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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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87 Mercedes 300TD, 81 300D, 95 Dodge Cummins 4x4 Last edited by SunWizard; 08-26-2008 at 08:45 PM. |
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Niiiicce!!!
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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. |
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There is no valve to shut off the gauge.
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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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87 Mercedes 300TD, 81 300D, 95 Dodge Cummins 4x4 |
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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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'01 Escape 2.0 5 speed- 101k '96 Cherokee 5 speed- 120k '92 Mercedes 2.5l turbo diesel- 212k '90 Aerostar ext Cargo 4.0- 29k '02 ZX2- 93k '98 F250 CNG- 54k |
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3 strokes.
Quote:
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87 Mercedes 300TD, 81 300D, 95 Dodge Cummins 4x4 |
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Nice effort
Excellent result!
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'84 300SD sold 124.128 |
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The search function is your friend:
Quote:
anyone know how to use a diesel pop tester? Danny
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1984 300SD Turbo Diesel 150,000 miles OBK member #23 (\__/) (='.'=) This is Bunny. Copy and paste bunny into your (")_(") signature to help him gain world domination |
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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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87 Mercedes 300TD, 81 300D, 95 Dodge Cummins 4x4 |
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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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2009 ML320 Bluetec 1985 300CD 1981 300TD Past Mercedes 1979 300TD 1982 300TD 2000 E320 4Matic Wagon 1998 E430 1984 300SD 1980 300SD |
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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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87 Mercedes 300TD, 81 300D, 95 Dodge Cummins 4x4 |
#12
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Quote:
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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2009 ML320 Bluetec 1985 300CD 1981 300TD Past Mercedes 1979 300TD 1982 300TD 2000 E320 4Matic Wagon 1998 E430 1984 300SD 1980 300SD |
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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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Quote:
Quote:
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87 Mercedes 300TD, 81 300D, 95 Dodge Cummins 4x4 |
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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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