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Denso Injector Test Plans 4
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Injector Designation:- 095000-0510 16600-8H800
Type Designation:- ref alla148p765
Manufacturer I.D.:- NISSAN X TRAIL
Engine:- EURO 3
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-0570
Type Designation:-
Manufacturer I.D.:-
Engine:-
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
1500 1350 900 75.0-79.0 Max Fuel
400 250 700 17.0-20 <30.0 Idle
2000 1350 Run pump only N/A <12-5/25.0 Seat test
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-0880 16600-AU600
Type Designation:-
Manufacturer I.D.:- NISSAN PRIMERA
Engine:- EURO 3
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-0940
Type Designation:- --
Manufacturer I.D.:- TOYOTA HI-ACE
Engine:- --
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-5080
Type Designation:-
Manufacturer I.D.:- OPEL MERIVA
Engine:- 4EE2 - ISUZU
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-513# AW402-AW4
Type Designation:-
Manufacturer I.D.:- NISSAN X TRAIL
Engine:- EURO 3
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1000 700 N/A - - Purge System & Check for Leaks
1500 1350 900 98-103 <50.0 <75.0 Max Fuel
400 250 700 2-4 <30.0 <12.0 Idle
2000 1350 Run pump only N/A <12.5 <25.0 Seat Test
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.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
PART No: 095000-5473
TYPE: -
O.E.M. REF: ISUZU-N SERIES
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
SOLENOID RESISTANCE @ 20°C - 600m
MERLIN D
IESEL S
YSTEMS LTD
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1000 700 N/A - - Purge System & Check for Leaks
1500 1350 900 137-142 <50.0 <75.0 Max Fuel
400 250 700 12-16 <30.0 <12.0 Idle
2000 1350 Run pump only N/A <12.5 <25.0 Seat Test
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.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
PART No: 095000-5600
TYPE: -
O.E.M. REF: MITSUBISHI L200
ENGINE:
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
SOLENOID RESISTANCE @ 20°C - 600m
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-5650
Type Designation:-
Manufacturer I.D.:- NISSAN PATHFINDER
Engine:- YD25
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1000 700 N/A - - Purge System & Check for Leaks
1500 1350 900 100-110 <50.0 <75.0 Max Fuel
400 250 700 9-13 <30.0 <12.0 Idle
2000 1350 Run pump only N/A <12.5 <25.0 Seat Test
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.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
PART No: 095000-5780
TYPE: -
O.E.M. REF: MAZDA
ENGINE:
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
SOLENOID RESISTANCE @ 20°C - 600m
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-5800 6C1Q-9KJ46
Type Designation:-
Manufacturer I.D.:- FORD TRANSIT
Engine:- PUMA 2.2 EURO 4
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1000 700 N/A - - Purge System & Check for Leaks
1500 1350 900 87-92 <50.0 <75.0 Max Fuel
400 250 700 15-17 <30.0 <12.0 Idle
2000 1350 Run pump only N/A <12.5 <25.0 Seat Test
400 150-250 700 N/A - - S.O.I
400 400 040 2.5-3.0 - - Pre Injection
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.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
PART No: 095000-6021
TYPE: -
O.E.M. REF: NISSAN X-TRAIL
ENGINE: -
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
SOLENOID RESISTANCE @ 20°C - 600m
MERLIN D
IESEL S
YSTEMS LTD
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1000 700 N/A - - Purge System & Check for Leaks
1500 1350 900 130-140 <50.0 <75.0 Max Fuel
400 250 700 25-30 <30.0 <12.0 Idle
2000 1350 Run pump only N/A <12.5 <25.0 Seat Test
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.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
PART No: 095000-6240
TYPE: -
O.E.M. REF: NISSAN NAVARA
ENGINE: 2.5L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
SOLENOID RESISTANCE @ 20°C - 600m
Injector Designation:- 095000-6250
Type Designation:-
Manufacturer I.D.:- NISSAN PATHFINDER
Engine:-
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
MERLIN S3000 COMMON RAIL TEST SYSTEM
Remove all washers from injectors. Fit injectors to rack. Fit injector pipe. Attach injector cables T031-3901. Close protective cover.
Pump Speed RPM
Rail Pressure
BAR
Pulse Width Delivery
cc/1000
Max Back Leak
cc/1000 cc/min Comments
1000 1000 700 N/A - - Purge System & Check for Leaks
1500 1350 900 112-120 <50.0 <75.0 Max Fuel
400 250 700 13-19 <30.0 <12.0 Idle
2000 1350 Run pump only N/A <12.5 <25.0 Seat Test
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.
S3000 Common Rail Test System
TEST DATA
INJECTOR DATA
PART No: 095000-7060
TYPE: -
O.E.M. REF: FORD TRANSIT
ENGINE: 2.4L
TEST CONDITIONS
TEST PUMP: SUITABLE CR PUMP
TEST OIL: ISO 4113
TEST OIL TEMP: 40°C
SOLENOID RESISTANCE @ 20°C - 600m
Injector Designation:- 095000-7581
Type Designation:-
Manufacturer I.D.:- Engine:-
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C -
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-7610
Type Designation:-
Manufacturer I.D.:- Engine:-
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C -
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-7730
*SIN ON OLD Type Designation:-
Manufacturer I.D.:-
Engine:-
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-7780
Type Designation:-
Manufacturer I.D.:-
Engine:-
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
Injector Designation:- 095000-7850
Type Designation:-
Manufacturer I.D.:-
Engine:-
Testing PrerequisitesMount Suitable Test Pump
Test Oil Specification- ISO 4113
Test Oil Temperature- 40 C
Solenoid Resistance @ 20°C - 600 m
S3000 Common Rail Test System
TEST DATA
Start of Injection (S.O.I)
Stop the test bench. Reduce rail pressure to zero, remove fuel connection, close cover and SLOWLY increase pressure as per test. Note:-When calibrating more than one injector of the same number ensure that all flow rates are matched through the set.
Pump Speed RPM
Rail Pressure BAR
Pulse Width Delivery cc/1000
Max Back Leak Mm3st/ccmin
Comments
1000 1000 1200 N/A - Purge System
2000 1500 1200 N/A - Check for Leaks
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
400 150-250 700 N/A - S.O.I
MERLIN D
IESEL S
YSTEMS LTD
