S3000 Common Rail

Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 095000-0360 TEST PUMP: SUITABLE CR PUMP
TYPE: 970950-0036 TEST OIL: ISO 4113
O.E.M. REF: VAUXHALL/OPEL/RENAULT/SAAB TEST OIL TEMP: 40°C
ENGINE: 3.0L SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 95-100 <60.0 <90.0 Max Fuel

400 250 700 10-13 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-0510 Testing Prerequisites
16600-8H800 Mount Suitable Test Pump

Type Designation:- ref alla148p765 Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- NISSAN X TRAIL Test Oil Temperature- 40 C

EM
Engine:- EURO 3 Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 135-145 <50.0 Max Fuel

400 250 700 20-22 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 095000-0530 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: TOYOTA LANDCRUISER TEST OIL TEMP: 40°C
ENGINE: 3.0TD, 1KD-FTV SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 110-120 <60.0 <90.0 Max Fuel

400 250 700 12-16 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-0570 Testing Prerequisites
Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- Test Oil Temperature- 40 C

EM
Engine:- Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 75.0-79.0 Max Fuel

400 250 700 10-15 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 095000-0750 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: TOYOTA LANDCRUISER TEST OIL TEMP: 40°C
ENGINE: 3.0TD, 1KD-FTV SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 110-120 <60.0 <90.0 Max Fuel

400 250 700 12-16 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-0880 Testing Prerequisites
16600-AU600 Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- NISSAN PRIMERA Test Oil Temperature- 40 C

EM
Engine:- EURO 3 Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 95-105 <50.0 Max Fuel

400 250 700 15-20 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-0940 Testing Prerequisites
Mount Suitable Test Pump

Type Designation:- -- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- TOYOTA HI-ACE Test Oil Temperature- 40 C

EM
Engine:- -- Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 85-95 <50.0 Max Fuel

400 250 700 14-16 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-5080 Testing Prerequisites
Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- OPEL MERIVA Test Oil Temperature- 40 C

EM
Engine:- 4EE2 - ISUZU Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 90.0-95.0 <50.0 Max Fuel

400 250 700 10.0-12.0 <30.0 Idle
2000 1350 Run pump only N/A <12.5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-513# Testing Prerequisites
AW402-AW4 Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- NISSAN X TRAIL Test Oil Temperature- 40 C

EM
Engine:- EURO 3 Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 145-160 <50.0 Max Fuel

400 250 700 12-14 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 095000-5473 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113

LT
O.E.M. REF: ISUZU-N SERIES TEST OIL TEMP: 40°C
ENGINE: - SOLENOID RESISTANCE @ 20°C - 600m

S
EM
 Remove all washers from injectors.
 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for

1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 98-103 <50.0 <75.0 Max Fuel

400 250 700 2-4 <30.0 <12.0 Idle

IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I

N

Start of Injection
LI

1) Stop test bench.

2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.

4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 095000-5600 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113

LT
O.E.M. REF: MITSUBISHI L200 TEST OIL TEMP: 40°C
ENGINE: SOLENOID RESISTANCE @ 20°C - 600m

S
EM
 Remove all washers from injectors.
 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for

1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 137-142 <50.0 <75.0 Max Fuel

400 250 700 12-16 <30.0 <12.0 Idle

IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I

N

Start of Injection
LI

1) Stop test bench.

2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.

4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-5650 Testing Prerequisites
Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- NISSAN PATHFINDER Test Oil Temperature- 40 C

EM
Engine:- YD25 Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Comments
RPM BAR cc/1000 Leak
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 180.0-190.0 <50.0 Max Fuel

400 250 700 24.0-28.0 <30.0 Idle
2000 1350 Run pump N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 095000-5780 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113

LT
O.E.M. REF: MAZDA TEST OIL TEMP: 40°C
ENGINE: SOLENOID RESISTANCE @ 20°C - 600m

S
EM
 Remove all washers from injectors.
 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for

1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 100-110 <50.0 <75.0 Max Fuel

400 250 700 9-13 <30.0 <12.0 Idle

IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I

N

Start of Injection
LI

1) Stop test bench.

2) Reduce rail pressure on S3000 to zero.
ER

3) Remove fuel connection T031-3052.

4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.
M

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-5800 Testing Prerequisites
6C1Q-9KJ46 Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- FORD TRANSIT Test Oil Temperature- 40 C

EM
Engine:- PUMA 2.2 EURO 4 Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 100-110 <50.0 Max Fuel

400 250 700 17-20 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

D
PART No: 095000-6021 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113

LT
O.E.M. REF: NISSAN X-TRAIL TEST OIL TEMP: 40°C
ENGINE: - SOLENOID RESISTANCE @ 20°C - 600m

S
EM
 Remove all washers from injectors.
 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.
ST
SY
Pump Rail Max Back Leak
Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min
L

Purge System & Check for

1000 1000 700 N/A - -
Leaks
SE

1500 1350 900 87-92 <50.0 <75.0 Max Fuel

400 250 700 15-17 <30.0 <12.0 Idle

IE

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only
D

400 150-250 700 N/A - - S.O.I

400 400 040 2.5-3.0 - - Pre Injection

N
LI

Start of Injection
ER

1) Stop test bench.

2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
M

5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 095000-6131 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: OPEL TEST OIL TEMP: 40°C
ENGINE: 1.7 CDTI SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 115-125 <60.0 <90.0 Max Fuel

400 250 700 17-23 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 095000-6240 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: NISSAN NAVARA TEST OIL TEMP: 40°C
ENGINE: 2.5L SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 115-120 <50.0 <75.0 Max Fuel

400 250 700 14-18 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-6250 Testing Prerequisites
Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- NISSAN PATHFINDER Test Oil Temperature- 40 C

EM
Engine:- Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Comments
RPM BAR cc/1000 Leak
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 190.0-200.0 <50.0 Max Fuel

400 250 700 20.0-25.0 <30.0 Idle
2000 1350 Run pump only N/A <12.5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 095000-7060 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: FORD TRANSIT TEST OIL TEMP: 40°C
ENGINE: 2.4L SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 112-120 <50.0 <75.0 Max Fuel

400 250 700 13-19 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-7581 Testing Prerequisites
Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- Test Oil Temperature- 40 C

EM
Engine:-
Solenoid Resistance @ 20°C -

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 70-72 <50.0 Max Fuel

400 250 700 8-10 <20 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-7610 Testing Prerequisites
Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- Test Oil Temperature- 40 C

EM
Engine:-
Solenoid Resistance @ 20°C -

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 100 <50.0 Max Fuel

400 250 700 9-12 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 095000-7640 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: TOYOTA RAV4, COROLLA VERSO TEST OIL TEMP: 40°C
ENGINE: 2.2L SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 88-98 <60.0 <90.0 Max Fuel

400 250 700 8-13 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 095000-7670 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: TOYOTA TEST OIL TEMP: 40°C
ENGINE: D4D 2.0L SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 80-90 <50.0 <75.0 Max Fuel

400 250 700 7-9 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-7730 Testing Prerequisites
Mount Suitable Test Pump
*SIN ON OLD
Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- Test Oil Temperature- 40 C

EM
Engine:- Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 108-112 <50.0 Max Fuel

400 250 700 8-10 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-7780 Testing Prerequisites
Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- Test Oil Temperature- 40 C

EM
Engine:- Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 100-110 <50.0 Max Fuel

400 250 700 10-12 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

D
LT
Injector Designation:- 095000-7850 Testing Prerequisites
Mount Suitable Test Pump

Type Designation:- Test Oil Specification- ISO 4113

S
Manufacturer I.D.:- Test Oil Temperature- 40 C

EM
Engine:- Solenoid Resistance @ 20°C - 600 m

ST
Pump Speed Rail Pressure Pulse Width Delivery Max Back Leak Comments
RPM BAR cc/1000 Mm3st/ccmin
SY
1000 1000 1200 N/A - Purge
System
2000 1500 1200 N/A - Check for
Leaks
EL

1500 1350 900 98.0-103 Max Fuel

400 250 700 8.0-10.0 <20.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
S

400 150-250 700 N/A - S.O.I

IE

Start of Injection (S.O.I)

D

Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close
cover and SLOWLY increase pressure as per test.
N

Note:-
When calibrating more than one injector of the same number ensure that all flow
LI

rates are matched through the set.

ER
M
 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 095000-7890 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: SUBARU LEGACY, OUTBACK TEST OIL TEMP: 40°C
ENGINE: 2.0D SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 125-135 <60.0 <90.0 Max Fuel

400 250 700 14-18 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S3000 Common Rail
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 295050-0010 TEST PUMP: SUITABLE CR PUMP
TYPE: - TEST OIL: ISO 4113
O.E.M. REF: MAZDA 3, 6, CX7 TEST OIL TEMP: 40°C
ENGINE: 2.2 L SOLENOID RESISTANCE @ 20°C - 600m

 Remove all washers from injectors.

 Fit injectors to rack.
 Fit injector pipe.
 Attach injector cables T031-3901.
 Close protective cover.

Pump Rail Max Back Leak

Pulse
Speed Pressure Delivery Comments
Width
RPM BAR cc/1000 cc/1000 cc/min

Purge System & Check for

1000 1000 700 N/A - -
Leaks

1500 1350 900 155-165 <60.0 <90.0 Max Fuel

400 250 700 13-17 <30.0 <12.0 Idle

Run pump
2000 1350 N/A <12.5 <25.0 Seat Test
only

400 150-250 700 N/A - - S.O.I

Start of Injection
1) Stop test bench.
2) Reduce rail pressure on S3000 to zero.
3) Remove fuel connection T031-3052.
4) Close protective cover.
5) Run test bench to 400RPM and increase rail pressure slowly until atomised fuel can just be
seen emitting from nozzle holes when rail pressure should be 150-200BAR.

Note:-
When calibrating more than one injector of the same number ensure that all flow rates are
matched through the set.

MERLIN S3000 COMMON RAIL TEST SYSTEM