottle jack and a bunch of parts from mcmaster-carr. total cost was about 60 bucks, maybe a shade more. doing it again I would use a portapower type pump setup as it would be much simpler to setup.

Here's the parts I used, with a portapower you might not need as much:

Compression Fitting for Steel Tubing
Straight Adapter for 6mm Tube OD x 1/8 NPT Male
5269K311

Compact Extreme-Pressure Steel Pipe Fitting
Bushing Adapter, 3/8 NPTF Male x 1/8 NPTF Female
50925K343

Vibration-Resistant Pressure Gauge with Plastic Case
Dual Scale, 1/4 NPT Male Bottom Connection, 0-3000 PSI
3845K1

Compact Extreme-Pressure Steel Pipe Fitting
Bushing Adapter, 3/8 NPTF Male x 1/4 NPTF Female
50925K345

Compact Extreme-Pressure Steel Pipe Fitting
Right-Angle Tee Adapter, 3/8 NPTF Female x Male
50925K198

High-Pressure Brass Pipe Fitting
Straight Reducer with Hex Body, 3/4 x 1/2 NPT Female
50785K187

Compact Extreme-Pressure Steel Pipe Fitting
Bushing Adapter, 1/2 NPTF Male x 3/8 NPTF Female
50925K352

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1982 300D (w123, "Grey Car")
1982 300D (w123, "Blue Car")
2001 Ford F150 "Clifford" (The Big Red Truck)
1997 Dodge Ram 2500 12V Cummins
1996 Dodge Ram 2500 12V Cummins
Previous Vehicles:
1995 E300D, 1980 300SD, 1992 Buick Century, 2005 Saturn Ion

It is worth noting that the Monark nozzles ARE louder than the Bosch nozzles. They give a sharper diesel "cackle", especially at idle. HOWEVER, their performance (in the 603 at least) is an improvement. Smoother, more power down low, and much easier starting due to a different spray pattern. Having had OEM Bosch "India" nozzles before the Monark's, they're a definite step (or 5) up over the crap Bosch slaps their name on nowadays.

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Current stable:
1995 E320 149K (Nancy)
1983 500SL 120K (SLoL)

Black Sheep:
1985 524TD 167K (TotalDumpster™)

Gone but not forgotten:
1986 300SDL (RIP)
1991 350SD
1991 560SEL
1990 560SEL
1986 500SEL Euro (Rusted to nothing at 47K!)

I can take a simple job and make it impossible with my obsessive compulsive disorder. I got my injector nozzles popping close and lapped the bodies to compensate for minor differences.

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

LOL .... the best I ever got was +/- 10 PSI and that took a normal 20 minute job for a set of 5 and dragged it out to a few hours ... However, closer you can balance them, the nicer the engine will purrr ...

Where I used to work we had a lapping machine. You put the parts in and walked away. The longer you left them in the machine the thinner the intermediate discs would get.

I have also started with coarse grits and worked down to finer grits. Not a time savings item but I was at home and had no extra shims back in the 1990s (had no internet or knew other places to get shims).
I did it while watching TV.

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84 300D, 82 Volvo 244Gl Diesel

yeah, no gimmick. Not for this app, but surface grindesr can handle .0001" cuts.

Back to the OP Topic: buying reman'd or rebuilding your own.

Excluding the gifted tinkerer who can take a few cans and smelt them, a few bottle tops, and presto - bingo you have a pop tester, if you end up doing them yourself, you will inevitably spend a lot more on rebuilding them yourself versus the reman'd. The reman'd are running around $250 for a set of 5 shipped to you or even less. I have seen them at $28 a pop. However, they are not German made and having such a part made in either India or China does not excite me. Of course, I am excluding from the above the gifted tinkerers who can make their own pop tester for under $10 ... and the endless stories of folks who made their own pop tester in a few hours in their garage from a bunch of junk they picked up here and there ...

It really boils down to cost, here in the UK prices are very high due to the limited number of specialists working with this stuff.

If I lived in the US, my first option (and preference) would be sending them off/or purchasing from greazzer ^

My solution owning two MB's needing nozzles was to order one set plus a pop tester from Indian Machine tools. Yep I know but these guys have been around for an age supplying tons of kit.

I had a lower rated gauge fitted specifically for MB nozzle pop pressures which are around 115 bar from memory, this imo is a must to get an accurate reading during the 'chatter' cycle of spray.

It is however an extremely labour intensive process, each adjustment whether adding or removing shims needs the valve body opening then re-torquing, mine took a whole morning first time around but I did manage to get within 1-2 bar across all six.

Fitted to the 606.962 the difference was remarkable, you could literally balance a coin on the rocker cover. Unfortunately, I don't cover huge miles so cannot comment on longevity as yet, if you need contact details drop me a line or search on Peach Parts for thread.

Pop tester with new gauge

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David


1996 Mercedes S124 E300TD - 129k - rolling restoration project -

1998 Mercedes W210 300TD - 118k (assimilated into above vehicle)

Dieselinjector.guru (greazzer) is the best way to go. It's seriously cheaper than buying a shim kit pop tester and doing all the work.

And especially since it sounds like it's ur first time u may make a mistake and not get the best possible quality or they leak or pop wrong.

$100 for all 5 injectors rebuilt by maybe the most experienced man in the country as of now is literally unbeatable no matter which way u look at it.

basically it all boils down to greazzer is the best way to go cheapest way to go piece of mind that it's done right and u don't have to spend a whole weekend throwing wrenches across the room cursing... Plus this guy isn't just spraying break cleaner on them they come professionally 100% spotless inside and out. Plus u get personal access to the man who literally did all the work right here on this forum if u have any questions or need help with anything.

Again it's literally the ONLY way to go

[\rant]

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Maybe you should just buy reman'ed nozzles, , , , ,

edit: Or maybe brand new.

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"I applaud your elaborate system of denial"