Happy to find and revive this thread.Thanks a lot.

Where to get the adjuster washers/shims? I saw a smaller custom kit on the mercedes website for around $49.
https://mercedessource.com/store/var...him-washer-kit
Not sure if that works. Other known sources?

Sorry can't help with that part yet, although i saw someone mentioning using cut pieces of tape measure as shims?

Posted to ask what injectors you have? As I'm after a set of Monark 039 305 138 nozzles but can't seem to find anywhere to buy then online

Mercedessource makes a shim kit that's not a bad deal, I have one and I'm sure I'll never use all of its pieces so would happily loan it out to anyone for free (with a deposit of course) who needs them for injector work, provided it were returned speedily.

Otherwise, any diesel fuel injection shop will have a mountain of these and should have no problem getting injectors set up properly for you, if you go that route. Local guys here do it for a few bucks an injector -- undoubtedly a good deal once you factor in the time, learning curve, and equipment to really do it properly yourself, unless you have no one near you who is capable... Even then, sending them out in the mail still seems like a better option to me. I've redone a few sets myself, not planning to do any more.

Im at 242k and rebuilding injectors and replacing the nozzles with updated ones has been something I've been thinking about doing for a couple of months now. I just don't have the knowlege or tools to pop test and rebuild mine.

Good starting primer on injector servicing:

HOW-TO: Rebuild Diesel IDI Injectors

Setting/balancing the pop pressure is tedious, messy, and time-consuming. Test, keep good notes on pressure readings, verify no drippage when pressure held to just under pop for several seconds, disassemble, reshim, reassemble, test again...

Not to mention cleanroom conditions.

Not to mention inherent dangers involved in high-pressure fuel jets near the human body...

Next time I need to service the injectors, I would probably find out from v8volvo who these "Local guys here do it for a few bucks an injector" are!

Good link. Thanks, I feel a little bit better now about doing this myself.

Alright. Just keep your hands away from the nozzle spray, and do not use non-hi pressure fittings on your pop tester (if you end up building one yourself).

oh yes that one i know.