There are a few options available to people having injector issues. Some of these options work for some people, fail for others and often have different results. Is this due soley to the option chosen?...or is it due to other underlying issues? I don't think anyone knows for sure really.

So...

*You can just simply replace your injectors with new/rebuilt units out of the box.
*You can have your new/rebuilt units tested/balanced by a shop prior to install
*You can have your originals tested, rebuilt and balanced by a shop
*You can do the whole rebuilding yourself
*You can simply do a partial rebuild, i.e. just replacing nozzles
*In some cases you can simply purge and fix the originals
*Or you can just remove thoroughly clean and reassemble the originals and see if this help, especially when coked up.

In essence your decision criteria will likely be based on cost, access to services, you knowledge and comfort level in doing this.

If you are getting a quote from a shop you trust at $45 each that's a good deal, same cost as rebuilt units, although guaranteed to have been balanced.
Up to you. For me, the nozzle approach was $28 each and I figured balancing was not needed as my idle and running quality was good to start with.

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Stable Mates:
1987 300TD 310K mi (Hans)
2008 Jeep Grand Cherokee OM642 165k mi (Benzrokee)

Dig a little deeper. In several of the diesel injection shops I have visited to talk to the techs, they had never heard of the pintle holes in the injectors for the 617 engine. In other words they had no idea of what it takes to make these injectors work correctly. There is no way that they can clean the pintle holes in your nozzles for the amount of money we are talking about here.

They do a lot of work on other diesels and very little on automotive diesels.

Often the guy with the certifications is not the one who will work on your injectors.

All,

After buying Indian made Bosch nozzles, which started shooting a thin stream before popping, so I think that means they're crap, where does one buy French made Bosch nozzles?

So is the concensus that if your engine idles well, (mine idles pretty smooth, but smokes a bit at idle and has mediocre performance) you can just replace the nozzles yourself? My shop here quoted $25 per injector for nozzle replacement, balance, and spray pattern test. Thats if I supply the nozzles (Bosio).

If I changed the nozzles myself I could save $125. How many here have done them themselves? I have read the writeup on the DG site and it doesn't look all that complicated....so I am sure I could change them....but is the balancing at testing really that necessary?

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-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)

The injectors should hold pressure less than pop pressure for a length of time. This is an important failure leading to fuel in the combusion chamber at the wrong time.

I would contact fastlane, the owners of this site, for parts.

You can replace nozzles yourself and not test them but then you have to guess if they are right. I bought a tester but I wanted to play some with diesels. It wasn't a money saving thing for me.

Well, I may try it, and if they're not working right I'll pull them again and have the shop just "balance and test them"....I think its only $12 each for that, since I'd have done the nozzle part myself.

__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)

Having recently done both Bosio`s and Indian Bosch ill pass along what i experienced.On my car which was running poorly and nailing badly on one injector,i first swapped that injector into another cylinder to be sure it was actually an injector problem.I then pop tested them and the bad one was just squirting,no spray pattern or atomization,the other 4 were decent and probably would have responded to a good cleaning.
I chose Bosio nozzles to replace with as there seems to be good results with them in VWs (see TDIclub.com) ,i pop tested them before i ran them and they were all just very slightly above the hi side of the spec but very consistent.The first few days there was a bit more combustion rattle than i would like but they soon quieted down and the car runs very well,starts instantly and no visible smoke in the daytime unless i really floor it from a standing start.
My sons car (both300d 2.5s his 93 mine 91) i did not hear run before we did the nozzle change but he said he also had one knocking pretty loud,loud enough that he was concerned about the possibility of an internal engine problem.We pop tested his and found one very poor the others probably ok.He ordered Bosch and of course ended up with the India made Bosch.We assembled them and pop tested them and found them all well above spec and one was way off.We of course did not have the shims to correct them.I dont remember the numbers but he felt they were too far off spec to run them so took them to a Bosch shop to have them set.when installed in the car they ran quieter than the Bosios did when first put in.His car runs good does not smoke seems to have good power.
I guess in a few years we may be able to tell which set held up better,but for now my thought on the subject is that the Bosios were more consistent which one would think points to better manufacturing quality control. My $.02 Don

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Red Green "This is only temporary,Unless it works!"

97 E300D 157000 miles
87 300TD ?141k? miles

I still have a supply of French Bosch injector nozzles that will work in the 616 and 617 engines. You are not going to find these anywhere for sale in a retail outlet as they are out of European production and outsourced to India now. So these are the real deal as far as quality goes per the original German design. They are still factory sealed in their original manufacturer's container. Mercedes dealer retail on the inferior Indian nozzles is $60 each, and my price is $50 each per French nozzle. I have sold several 5-piece sets and am slowly getting down to the minimum supply I need to maintain my fleet.

You can PM me for purchase details - I prefer PayPal and have an established history on the account that can be reviewed.

Other than these nozzles, if I were given the choice between Indian Bosch and the Italian Bozios, I'd go with the Bozios for the better chance of success. However, the long-term running capability of Bozios is still undetermined in my mind, so you may want to consider using a higher quality part to do the job right the first time and for the long term running of the car. It's no fun to pull injectors multiple times and still not get a good running car.

Ken300D

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1982 300D at 351K miles
1984 300SD at 217K miles
1987 300D at 370K miles

the "thin stream" you refer to is actually normal and desireable.what you have observed is called the "pilot injection" which contributes to smoother running.

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michael cole 1980 300SD gone now but not forgotten,87tdt,90 300te 4matic 95 e320 wagon

I just put Bosio nozzles into my injectors yesterday, and it runs great! More torque, smoother starts, and smoother idle. Less smoke too. Our '83SD has had them for almost 15,000 miles and it runs smooth and great as well. Old nozzles were shot (originals!)

__________________
-diesel is not just a fuel, its a way of life-
'15 GLK250 Bluetec 118k - mine - (OC-123,800)
'17 Metris(VITO!) - 37k - wifes (OC-41k)
'09 Sprinter 3500 Winnebago View - 62k (OC - 67k)
'13 ML350 Bluetec - 95k - dad's (OC-98k)
'01 SL500 - 103k(km) - dad's (OC-110,000km)
'16 E400 4matic Sedan - 148k - Brothers (OC-155k)