I pulled 5 injectors from a 190D non-turbo at Pick-N-Pull hoping to use them in my OM617 turbo engine. Is it possible to adjust them to work in my engine or will I be selling them to someone with a 190D?

They are KCA 27 S 55 648 115 bar.

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1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

If I recall correctly.

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It's always something simple
91 300D 603.960 (from japan) 194K
92 Toyota Diesel Landcruiser HDJ81-t 116K
02 Golf TDI new head courtesy of PO
87 300D
97 BMW 525 TDS Wagon 5spd
bunch of Onan and other diesel generators

the 617 requires 135 bar opening pressure; the injector body part number for the OM617 is KCA30S35 and as bigblockchev noted the threads are different (the 190D injector threads are on the very bottom, whereas the 300SD are further up). i think you can get remaned injectors for about $70 complete or find a diesel service shop that will rebuild yours (probably cheaper if you source the nozzles for them)

I am looking for Monarch nozzles. Where do you guys usually get them? Kent seems to be out of stock. I searched online but the results were few and people wanted $300+.

I'm working on building a pop tester out of a 10 ton porta-power.

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

How effective would it be if I took my injectors apart, cleaned them, lapped the mating surfaces and reinstalled them after pop testing and replacing the heat shields? I have started running some UMO, so I don't want to put a lot of money into injectors right now just in case I find bad things happen to them.

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

Looks like the ETA for Monark nozzles is some time in June.

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

yeah kent is the only source in the US for the monark nozzles; sometimes you can find them on ebay from a private seller. if you got the pressure shims for your injectors then yeah i'd go ahead and disassemble them and pop test them. i use acetone to clean mine (just soak em, the acetone will take any gunk off), just don't let the parts dry or you will get surface rust real quick. i usually take mine straight out of the acetone bath in dip em in clean diesel.

Looks like I'll have a weekend project, then.

I have worked with other types of injectors that use shims behind the spring to adjust pop pressure; is that the case here? How would I go about actually adjusting the pop pressure if I find one is too far off?

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

yes our bosch injectors have the same setup; only 5 parts inside the injector. i think a .05mm shim increases pressure by 3 bar. the diameter for the shims is 11.5 mm

I'm going to look around but do you know where I could find a kit of assorted shims?

Thanks for your help so far!

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

maybe see if any local diesel shops have a shim set, the only other source i know of is kent or ennis products. you have a pop tester right? otherwise it would be a whole lot cheaper to send them off

OK, thanks. I saw the kit Kent has; these things must be gold plated or something. I am building a pop tester. I am waiting for a few fittings to come in from McMaster Carr and I can put it all together. Can't beat a sub $100 pop tester...that is if it actually works.

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

The main reason I want to inspect and clean my current injectors is because I suspect I have at least one that is bad or really far from spec. The whole car shakes at idle pretty bad. I'm also doing a valve adjustment this weekend. Between the two, I am hoping for a better running engine and more power. It should hold me over until I can get the new Monark nozzles.

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge

yeah that'll be a good idea once you have your pop tester; i found on my SD if you do a warm engine valve adjustment it helps to get rid of some of the shaking

Warm engine? I thought it had to be cold. I'll have to research this and the benefits of one versus the other.

__________________
1991 F250 super-cab 7.3 IDI. (rebuilt by me) Banks Sidewinder turbo, hydroboost brakes, new IP and injectors.
2003 S430 - 107K
1983 300SD - Tanoshii - mostly restored ~400K+.
1983 300SD - Good interior. Engine finally tamed ~250K.
Monark Nozzle Install Video - http://tinyurl.com/ptd2tge