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I ordered the nozzles from mercsource brand new, and properly lapped and thoroughly cleaned all the surfaces. i almost believe the injectors had never been serviced they were so bad.
but no, i actually did not pop test them, 1.) being i didn't want to buy all the stuff just to do it once and 2.) no one in my area even wanted to TOUCH the injectors. all shops local to me like to say "everybody stopped wrenching on those cars ten years ago, give it up" to hell with them
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The old injectors may not have been serviced, but how could you possibly know anything unless you STARTED with pressure testing them?
There is a range for pressure on the injectors and after that they need to be balanced within 50 psi of each other. If they are within spec, but not balanced you could have some funny stuff with your engine like you are mentioning. Also, you have no way of knowing the injectors are actually producing the mist they need and not just drizzling out diesel fluid.
At this point, you NEED the proper equipment or to get the injectors to someone who has the proper equipment to test and balance them.
Most of the original mushroom pumps leak. It's a cheap part and about 15 minutes of labor, so I would replace it.
Dkr.