Another caveat is the turbo injectors have a stronger spring so the .001 inch equals 40 psi probably won't work. Don't know but I suspect the value to be much higher. Say 50 psi per. 001 inch shim. So my previous prediction isn't to be followed for the 98 & 99 e300 injectors. So yeah it's really a crap shoot ordering in the blind.
When someone can confirm the 98 & 99 shim factor let us in on it.
Roddy

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Well I am fixing to go down this road so I will figure it out and post results. I am still debating on ordering an assortment of shims from McMaster or ordering shim stock and a shim punch and doing my own. I would still have to order an assortment of different thickness of shim stock. With your figures I can at least get a wild guess about what it could be and go from there.

Bosio nozzles are shorter than the factory nozzles.
Well that makes sense. If new nozzles tend to pop at a higher pressure then a thinner shim would be required. The factory shims are one thickness. So it's understandable that the new nozzles are shorter to allow for an adjustment with new shims under the factory shims. Someone at Bosio did us all a favor because going thinner would require a surface grinder. A lot more expensive than buying a few shims.

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Ok So I just finished the job of swapping in the Bosio nozzles. I ended up ordering a variety of sizes from McMaster. I ended up using a .012 shim and a .003 shim so a total of .015 to raise the pressure that 40 bar or 580 psi. All of them are now popping right at about 2000 psi. I checked the injectors with the original nozzles before taking them apart and all of those were popping about 75-100 psi too low to start with. Started the engine with the new nozzles and it sure sounds quieter than it was before but still does not sound as quiet as my other 98 E300 I just sold my dad. It might take a few miles for them to settle in but so far it seems like an improvement.

I took the car out on the highway just now to get it good and warmed up. From about 3-4k under heavy load I am getting diesel pinging like you would on an old 61x. It could be full of crud from running 80k+ miles with the previous injectors that were popping low. It is much more quiet at idle for sure and I do not notice the white/grey smoking after it sits idling for a while. Will be interesting to see if the mileage goes up.

Remember that most shims come stepped at .05m. The M-C ones are stepped at .10 The OM606 injector is much more sensative to shimming than the OOM616/617 family of engines' injector shimming. The rule of thumbs are OK relative to shim thickness = PSI increases, but the OM606 really needs steps at the .025 and .05 level since adding an additional .05 will push the pressue way too high if you use the .10 shim. OR, you can pop test them, identify your shims, and figure out their thickness to see if you can swap around your 6 shims. Normally a set of 6 will have 2 to 4 different sized shims. Those thicker or thinner (normally you will need thicker) shims can be used with your original six injectors. However, you will be super lucky if stepped shims at .10 will work on the remainder.

I ordered the following sizes, .012, .01, .001, .003, .004, .005". After trial and error the .012 and .003 put the pressure at 2k. All of mine started out at pretty much the same pressure, so the same shims ended up working to bring them up to the proper pressure.

I'm new to the turbo 606 so keep that in mind. The ping might be egr valve related. The value is supposed to be closed at idle and opens up during light load. The egr valve is supposed to be closed at wot (heavy load). The other cause could be the increased pressure affected timing.
Or you might have let the car sit for a while and the fuel might be compromised.
But I'm glad you have your car back on the road. Drive the car as is for a month and see if there's an improvement. I'd like to see if the ping goes away.
If it doesn't then I'd check the timing. Although my experience is the timing chain doesn't stretch in a 606. Replace the fuel filters and air filter if they haven't been changed in a while.
Has to be something simple it might take some trial and error to identify the issue. Just don't get into a hurry and do one improvement at a time to isolate the fix. And let us know what worked on your car.
Roddy


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hi can anyone post a link to the mcmaster car injector shims? ive been searching through the forums with no luck, and all i came up with was generic washers from mcmasters website. thanx

actually, i just came up with this, https://www.mcmaster.com/shims

would spring steel be the best material, and would the OD be 10mm, or 12mm? i found another thread that said all shims were 11.4 OD, so maybe ill stick with 10mm to be safe?

Did you find the answer?? what are the best shims needed? thanks