David wrote:Someone I know recently did their nozzles but used the bosch ones ( no doubt made in india) and didn't set them. Unsurprisingly he has said he didn't get much improvement with the new ones.
Yes all the Bosch ones are now made in India, unless you can find someone who has very old rare stock made in Germany (stamped on the nozzles.)
Did you find the pressure setting to be very difficult or time consuming?
No, it took about an hour to test the 6 old nozzles, replace with new ones, which all tested at 2000psi, then open each one up and add a 0.10mm shim which raises the pressure 100psi, and test a 3rd time.
Did you need many shims or a great variety to get the pressures right.
1 shim per injector, yours may vary, I got their $40 kit with a variety of shims but only needed 1 size in each since mine were very consistent. This is another sign of very high quality manufacture of these nozzles.
Does the viscosity of the fluid used affect the pop off pressures. if one mainly ran svo would it be best to set the nozzles using that and would the nozzles work different is set up by a shop that just used diesel?
I didn't try pure diesel, that is something I will try next time I have some injectors off. I wanted to set them for WVO so only tested with that, and its safer as you note. It does affect the spray pattern, which is something important to look at and why I used a clear jar.
Could you give some more description of how you made your tester and the fundamental principals behind it so one could understand what they needed if they couldn't find the same sort of pump you used.
Its a hand hydraulic pump that can do 4000psi, some have used 2 ton bottle jacks for this, but that requires welding, and epoxy, and is subject to leaks which could be dangerous. Others have used grease guns, which don't pump near the volume this rig does, and many have failed with trying to make testers from those. Mine has no place to leak and worked easily, and required only a few plumbing fittings shown in the pics, since it already had a threaded inlet and outlet on the pump. The other nice thing this pump has a knob you can see on the right end of the pump which releases the pressure, making it safer when you unscrew the injector.
A search on mercedes or VW forums for pop tester will give you some threads about making one from a bottle jack. You just need to add a container for a reservoir, and a feed line from there to the pump (or a hose fitting epoxied into the jack fill hole) and then a tee (which is welded on top of a jack instead of the ram, the weld is a leak danger point), and a guage (3000 psi glycerine filled is best) and a 6mm compression fitting which hooks directly to a stock mercedes injector line.
Mercedes source sells a pop tester they make from a bottle jack for $179, and I think they sell a lot of them. I made a much better one for cheaper, but it took some engineering and 2 parts sources, ebay and mcmaster.
I have also read about setting the pressures higher than factory spec for running veg. Has anyone heard or know anything about this?
Yes this is one of the "secrets" of the Elsbett kit, and is why you must remove your injectors and send them to Germany. This is supposed to give better atomization, and my results show it does, and also that these Monark nozzles are just better for WVO. I went for the high end of the factory spec, which I think is about what Elsbett does. Any higher pressures and I think you need to re-time the IP, and some old IPs might not like (or might not be capable of) the extra work.
Much as I hate safety warnings, I did read something a while back on injuries caused by High pressure injection of diesel through the skin.
Yes thats 1 reason I didn't get into much details of making your own pop tester since if you do it wrong it can be dangerous. Breathing the fine diesel or even WVO fog they put out can't be healthy either, so thats another reason to have them spray into a sealed jar as I did. The hole I cut in the lid of the jar is just the right size to screw the injector threads into.
More tech info on why the Monark nozzles are better, they don't have the tiny holes in the pintle like the Bosch ones, which tend to get clogged up even on diesel but especially on WVO. These have a flat cut pintle, which is another "secret" of the Elsbett kit. So they should give their improved performance for much longer than the Bosch. This car hadn't been run on WVO, and they were all clogged up. Unknown how many miles were on them. When those tiny holes get plugged, they no longer atomize and simply spray a stream. This is a very bad thing for many reasons: smoking, coking, harder starting, less power, less mileage.
Now I am firmly in the camp with many others who I have read recommending getting your injectors pop tested. But go beyond that, change to these new nozzles, which I haven't heard much about with respect to WVO use on the forums.
YVORMV - Your veg. oil results may vary.
95 Dodge Cummins 4x4 +87 300TD SVO WVO conversion.
81 Mercedes 300D- stock and happy on V80/D20 blend.
Low fossil house- 100% solar/wind power, 90% solar heated.
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