Hi all,
Regarding the turbo 240D. The engine is a 616 four cylinder with a Garret/ Air Research T3 turbo added. No the fuel system is Not stock! It will smoke with only 5 pounds of boost at full throttle, but at 8 to 9 pounds it runs clean
( and makes more power! ). I also run 3.07 gears and the large oil cooler from a 300TD which makes for a much happier engine at 75 MPH.

I realize that the Stock pop pressure for a 616 is 115 bar, but all of the turbos use 135 bar. The injectors I built are 135 bar turbo injectors. I did not shim the 115 bar injectors to 135 bar. I don't think you could. The 135 bar injectors use a much heavier spring and the piece that pushes on the back of the pintle is different too. Anyway, she runs like a scalded cat, which in 240D parlance means I can out drag a Yugo! I also don't have to get out and push on steep hills.

I don't know why the Bosio Nozzles went to poo so fast. What I can say is that they did, and ALL of them did. I tested all four, and the spray pattern was lousy on all four. The other thing is that the design is obsolete. The pilot injection hole on the Bosch nozzles has been universal in MB engines since what, the early 70s? If the Bosio Nozzles are so wonderful why don't they at least match stock Bosch nozzles in technical sophistication? I'm really tempted to fire up the lathe and try making my own!

Cheers, Chris