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+--- Thread: POP testing question (/showthread.php?tid=4310)
POP testing question - tjts1 - 01-30-2013
I'm pop testing the 135 bar injectors from my 87 OM603 turbo. The engine has 178k miles, no injector service history as far as I know. The first injector pops at exactly 2000psi with a nice vibration, good pattern and no leaks as far as I can tell. At first I thought great, I don't have to do anything to this one.
Then after about the 50th pump I tried pushing down on the handle faster. Suddenly the nozzle started pissing and wouldn't reach more than 1000psi and it dropped down to zero very quickly. Weird...
Then I tried pumping it slowly again and it went right back to 2000psi, good pattern, no leaks. I've never done this before so its a bit of a head scratcher
Is this the behavior of a worn out nozzle? http://i.imgur.com/C31jB9X.jpg
http://i.imgur.com/SUo01p0.jpg
thanks
Justin
RE: POP testing question - Greazzer - 01-30-2013
You got dirt swirling around in your injector most likely. If they are used nozzles, you should set them at a nominal 1,950 psi and balance at no more than +/- 50 PSI.
RE: POP testing question - tjts1 - 01-30-2013
Thank you for the help. Before I had a chance to read the response I put in a new nozzle ($10 bosch india) which pop tested at 2050. I put it in the car and its nailing very loud just at idle. The noise goes away as soon as rev the engine. I did clean out the injector but I think i'm going to give the old bosch germany nozzle another chance after another good cleaning and set to 1950. I only did 1 injector as a test, haven't messed with the other 5 yet.
RE: POP testing question - tjts1 - 01-31-2013
I put the india nozzle back on the pop tester and it seems to work fine when I press down quickly but it will piss if I go slow on the handle, no chatter. The India nozzle has a bevel cut off on the tip for noise which the german nozzle doesn't. Even tho it carries the same PN, I'm not sure this nozzle is designed to work this injection pressure and ramp up. It just ends up pissing a stream at idle which causes nailing. If it wasn't beveled I bet this nozzle would work fine. Oh well.
I cleaned and re installed the old german nozzle and now injector 1 is by far the quietest of the 6. I guess I'll just clean, rebuild and pop test the other injectors.
If anybody wants to try the 6 Bosch India DN0SD265 for yourself, you can have them for $20 + shipping. Only one was opened and used in the car for about 3 minutes.
RE: POP testing question - Greazzer - 01-31-2013
$20 for all 6 ? SOLD. send me your email by PM and I will pay pal you the $$ by tonight !
Thanks.
RE: POP testing question - Greazzer - 01-31-2013
Thank You !!!!!!!!!!!! Money Sent !!!!!
RE: POP testing question - tjts1 - 01-31-2013
It'll go out tomorrow morning. Let me know if you have better luck with these than I did.
cheers
RE: POP testing question - Greazzer - 01-31-2013
These will be going into VSTECH's injectors from Peachparts !
RE: POP testing question - tjts1 - 02-01-2013
Turns out my engine has 5 bosch germany injectors and 1 bosch india injector which was popping at 1500psi and dripping. Unfortunately I had use one of the other 6 injector nozzles as a temporary fix until I can find another german injector. I'm going to have to hold on to these nozzles after all and I sent your paypal a refund. Sorry for the inconvenience.
RE: POP testing question - Greazzer - 02-01-2013
Well poop ! OK, whatever works best for you. Do you want 6 German USED in exchange for the 6 new and the 6 USED Germans have a good spray pattern ? If not, all is good ! Hope you get them working tip-top !
RE: POP testing question - tjts1 - 02-01-2013
Well the 5 german ones that I have seem to be in very good shape after cleaning. The 1 India whole injector is the trouble maker. It looks like the India nozzle in the car is slightly different from the 6 india nozzles in the box. The one in the injector has no bevel.
I would be very happy to give you the set of 6 India nozzles and the 1 India injector for 1 good German injector and German nozzle for the 87 OM603 #14 head. I just want to have a matching set of injectors and nozzles. Again, I apologize for going back on our deal I just felt like I was in a bind had to do something to keep the car on the road.
http://i.imgur.com/AaLFFn4.jpg
RE: POP testing question - Greazzer - 02-01-2013
Howdy,
No problems. You didn't really go back on the deal as the deal was untenable. I can get you one rebuilt 87 603 injector (entire injector) with a very nice USED German nozzle. Is that what you are looking for ? A swap maybe ? If so, I am 3 set of injectors behind the eightball ... that is, very late for certain customers, so I am looking at mid-next week as I HAVE to get out 3 sets by Saturday or Monday at the latest. Please let me know either way. Thanks !
RE: POP testing question - tjts1 - 02-01-2013
No problem, the nozzles are going out today. I put the matched set of 6 back together for you. I managed to bring the indian injector back up to about 1900 by lapping the mating surfaces so I'll live with that until the German injector arrives.
Please make sure the German injector body is for a #14 head. I know the later #17 and up heads use a different thread into the combustion chamber. My injector body is stamped KCA30S44.
http://i.imgur.com/jXavKFS.jpg
If I can get to a complete matching set for injection components I'll be very happy. I'll PM you with mailing address.
cheers
Justin
RE: POP testing question - Greazzer - 02-01-2013
OK ... no problems. I will send you a snappy of the injector before I mail it out to you.