I think I need new return lines. Where would I get those locally? They just look like small fuel line. Sorry for the dumb question.

so I still havent gotten around to installing the injectors....sad I know...but at any rate, what exactly is 'pop testing'....

The Spray Nozzles on the Injectors are under spring tension and set to open up (begin injecting the Fuel) within a specific pressure and and all of the Injectors are supposed to be within a min and max pressure of each other.
The pressure is changed by changing the size of shims that go inside of the Injectors upper Body.
A hand pumped Nozzle Tester/Pop-Tester with a Pressure Gauge is used to check when the Spray Nozzles open.

While the Factory Service Manual has a worne min spec, and a new min-max range of opening pressures that are acceptable; Bosch has provided a pressure stamped into the upper body of the Injectors. On my Engine as examble it has 135bar.
One Bar of pressure is aproximately 14.5 pounds per square inch.

The importance of the opening pressure is that it has an effect on the Atomization of the fuel when injected into the Cylineder and a slighe effect on the timing.
If the whole set is not close to the same pressure your Engine may not run smoothly.

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84 300D, 82 Volvo 244Gl Diesel

Here is a pic of a typical tester:

Attached Thumbnails

 

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84 300D, 82 Volvo 244Gl Diesel

bought a meter of it at a local VW dealership last time I replaced mine. They have the nice cloth braided line, maybe 6 bucks for a meter. It's either 3 or 4 mm, can't remember, I'm sure its posted here somewhere.

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1985 300D Gretchen (Astral Silver) 220k
1983 240D 4-speed Evelyn (Orient Red) 203k


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