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Discussion Starter #1
I don’t have any history on injector service on the new to me 96 2500. I’m familiar with doing pop testing, shimming and balancing the IDI injectors on my Mercedes diesels, but understand these are different.

I am not planning to do any big power mods. It is doubtful I’ll even mess with the aneroid.

  • what are the best “stock” injectors if I want to get a new or rebuilt set? Best source?
  • are the nozzles replaceable themselves?
  • any recommendations for specialists that are good with the 12v injectors? I can deal with some downtime to ship them somewhere and back to get someone who does good work.
Thanks!
 

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The best stock injectors will be from a 96 or 97 manual transmission truck ( the 215hp injectors ). They can be had from various places but I’d suggest you steer clean of the new Chinese knockoffs and stick with Bosch bodied injectors.

I’ve had good luck with reman injectors from Power Driven Diesel. They’re available in several different nozzle tips to suit whatever your power needs are.

You can also get replacement nozzles and build them yourself assuming you have the tools. Shouldn’t be that much different from installing monarch nozzles on OM617 injectors.

Although the availability of quality remains for the 6bt is WAY better than for the OM617/ 616 ( I owned a w123 chassis 300td and 240d before I got the 6bt cummins), so for me it isn’t worth the time to replace nozzles and balance injectors myself when I can order up good remains for a reasonable price.
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Discussion Starter #3
Thank you.

Curious if the injectors on the 96-98 180hp vs 215 (AT vs MT rating) are the same, or if there is a difference in the body, pressure, or nozzle.

It would seem to me that the injector body would be the same, the pump would just be “turned back” to provide a bit less fuel, and possibly boost (which I guess would dial back the fuel via the android). But I don’t know enough to be certain.

Reason why I ask is that it seems like there’s anecdotal evidence that 215hp
Injectors on lower rated engines can cause more smoke. For my uses, the base power level for my 96 is sufficient, so I’m looking for efficiency and clean running.

Thanks!
 

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Thank you.

Curious if the injectors on the 96-98 180hp vs 215 (AT vs MT rating) are the same, or if there is a difference in the body, pressure, or nozzle.

It would seem to me that the injector body would be the same, the pump would just be “turned back” to provide a bit less fuel, and possibly boost (which I guess would dial back the fuel via the android). But I don’t know enough to be certain.

Reason why I ask is that it seems like there’s anecdotal evidence that 215hp
Injectors on lower rated engines can cause more smoke. For my uses, the base power level for my 96 is sufficient, so I’m looking for efficiency and clean running.

Thanks!
Nozzel size are slightly different. .0095 vs . 01025" hope size.

I doubt on a decently tuned engine you'll see a smoke difference. If anything, keeping the pump settings stock, the slight shortening of the injection window may gain you something.

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I looked at Rock auto, they had three new Bosch 180 injectors. About $75 each. They normally have the 180s, it is the 215s that are hard to snag.
 

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Discussion Starter #6
I too saw the three there. I’ll wait and see if they get more.
Are there any recommended sources for stock Bosch nozzles? I may do a pop and balance, but would want the correct 180hp nozzles. I can’t seem to find a p/n or source.

thanks!
 
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