hi,

I got one of these 'pop' injector testers, but the owner's manual is in polish.

Any tips would be appreciated.


Marty

What type did you get? Do you have a picture?

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Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John

Possibly locate a polish national? My limited understanding of any pop testers function is to take injector up to spray or release pressure and observe pressure gauge for point of fuel release. Next observation is to study spray pattern for uniformity. Watching for any leakage prior to the injectors release pressure as well. The instructions may contain some information on modification of injector release point by changing internal shims. This may not be the information you are looking for though. If I am wrong I do not mind someone correcting me. Importance of keeping tester clean internally and using really clean fuel to avoid getting dirt into injectors under test probably is stressed as well.

One thing I might add that you probably already know is, dont get your fingers under the spray.

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

Read the factory shop manual for your car. It has an in-depth section on cleaning and setting injectors. I posted to a similar thread recently with some links to some of my favorite threads on the subject.

Good ventilation, don't breath the diesel you spray.

http://www.peachparts.com/shopforum/showthread.php?t=122334

I do pop testing with corn oil. It's safer and doesn't stink. The oil and injector temperature can vary your pressures by 50 lbs, so start with both at a known (room) temperature.

Pump the injector till it pops 2 dozen times just to clean it out and get it stabilized. Then pump with rapid hard movements and look at the spray pattern. It should be a fine narrow spray jet, not a squirt. I also use the rapid pump to determine the pop pressure. The pressure guage needle should be bouncing around the pop point. Some folks use a slow pump to determine pop pressure. Just be consistent when you're trying to match pop pressures.

Squirting is most often caused by having the tiny cross flow hole in the tip of the nozzle plugged.

Take it apart and clean it again, use a fine nylon brush bristle or a fine brass wire to poke through the cross flow hole. You must clean everything like it was a NASA project- and bits of dirt can mess things up.

Soaking the nozzle parts in corn oil and scrubbing with a toothbrush seems sufficient for cleaning. Varnish and and carbon should be cleaned off completely. I also use ethanol for cleaning, but corn oil the parts before assembly. If the pattern is still no good, it's probably time for a rebuilt nozzle.

I only bought a few spacer washers and then used a diamond hone to get the sizes I needed. You'll need a micrometer to measure the washers.

My pop tester was homemade from a grease gun, grease gun hose, some hydraulic fittings, and an injector adapter made from an old injector line end with fitting epoxy steel'd into a drilled 1/4 NPT plug.

I found it fun and very satisfying to match my injectors. My idle is now very smooth.

Bruce McCreary
(2) '85 300Ds 83 300CD
Snowflake, AZ

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achtung!!!

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michael cole 1980 300SD gone now but not forgotten,87tdt,90 300te 4matic 95 e320 wagon

Does Autozone not carry a pop tester in their rental tools? Seems it would be easier to rent one.

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2005 Accord Hybrid (Wifes)
1995 Subaru Impreza L AWD (Snow car)
1984 GMC Sierra 1500 (Mine)
1983 300CD Best $ I ever spent. (Mine)
1984 190D (sold and glad I did)
1983 300D (sold and wished I hadn't)

The pop tester is a highly precise and delicate instrument. Not your ordinary run of the mill rental tool.

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Closing the store
Benzbonz.biz on your smart phone or tablet.

Here's a list of all the parts I ordered for mine from mcmaster.com. It includes the more expensive max pressure needle gauge. All you need to add to this list to have a pop tester is a grease gun, grease extenstion hose and an old injector line

Line Part Number Description
1 5269K311
General Purpose Steel Metric Tube Fitting Male Straight Adapter For 6 Mm Tube Od, 1/8" Npt

2 50925K121
Compact Extreme-Pressure Steel Thrd Fitting 1/8" Pipe, Female Tee, 5000 Psi

3 50925K251
Compact Extreme-Pressure Steel Thrd Fitting 1/4"X1/8"PIPE,1-7/32"L,FEM X Male ADAPTER,6000 Psi

4 3842K63
Max-Indicating Glycerin-Filled Gauge 1.5% ACCURACY,2-1/2" Dial, 1/4" Bottom, 0-3000 Psi

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1983 240D Silver/Blue "Sadie", unknown miles. 100k miles on WVO single tank, converted to 2 tank about 10k miles ago, FPHE, Injector Heaters, Aux Fuel pump. Alcohol/Water injection. Frantz oil bypass filter
1992 300D 2.5 Turbo Green/Tan "Jade" 267K miles Stock.
1992 300D 2.5 tan/tan "Rocky" on 2 tank WVO. Pressure actuated Turbo "rat's nest" surgery completed. 197k miles

I need to work on some injectors and I have forgotten where I found a picture of the proper spray pattern. Could someone please post a pic of what a proper pattern for the 617 would look like? Thanks
bb

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For Sale: 1982 MB 300TD
1995 Chevrolet Suburban 6.5TD

Sold: 1980 IH Scout Traveler- Nissan SD33T Diesel

So, no pics out there? I have searched and searched, but can't find anything beyond "no pee streams". So, is that the most important thing to look for, any little streamers (a uniform mist)?
bb

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For Sale: 1982 MB 300TD
1995 Chevrolet Suburban 6.5TD

Sold: 1980 IH Scout Traveler- Nissan SD33T Diesel

bump?

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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

Some work I did with my tester in bosch injectors for my GM 6.5 here http://asnowsquall.smugmug.com/gallery/1424687#67645826
Some pictures and some video.

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Currently driving a very clean 1985 300SD from the West Coast.

For me the problem with using a pop tester is not with the testing but with the results. When you test a used set or even a set of injectors with new spray nozzles the nozzles may not all will not preform the same. I hate when there is something on the border line and sometimes new nozzles can preform poorly. Do you return it or as my old boss used to say "let it wear in".

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84 300D, 82 Volvo 244Gl Diesel