Fuel Pumps Parts Test Equipment Filters New Generation Workshop Diagnostic & Vehicle Care Centre Miscellaneous Accessories Merlin Common Rail / EUI Tools and Accessories Catalogue Leading The Way in Diesel Technology Merlin Common Rail / EUI Tools www.merlindiesel.com
CONTENTS COMMON RAIL INJECTORS REPAIR TEST Sockets 1 Test Adaptors 7-8 Special Tools/Tool Kits 2-3 Back-Leak Connectors 8-9 Injector Holders/Lapping Kits 4 High Pressure CR Test Pipes 10 Measuring Kits 5 S300-1 Adaptor Cables 11 P350 Assembly Press 6 Shim Kits Please ask for a copy of our new Common Rail Shim Catalogue for the full range of shims. COMMON RAIL PUMPS REPAIR TEST General Tools 12-15 Adaptors 16 Drive Couplings 17 Pump Mountings 18-19 ON-ENGINE TOOLS Injector Pullers 20-21 General 22-23 Tool Kits 24-25 Delphi Diagnostic Equipment 26 CR Electrical Connectors 27 EUI REPAIR TEST Sockets 28 Test Adaptors 31-32 Shims & Valves 29 Miscellaneous Tools & Equipment 30 COMMON RAIL & EUI GENERAL EQUIPMENT 33-36 TEST EQUIPMENT 37 Details of our range of the latest MERLIN common rail and EUI test equipment are available in our new Automotive and Marine Product Range Catalogues. Please ask for a copy.
COMMON RAIL INJECTOR REPAIR SOCKETS 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 16mm 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 T016-834 TX40 for CP1 T021-927 Siemens Socket 1.4/1.6 PSA Ford T016-704A Pins for Denso Kit T016-704K T016-704K 3 Pin Denso Kit Note: Available in kit T021-1002 on page 3. 1
COMMON RAIL INJECTOR REPAIR SPECIAL TOOLS T021-947 Ball Bearing Stroke Measuring Tool (see page 3) T021-948 Injector Assy Tool M27 0 986 613 613 Bosch CRI T021-948NG As above but non-gen. T021-952 Fibre Ring Insert Tool 0 986 613 640 Bosch CRI T021-952NG As above but non-gen. T021-965 Fibre Ring Insert Tool (Truck) Bosch CRIN T021-968 Valve Assembly Puller T021-992 25mm Siemens Inj Nut T021-946 Extractor For Fibre Ring Valve Seat Extractor T021-961 15mm 0 986 613 623 T021-962 17mm 0 986 613 626 Bosch CRI T021-930 Fibre Ring Puller Kit 2
COMMON RAIL INJECTOR REPAIR TOOL KITS T021-973 35 Piece Bosch Stage 3 Repair Tool Kit Contents Fibre Ring Insert Tool Fibre Ring Insert Tool Valve Seal Extractor Valve Seal Extractor Pilot Valve Socket CRI CRIN 15mm 17mm CRIN Pilot Valve Socket Angle Setting Piece Solenoid Sockets Solenoid Sockets HP Seal Removal Tool CRI CRI T021-1001 CAT6.6 CR Injector Stripping Kit T021-1002 Denso CR Injector Stripping Jig 3
COMMON RAIL INJECTOR REPAIR GENERAL ACCESSORIES BALL SEAT LAPPING T021-924 Tool kit for lapping CR injector ball seat INJECTOR HOLDERS T021-019 Injector Holder 13, 15mm T021-922 Injector Holder 14, 16, 20mm Volvo, BMW, Ducato T021-925 Injector Holder 15, 17, 18, 22mm T021-969 Common Rail Injector Mounting Clamp Universal vice mounted injector clamp for holding various types of common rail injectors. T021-1003 Denso Injector Mounting Clamp 4
COMMON RAIL 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 Armature Stroke Measuring Tool 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 FOR A FULL RANGE OF SHIM KITS PLEASE REFER TO OUR NEW SHIM KIT CATALOGUE 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: 23.70 mm/19.00mm Range: 0.90-1.00mm by 0.01mm 5
COMMON RAIL INJECTOR REPAIR ASSEMBLY PRESS MERLIN P350 STAGE 3 PNEUMATIC PRESS Allows adjustment of air gap on CR 2.1 injectors Easy removal & re-fitting of solenoid sleeve Mandrels included to remove and fit sleeve Acrylic enclosure & two switch operation for safety Requires workshop air supply at 6bar pressure BOSCH FSA 050 FSA 050 Electrical testing of all makes of Common Rail Injectors for workshops carrying out Piezo injector repair. The unit offers a quick and accurate way to determine the integrity of the piezo stacks and solenoid windings. Some of the other functions include insulation analysis, continuity measurement, resistance measurement, capacitance measurement and can be linked via Bluetooth to PC so results can be stored and printed out. 6
COMMON RAIL INJECTOR 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 Denso Injector Test Adaptor T021-934 095000-055* J. Deere T021-935 095000-5480/5050 T021-949 Bosch Injector Test Adaptor 26mm Man T021-950 Bosch Injector Test Adaptor 28mm Volvo Deutz Quick Test Connector T021-970 6.5mm T021-971 9.0mm T021-980 Injector Test Adaptor Cummins/Case T021-994 Delphi smart Injector Test Adaptor T031-3050 CR Injector Test Clamp Kit for most test benches, suitable for Bosch, VDO and Denso injectors T031-3051 Universal Test Injector Clamp T031-3053 Caterpillar Back-leak Adaptor Kit (A12077) 7
COMMON RAIL INJECTOR TEST ADAPTORS BACK-LEAK ADAPTORS T021-972 12 pcs Bosch CRIN Test Adaptor Kit T021-1004 Universal Commercial Vehicle Injector Test Kit T021-202A Bosch Back-leak Connectors M003-501 BOSCH BACK-LEAK ADAPTORS M003-502 T021-205 Bosch Back-leak Connectors 180 0 Back-leak Pipe for Bosch Piezo 0 986 612 922 YDT562 Bosch Euro 5 Back-leak Adaptor DELPHI BACK-LEAK ADAPTORS T021-201 Delphi Back-leak Connectors YDT275 HK1120 Delphi DFI 1.5 Back-leak Adaptor M003-503 Delphi xc4 8
COMMON RAIL INJECTOR TEST ADAPTORS DENSO T021-945A Denso Back-leak Connectors M003-510 Denso Back-leak Connectors 180 0 M003-512 Leak-off clip SIEMANS YDT561 Continental Euro 5 Back-leak Adaptor M003-505 Y Back-leak Adaptor M003-506 Back-leak Adaptor 180 0 M003-507 Back-leak Adaptor 45 0 M003-508 Back-leak Adaptor 90 0 9
COMMON RAIL INJECTOR TEST TEST PIPES INJECTOR HP FLEXIBLE TEST PIPES FLEXIBLE TEST PIPES T014-101 550 x 2.0 (14X14) T014-102 450 x 2.0 (12X14) T014-103 450 x 2.0 (14X14) T014-104 220 x 2.0 (12X14) T014-105 220 x 2.0 (14X14) T014-106 550 x 2.0 (12X14) T014-107 550 x 2.0 (12X12) TEST BENCH HP FLEXIBLE TEST PIPES MERLIN S3000 BOSCH 815 HARTRIDGE T014-108 1/4 NPT x 1/4 NPT T014-150 M14 x M14 (Similar to 1 680 712 227) T014-109 M12 x M14 (Similar to 1 680 712 229) T014-110 M12 x 1/4NPT (Similar to A079B11) T014-111 M14x1/4NPT 10
COMMON RAIL INJECTOR TEST S300-1 ADAPTOR CABLES The MERLIN S300-1 is a single unit designed to test both electro-hydraulic and piezo type injectors. 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. Supplied complete with electrical mains cable, connection cable with 4 adaptor cables to suit Bosch, Denso, Delphi, Piezo and general purpose applications. S300-1 Common Rail Injector System tester, one unit for the following systems: Bosch, Delphi, Denso & Siemens (VDO) Piezo function. MERLIN S300-1 COMMON RAIL TEST SYSTEM REFER TO PAGE 38 FRO DETAILS OF ALL MERLIN CR/EUI TEST EQUIPMENT T031-3402 Adaptor Cable Delphi DFI 1.5 Euro 5 for S300-1 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 11
COMMON RAIL PUMP REPAIR GENERAL PUMP VICE 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 YDT358 Tray for rollers TAPPET LIFTERS RE-BUSHING TOOL KITS TAPPET LIFTERS T016-675 0 986 612 427 T016-675L Ford 110 Duramax Bosch CP3 T016-682 Re-Bushing Tool Kit Bosch CP3 T016-683 Re-Bushing Tool Kit Bosch CP1 12
COMMON RAIL PUMP REPAIR GENERAL SOCKETS T016-626 T40 Torx Socket Renault Bosch CP2 T016-627 T40 Torx Screwdriver Renault Bosch CP2 T016-681 Torx Socket For Suction Valve Bosch CP3 T016-684 High Impact Torx Socket Set T016-701 Socket for Inlet Connectors 0 986 612 991 Bosch CP3 T016-864 Siemens pump sensor wrench T021-988 30mm Socket T021-989 28mm Socket Siemens Sensor CP1 T021-990 Socket CP4 Value T021-991 Socket Torx Denso HP3/HP4 T021-993 Camcar Kit T10-T45 13
COMMON RAIL PUMP REPAIR ASSEMBLY TOOLS 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 T016-680 Shaft Seal Inserter 0 986 612 422 Bosch CP1, CP3 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 14
COMMON RAIL PUMP REPAIR GENERAL ASSEMBLY TOOLS 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 15
COMMON RAIL PUMP TEST 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 T016-876 Bosch CP4.2 fuel connection adaptor for use with M14 high pressure test pipe. WAS T021-979 16
COMMON RAIL PUMP TEST TEST COUPLINGS 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 T011-041 Tang Drive 8mm Mercedes T011-042 Tang Drive 9mm Siemens T011-043 Tang Drive 10mm Denso, Transit, Fiat Multijet T011-053 Drive Coupling, splined MAN CP3 T011-054 Mercedes Drive Coupling T011-054A Threaded Adaptor for T011-054 17
COMMON RAIL PUMP TEST MOUNTING FLANGES BOSCH TEST BENCHES T012-039 Mounting Flange 68mm Ø Delphi T012-040 Mounting Flange Bosch CP1-K T012-044 Mounting Flange 50mm Ø Bosch CP4 T012-204 Mounting Flange 50mm Ø Mercedes Bosch CP3 T012-301 Mounting Flange 50mm Ø Renault 1.5 dci Delphi T012-001 Merlin Universal Mounting Bracket which permits Hartridge and Merlin mounting flanges to be used on Bosch test benches. T012-029 Universal Mounting for Bosch test benches 1 688 010 129 T012-015 Universal Mounting for Bosch test benches 1 688 010 124 18
COMMON RAIL PUMP TEST MOUNTING FLANGES MERLIN/HARTRIDGE TEST BENCHES T012-004 Mounting Plate 50mm Ø For CP3 0 445 020 007 Pump T012-302 Mounting Plate 50mm Ø Mercedes Tang Drive T012-303 Mounting Plate 50mm Ø Delphi Renault 1.5 dci T012-305 Mounting Plate 68mm Ø With 50mm Ø insert Universal including Delphi DFP1 T012-305-46 46mm Ø insert for T012-305 T012-305-60 60mm Ø insert for T012-305 T012-306 Mounting Plate 50mm Ø Bosch CP4 T012-307 Mounting Plate 107mm Ø With 80mm Ø Insert Bosch T012-308 Mounting Plate Siemens Lion V6 T012-309 Siemens Renault/Nissan 1.5 dci 19
COMMON RAIL ON-ENGINE INJECTOR PULLERS 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 20
COMMON RAIL ON-ENGINE INJECTOR PULLERS COMMON RAIL INJECTOR PULLER KIT T021-007 Common Rail Injector Puller Kit for Renault/Vauxhall/Nissan Specifically for Renault 2.0 dci M9R series engines fitted 0 445 115 007* injector. (*Official Renault reference for 0 445 115 022) These are fitted to Renault/Vauxhall/Nissan applications as follows: RENAULT: ESPACE, KOLEOS, LAGUNA, MEGANE, SCENIC, TRAFIC 2.0 dci NISSAN: QASHQAI, X-TRAIL 2.0 dci VAUXHALL: VIVARO 2.0 CDTI This puller kit can also be used with some other types of injectors. 21
COMMON RAIL ON-ENGINE GENERAL TOOLS 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 22
COMMON RAIL ON-ENGINE GENERAL TOOLS T016-806 Timing/Tool Kit YDT250 Peugeot/Citroen Suzuki T016-807 Timing Kit YDT201 Engine & Camshaft Pins Renault K9 T016-808 Timing Kit YDT202 Camshaft Bar & Engine Pin Ford Lynx T016-809 Pump Puller & Stroke Holding Tool Renault 2.2 dci T016-815 Timing Kit YDT381 Ssangyong T021-916 Cyl Head Reamer Kit For Delphi/Bosch CR Injectors T026-027 Kneeling Pad 14 X 21 T016-874 Rail Pressure Sensor Adaptor Available separately: Nipple A11783 14mm nut 45159104 12mm nut M001-105 T021-975 Universal Rail Pressure Tester Designed to diagnose faults on rail pressure sensors fitted to Bosch, Delphi and Denso CR systems. Can be used on the vehicle or test bench. 23
COMMON RAIL ON-ENGINE TOOL KITS T026-001 Common Rail Injector Extractor Kit 3 PC Fitted mainly to Mercedes C & E class, Sprinter and Chrysler Grand Cherokee 2.7CRD (00>) T026-005 Common Rail Injector Extractor Kit 9PC Length 350mm Includes 17 & 27mm adaptors T026-002 Common Rail Injector Extractor Kit Suitable for Peugeot and Citroen 2.0 HDI, 110,135 HP with DW 10 engine code T026-006 Common Rail Injector Extractor Kit 7 PC For Mercedes 611, 612, 613 etc engines T026-003 Common Rail Injector Extractor Kit VW/Audi T026-007 Injector Extractor Kit Heavy duty kit for traditional truck injectors plus Mercedes injector-pump system T026-004 Injector Extractor Short length 230mm with 8, 12 & 14mm adaptors T026-008 Washer Removal Tool Collet type for removing copper washers. Length 350mm. Inner hole 7mm. 24
COMMON RAIL ON-ENGINE TOOL KITS T026-009 Injector Socket Kit 4 PC, 1/2 drive. 25, 27, 29 & 30mm T026-016 Injector Seat Cutter 7 PC 15, 17, 19 & 21mm flat & angled reamers T026-010 Glow Plu Removal Kit 16 piece kit for removing glow plugs T026-017 Injector Seat Cutter 8 PC 15, 17, 19 & 21mm flat & angled reamers and 58-60 0 injector cleaner T026-011 Compression Tester Kit 37 piece kit for diesel engines T026-024 Injector Seat Cutter 6PC 15, 17, 19 & 21mm flat & angled reamers T026-013 Common Rail Back-leak Kit 6 cylinder kit for checking back leak flow. (With 24 adaptors for Bosch, Delphi, Denso & Siemens) T026-026 Washer Removal Tool 12 pcs universal terminal release kit T026-014 COMMON RAIL BACKLEAK KIT 24 adaptors only kit for Bosch, Delphi, Denso & Siemens) 25
COMMON RAIL ON-ENGINE DELPHI KITS T016-816 False Actuator Kit YDT410 Determines electrical or mechanical pump problem. All-makes compatible: Delphi, Bosch, Denso & Siemens (VDO). Reduces time and cost in identifying problem part. T021-200 Sealed Rail Diagnostic Kit YDT850 Checks pump pressure and identifies faulty injector. All-makes compatible: Delphi, Bosch, Denso & Siemens (VDO). Reduces time and cost in identifying problem part. YDT553 Hand-held, easy to use unit providing immediate analysis of diesel fuel. YDT 720 Electronic injector test kit Buzz Box. Delphi DS350E Convertible PC Diagnostic Kit Delphi DS150E VCI and software only YDT 566 Delphi Pico Scope Heavy duty kit for traditional truck injectors plus Mercedes injector-pump system. YDT 586 All makes back-leak kit. 10 x all makes back leak connectors/ adapters. 3 x types of protection plugs. Replacement O- Rings. 9109-947 Quick-fits kit. 15 x "Quick-Fit" fittings all makes. 3 x protection caps diameter, (8.0 mm, 9.49mm and 10.0 mm) male and female types. 26
COMMON RAIL ON-ENGINE ELECTRICAL CONNECTORS 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 Delphi Euro 3 & 4 9001-845 Connector Kit Delphi Euro 3 & 4 2001 9001-845NG Connector Kit Delphi Euro 3 & 4 2001 T031-3217 Connector Kit (9001-886) Delphi Euro 5 PSA, Ford 2.0L TDCI T031-3218 Boot 2 way moisture cover T031-3219 Denso Connector Transit 27
EUI INJECTOR REPAIR SOCKETS AUDI/VW T021-062 VW-AUDI A6 Solenoid Socket 37mm T021-063 VW-AUDI A6 Solenoid socket 12 sides T021-064 VW-AUDI A6/nozzle nut socket 18 teeth T021-074 VW-SIEMENS Piezo ring nut socket 30mm T021-075 VW-SIEMENS Piezo Solenoid Socket 25mm T021-076 VW-SIEMENS Piezo nozzle nut socket 17mm T021-087 VW nozzle nut socket 20mm T021-077 VW-SIEMENS Piezo ring nut socket 29mm LAND ROVER VOLVO (DELPHI) VOLVO/ROVER (DELPHI) T021-053 L/ROVER Socket (4 PIN) T021-054 VOLVO 500 socket 39mm dia 2 PIN T021-093 VOLVO ROVER, E1 & E3 Nozzle nut clamp No holes/hex 28
EUI INJECTOR REPAIR VALVES & SHIMS UNIT INJECTOR VALVE UNIT PUMP VALVE T021-067-1 EUI VALVE 6.995mm T021-863-1 EUP VALVE 6.995mm T021-067-2 EUI VALVE 7.000mm T021-863-2 EUP VALVE 7.000mm T021-067-3 EUI VALVE 7.005mm T021-863-3 EUP VALVE 7.005mm T021-067-4 EUI VALVE 7.010mm T021-863-4 EUP VALVE 7.010mm T021-067-5 EUI VALVE 7.015mm T021-863-5 EUP VALVE 7.015mm T021-067-6 EUI VALVE 7.020mm T021-863-6 EUP VALVE 7.020mm T021-067-7 EUI VALVE 7.025mm T021-863-7 EUP VALVE 7.025mm T021-067-8 EUI VALVE 7.030mm T021-863-8 EUP VALVE 7.030mm T021-067-9 EUI VALVE 7.035mm T021-863-9 EUP VALVE 7.035mm T021-067-10 EUI VALVE 7.040mm T021-863-10 EUP VALVE 7.040mm T021-067-11 EUI VALVE 7.045mm T021-863-11 EUP VALVE 7.045mm T021-067-12 EUI VALVE 7.050mm T021-863-12 EUP VALVE 7.050mm T021-067-13 EUI VALVE 7.055mm T021-863-13 EUP VALVE 7.055mm T021-067-14 EUI VALVE 7.060mm T021-863-14 EUP VALVE 7.060mm T021-067-15 EUI VALVE 7.065mm T021-863-15 EUP VALVE 7.065mm T021-067-16 EUI VALVE 7.070mm T021-863-16 EUP VALVE 7.070mm T021-067-17 EUI VALVE 7.075mm T021-863-17 EUP VALVE 7.075mm T021-067-18 EUI VALVE 7.080mm T021-863-18 EUP VALVE 7.080mm SHIM KITS T021-068 1.9L Armature Shim 1.00-1.45 9.2 diam T021-069 1.9L Opening Pressure 1.00-1.45 7.3 diam T021-070 2.0L Opening Pressure 1.00-1.45 5.5 diam T021-092 2.0L Armature Shim VW Series 2 29
EUI INJECTOR TEST MISCELLANEOUS LAPPING TOOLS T021-078 Lapping Kit T025-001 EXTRA COURSE T025-002 COURSE T025-003 MEDIUM T025-004 FINE T025-005 SUPER FINE Lapping paste for T021-078 ON-ENGINE TOOLS T021-042 Torx Socket VW Lupo EUI for installation in engine T021-037 Extractor Adaptor for EUI VW Lupo used with T021-036, page 20 30
EUI INJECTOR TEST TEST ADAPTORS AUDI/VW T021-052 VW T021-057 VW T021-061 VW-SIEMENS PIEZO 24x1.0mm T021-072 VW CATERPILLAR/J.DEERE DETROIT T021-073 VW 25x0.75mm T021-090 VW Series 2 T021-081 CATERPILLAR, J.DEERE 28x1mm T021-082 DETROIT 32x1.5mm CUMMINS CUMMINS VOLVO T021-083 CUMMINS L10-M11 30x1.5mm T021-084 CUMMINS N14 11/8 x18unf T021-094 Injector Test Adaptor Volvo 4 pin, E3 (34x1mm) 31
EUI INJECTOR TEST TEST ADAPTORS LAND ROVER NISSAN T021-050 LAND ROVER 24x1mm T021-091 NISSAN 440 31x1mm IVECO / SCANIA / VOLVO T021-058 (DELPHI) VOLVO 460 EURO 2 / SCANIA 31x1mm T021-059 (DELPHI) SCANIA, VOLVO 420, CURSOR 430 31x1mm T021-079 VOLVO, CURSOR 350 28x1mm T021-080 VOLVO FH12, 420, 460 28x1mm T021-085 VOLVO 520CV 34x1mm T021-086 IVECO STRALIS 36x1mm 32
COMMON RAIL & EUI GENERAL EQUIPMENT CR/EUI INJECTOR ASSEMBLY KIT T021-065 CR AND EUI INJECTOR DISASSEMBLY TOOL Special fixture to disassemble and re-assemble EUI and Common Rail Injectors (Similar to Bosch 0 986 613 400 & 0 986 613 500) Illustration shows the fixture together with optional T021-066 Digital display torque sensor. 0-2500 kg (25000 nm) (similar to bosch 0 986 612 997) T021-071 Kit of 3 assembly bushes 7mm, 7mm with step & 9mm used with T021-065 DIGITAL TORQUE WRENCHES T016-865 DIGITAL TORQUE WRENCH T016-866 DIGITAL TORQUE SCREWDRIVER ACCESSORIES: T016-867 Torque Protractor 1/2X1/2 T016-868 28mm open ended insert T016-869 29mm open ended insert T016-870 30mm open ended insert T016-871 32mm open ended insert T016-872 27mm ring insert T016-873 Ratchet Head 3/8" T016-873-1/4 Ratchet Head 1/4" T016-875 27mm open ended insert Digital torque wrench units: N-m/lbf-ft/lbf-in/kgf-m Digital torque screwdriver units: cnm/lbf-in/ozf-in/kgf-cm 33
COMMON RAIL & EUI GENERAL EQUIPMENT T016-848 40x Magnifier T016-851 Tweezers for steel ball T016-852 Digital External Micrometer Range: 0-25mm Resolution: 0.001mm T021-958 Vacuum pen for steel ball T021-959 Insulation Tester For pre-checking CR injectors T021-974 Bosch CR injector stripping jig T021-978 USB Magnifier T021-998 Multimeter T021-975 Universal Rail Pressure Tester Designed to diagnose faults on rail pressure sensors fitted to Bosch, Delphi and Denso CR systems. Can be used on the vehicle or test bench. 34
COMMON RAIL & EUI GENERAL EQUIPMENT COMPONENT TRAYS & CLEANING TANKS ULTRASONIC CLEANING TANKS Ultrasonic cleaning tanks can be used to clean almost any item from watch and clock mechanisms, surgical and dental tools, glassware, filters to carbu- retors and engine/machine parts, especially diesel fuel injection components and nozzles. T021-953 Common Rail Pump or Injector Components Tray T041-502 2 Litre Capacity T041-505 5 Litre Capacity T041-515 15 Litre Capacity T041-520 20 Litre Capacity T041-530 30 Litre Capacity One to three minutes is usually adequate to clean the parts, which it does without damaging any of the surfaces. All units are supplied complete with stainless steel baskets and lids. Larger sizes available, please contact our office for details. A range of specialist cleaning agents are available as follows: T040-001 Bench Mounted Wash Tank T040-001CR As above but fitted with a 2 micron filter, ideal for cleaning common rail components. T026-025 Brush T042-005 Cleaning powder for aluminium (1 Kg) T042-006 Cleaning powder for steel (1 Kg) STEEL TRAYS & HOLDERS FOR USE IN ULTRASONIC CLEANING TANKS T021-963 Multi Steel Tray 240 x 170 x 50mm T021-964 Single Steel Tray 175 x 125 x 50mm T021-981 General purpose common rail injector holder stand. T016-862 Filter ball for ultrasonic cleaning of small common rail parts. 35
COMMON RAIL & EUI GENERAL EQUIPMENT TOOL CABINETS AVAILABLE IN 5, 6 & 7 DRAWER COMBINATIONS. MTC-005 MTC-006 MTC-007 MISCELLANEOUS T026-200 Fume extraction aspirator for use when testing injectors. ISO 4113 25 litre drum of ISO calibration fluid S9365. 36
COMMON RAIL & EUI TEST EQUIPMENT S4000 Common Rail Injector Tester A fully automatic common rail injector test bench designed to test Bosch, Denso, Delphi and Siemens injectors. S8000 Common Rail Injector Tester A fully automatic 6 cyl common rail injector & pump test bench designed to test Bosch, Denso, Delphi and Siemens injectors. Full details of Merlin test equipment products can be found in our Automotive and Marine Equipment Catalogues, available from our office. S300-1 Common Rail System Tester For testing the following CR injectors: Bosch, Delphi, Denso & Siemens (VDO) plus a Piezo function. S3000 Common Rail System Test Rail Retro-fit Kit The Merlin S3000 common rail retro-fit kit can be mounted on various test benches. S300-1 Special Build Injector Testers Two injector testers, Merlin S400A and Merlin S400-5 are now available with a built-in a Merlin S300-1. MM815-CR Common Rail Pump & Injector (4cyl) Tester (Can also be a 8cyl standard test bench) S400A-CRC Common Rail Injector Test Comparator Can also be used as a conventional injector tester. Optional cabinet available. Merlin MPU 500 EUI/MUI/EUP Cambox Kit Suitable for various applications as follows: Volvo - Scania - Land Rover - Siemens Audi/VW Piezo - Cummins Celect 37
Common Rail & EUI Tools MERLIN DIESEL SYSTEMS LTD Merlin Diesel Systems Limited Our test equipment division manufactures Merlin diesel fuel injection test equipment, cleaning tanks and engine valve re-facing machines. The product range covers automotive, marine, rail and power generation applications and includes test equipment for electronic unit injectors, common rail injectors and electronic governed fuel pumps. Ultrasonic cleaning tanks, tachometers, service tools and test bench spares, plus a comprehensive selection of reconditioned test equipment complement the range. Parts Division Merlin Diesel Systems Parts Division supply diesel injection spare parts and complete units for Delphi, Bosch, Zexel, Denso, Yanmar, Stanadyne and Woodward applications. These include nozzles, fuel pumps, injectors, lift pumps, filters and glow plugs. T: +44 (0)1772 694130 F: +44 (0)1772 316375 E: parts@merlindiesel.com Test Equipment Division T: +44 (0)1772 694180 F: +44 (0)1772 314565 E: sales@merlindiesel.com DIESEL FUEL INJECTION TEST AND SERVICE EQUIPMENT Merlin Diesel Systems Ltd, Unit 189-191, Bradkirk Place, Walton Summit Centre, Preston, Lancashire, PR5 8AJ. England T: +44 (0)1772 694130 F: +44 (0)1772 316375 E: sales@merlindiesel.com www.merlindiesel.com Distributed By: ILLUSTRATIONS AND TECHNICAL DATA ARE NON-BINDING. SUBJECT TO CHANGE AS A RESULT OF TECHNOLOGICAL PROGRESS. www.merlindiesel.com DATA No. 785/CR-EUI/0914 - September 2014-2,500 Printed in England.