I was visiting a local FI shop where they offered to pop test my injectors for free. I watched as the tech tested each one, it was interesting and a learning experience. Three of them failed to pop properly. Not totally unexpected since these were from my '74 240D and it was nailing pretty seriously.

Anyway, I went back the next day to thank the tech who help me to diagnose the problem and learned he was rushed to the hospital after accidentally injecting diesel fuel through his skin on his hand. Apparently this can happen quite easily since the fuel leaves the injector at pressures higher than those used by the "needle-less" type injection equipment used in medical procedures. But, having diesel injected into the human body is extremely dangerous and can result in amputation of the limb or death!

So, anyone contemplating doing home "pop" testing be aware that if it can happen to someone who does this sort of testing daily it can happen to you too. I don't know how he did after being taken to the hospital, but everyone at the shop seemed pretty shaken up by it.

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Marty D.

2013 C300 4Matic
1984 BMW 733i
2013 Lincoln MKz

yes, there are many posts on this. very nasty stufff. I dont use diesel when I test, but new veg oil. I do know in my HPT thread, there are pics posted and links to nasty stories.

thanks for the reminder, and wishes go out to that unfortunate soul....

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1984 123.193 372,xxx miles, room for Seven.

1999 Dodge Durango Cummins 4BTAA 47RE 5k lb 4x4 getting 25+mpgs, room for Seven.

substitutes for safe and sane shop procedures. NOT chastising the shop staff, of course.

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1987 300D (230,000 mi on a #14 head-watching the temp gauge and keeping the ghost in the machine)
Raleigh NC - Home of deep fried sushi!

This is a good heads up.

hyraulic hoses, like on back hoes, and other equipment that develope a leak can cause the same problems. It`s just natural to run your hand along the hose to find the leak, and all of a sudden your hand or one of your fingers swells up with hydraulic fluid.

lots of times the leak is so fine, but under such high pressure it is hard to see.

I`ll take my injectors to the experts and let them do the testing and not worry about building a pop tester. just one thing to hurt myself on .

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