CONTENTS

INJECTOR REPAIR GENERAL TOOLS INJECTOR HOLDERS ARMATURE STROKE MEASURING KITS MISCELLANEOUS CLEANING TANKS AND TRAYS INJECTOR TESTING TEST ADAPTORS BACK-LEAK CONNECTORS HIGH PRESSURE CR TEST PIPES SHIM KITS PUMP REPAIR GENERAL TOOLS PUMP TESTING ADAPTORS DRIVE COUPLINGS PUMP MOUNTINGS FOR BOSCH TEST BENCHES PUMP MOUNTINGS FOR MERLIN/HARTRIDGE TEST BENCHES ENGINE TOOLS INJECTOR PULLERS GENERAL DELPHI DIAGNOSTIC EQUIPMENT COMMON RAIL TEST EQUIPMENT MERLIN S300-1 MERLIN MM815CR MERLIN S400A-CRC MERLIN S3000 MISCELLANEOUS CR ELECTRICAL CONNECTORS

1-2 2 3 4 4

5 6 6 7-8

9-11

12 13 13 14

15 16-17 17

18 19 19 20

21

TO ORDER PLEASE CONTACT: 01772 694180 or sales@merlindiesel.com

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.

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

INJECTOR REPAIR - GENERAL TOOLS

Pilot Valve Sockets T021-921 6.5mm T021-926 7.5mm

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

Window Sockets T021-931 27mm MAN T021-933 28mm CRIN

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

T021-946 Extractor For Fibre Ring

T021-947 Ball Bearing Stroke Measuring Tool (see page 3)

T021-948 Injector Assembly Tool M27 0 986 613 613 Bosch CRI T021-948NG (same as above)

T021-952 Fibre Ring Insert Tool 0 986 613 640 Bosch CRI

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

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

T021-968 Valve Assembly Puller

T021-973 35 Piece Bosch Tool Kit

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

INJECTOR REPAIR - GENERAL TOOLS

T021-927 Siemens Sockets 1.4/16 PSA Ford

T021-924 Tool Kit for Lapping CR Injectors

T021-930 Fibre Ring Puller Kit

INJECTOR HOLDERS
T021-019 Injector Holder 13, 15mm

T021-922 Injector Holder 14, 16, 20mm Volve, BMW, Ducato

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

T021-969 Universal Injector Clamp

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

INJECTOR REPAIR - MEASURING KITS

ARMATURE STROKE MEASURING KITS
T021-947 Armature Stroke Measuring Tool For Stage 3 Repair (Pilot Valve Replacement) On Bosch Common Rail Injectors Types CR1, CR2.0 & CR2.2 MERLIN S350K Merlin Kit for Stage 3 Repair (Pilot Valve Replacement) on all Bosch Common Rail Injectors including: CRI 2.1 AND CRIN 1, 2 & 3 Consists of:T021-956 Dial gauge holder kit For measuring ball bearing stroke on all Bosch common rail injectors. Supplied with 17 & 19mm adaptors S350 Armature stroke test unit c/w 3 adaptor cables T016-850 Digital Dial Indicator T021-957 Pin

All parts are available separately.

T016-850 Digital Dial Indicator Range: 12.500mm Resolution: 0.001mm

T021-942 Shim Kit Solenoid Diameter/Hole: 15.70mm/10.50mm Range: 1.20-1.30mm by 0.01mm

T021-960 Shim Kit Solenoid Diameter/Hole: 23.70mm/19.00mm Range: 0.90-1.00mm by 0.01mm

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

INJECTOR REPAIR - MISCELLANEOUS

T016-851 Tweezers for steel ball

T016-852 Digital External Micrometer Range: 0-25mm Resolution: 0.001mm

T016-848 40x Magnifier

T021-958 Vacuum pen for steel ball

T021-959 Insulation Tester For pre-checking CR injectors

CLEANING TANKS & TRAYS

T040-001 Bench Wash Tank T040-001CR Bench Wash Tank fitted with a 2 micron filter T041-515 Ultrasonic Cleaning Tank (15 ltr) Other sizes available

T021-953 Common Rail Pump or Injector Components Tray

T021-963 Multi Steel Tray 240x170x50mm

T021-964 Single Steel Tray 175x125x50mm

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

INJECTOR TESTING - TEST ADAPTORS

T021-027 Bosch Injector Test Adaptor 29mm MAN 464

T021-918N Bosch Injector Test Adaptor 26.5mm Cummins Iveco

T021-920 Bosch Injector Test Adaptor 32mm Renault Bus

T021-934 Denso Injector Test Adaptor 095000-055* J. Deere

T021-935 Denso Injector Test Adaptor 095000-5480/5050

T021-949 Bosch Injector Test Adaptor 26mm Man

T021-950 Bosch Injector Test Adaptor 28mm Volvo Deutz

T021-970 Quick Test Connector 6.5mm

T021-971 Quick Test Connector 9.0mm

T021-972 12 pcs Bosch CRIN Test Adaptor Kit

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

INJECTOR TESTING - BACK-LEAK CONNECTORS

T021-201 Delphi Back-leak Connectors YDT275

T021-202 Back-leak Connectors Bosch T021-202A Back-leak Connectors 180 Bosch

T021-205 Back-leak Pipe for Bosch Piezo 0 986 612 922

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

INJECTOR TESTING - HP TEST PIPES

T014-101 T014-102 T014-103 T014-104 T014-105 T014-106 T014-107 HP Flexible Test Pipe HP Flexible Test Pipe HP Flexible Test Pipe HP Flexible Test Pipe HP Flexible Test Pipe HP Flexible Test Pipe HP Flexible Test Pipe 550 x 2.0 (14x14) 450 x 2.0 (12x14) 450 x 2.0 (14x14) 220 x 2.0 (12x14) 220 x 2.0 (14x14) 550 x 2.0 (12x14) 550 x 2.0 (12x12)

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

INJECTOR TESTING - SHIM KITS

T021-939 Shim Kit Idle Diameter 5.30 mm Hole 3.50 mm Range 1.20-1.70 mm Increments 0.05 mm T021-939X Shim Kit Idle Diameter 5.30 mm Hole 3.50 mm Range 1.40-1.86 mm Increments 0.02 mm T021-939V Shim Kit Idle Diameter 5.30 mm Hole 3.50 mm Range 0.90-1.90 mm Increments 0.05 mm

T021-940 Shim Kit Solenoid Diameter 4.50 mm Hole 2.50 mm Range 1.20-1.70 mm Increments 0.05 mm T021-940X Shim Kit Solenoid Diameter 4.50 mm Hole 2.50 mm Range 1.64-1.86 mm Increments 0.02 mm T021-940Y Shim Kit Diameter 4.20 mm Hole 2.30 mm Range 1.70-1.96 mm Increments 0.02 mm

T021-941 Shim Kit Solenoid Hexagonal Diameter 22.00 mm Hole 19.00 mm Range 1.00-1.01 mm Increments 0.01 mm RLS CRIN

T021-942 Shim Kit Solenoid Diameter 15.70 mm Hole 10.50 mm Range 1.20-1.30 mm Increments 0.01 mm Armature Stroke CR! 1, 2.0, 2.2

T021-943 Shim Kit, with flat Diameter 5.90 mm Range 8.40-8.50 mm Increments 0.01 mm

T021-944 Shim Kit Phase 2 Diameter 2.25 mm Range 1.14-1.25 mm Increments 0.01 mm Max. Fuel

T021-943X Shim Kit, with flat Diameter 5.90 mm Range 8.50-8.70 mm Increments 0.01 mm T021-943Y Shim Kit, round Diameter 5.70 mm Range 8.50-8.70 mm Increments 0.01 mm Max. Fuel

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

INJECTOR TESTING - SHIM KITS

T021-954 Shim Kit Diameter 5.30 mm Hole 2.40 mm Range 1.72-1.90 mm Increments 0.02 mm

T021-955 Shim Kit Diameter 23.70 mm Hole 19.00 mm Range 0.90-1.00 mm Increments 0.01 mm T021-960 Shim Kit Diameter 23.70 mm Hole 19.00 mm Range 1.00-1.10 mm Increments 0.01 mm RLS CRI 2.1 Armature Stroke CRI 1, 2.0, 2.2

T021-966 Shim Kit Diameter hex Hole 17.00 mm Range 0.950-0.994 mm Increments 0.004mm Armature Stroek CRIN 1

T021-967 Shim Kit Diameter hex Hole 17.00 mm Range 0.998-1.042 mm Increments 0.004mm Armature Stroek CRIN 1

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

PUMP REPAIR - GENERAL TOOLS

T016-202A Swivel Vice Base

T016-202B Swivel Vice Flange Attachment Bosch CP1

T016-202C Swivel Vice Flange Attachment Renault 1.5 dCi Delphi

T016-202D Swivel Vice Flange Attachment Bosch CP3

T016-626 T40 Torx Socket Renault Bosch CP2

T016-627 T40 Torx Screwdriver Renault Bosch CP2

Tappet Lifters T016-675 0 986 612 427 T016-675L Ford 110 Duramax Bosch CP3

T016-677 Insert Tool Low Pressure Connection 0 986 612 200 Bosch CP1

T016-678 Insert Tool Low Pressure Connection 0 986 612 201 Iveco Bosch CP1

T016-679 Insert Tool Low Pressure Connection 0 986 612 205 Renault Bosch CP1

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

10

PUMP REPAIR - GENERAL TOOLS

T016-680 Shaft Seal Inserter 0 986 612 422 Bosch CP1, CP3

T016-682 Re-Bushing Tool Kit Bosch CP3

T016-681 Torx Socket For Suction Valve Bosch CP3

T016-683 Re-Bushing Tool Kit Bosch CP1

T016-684 High Impact Torx Socket Set

T016-701 Socket for Inlet Connectors 0 986 612 991 Bosch CP3

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

PUMP REPAIR - GENERAL TOOLS

11

T016-702 Drive Seal Tool

T016-703 Bearing/Oil-seal Tool Kit Delphi DFP1

T016-709 DRV Valve Dismantling Tool Bosch CP1-H, CP3, CP4

T016-825 Mounting Mandrel for Gear Pump 0 986 611 665 Bosch CP1-H Use with T016-826

T016-826 Mounting Mandrel for Gear Pump 0 986 611 675 Bosch CP1-H Use with T016-825

T016-827 Assembly Tool for Return Valve 0 986 612 911 Bosch CP1-H T016-827NG Non-genuine version

T016-828 Press In Tool 0 986 612 970 Bosch CP1-H

T016-829 Filter Extractor Tool 0 986 613 153 Bosch CP1-H T016-829NG Non-genuine version

T016-830 Filter Insert Tool 0 986 613 154 Bosch CP1-H

T016-831 Assembly Tool 0 986 613 169 Bosch CP1-H

T016-832 Assembly Tool 0 986 613 161 Bosch CP1-H

T016-833 Puller Tool 0 986 613 165 Bosch CP1-H

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

12

PUMPING TESTING - ADAPTORS

T016-693 Fuel Connection Kit Bosch CP1-K

T016-694 Transfer Pressure Adaptor Delphi

T016-695 Transfer Pressure Adaptor Bosch CP3

T016-697 Transfer Pressure Adaptor Bosch CP1-H

T016-698 Transfer Pressure Adaptor Siemens

T016-699 Transfer Pressure Adaptor Denso HP2

T016-708 Pressure Sensor Adaptor Bosch / Siemens

T016-822 Adaptor - Dummy Regulator Denso HP3

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

PUMP TESTING - COUPLINGS & MOUNTINGS

13

T011-005 Drive Coupling 20mm ADC95-1

T011-039 Drive Coupling 25mm 1 686 430 026 Bosch CP3

T011-040 Drive Coupling ADC288 Delphi DFP1

MOUNTING PLATES FOR BOSCH TEST BENCHES

T011-041 Tang Drive 8mm Mercedes T011-042 Tang Drive 9mm Siemens T011-043 Tang Drive 10mm Denso, Transit, Fiat Multijet T012-039 Mounting Flange 68mm Delphi

T012-040 Mounting Flange Bosch CP1-K

T012-044 Mounting Flange 50mm Bosch CP4

T012-204 Mounting Flange 50mm Mercedes Bosch CP3

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

T012-301 Mounting Flange 50mm Renault 1.5 dCi Delphi

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

14

PUMP TESTING - MOUNTINGS

MOUNTING PLATES FOR MERLIN/HARTRIDGE TEST BENCHES

T012-004 Mounting Plate 50mm For CP3 0 445 020 007 Pump T012-302 Mounting Plate 50mm Mercedes Tang Drive

T012-303 Mounting Plate 50mm Delphi Renault 1.5 dCi

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

T012-305-46 46mm insert for T012-305 T012-305-60 60mm insert for T012-305

T012-306 Mounting Plate 50mm Bosch CP4

Mounting Plate 107mm With 80mm Insert. Bosch

T012-308 Mounting Plate Siemens Lion V6

T012-309 Siemens Renault/Nissan 1.5 dCi

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

ENGINE TOOLS - INJECTOR PULLERS

15

T021-035 Injector Extractor Iveco Tector

T021-036 Injector Extractor Mercedes A

T021-036A Injector Extractor Mercedes A Twin Version

T021-038 Injector Extractor Alfa 156, Fiat

T021-048 Injector Extractor Mercedes A & E

T021-048A Bosch Adaptor M27 x 1 For T021-048

T021-917 Injector Puller Mercedes Sprinter

T021-923 Injector Extractor Mercedes OM611, 612, 613 Etc

T021-929 Injector Puller Siemens

T021-932 Injector Removal & Rotating Tool 0 986 611 481

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

16

ENGINE TOOLS - GENERAL

T016-625 Puller BMW CP1

T016-704 Rail Plug Socket Delphi 3 Pin

T016-705 Drive Gear Puller Delphi Kia/Hyundai

T016-801 Timing Kit Fiat/Iveco Multijet 1300-1900

T016-802 Timing Kit Renault 2.2, 2.5 dCi

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

T016-803 Timing Kit Iveco

T016-804 Timing Kit Renault, Peugeot, Citroen

T016-805 Mounting Tool Ford Duratorq 2.0, 2.2, 2.4

T016-806 Pump Puller & Stroke Holding Tool Renault 2.2 dCi

T016-807 Timing Kit YDT201 Engine & Camshaft Pins Renault K9

T016-808 Timing Kit YDT202 Camshaft Bar & Engine Pin Ford Lynx

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

ENGINE TOOLS - GENERAL

17

T016-815 Timing Kit YDT381 Ssangyong

T016-809 Timing/Tool Kit YDT250 Peugeot/Citroen Suzuki

T021-916 Cyl Head Reamer Kit For Delphi/Bosch CR Injectors

DELPHI DIAGNOSTIC KITS

T016-816 False Actuator Kit YDT410

T021-200 Sealed Rail Diagnostic Kit YDT278

T021-203 Sealed Rail Diagnostic Kit Heavy Duty Version YDT500

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

18

COMMON RAIL TEST EQUIPMENT

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 sufficiently 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 H15cm Weight: 10kg

Merlin S300-1 Common Rail Test System

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

T021-301 Adaptor Cable Delphi for S300-1

T021-303 Adaptor Cable Bosch for S300-1

T021-304 Adaptor Cable Piezo for S300-1

T021-305 Adaptor Cable Universal for S300-1

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

T021-307 Lead for S350 S300-1

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

COMMON RAIL TEST EQUIPMENT

19

A range of common rail test equipment manufactured in the UK by Merlin Diesel Systems 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 specification same as retro-fit 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 effective method of flow-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 flows. When the modified Merlin S300-1 Common Rail Injector System is used in conjunction with the Merlin S400A Injector Tester, a common rail injector can be operated sufficiently to observe the nozzle spray pattern and measure the backleak time. The injector is then repositioned into a holder in the spray chamber from where delivery and back-leak flows 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.

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

20

COMMON RAIL TEST EQUIPMENT

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 S3000 Standard equipment includes: Interlocked Safety Enclosure Merlin common rail assembly 2000 bar transducer Injector nozzle connectors Delphi Leak-o connections Test data with on-going updates CR Flexi HP Pipes CP3 Fuel Pump Pump mounting plate Mobile Cabinet Bosch Leak-o connections Range of adaptor cables

Merlin S3000 Common Rail Retro-fit Kit

A cost effective option utilising an existing bench

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

Can be operated remotely via this control panel utility when installed on PC/Laptop.

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

MISCELLANEOUS - ELECTRICAL CONNECTORS

21

T031-3210 Connector Siemens/Bosch

T031-3211 Connector Siemens / Bosch CP1

T031-3212 Connector Bosch

T031-3213 Connector Bosch CP1H, CP3 & Piezo

T031-3214 Connector 2 Pole Super Seal -Male

T031-3215 Connector 2 Pole Super Seal -Female

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

T031-3216NG Connector Delphi Euro 3 & 4

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

T031-3218 Boot 2 way moisture cover

T031-3219 Denso Connector Transit

MERLIN COMMON RAIL REPAIR & TEST CATALOGUE

Common Rail Repair & Test Catalogue DATA 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.

Merlin Diesel Systems Ltd 189-191, Bradkirk Place, Walton Summit Centre, Preston, Lancashire, PR5 8AJ, England Tel: +44 (0)1772 694180 Fax: +44 (0)1772 314565 Email: sales@merlindiesel.com www.merlindiesel.com