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  #1  
Old 08-26-2008, 08:20 PM
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Easy homemade pop tester

Here is my homemade pop tester made from parts I bought used on ebay (like a portapower), a 3000psi guage, an injector line for free from a junkyard, and a clear salsa jar it sprays into:

Its a hand hydraulic pump that can do 4000psi, some have used 2 ton bottle jacks for this, but that requires welding, and epoxy, and is subject to leaks which could be dangerous (due to injection of high pressure diesel under the skin.) Mine was easy to build, no leaks and pumps easily, and required only a few plumbing fittings shown in the picture, since it already had a pipe threaded inlet and outlet on the pump. This pump has a knob you can see on the right end of the pump which releases the pressure, making it safer when you unscrew the injector. I got the portapower type pump (power team P23) barely used on ebay, for $67, and I have seen several like it on ebay sell for $40-60. Then I added these parts from mcmaster:
5269K311 METRIC STEEL COMPRESSION TUBE FITTING, ADAPTER FOR 6 MM TUBE OD X 1/8" NPT MALE PIPE 3.47
50925K343 COMPACT EXTREME-PRESSURE STEEL THRD FITTING, 3/8"MALE X 1/8"FEM PIPE, HEX HEAD BUSHING,6000 PSI 1.53
3845K23 GLYCERIN-FILLED GAUGE - 1% MID-SCALE ACCURACY, 2-1/2" DIAL, 1/4" BOTTOM, 0 - 3000 PSI 18.49
50925K345 COMPACT EXTREME-PRESSURE STEEL THRD FITTING, 3/8"MALE X 1/4"FEM PIPE,HEX HEAD BUSHING, 6000 PSI 1.30
50925K198 COMPACT EXTREME-PRESSURE STEEL THRD FITTING, 3/8" PIPE, FEMALE X FEMALE X MALE TEE, 4500 PSI 7.11

Here is a thread where I discuss using the pop tester for my new nozzles:
Monark vs. Bosio nozzles

I highly recommend getting your injectors pop tested, it made a big difference for me.

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Last edited by SunWizard; 08-26-2008 at 08:45 PM.
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  #2  
Old 08-26-2008, 08:28 PM
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Niiiicce!!!
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  #3  
Old 08-26-2008, 08:31 PM
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There is no valve to shut off the gauge.
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  #4  
Old 08-26-2008, 08:37 PM
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No need to shut off the gauge when you use this glycerin filled guage. No matter how fast you pump, it won't damage the gauge (which is the only reason I have seen why some have a shutoff.)
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  #5  
Old 08-26-2008, 10:16 PM
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How many strokes 'till the injector lets go?
It looks nice...After i rebuilt mine using bosio nozzles 1 year ago,
i took them to a place near chicago called 'midwest fuel injection', they are bosch certified..and paid for a pop-test /balance. I Told them and wrote down that i wanted them to go off at 140, but they announced when i picked them up that they went to 145, "because the springs settle down later, it's best this way".
Well, I am a machinist, not a diesel mech., but the car had 200,000 miles,
i think the springs are done settling...but i dunno?
I cannot remember the bill, so it must have been low. But a couple of uses on your tool,
and it's paid off, sweet. Plus, you will do a better job than a rushed tech.
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  #6  
Old 08-27-2008, 12:20 AM
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Quote:
Originally Posted by Marty600 View Post
How many strokes 'till the injector lets go?
3 strokes.
Quote:
But a couple of uses on your tool, and it's paid off, sweet. Plus, you will do a better job than a rushed tech.
I agree. It was paid off with 1 use, since several people on here said they pay $20 per = $120 for my 6cylinder, for a pop test and shimming. Next I have another old Mercedes thats probably never had injectors tested, and I need to find out if I can shim my Cummins injectors too.
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  #7  
Old 08-27-2008, 01:37 AM
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Nice effort

Excellent result!
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  #8  
Old 08-27-2008, 09:32 AM
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The search function is your friend:

Quote:
I bought all the parts from www.McMaster.com

1 8803T51 Bottle Jack ($12.74)
1 4000K763 3000psi gauge, 3/4" NPT ($10.04)
1 5269K311 Metric fitting, 1/8" NPT to 6mm tube ($3.12)
1 50925K197 Steel T fitting, 1/4" NPT, MxFxF ($4.27)
1 4513K341 Hex bushing, 1/4" NPT to 1/8" NPT ($0.85)
1 4513K347 Hex bushing, 3/4" NPT to 1/2" NPT ($1.18)
1 4513K344 Hex bushing, 1/2" NPT to 1/4" NPT ($0.95)

The jack must be disassembled, and the pressure relief in the cylinder plugged. I tapped it, JB welded a set screw into it, then ground it flat. Remove the seal from the top nut and tap it 3/4" NPT. I JB welded the bushing into this thread as well. The gauge and 1/8" NPT bushing thread into the T, the injector line is cut and is fitted into the metric tube adapter. I also tapped and fit the bottle jack for a funnel into the reservoir to keep fluid in the cylinder, as quite a bit is pumped out as you test injectors. I used ATF and Marvel mystery oil to fill the tester.
Check this out:
anyone know how to use a diesel pop tester?

Danny
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  #9  
Old 08-27-2008, 05:26 PM
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I had already searched and read several threads about pop testers made from jacks and grease guns, and made mine this way because it was much easier to make since there is no tapping, welding, or epoxying of multiple fittings needed like in all the other threads I have seen. My pump has higher volume per stroke so not as much pumping needed.
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  #10  
Old 09-02-2008, 01:08 PM
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Can I use any hand pump?

Will this hand pump work?
http://65.36.183.19/greenlee/im/IM1317REV07.pdf
It says it works at 6500 psi. I have seen others that say 10,000 psi but none like Sunwizard's at 4000 psi.

Thanks.
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  #11  
Old 09-02-2008, 01:28 PM
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You can use any pump thats >3000 psi. That one might be a trick since it looks like the inlet isn't threaded. This one might be better, one person is trying it:
http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200333147_200333147
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  #12  
Old 09-02-2008, 01:36 PM
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Quote:
Originally Posted by SunWizard View Post
You can use any pump thats >3000 psi. That one might be a trick since it looks like the inlet isn't threaded. This one might be better, one person is trying it:
http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200333147_200333147
Great. Thanks for the link. I've got a Northern Tool about 5 miles away.

The pump you linked says it has 1/4" connections. Is that what size are on yours? I only ask because I wanted to double check that all the parts you listed will work with this pump.

Thanks for the details...
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1985 300CD
1981 300TD


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1979 300TD
1982 300TD
2000 E320 4Matic Wagon
1998 E430
1984 300SD
1980 300SD
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  #13  
Old 05-01-2009, 11:56 PM
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pop tester question

I see you did not use any sort of filter. Have you had any issues with that?
Also, I am assuming that you have to drain all of the regular hydraulic fluid and put in some sort of injector testing fluid? I am guessing that you can not use diesel fuel through the pump body.
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  #14  
Old 05-03-2009, 02:42 PM
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Quote:
Originally Posted by vitop View Post
I see you did not use any sort of filter. Have you had any issues with that?
No problems, I make sure the fuel I use is very clean and run through a good filter before I put it in the tester.
Quote:
Also, I am assuming that you have to drain all of the regular hydraulic fluid and put in some sort of injector testing fluid? I am guessing that you can not use diesel fuel through the pump body.
I use diesel and it works fine. I rinsed the old hydraulic fluid out with diesel.
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  #15  
Old 05-25-2009, 04:55 PM
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Question about parts

I finally have started to get together the parts I am going to need to build a pop tester. I have the hydraulic pump and I sourced a liquid filled 160 bar gauge with a max pressure arm. Now I need to get some of the other stuff. One thing I am having a little problem with is with the fluid reservoir. I would like to find something similar to what mercedes source (no space) uses on their tester http://**************.com/node/5180

That is basically just a plastic reservoir with a fitting on the bottom and a lid on it.

All I have been able to find are some pretty expensive oil reservoirs from McMaster. Does anyone have a source for something like that? I should be able to put the rest together after that. I am using the same sort of hydraulic pump as shown in this thread. I did not want the hassle of modifying a bottle jack. This just seemed so mush easier.

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