I came across two Diesel Injector testers. They seem identical, but the 1962 tester is labeled "Diesel Kiki' and the Zexel is 1963. I don't know too much about them, but it seems these are the Bosch (designed or approved ...and now copied) injector pop testers.

Unfortunately some parts are missing and some are damaged. Before they become workshop art, I'd like to try and resurrect at least one of them.

Does anyone have a parts diagram for these? What about an operation manual? Source of new parts?

The one part I absolutely must either replace or fix is the pressure adjuster valve. It looks as though in their previous lives, the knobs went missing on both pumps and then VICE GRIPS (!) were used to turn the valve stems. Both stems are pretty chewed up.

Anyone have a spare they can part with? I might be able to trade some parts after one of mine is operational.

Full Wanted List:

1) Pressure Valve
2) Copper O-rings (if sizes can be determined)
3) Strainer / Filter (modern upgrade to the stacked cardboard type from the 1960s)
4) Reservoir Cover Plate with chain

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Michael
300TD
300D 5-Speed

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I once had an '82 Datsun/Nissan PU with a diesel motor. The governer (injection pump) was labeled 'Bosch - Diesel Kikki'. Looked basically the same as in my 300CD but the body was made of aluminum. Apparently, Diesel Kikki made pumps under license from Bosch.

Maybe check with Bosch.
-c-

Nice finds.
Do a Google image Search for Disel Kiki Diesel Nozzle Tester and Zexel Diesel Nozzle Tester and see what comes up.
Or add "parts" at the end.

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84 300D, 82 Volvo 244Gl Diesel

See if the Zexel is the same as the sold one pictured:
Zexel diesel injector tester | no-reserve auction on Tuesday, September 22, 2009 |

If yours is the same the Model Number could be useful
Zexel diesel injector tester
· Model 105785-0980
· Working condition

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84 300D, 82 Volvo 244Gl Diesel

Could you not disassemble that pressure valve and weld/fabricate/extend the "stem" to accept a handle of some sort?

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You can't always get what you want, but if you try sometime you just might find you get what you need.

Thanks for the tips, Diesel911 and for the suggestion, Walkenol!

I did Google searches earlier and came across that old auction. Exactly as mine, indeed - 105785-0980. BTW, both of my units are from the 1960's and the tags say "Made in Japan."

Interestingly, some part numbers still do come up through online searches, for example the Zexel supply strainer. The original is a set of stacked cardboard (or similar) disks, arranged into a stack - like a motorcycle "clutch pack" - sandwiched between two metal end plates and held together with guide wire. They had an entirely different filtration technology in the 1960s! In any event, those filters, part number 152600-0720 are still available, according to one website. I suspect that the Indian Mico Bosch 9443611872 is the modern equivalent.

The trick in any case is to find the original part number. I wish I had a parts catalog.

Walkenol, we are thinking alike. I am in the process of doing as you suggest. I've disassembled the valve. Discovered that the damaged outside shaft threads through the hex coupling and contains a flat disk on the other end. That disk will push the plunger pin. It only needs to move a tiny bit, my guess, less than 1mm, if that.

There are two ways I can go, either extract the threaded part and then fabricate a new one or attempt to dress and attach an extension or a handle to the existing stub.

The damaged area used to be threads - which would have allowed the original piece to thread out of the inside of the housing - and the piece will no longer get through. Now, the only option is to remove the damaged threads to gain clearance through the housing. I was going to do it on a lathe, but it's impossible to center the assembly. Hand filing is the way to go.

...and if I am going to do any such hand filing, I might as well try to square the shaft sides and fit a handle. If no go, then more filing to remove the stem altogether.

All in the interest of vintage technology, because, truth be told, a $150 contemporary Indian eBay unit will pop my injectors a lot sooner than will Zexel and Kiki.

--
Michael

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Any way to fit a die on it to clean up those threads?

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You can't always get what you want, but if you try sometime you just might find you get what you need.

Looks like Zexel is still open.

https://www.google.com/search?q=Zexel+Diesel+Nozzle+Tester&ie=utf-8&oe=utf-8&aq=t&rls=org.mozilla:en-USfficial&client=firefox-a&channel=rcs

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1985 300D 198K sold
1982 300D 202K
1989 300E 125K
1992 940T

"If you dont have time to do it safely, you dont have time to do it"

"The democracy will cease to exist when you take away from those who are willing to work and give to those who would not."

There is no way to run the die down to the top of the housing, but I will try to clean up the threads with an edge of a dremel cut off disk. It will be tricky and slow, but may be the best chance.

I am on a dual track, with repairs to existing material on one side and pursuit of new spares on the other.

I have been directed by Zexel / Bosch to get in touch with their Diesel Service shops; it was a generic suggestion without any contact info.

I do have a lead, from my professional network, on one potential Diesel Service shop in the Boston area. Will know more tomorrow...

...here is an update:

- I used a small dremel with a thin cut off disk to clean up the damaged threads on the stem.

- An extractor helped guide the finished product out, where extra torque was required (not all that much).

- Once out, I was happy to see that most of the stem threaded run sits within the bushing, with plenty of engagement.

- Final cleanup of the threads made with a 1.5 x 12 die.

Next available time I have I'll work on the deformed handle holder threads and will adapt or fabricate a handle.

- did some caliper work and have a pretty accurate feel for the sizes of all copper washers I can think of. Ordering them now...

- Bosch.de forwarded my request through some channels. Long story short: Bosch USA emailed me the Japanese Zexel parts diagram. If I am interpreting my Japanese correctly, the pump was designed in April or May, 1927. Yes, 1927. That said, I do not read Japanese, but that's the date on the parts list.

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…picking up right where we left off, a few years ago, …nothing to worry about, …just your classic thread resurrection technique here, folks:


I did not get a chance to source the tiny seal to further resurrect the pressure valve for my 1962 and 1963 Zexel and Diesel Kiki pop testers, and instead decided to possibly source a replacement valve. The shortest path to success was an eBay Indian manufactured Bosch pump knockoff. Let me just say right off the bat, for those who like to complain about putative poor quality of the Chinese tools. You ain’t seen nothing poor quality, yet …not until you get yourself an Indian eBay special. The fit and finish are terrible, the metal is playdough and the whole thing appears rickety. That said, the pump seems to work, at least for now.

The good news for my needs is that the Indian Bosch pressure valve bolts right up to my old testers. This being accomplished (and the missing link to operation now in place) I could proceed with testing. I assembled the better of the two – 1962 Diesel Kiki - filled the tank with MMO and connected an OM617 injector for testing.

After bleeding the air, I was able to get the Diesel Kiki pump to operate and pop the injector. But, unfortunately, for now at least, the old tester is still useless because it will not hold pressure, …not without pumping. The pressure will build up and I can even get it to hold when the handle is in the downward pumping stage. However, as soon as the handle is released (like for another slow pump) the pressure will go down to nearly zero. Only rapid pumping can raise the pressure sufficiently to fire off the injector, but even with a glycerin filled gauge, an accurate reading of the release point is nearly impossible.

So, I will need to recheck the connection points and probably eventually remove the pressure piston for evaluation.

Before I veer off on the wrong path …can someone confirm that this tester is designed to do what I’ve seen most others do …i.e. to hold the pressure allowing a gradual and controlled pressure build up. Anyone with an old Bosch or Zexel or Diesel Kiki tester, chime in, please.

I am including some photos where the 1960s vintage Japanese built, Bosch-licensed Zexel unit is next to the modern Indian built Bosch knockoff.


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Michael

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