Hi All,

I just replaced my injectors with new balanced Bosio's but the engine is still running rough. Cranks well, idles well, shakes at 1000 rpm and throughout turbo boost.

I did not replace the heat shields. I out some soapy water on the injectors today and saw bubbles on three cylinders. The last time I replaced the heat shields, I boogered up a prechamber and had to replace it. Before I take it to my indie, I want to replace all the heat shields to see if this cures the problem.

My question is: How do you take them out without boogering up the Prechamber? I have tried needle nose, a pick, cranking the engine, to no avail. I am a little shy about prying on it with anything metal.

Thanks in advance for your help.

1992 300d 248,000 miles

I spray a little Kroil on them and then use a flat bladed screwdriver that will barely fit into the ID. Usually, I can shove the screwdriver in there tight and it will lift out. May have to try it in a couple different places and wiggle it loose.

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Jim

Back in 2007 most places were selling Heat Shields with a samall hole (5mm) in them. The are easeier to get something to hook onto them.
After that time more and more of the sellers started selling the Heat Shields with a larger hole (10) in them.

Finding or making some sort of Hook shaped Tool is one of the ways people get them out when they are stuck.

After that if you order the Injector Heat Shields for the VW Rabbit Diesels from the 1908s I believe you will get the Heat Shields with the smaller holes in them and they will be easier to pull the next time.

If you are having a really bad time of it and still have the Tools to pull the Prechamber you could pull the Chambers. A lot of work though.

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84 300D, 82 Volvo 244Gl Diesel

Every VW I have seen has the shields with the 5mm hole.

-J

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1991 350SDL. 230,000 miles (new motor @ 150,000). Blown head gasket

Tesla Model 3. 205,000 miles. Been to 48 states!
Past: A fleet of VW TDIs.... including a V10,a Dieselgate Passat, and 2 ECOdiesels.
2014 Cadillac ELR
2013 Fiat 500E.

Didn't Mercedes upgraded the heat shields to the larger holes due to some technical reason?

One technique that worked for me in removing stuck heat shields is to take a 1/4 diameter flat faced punch and tap all around the outer diameter of the heat shield with a hammer. This will loosen the carbon binding them and then you can lift them out easily with a wire hook.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I just bought 55 seals at the local VW Performance shop, they have the 5mm hole, and were $1.50 ea.

Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Try a magnet. I forgot to remove the heat shields while checking compression and the engine was kind enough to cough them out for me.

Sixto
87 300D

Let some penetrating oil soak in there and break the carbon loose. Canola works well too.

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Remember, Safety Third!
'99 E300 Turbodiesel, '82 300TD, 1996 12V Cummins Turbo, '94 Neoplan - Detroit 6V92TA

I have read nothing to substantiate that the large hole heat shields are an update; and; the Sellers do not mention that in their Ads.
For a time some Sellers sold the Small Holed ones and another Seller was selling the large holed ones and they were for the same year and models.

My Volvo Diesel used the small Hole Heat Shields and the Pop Pressure is Higher than a Turbo Engine and the Injector Body has the same dimensions and the Heat Shield does the same thing.

Like the other Member I also bought fifty somthing of the small holed ones.

I did see a picture one time where a person is holding 2 prechambers in their hand and one prechamber has a larger Hole in the top than the other.
I saved that pic but I have not been able to find it.

I am speculating that the later Model Engines use the big hole Heat Shield and Mercedes just decided not to stock 2 different parts and decided to use the ones with the Big Hole.
That would also be considered an update but not for the benefit of a mechanical reason.

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84 300D, 82 Volvo 244Gl Diesel

I bought about the same amount way back. The price keeps going up on them and if you need one or a set right now you are going to pay $2-3 to buy them local.
If it seems like an excessive amount of parts to keep on hand as the price goes up on them I can re-sell them later; likely at a tiny profit.
They may be an inflation proof investment.

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84 300D, 82 Volvo 244Gl Diesel

when the penetrating oil and the magnet does not work, bring out the hammer and punch. BTDT

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Guess I was lucky - just used my little finger, no tools required to get the heat shields out.

Did you pop test the injectors yourself? I wonder whether they are in fact balanced? I just rebuilt mine with new nozzles and balancing them with a limited number of shims was a fun game to play. I scrimped a little on lapping and one is leaking a little at the joint but the engine is very smooth - well, for a 5 cyl diesel anyway.

I use a small pick with a curved end to pry the shield upward, then grab it with fine needlenose pliers to pull it out of the opening.

I have seen a mechanic take them out using small needlenose inserted into the hole (on the ones with the larger opening, obviously) then spread the nose of the pliers and pull the shield out. Didn't work well when I tried that method....

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Mac
2002 e320 4matic estate│1985 300d│1980 300td
Previous: 1979 & 1982 & 1983 300sd │ 1982 240d

“Let's take a drive into the middle of nowhere with a packet of Marlboro lights and talk about our lives.” ― Joseph Heller, Catch-22

I use the needle nose for placing the new one`s back in, mine have a little spring to hold the nose open.

I use a telescopic magnate to lift the old one`s out. "the easy one`s."


Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

I put the new heat shields in the simplest way I can think of. I insert a heat shield(with correct orientation) onto a screwdriver held with my fingers, insert screwdriver into pre chamber, let go of my finger and let it drop.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked