How to build a diesel injector pop tester, big improvement!

For discussing the modifications needed for diesel vehicles to run with 2 tank veggie oil conversions.

Moderators: SunWizard, coachgeo

Postby SunWizard » Tue Oct 28, 2008 10:30 pm

green bus wrote:Can anyone help a newbie out with info on options for the 7.3 IDI with this stuff?

I haven't run VO yet and am installing a new IP and injector nozzles very soon. ....

Is there a source for Ford/IH nozzles best suited for VO, like the Monark?
I think the Ford injectors are all about the same, but since you are probably getting rebuilt ones, there are probably differences in the quality of work. I don't know who has the best reputation. They may know here:
http://www.thedieselstop.com/forums
YVORMV - Your veg. oil results may vary.
95 Dodge Cummins 4x4 SVO WVO conversion.
81 Mercedes 300D- stock and happy on V80/D20 blend.
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Postby green bus » Wed Oct 29, 2008 10:46 am

Sunwizard: your post shows how well the Monark injectors work (i.e., the 'secret' of Elsbett). Are there nozzles similarly suited specifically for VO use for any other make of vehicle than VW and Mercedes?

If nothing like Monark exists for Ford/IH, I would like to know if anyone has shimmed/increased pop-off pressure to burn VO with either Deplphi or Bosch nozzles.

If so, how many bar?

I'm basically looking for tips from anyone with experience in nozzle/IP mods for more efficient VO use in Ford/IH.

I think it fits in this thread, but I could start a new one if this thread is meant just for VW/Mercedes...
'89 7.3L IDI in a Blue Bird short bus

VO system: 25gal plastic tank > heated pickup > Webb 525 coolant-heated 30 u pre-filter > aluminum TIH > manual valves > Walbro FRB-13 > 2u coolant-heated filter > 30 pl FPHE > IP
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Postby SunWizard » Wed Oct 29, 2008 11:35 am

green bus wrote:Are there nozzles similarly suited specifically for VO use for any other make of vehicle than VW and Mercedes?

Thats the only brands I have heard of new nozzles. The dodge cummins injectors are easy to shim for increased pressure. I don't know about the Powerstrokes since they are far more complex and expensive. Since they are computer controlled it would probably take a custom chip to change pressure as it does for timing.
YVORMV - Your veg. oil results may vary.
95 Dodge Cummins 4x4 SVO WVO conversion.
81 Mercedes 300D- stock and happy on V80/D20 blend.
Low fossil net zero house- 100% solar power and heat.
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Postby djenkins6 » Wed Dec 03, 2008 7:53 am

Hi Sunwizard,
I have a cummins D250 1st Gen, should the pop pressure on VO be the same (2100psi) as for the mercedes?
David
1981 300SD
1989 Dodge D250 Cummins
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Postby SunWizard » Wed Dec 03, 2008 9:19 am

djenkins6 wrote:Hi Sunwizard,
I have a cummins D250 1st Gen, should the pop pressure on VO be the same (2100psi) as for the mercedes?

Probably not, I don't know what it is for that injector.
YVORMV - Your veg. oil results may vary.
95 Dodge Cummins 4x4 SVO WVO conversion.
81 Mercedes 300D- stock and happy on V80/D20 blend.
Low fossil net zero house- 100% solar power and heat.
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Postby hheynow » Tue Mar 31, 2009 10:03 pm

SunWizard wrote: I don't know about the Powerstrokes since they are far more complex and expensive. Since they are computer controlled it would probably take a custom chip to change pressure as it does for timing.


The Powerstroke injector is a HEUI (Hydraulically actuated Electronically controlled Unit Injector).

Running WVO in a Powerstroke with a chip I've heard is bad so I only use mine on #2.
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Postby westcoastslider » Sun Apr 12, 2009 7:54 am

If you don't know when the last time your injectors where cleaned and balanced, now is the time.

Very nice job with the pop tester Sunzirad. After testing with the 80/20 mix you may want to rinse it out with some straight diesel to avoid buildup associated with storing veg in steel.

Considering that I will be running veg I like to be just at or even a little past the top end of the specs for opening pressure. Too far and it will not only throw off timing(which is correctable) but will also create a secondary injection. I rebuilt a set using Monarch nozzles and set the pressure to 165 bar. IP Timing was at 26*. It sounded horrible below 1500 rpm's. Nailed like crazy and didn't idle very well. It had good power and sounded good only above 1500 rpm's. I backed pressure down to 145 bar and it idles and sounds much better.

djenkins6, the Cummins injectors run at almost twice the pressure as Mercedes. IIRC it was over 200 bar. Should be stamped on the side of the injector.

The IDI Ford diesel(pre 94) have a set opening pressure just like the Mercedes and Dodge. Not sure the number. The powerstroke is a whole different beast. To avoid highjacking and confusion between IDI and HEUI I will start a different thread about the HEUI.
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Postby SunWizard » Sun Apr 12, 2009 10:45 am

westcoastslider wrote:Very nice job with the pop tester Sunzirad. After testing with the 80/20 mix you may want to rinse it out with some straight diesel to avoid buildup associated with storing veg in steel.

Good point. I put mine back in my car where they get rinsed and stored with D2 with every purge.
YVORMV - Your veg. oil results may vary.
95 Dodge Cummins 4x4 SVO WVO conversion.
81 Mercedes 300D- stock and happy on V80/D20 blend.
Low fossil net zero house- 100% solar power and heat.
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Postby westcoastslider » Sun Apr 12, 2009 11:02 am

SunWizard wrote:Good point. I put mine back in my car where they get rinsed and stored with D2 with every purge.


I meant rinse the pop tester. A little chicken skin in the pop test wouldn't help the spray pattern of your new nozzles very much. :wink:
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Postby canolafunola » Sun Nov 14, 2010 5:43 pm

Hi Sunwizard,

How well does the fitting 5269K311 M12 x 1.5 end fit the male flare of Mercedes injector lines? Is that the same thread for W123 injectors?
93 Gulfstream RV w Cummins 5.9 diesel pusher
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Postby SunWizard » Sun Nov 14, 2010 10:51 pm

canolafunola wrote:How well does the fitting 5269K311 M12 x 1.5 end fit the male flare of Mercedes injector lines? Is that the same thread for W123 injectors?

It fits fine, no leaks in many times used. Same for W123.
YVORMV - Your veg. oil results may vary.
95 Dodge Cummins 4x4 SVO WVO conversion.
81 Mercedes 300D- stock and happy on V80/D20 blend.
Low fossil net zero house- 100% solar power and heat.
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cummins injectors pressure limit?

Postby 88tlc » Tue Apr 05, 2011 2:43 pm

what is the dodge cummins pressure range supposed to be? would this same process help with VO burn on a cummins? or is it already so dang high ( i think the target is like 235 bar), that its already good to go?


my dodge has original injectors in them, and i would like to have them tested, and worked on if necessary.
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