Ahh the kiddie pool! I wasn't paying any attention to its graphics nor did I ever watch sesame street. This kiddie pool was picked up on the street as trash. Also useful for a lot of things other than a kiddie pool.

I have not driven the car yet, just started the car with no glow plugs from overnight cool off since the last test start after the new injectors went in. It took 20 seconds at 75 F ambient. The old injectors took 29 seconds at 85 F ambient so the new nozzles are clearly an improvement. It will be interesting to see if the timing changes from the 300 psi higher injector pop pressures of the new injectors with my RIV strobe timing light.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I went back to my post Electronic Pop Tester Cheap
Your question was about finding McMaster-Carr PN 5269K311 Metric fitting, 1/8" NPT-M to 6mm tube ($4.11)
I opened their website today, entered PN and below showed. That fitting is critical in fab'ing any custom pop tester since the M-B injector tube attaches to it (same fitting as M-B Delivery Valve). I read where some people machined their own. Somewhere (VW TDI site?), I saw reference to the fitting description and that someone bought one from McMaster, so searched and found it. While on the site, lookup the PN's I used for injector shims.

Correct that I didn't notice a difference in the idle from when it had 3 1600 psi and 2 1950 psi injectors in the 1984 300D. Of course, hard to compare then and now. It does idle fairly smooth now, perhaps slightly better but I don't recall significant shaking before, though the air cleaner danced then and now.

Your videos of the pressure gage needle and spray are similar to my results, (and most on youtube). It is hard to resolve better than 50 psi with the gage needle. One might get more consistent results with a gage with a "peak grabber" needle. I added an electronic pressure sensor to try to get better resolution, but even then the results vary a bit with the way the handle is pumped. I found that if I didn't press hard enough (I think), I could sometimes get a continuous spray from an injector instead of pops. Faster strokes tended to give more consistent results, and is probably closer to the real engine. I would get ~10 pops from one stroke of the handle, coming much faster than in your video.

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Thanks for the info Bill, I searched 5269K311 McMaster just now and found it no issue. Their search engine must have been down the other day (searching exactly the same way).

I made a custom fitting for the adapter between injector to the pop tester by using a broken 1/4" NPT pressure gauge brass block, cut in half, drilled and tapped for the 6mm injector hard line cut in half, threaded the end with a die, screwed into the brass block then either brazed or silver soldered it. It's workin fine so far. Lot's of DIY pop tester articles says to use all steel fittings, not brass. The gauge that you are using has a brass NPT base (similar to what I used except I used the next size 1/4 NPT, heftier than 1/8 NPT) so I think I should be OK?

To see the gauge needle better I may try using a borescope magnified on a PC and see if that helps.

Took the car for a spin and wow, big improvement in power! There was a lot of traffic, no room to do a 0-60 timed run. I do have a leak on #4 maybe #5 injectors coming from either the return nipples or the injector flare...will have to isolate which. I need to buy some braided return lines to replace those clear (now browned) Tygon polyurethane return lines which are 1.5 years old and in my experience will fail soon.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Long nose pliers + wads of toilet paper made quick diagnosis of where it was leaking from. With pliers, I pushed in the return lines on #4 and 5 all the way with a hot engine and they seated all the way to bottom. Also loosened /retightened #4 and 5 injector nuts till the leak stopped. It's bone dry now.

I hate leaks! it seems by replacing the oil filler cap with a metal one (was plastic) and smearing a thin layer of epoxy on the breather nipple stopped both from leaking. Previously, I tried sanding smooth the nipple but it still leaked because of casting imperfections. Mercedes did not machine the nipple from the casting and that's the reason it leaks. If you look closely at it you will see.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I hope thats not weed eater hose on the return lines. Won't hold up to the heat...

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http://superturbodiesel.com/images/sig.04.10.jpg
1995 E420 Schwarz
1995 E300 Weiss
#1987 300D Sturmmachine
#1991 300D Nearly Perfect
#1994 E320 Cabriolet
#1995 E320 Touring
#1985 300D Sedan
OBK #42

Not weed eater hose. Polyurethane from MacMaster. I am changing it back to OEM braided line. Do you know who sells a quality OEM braided return line? I've read of forum members with problems with dealer supplied hose which is not confidence inspiring.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

I have purchased return line at the local VW parts counter. They are not as in love with their parts as my local MB parts counter. Someone on the site told me earlier that the hose is rated the same, and my experience bears them out.

I am interested to have my injectors tested in early September. Might I UPS them to you?

Local VW dealer wants $30 for 3 feet, more than I like to pay.

The free pop testing is for people who bring the injectors to me already out of the car ready to go on the pop tester. If you ship them to me there will be a fee since I have to ship them back. I will take a video of each injector being pop tested and mark each one so you get a warm fuzzy feeling for your $$ spent.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked

Of course I'd expect to pay round trip freight in addition to your work! The video is a nice touch, but I still value a man's word.

Nipples, did I hear nipples ?

Steve have you replaced the rubber Elbo and rubber Gasket under the Oel Cap? Those Elbo`s get hard from the heat and don`t seal very well. replaced mine and he Oel cap seal and leaks disappeared.

Nice clean engine.


Charlie

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there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

Nipple, not nipples! Were you dreaming? I did replace the elbow, still leaked. The epoxy coat on the nipple did it. I refuse to spend $20 for an oil cap seal. I will make my own if needed. So far the metal oil cap is not leaking.

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85 300D turbo pristine w 157k when purchased 161K now
83 300 D turbo 297K runs great. SOLD!
83 240D 4 spd manual- parted out then junked