Building a diesel IDI injector pop tester, which will evolve into a DIY once the build is done. My build will combine aspects of other DIY pop testers I've seen around...

Parts List

• Bottle Jack, Torin 2T "Black Jack" (Walmart ~$12)
• Gauge, Ashcroft Duragauge 3000 psi, 4.5", 1/2" NPT (eBay ~$35)
• Ball Valve, Discover Valve 1/2" NPT Carbon Steel 2000 PSI (Discover Valve ~$15)
• Seamless Nipple, 1/2" NPT, 1.5" Long (Discount Hydraulic Hose.com ~$7)
• Street Tee, 1/2" NPT, Male, Female, Female (Discount Hydraulic Hose.com ~$5)
• Adapter, #6 SAE/ORB Female to 1/2" NPT Male (Discount Hydraulic Hose.com ~$5)
• Seamless Nipple, 1/8" NPT, 1.5" Long (Discount Hydraulic Hose.com ~$3)
• 90° Street Elbow, 1/8" NPT Male to NPT Female (Discount Hydraulic Hose.com ~$2)
• Delivery Valve Holder, 80's VW or Merc
• Steel Injector Line, 80's VW or Merc

save for future

Mechanic at local GM dealer shop *gave* me the pop tester they had sittin' around. Hadn't used it for years. Injectors nowadays pop way higher than what it can do (suits me fine, I only need half of its 4000psi scale!) and they just replace injectors now, don't service them (whatever!).

Woo hoo

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Cheers!
Scott McPhee

1987 300D

Nice project! I hope you have fun.

However, for the prices you've given so far you've spent 84USD. I think I saw one recently - new - for under 100 euros... (I'll check)

Sorry I don't want to rain on your parade.

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

That's about ~130 USD plus shipping from overseas... I haven't seen a similar build for less than 200 USD. Also a majority of them only use 2.5" gauges, whereas this one is 4.5" and has 25 psi or 1.7 bar graduations.

Admirable project, wish I knew how to assemble the thing. I see them on junkbay for $185 shipped, small pump etc, and have wondered how they assemble the bits.

In this day and age any project that involves building something from scratch is good.

steve a

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Steve A
92 W140 OM603
97 VW Jetta TDI
90 Passat variant TDI 6 speed MT
94 Chevy K1500 6.5TD
05 E320 CDI
+ others

All looking good! What are you going to use as a container for the diesel supply? filter?

Thanks guys.

I WAS going to use a HVLP paint cup, but finding one with the correct thread and price was proving difficult. I'm just going to use some ABS or PVC pipe in which a 5 micron sock filter will reside for filtration.

Here's the one I found

http://www.barntools.nl/index.php?item=diesel-verstuiver-tester&action=article&group_id=10000019&aid=1676&lang=NL

Is it any good?

Your opinion(s) would be welcome

__________________
1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Looks like your typical commericial pop tester, good stuff. The gauge does go up to 6000 psi, so the graduations on the gauge can't be that small...

Update, #6 ORB fitting is NOT compatible with MB Delivery Valve Holders, VW ones seem to fit. I believe the MB DV Holders are metric threaded, 16 x 1.5 mm.

When I built my tester, the #6 O ring boss leaked pretty badly with the MB delivery valve fitting. I was able to make it leak-free by installing an O ring in the boss.

It does NOT fit period, #6 ORB is too small for MW pump style DV holder. #6 ORB is sized .51 to .56 in and the DV is .63 in (diameter).

Whatever.

Thanks for the response I was simply stating for ME that it did not work. Are you using M pump DV holders? Maybe they sent me the wrong #6 ORB fitting, but looking up the specs for it... it seems too small for the MW pump DV holders I got.