Testing

1. Remove nozzles from engine and clean outside of injector.
2. Install a nozzle onto the tester. Close the pressure gauge valve on the tester. Depress the pump lever rapidly (equivalent to 6-8 strokes per second) to bleed the system.
3. Depress pump lever with short, fast partial strokes (equivalent to 4-6 strokes per second). The spray pattern should be uniform and well atomized. If it is not, replace the injector.
4. A new injection nozzle should have a soft chatter at lever speeds of 1-2 strokes per second. If a new nozzle does not chatter, replace the injector.
Note: Used injection nozzles should not be evaluated for chatter at lower speeds. A used nozzle can generally be used if it passes the Opening Pressure Test, Leakage Test, and Spray Pattern Test.
5. Open pressure gauge valve on tester. Depress pump lever slowly (1 stroke per second) and read the opening pressure (the pressure when the nozzle opens and the jet starts). The opening pressure should be 115 to 125 bar (1668 to 1813 psi). The variation between nozzles must not exceed 5 bar (72.5 psi). If the nozzle does not meet these specifications, replace the injector. If the engine shakes at idle, have equal delivery adjusted to a difference between injectors of less than 0.5 ccm/1000 strokes at a Bosch Service Center.
6. Depress pump lever until the pressure gauge reads 20 bar (290 psi) below the opening pressure. No drop should fall from the nozzle within 10 seconds. If the nozzle does not meet these specifications, replace the injector. If the engine shakes at idle, have equal delivery adjusted to a difference between injectors of less than 0.5 ccm/1000 strokes and a Bosch Service Center.