a5 common rail

CONTENTS

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

INJECTOR REPAIRGENERAL TOOLSINJECTOR HOLDERSARMATURE STROKE MEASURING KITSMISCELLANEOUSCLEANING TANKS AND TRAYS

INJECTOR TESTINGTEST ADAPTORSBACK-LEAK CONNECTORSHIGH PRESSURE CR TEST PIPESSHIM KITS

PUMP REPAIRGENERAL TOOLS

PUMP TESTINGADAPTORSDRIVE COUPLINGSPUMP MOUNTINGS FOR BOSCH TEST BENCHESPUMP MOUNTINGS FOR MERLIN/HARTRIDGE TEST BENCHES

ENGINE TOOLSINJECTOR PULLERSGENERALDELPHI DIAGNOSTIC EQUIPMENT

COMMON RAIL TEST EQUIPMENTMERLIN S300-1MERLIN MM815CRMERLIN S400A-CRCMERLIN S3000

MISCELLANEOUSCR ELECTRICAL CONNECTORS

TO ORDER PLEASE CONTACT:01772 694180 or [email protected]

1-22344

5667-8

9-11

12131314

1516-1717

18191920

21

Manufacturers part numbers are given for reference purposes only and do not imply that in all cases the parts are of their manufacture. Illustrations and Technical Data are non-binding and are subject to change as a result of technological progress.

Pilot Valve SocketsT021-921 6.5mmT021-926 7.5mm

Window SocketsT021-931 27mm MANT021-933 28mm CRIN

Nozzle AdaptorsT021-928 17.5mm x 8T021-938 14,15,17,19mm x 6 kitT021-951 16.0mm x 8

Torx SocketsT021-937 10mm 0 986 613 632T021-937a 12mm 0 986 613 631

T021-948Injector Assembly Tool M270 986 613 613 Bosch CRIT021-948NG (same as above)

T021-965Fibre Ring Insert Tool (Truck)Bosch CRIN

T021-947Ball Bearing StrokeMeasuring Tool (see page 3)

Valve Seat ExtractorT021-961 15mm 0 986 613 623T021-962 17mm 0 986 613 626Bosch CRI

T021-97335 Piece Bosch Tool Kit

T021-946Extractor For Fibre Ring

T021-952Fibre Ring Insert Tool0 986 613 640 Bosch CRI

T021-968Valve Assembly Puller

INJECTOR REPAIR - GENERAL TOOLS


1

T021-927Siemens Sockets1.4/16 PSA Ford

T021-924Tool Kit for Lapping CR Injectors

T021-922Injector Holder 14, 16, 20mmVolve, BMW, Ducato

T021-930Fibre Ring Puller Kit

T021-019Injector Holder 13, 15mm

T021-969Universal Injector Clamp

T021-925Injector Holder 15, 17, 18, 22mm

INJECTOR REPAIR - GENERAL TOOLS


INJECTOR HOLDERS

2

T016-850Digital Dial IndicatorRange: 12.500mmResolution: 0.001mm

T021-960Shim Kit SolenoidDiameter/Hole: 23.70mm/19.00mmRange: 0.90-1.00mm by 0.01mm

T021-942Shim Kit SolenoidDiameter/Hole: 15.70mm/10.50mmRange: 1.20-1.30mm by 0.01mm

INJECTOR REPAIR - MEASURING KITS


ARMATURE STROKEMEASURING KITS

T021-947Armature StrokeMeasuring Tool

For Stage 3 Repair (Pilot Valve Replacement)On Bosch Common Rail Injectors Types CR1, CR2.0 & CR2.2

MERLIN S350KMerlin Kit for Stage 3 Repair(Pilot Valve Replacement) on all Bosch CommonRail Injectors including:CRI 2.1 AND CRIN 1, 2 & 3

Consists of:-

T021-956Dial gauge holder kitFor measuring ball bearing stroke on all Boschcommon rail injectors.Supplied with 17 & 19mm adaptors

S350Armature stroke test unit c/w 3 adaptor cables

T016-850Digital Dial Indicator

T021-957Pin

All parts are available separately.

3

T016-852Digital External MicrometerRange: 0-25mmResolution: 0.001mm

T016-851Tweezers for steel ball

T016-84840x Magni�er

T021-953Common Rail Pump or InjectorComponents Tray

T041-515Ultrasonic Cleaning Tank (15 ltr)Other sizes available

T021-964Single Steel Tray175x125x50mm

T021-958Vacuum pen for steel ball

T040-001 Bench Wash TankT040-001CR Bench Wash Tank�tted with a 2 micron �lter

T021-963Multi Steel Tray240x170x50mm

INJECTOR REPAIR - MISCELLANEOUS


T021-959Insulation TesterFor pre-checking CR injectors

CLEANINGTANKS & TRAYS

4

T021-027Bosch Injector Test Adaptor 29mmMAN 464

T021-920Bosch Injector Test Adaptor 32mmRenault Bus

T021-918NBosch Injector Test Adaptor 26.5mmCummins Iveco

T021-934Denso Injector Test Adaptor095000-055* J. Deere

T021-97212 pcs Bosch CRIN TestAdaptor Kit

T021-949Bosch Injector Test Adaptor 26mmMan

T021-971Quick Test Connector 9.0mm

T021-935Denso Injector Test Adaptor095000-5480/5050

T021-970Quick Test Connector 6.5mm

INJECTOR TESTING - TEST ADAPTORS


T021-950Bosch Injector Test Adaptor 28mmVolvo Deutz

5

T021-201Delphi Back-leak ConnectorsYDT275

T021-205Back-leak Pipe for Bosch Piezo0 986 612 922

T021-202Back-leak Connectors BoschT021-202ABack-leak Connectors 180° Bosch

T021-945Denso Back-leak Connectors(Use With T021-202)

T014-101 HP Flexible Test Pipe 550 x 2.0 (14x14)







INJECTOR TESTING - BACK-LEAK CONNECTORS


INJECTOR TESTING - HP TEST PIPES

6

T021-939Shim Kit IdleDiameter 5.30 mm Hole 3.50 mmRange 1.20-1.70 mmIncrements 0.05 mm

T021-939XShim Kit IdleDiameter 5.30 mm Hole 3.50 mmRange 1.40-1.86 mmIncrements 0.02 mm

T021-939VShim Kit IdleDiameter 5.30 mm Hole 3.50 mmRange 0.90-1.90 mmIncrements 0.05 mm

T021-941Shim Kit Solenoid HexagonalDiameter 22.00 mm Hole 19.00 mmRange 1.00-1.01 mmIncrements 0.01 mm

RLS CRIN

T021-940Shim Kit SolenoidDiameter 4.50 mm Hole 2.50 mmRange 1.20-1.70 mmIncrements 0.05 mm

T021-940XShim Kit SolenoidDiameter 4.50 mm Hole 2.50 mmRange 1.64-1.86 mmIncrements 0.02 mm

T021-940YShim KitDiameter 4.20 mm Hole 2.30 mmRange 1.70-1.96 mmIncrements 0.02 mm

T021-944Shim Kit Phase 2Diameter 2.25 mmRange 1.14-1.25 mmIncrements 0.01 mmMax. Fuel

T021-943Shim Kit, with �atDiameter 5.90 mmRange 8.40-8.50 mmIncrements 0.01 mm

T021-943XShim Kit, with �atDiameter 5.90 mm Range 8.50-8.70 mmIncrements 0.01 mm

T021-943YShim Kit, roundDiameter 5.70 mm Range 8.50-8.70 mmIncrements 0.01 mmMax. Fuel

INJECTOR TESTING - SHIM KITS


T021-942Shim Kit SolenoidDiameter 15.70 mm Hole 10.50 mmRange 1.20-1.30 mmIncrements 0.01 mm

Armature Stroke CR! 1, 2.0, 2.2

7

T021-954Shim KitDiameter 5.30 mmHole 2.40 mmRange 1.72-1.90 mmIncrements 0.02 mm

T021-966Shim KitDiameter hexHole 17.00 mmRange 0.950-0.994 mmIncrements 0.004mm

Armature Stroek CRIN 1

T021-955Shim KitDiameter 23.70 mmHole 19.00 mmRange 0.90-1.00 mmIncrements 0.01 mm

T021-960Shim KitDiameter 23.70 mmHole 19.00 mmRange 1.00-1.10 mm Increments 0.01 mm

RLS CRI 2.1 Armature Stroke CRI 1, 2.0, 2.2

INJECTOR TESTING - SHIM KITS


T021-967Shim KitDiameter hexHole 17.00 mmRange 0.998-1.042 mmIncrements 0.004mm

Armature Stroek CRIN 1

8

T016-202ASwivel Vice Base

T016-202CSwivel Vice Flange AttachmentRenault 1.5 dCiDelphi

T016-202BSwivel Vice Flange AttachmentBosch CP1

T016-202DSwivel Vice Flange AttachmentBosch CP3

T016-677Insert Tool Low Pressure Connection0 986 612 200Bosch CP1

Tappet LiftersT016-675 0 986 612 427T016-675L Ford 110 DuramaxBosch CP3

T016-679Insert Tool Low Pressure Connection0 986 612 205Renault Bosch CP1

T016-627T40 Torx ScrewdriverRenaultBosch CP2

T016-678Insert Tool Low Pressure Connection0 986 612 201Iveco Bosch CP1

PUMP REPAIR - GENERAL TOOLS


T016-626T40 Torx SocketRenaultBosch CP2

9

T016-680Shaft Seal Inserter0 986 612 422Bosch CP1, CP3

T016-682Re-Bushing Tool KitBosch CP3

T016-681Torx SocketFor Suction ValveBosch CP3

T016-683Re-Bushing Tool KitBosch CP1

T016-701Socket for Inlet Connectors0 986 612 991 Bosch CP3

T016-684High Impact Torx Socket Set



10

T016-828Press In Tool0 986 612 970Bosch CP1-H

T016-830Filter Insert Tool0 986 613 154Bosch CP1-H

T016-829Filter Extractor Tool0 986 613 153 Bosch CP1-HT016-829NG Non-genuine version

T016-831Assembly Tool0 986 613 169Bosch CP1-H

T016-833Puller Tool0 986 613 165Bosch CP1-H

T016-832Assembly Tool0 986 613 161Bosch CP1-H



11

T016-825Mounting Mandrel for Gear Pump0 986 611 665 Bosch CP1-HUse with T016-826

T016-709DRV Valve Dismantling ToolBosch CP1-H, CP3, CP4

T016-827Assembly Tool for Return Valve0 986 612 911 Bosch CP1-HT016-827NG Non-genuine version

T016-703Bearing/Oil-seal Tool KitDelphi DFP1

T016-826Mounting Mandrel for Gear Pump0 986 611 675 Bosch CP1-HUse with T016-825

T016-702Drive Seal Tool

T016-693Fuel Connection KitBosch CP1-K

T016-695Transfer Pressure AdaptorBosch CP3

T016-694Transfer Pressure AdaptorDelphi

T016-697Transfer Pressure AdaptorBosch CP1-H

T016-699Transfer Pressure AdaptorDenso HP2

T016-698Transfer Pressure AdaptorSiemens

T016-822Adaptor - Dummy RegulatorDenso HP3

PUMPING TESTING - ADAPTORS


T016-708Pressure Sensor AdaptorBosch / Siemens

12

T011-005Drive Coupling 20mmADC95-1

T011-040Drive CouplingADC288Delphi DFP1

T011-039Drive Coupling 25mm1 686 430 026Bosch CP3

T011-041 Tang Drive 8mm MercedesT011-042 Tang Drive 9mm SiemensT011-043 Tang Drive 10mm Denso,Transit, Fiat Multijet

T012-300Mounting Flange 50mm ØSiemens PSA V6, Lion

T012-039Mounting Flange 68mm ØDelphi

T012-204Mounting Flange 50mm ØMercedesBosch CP3

T012-044Mounting Flange 50mm ØBosch CP4

T012-301Mounting Flange 50mm ØRenault 1.5 dCiDelphi

PUMP TESTING - COUPLINGS & MOUNTINGS


T012-040Mounting FlangeBosch CP1-K

MOUNTINGPLATES FOR BOSCH

TEST BENCHES

13

T012-302Mounting Plate 50mm ØMercedes Tang Drive

T012-004Mounting Plate 50mm ØFor CP3 0 445 020 007 Pump

T012-303Mounting Plate 50mm ØDelphi Renault 1.5 dCi

T012-309Siemens Renault/Nissan 1.5 dCi

T012-305-4646mm Ø insert for T012-305T012-305-6060mm Ø insert for T012-305

T012-308Mounting PlateSiemens Lion V6

T012-305Mounting Plate 68mm ØWith 50mm Ø insert.Universal including Delphi DFP1

Mounting Plate 107mm ØWith 80mm Ø Insert.Bosch

PUMP TESTING - MOUNTINGS


T012-306Mounting Plate 50mm ØBosch CP4

MOUNTINGPLATES FOR

MERLIN/HARTRIDGETEST BENCHES

14

T021-035Injector ExtractorIveco Tector

T021-036AInjector ExtractorMercedes ’A’Twin Version

T021-036Injector ExtractorMercedes ’A’

T021-038Injector ExtractorAlfa 156, Fiat

T021-932Injector Removal & Rotating Tool0 986 611 481

T021-048ABosch AdaptorM27 x 1 For T021-048

T021-929Injector PullerSiemens

T021-048Injector ExtractorMercedes ’A’ & ’E’

T021-923Injector ExtractorMercedes OM611, 612, 613 Etc

ENGINE TOOLS - INJECTOR PULLERS


T021-917Injector PullerMercedes Sprinter

15

T016-625Puller BMWCP1

T016-705Drive Gear PullerDelphi Kia/Hyundai

T016-704Rail Plug SocketDelphi 3 Pin

T016-801Timing KitFiat/Iveco Multijet 1300-1900

T016-806Pump Puller & Stroke Holding ToolRenault 2.2 dCi

T016-802nTiming Kit (New Type)Renault 2.2, 2.5 dCi

T016-805Mounting ToolFord Duratorq 2.0, 2.2, 2.4

T016-808Timing Kit YDT202Camshaft Bar & Engine PinFord Lynx

T016-802Timing KitRenault 2.2, 2.5 dCi

T016-804Timing KitRenault, Peugeot, Citroen

T016-807Timing Kit YDT201Engine & Camshaft PinsRenault K9

ENGINE TOOLS - GENERAL


T016-803Timing KitIveco

16

T016-809Timing/Tool Kit YDT250Peugeot/CitroenSuzuki

T021-916Cyl Head Reamer KitFor Delphi/Bosch CR Injectors

T016-815Timing Kit YDT381Ssangyong

T016-816False Actuator KitYDT410

T021-203Sealed Rail Diagnostic KitHeavy Duty VersionYDT500

T021-200Sealed Rail Diagnostic KitYDT278

ENGINE TOOLS - GENERAL


DELPHI DIAGNOSTIC KITS

17

The MERLIN S300-1 is a single unit designed to test both electro-hydraulic and piezo type injectors. With common rail injectors the duration of the applied pulse along with the rail pressure determines the amount of fuel injected into the cylinder. The S300-1 can generate pulses suitable to drive piezo injectors as well as conventional solenoid types. Pulse duration and repetition rate are adjustable to simulate a range of operating conditions. The Merlin S300-1 is designed to operate Bosch, Delphi, Denso and Siemens series of automotive common rail injectors and, when used in conjunction with a Merlin S400A or S425A air operated injector tester, a common rail injector can be operated su�ciently to observe the nozzle spray pattern and measure the back-leak time. It can also be used with manually operated injector testers. Fault detection of injector short circuit, injector open circuit, incorrect injector type connected. No calibration required. Supplied complete with electrical mains cable, connection cable with 4 adaptor cables to suit Bosch, Denso, Delphi, Piezo and general purpose applications.

Shipping details:L21 x W30 x H15cmWeight: 10kg

T021-305Adaptor CableUniversal for S300-1

T021-304Adaptor CablePiezo for S300-1

T021-307Lead for S350S300-1

T021-303Adaptor CableBosch for S300-1

T021-306Main Lead for S300-1S300-1

COMMON RAIL TEST EQUIPMENT


T021-301Adaptor CableDelphi for S300-1

Merlin S300-1Common Rail Test SystemS300-1 Common Rail Injector System tester, one unit for the following systems: Bosch, Delphi, Denso & Siemens (VDO) Piezo function.

18

A range of common rail test equipment manufacturedin the UK by Merlin DieselSystems Ltd.

Suitable for testing:-Bosch CP1, CP1H, CP1K, CP3, Delphi, Denso and Siemens systems.

MM8-15CR Common Rail Test Stand

Stand alone common rail test bench. Can also be used as a conventional test bench if required.

Graduate Metering 15hp AC Inverter Drive S3000 speci�cation same as retro-�t kit.



S400A-CRC Injector Tester for comparative testing of common rail injectors.

An air operated S400A with integrated S300-1 system tester and C302 twin calibration unit. Can also be used as a conventional injector tester. Optional cabinet available. This system provides a simple e�ective method of �ow-testing common rail injectors using test equipment from our product range.

The system consists of two test machines, Merlin models S400A and S300-1, plus a new twin tube calibrator for measuring delivery and back-leak �ows. When the modi�ed Merlin S300-1 Common Rail Injector System is used in conjunction with the Merlin S400A Injector Tester, a common rail injector can be operated su�ciently to observe the nozzle spray pattern and measure the back-leak time.

The injector is then repositioned into a holder in the spray chamber from where delivery and back-leak �ows are measured over a set count and at a set air supply pressure on the Merlin C402 Calibration Unit. Maximum rating is 700 bar, this is considered acceptable for the type of testing for which this unit is designed and will identify most faults with these injectors.

19

• Drives up to four injectors

• Suitable for both piezo operated and electro-hydraulic injectors

• Suitable for SCV (e.g. Delphi) or PCV (e.g. Bosch) type DRV valves

• Auxiliary switched output (e.g. for third vane disable on certain pumps)

• Sequential injector drive, i.e. fuel delivery shots are timed as in a conventional mechanical pump

• Gives complete control of rail pressure, injector pulse width and pulse frequency via simple front panel controls

• Digital displays for injector pulse width and frequency, DRV valve drive percentage and rail pressure

• Automatic detection of short or open circuit injectors, as well as detection of the wrong type being connected

• Microprocessor based for extreme timing accuracy and having the ability to be controlled via a PC using the built in serial interface

The Merlin S3000 Common Rail Retro-Fit kit can be mounted onvarious test benches such as Bosch 515, Hartridge 1100MK2 and the HA2500 as shown in this illustration.

S3000 Standard equipment includes:-

• Interlocked Safety Enclosure • CR Flexi HP Pipes• Merlin common rail assembly • CP3 Fuel Pump• 2000 bar transducer • Pump mounting plate• Injector nozzle connectors • Mobile Cabinet• Delphi Leak-off connections • Bosch Leak-off connections• Test data with on-going updates • Range of adaptor cables

Can be operated remotely via this control panel utility when

installed on PC/Laptop.



Merlin S3000Common Rail Retro-�t KitA cost e�ective optionutilising an existing bench

20

T031-3210ConnectorSiemens/Bosch

T031-3212ConnectorBosch

T031-3211ConnectorSiemens / Bosch CP1

T031-3213ConnectorBosch CP1H, CP3 & Piezo

T031-3218Boot2 way moisture cover

T031-3215Connector2 Pole Super Seal -Female

T031-3217Connector KitDelphi Euro 5PSA, Ford 2.0L TDCI

T031-3214Connector2 Pole Super Seal -Male

T031-3216NGConnectorDelphi Euro 3 & 4

T031-3219Denso ConnectorTransit

MISCELLANEOUS - ELECTRICAL CONNECTORS


T031-3216Connector Kit 9001-845Delphi Euro 3 & 4 2001

21

Merlin Diesel Systems Ltd189-191, Bradkirk Place, Walton Summit Centre, Preston, Lancashire, PR5 8AJ, EnglandTel: +44 (0)1772 694180 Fax: +44 (0)1772 314565 Email: [email protected]

www.merlindiesel.com

Common Rail Repair & Test CatalogueDATA REF: MDS-TC-CR 0912

Manufacturers part numbers are given for reference purposes only and do not imply that in all cases the parts are of their manufacture. Illustrations and Technical Data are non-binding and are subject to

change as a result of technological progress.

a5 common rail

Documents