Denso-Injectors Flow Test Plan PDF

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
D
LT
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
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 17.0-20 <30.0 Idle
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
16600-AU600 Mount Suitable Test Pump
S
Manufacturer I.D.:- NISSAN PRIMERA Test Oil Temperature- 40 C
EM
ST
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
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
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
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
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- OPEL MERIVA Test Oil Temperature- 40 C
EM
Engine:- 4EE2 - ISUZU Solenoid Resistance @ 20°C - 600 m
ST
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

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
Injector Designation:- 095000-513# Testing Prerequisites
AW402-AW4 Mount Suitable Test Pump
S
Manufacturer I.D.:- NISSAN X TRAIL Test Oil Temperature- 40 C
EM
ST
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
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
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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
D
LT
O.E.M. REF: MITSUBISHI L200 TEST OIL TEMP: 40°C
ENGINE: SOLENOID RESISTANCE @ 20°C - 600m
S
EM
ST
SY
Pulse
Width
L

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.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
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

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: MAZDA TEST OIL TEMP: 40°C
ENGINE: SOLENOID RESISTANCE @ 20°C - 600m
S
EM
ST
SY
Pulse
Width
L

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.

ER

M
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
6C1Q-9KJ46 Mount Suitable Test Pump
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
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
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
O.E.M. REF: NISSAN X-TRAIL TEST OIL TEMP: 40°C
ENGINE: - SOLENOID RESISTANCE @ 20°C - 600m
S
EM
ST
SY
Pulse
Width
L

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.

M
Note:-

S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: NISSAN NAVARA TEST OIL TEMP: 40°C
ENGINE: 2.5L SOLENOID RESISTANCE @ 20°C - 600m


Pulse
Width

1000 1000 700 N/A - -
Leaks
1500 1350 900 130-140 <50.0 <75.0 Max Fuel
400 250 700 25-30 <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.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
Manufacturer I.D.:- NISSAN PATHFINDER Test Oil Temperature- 40 C
EM
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

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA

O.E.M. REF: FORD TRANSIT TEST OIL TEMP: 40°C
ENGINE: 2.4L SOLENOID RESISTANCE @ 20°C - 600m


Pulse
Width

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.
Note:-

S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:-
Solenoid Resistance @ 20°C -
ST
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
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
Engine:-
Solenoid Resistance @ 20°C -
ST
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
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
*SIN ON OLD
S
EM
ST
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
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
ST
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
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
LI

ER
M
S3000 Common Rail
Test System
TEST DATA
D
LT
S
EM
ST
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
S
400 150-250 700 N/A - S.O.I

IE

D
N
Note:-
LI

ER
M

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Denso-Injectors Flow Test Plan PDF

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S3000 Common Rail

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

1500 1350 900 135-145 <50.0 Max Fuel

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

Start of Injection (S.O.I)

rates are matched through the set.

Type Designation:- Test Oil Specification- ISO 4113

1500 1350 900 75.0-79.0 Max Fuel

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

Start of Injection (S.O.I)

rates are matched through the set.

Type Designation:- Test Oil Specification- ISO 4113

1500 1350 900 95-105 <50.0 Max Fuel

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

Start of Injection (S.O.I)

rates are matched through the set.

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

1500 1350 900 85-95 <50.0 Max Fuel

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

Start of Injection (S.O.I)

rates are matched through the set.

Type Designation:- Test Oil Specification- ISO 4113

1500 1350 900 90.0-95.0 <50.0 Max Fuel

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

Start of Injection (S.O.I)

rates are matched through the set.

Type Designation:- Test Oil Specification- ISO 4113

1500 1350 900 145-160 <50.0 Max Fuel

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

Start of Injection (S.O.I)

rates are matched through the set.

INJECTOR DATA TEST CONDITIONS

Purge System & Check for

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

400 250 700 2-4 <30.0 <12.0 Idle

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

1) Stop test bench.

3) Remove fuel connection T031-3052.

MERLIN S3000 COMMON RAIL TEST SYSTEM

INJECTOR DATA TEST CONDITIONS

Purge System & Check for

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

400 250 700 12-16 <30.0 <12.0 Idle

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

1) Stop test bench.

3) Remove fuel connection T031-3052.

MERLIN S3000 COMMON RAIL TEST SYSTEM

Type Designation:- Test Oil Specification- ISO 4113

1500 1350 900 180.0-190.0 <50.0 Max Fuel

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

Start of Injection (S.O.I)

rates are matched through the set.

INJECTOR DATA TEST CONDITIONS

Purge System & Check for

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

400 250 700 9-13 <30.0 <12.0 Idle

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

1) Stop test bench.