Merlin Common Rail / EUI Tools and Accessories Catalogue

• Fuel Pumps
• Parts
• Test Equipment
• Filters
• New Generation Workshop
• Diagnostic & Vehicle Care Centre
• Miscellaneous Accessories
Merlin Common Rail / EUI Tools

Merlin Common Rail / EUI Tools
and Accessories Catalogue
Leading The Way in Diesel Technology
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 Nozzle Adaptors Window Sockets

T021-921 6.5mm T021-928 17.5mm x 8 T021-931 27mm MAN
T021-926 7.5mm T021-938 14, 15, 17, 19mm x 6 kit T021-933 28mm CRIN
T021-951 16mm x 8
Torx Sockets T021-927 T016-704A

T021-937 10mm 0 986 613 632 Siemens Socket Pins for Denso Kit T016-704K
T021-937a 12mm 0 986 613 631 1.4/1.6 PSA Ford
T016-834 TX40 for CP1
T016-704K
3 Pin Denso Kit
Note: Available in kit T021-1002 on page 3.
Please contact 01772 694180 or sales@merlindiesel.com for more detailed information 1

Illustrations and technical data are non-binding. Subject to change as a result of technological progress.
SPECIAL TOOLS
T021-947 T021-948 T021-952

Ball Bearing Stroke Measuring Tool Injector Assy Tool M27 0 986 613 613 Fibre Ring Insert Tool 0 986 613 640
(see page 3) Bosch CRI Bosch CRI
T021-948NG As above but non-gen. T021-952NG As above but non-gen.
T021-965 T021-968 T021-992

Fibre Ring Insert Tool (Truck) Valve Assembly Puller 25mm Siemens Inj Nut
Bosch CRIN
T021-946 Valve Seat Extractor T021-930

Extractor For Fibre Ring T021-961 15mm 0 986 613 623 Fibre Ring Puller Kit
T021-962 17mm 0 986 613 626
Bosch CRI
2 Please contact 01772 694180 or sales@merlindiesel.com for more detailed information

TOOL KITS
T021-973
35 Piece Bosch Stage 3
Repair Tool Kit
Contents
Fibre Ring Insert Tool CRI Pilot Valve Socket CRI

Fibre Ring Insert Tool CRIN Angle Setting Piece
Valve Seal Extractor 15mm Solenoid Sockets CRI
Valve Seal Extractor 17mm Solenoid Sockets
Pilot Valve Socket CRIN HP Seal Removal Tool
T021-1001 T021-1002
CAT6.6 Denso CR Injector
CR Injector Stripping Jig
Stripping Kit

GENERAL ACCESSORIES
BALL SEAT LAPPING
T021-924
Tool kit for lapping CR injector ball seat
INJECTOR HOLDERS
T021-019 T021-922 T021-925

Injector Holder 13, 15mm Injector Holder 14, 16, 20mm Injector Holder 15, 17, 18, 22mm
Volvo, BMW, Ducato
T021-969 T021-1003
Common Rail Injector Mounting Clamp Denso Injector Mounting Clamp
Universal vice mounted injector clamp
for holding various types of
common rail injectors.

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 FOR A FULL RANGE OF SHIM KITS PLEASE REFER TO OUR
All parts are available separately
NEW SHIM KIT CATALOGUE
T016-850 T021-942 T021-960

Digital Dial Indicator Shim Kit Solenoid Shim Kit Solenoid Diameter/Hole: 23.70
Range: 12.500mm Diameter/Hole: 15.70mm/10.50mm mm/19.00mm
Resolution: 0.001mm Range: 1.20-1.30mm by 0.01mm Range: 0.90-1.00mm by 0.01mm

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.

COMMON RAIL INJECTOR TEST
ADAPTORS
T021-027 T021-918N T021-920 Denso Injector Test Adaptor

Bosch Injector Bosch Injector Bosch Injector T021-934 095000-055* J. Deere
Test Adaptor 29mm Test Adaptor 26.5mm Test Adaptor 32mm T021-935 095000-5480/5050
MAN 464 Cummins Iveco Renault Bus
T021-949 T021-950 Quick Test Connector T021-980

Bosch Injector Bosch Injector T021-970 6.5mm Injector Test Adaptor
Test Adaptor 26mm Test Adaptor 28mm T021-971 9.0mm Cummins/Case
Man Volvo Deutz
T021-994 T031-3050 T031-3051 T031-3053

Delphi smart Injector Test CR Injector Test Clamp Kit for Universal Test Injector Clamp Caterpillar Back-leak Adaptor Kit
Adaptor most test benches, suitable for (A12077)
Bosch, VDO and Denso injectors

ADAPTORS
BACK-LEAK ADAPTORS
T021-972 T021-1004 T021-202A

12 pcs Bosch CRIN Universal Commercial Vehicle Bosch Back-leak Connectors
Test Adaptor Kit Injector Test Kit M003-501
BOSCH BACK-LEAK ADAPTORS
M003-502 T021-205 YDT562

Bosch Back-leak Connectors 1800 Back-leak Pipe for Bosch Piezo Bosch Euro 5 Back-leak Adaptor
0 986 612 922
DELPHI BACK-LEAK ADAPTORS
T021-201 HK1120 M003-503

Delphi Back-leak Connectors Delphi DFI 1.5 Back-leak Adaptor Delphi xc4
YDT275

ADAPTORS
DENSO
T021-945A M003-510 M003-512

Denso Back-leak Connectors Denso Back-leak Connectors 1800 Leak-off clip
SIEMANS
YDT561 M003-505 M003-506

Continental Euro 5 Back-leak Adaptor ‘Y’ Back-leak Adaptor Back-leak Adaptor 1800
M003-507 M003-508
Back-leak Adaptor 450 Back-leak Adaptor 900

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 T014-150 T014-110

1/4 NPT x 1/4 NPT M14 x M14 (Similar to 1 680 712 227) M12 x 1/4NPT (Similar to A079B11)
T014-109 T014-111
M12 x M14 (Similar to 1 680 712 229) M14x1/4NPT

S300-1 ADAPTOR CABLES
MERLIN S300-1 COMMON RAIL TEST SYSTEM

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 S300-1 Common Rail
time. Injector System tester,
one unit for the
It can also be used with manually operated following systems:
injector testers. Supplied complete with
electrical mains cable, connection cable with Bosch, Delphi, Denso
4 adaptor cables to suit Bosch, Denso, Delphi, & Siemens (VDO) Piezo
Piezo and general purpose applications. function.
REFER TO PAGE 38 FRO DETAILS OF ALL MERLIN CR/EUI TEST EQUIPMENT
T031-3402 T021-301 T021-303 T021-304

Adaptor Cable Adaptor Cable Adaptor Cable Adaptor Cable
Delphi DFI 1.5 Euro 5 for S300-1 Delphi for S300-1 Bosch for S300-1 Piezo for S300-1
T021-305 T021-306 T021-307

Adaptor Cable Main Lead for S300-1 Lead for S350
Universal for S300-1 S300-1 S300-1

COMMON RAIL PUMP REPAIR
GENERAL
PUMP VICE
T016-202A T016-202B T016-202C

Swivel Vice Base Swivel Vice Flange Attachment Swivel Vice Flange Attachment
Bosch CP1 Renault 1.5 dCi Delphi
T016-202D YDT358
Swivel Vice Flange Attachment Tray for rollers
Bosch CP3
TAPPET LIFTERS RE-BUSHING TOOL KITS
TAPPET LIFTERS T016-682 T016-683

T016-675 0 986 612 427 Re-Bushing Tool Kit Re-Bushing Tool Kit Bosch CP1
T016-675L Ford 110 Duramax Bosch CP3
Bosch CP3

GENERAL
SOCKETS
T016-626 T016-627 T016-681 T016-684

T40 Torx Socket Renault T40 Torx Screwdriver Renault Torx Socket For Suction Valve High Impact Torx
Bosch CP2 Bosch CP2 Bosch CP3 Socket Set
T016-701 T016-864 T021-988 T021-989

Socket for Inlet Connectors Siemens pump sensor wrench 30mm Socket 28mm Socket
0 986 612 991 Bosch CP3 Siemens Sensor CP1
T021-990 T021-991 T021-993

Socket CP4 Value Socket Camcar Kit T10-T45
Torx Denso HP3/HP4

ASSEMBLY TOOLS
T016-677 T016-678 T016-679

Insert Tool Low Pressure Insert Tool Low Pressure Connection Insert Tool Low Pressure Connection
Connection 0 986 612 200 0 986 612 201 0 986 612 205 Renault
Bosch CP1 Iveco Bosch CP1 Bosch CP1
T016-680 T016-702 T016-703

Shaft Seal Inserter Drive Seal Tool Bearing/Oil-seal Tool Kit
0 986 612 422 Delphi DFP1
Bosch CP1, CP3
T016-709 T016-825 T016-826

DRV Valve Dismantling Mounting Mandrel for Gear Pump Mounting Mandrel for Gear Pump
Tool Bosch CP1-H, CP3, CP4 0 986 611 665 Bosch CP1-H 0 986 611 675 Bosch CP1-H
Use with T016-826 Use with T016-825

GENERAL
ASSEMBLY TOOLS
T016-827 T016-828 T016-829

Assembly Tool for Return Valve Press In Tool 0 986 612 970 Filter Extractor Tool 0 986 613 153
0 986 612 911 Bosch CP1-H Bosch CP1-H Bosch CP1-H
T016-827NG Non-genuine version T016-829NG Non-genuine version
T016-830 T016-831 T016-832

Filter Insert Tool Assembly Tool Assembly Tool
0 986 613 154 0 986 613 169 0 986 613 161
Bosch CP1-H Bosch CP1-H Bosch CP1-H
T016-833
Puller Tool
0 986 613 165
Bosch CP1-H

COMMON RAIL PUMP TEST
ADAPTORS
T016-693 T016-694 T016-695

Fuel Connection Kit Transfer Pressure Adaptor Transfer Pressure Adaptor
Bosch CP1-K Delphi Bosch CP3
T016-697 T016-698 T016-699

Transfer Pressure Adaptor Transfer Pressure Adaptor Transfer Pressure Adaptor
Bosch CP1-H Siemens Denso HP2
T016-708 T016-822 T016-876

Pressure Sensor Adaptor Adaptor - Dummy Regulator Bosch CP4.2 fuel connection adaptor for
Bosch / Siemens Denso HP3 use with M14 high pressure test pipe.
WAS T021-979

TEST COUPLINGS
T011-005 T011-039 T011-040

Drive Coupling 20mm Drive Coupling 25mm Drive Coupling
ADC95-1 1 686 430 026 ADC288
Bosch CP3 Delphi DFP1
T011-041 Tang Drive 8mm Mercedes T011-053 T011-054

T011-042 Tang Drive 9mm Siemens Drive Coupling, splined Mercedes Drive Coupling
T011-043 Tang Drive 10mm Denso, MAN CP3 T011-054A
Transit, Fiat Multijet Threaded Adaptor for T011-054

MOUNTING FLANGES
BOSCH TEST BENCHES
T012-039 T012-040 T012-044

Mounting Flange 68mm Ø Mounting Flange Mounting Flange 50mm Ø
Delphi Bosch CP1-K Bosch CP4
T012-204 T012-301 T012-001

Mounting Flange 50mm Ø Mounting Flange 50mm Ø Merlin Universal Mounting Bracket which
Mercedes Renault 1.5 dCi permits Hartridge and Merlin mounting
Bosch CP3 Delphi flanges to be used on Bosch test benches.
T012-029 T012-015
Universal Mounting for Universal Mounting for Bosch test benches
Bosch test benches 1 688 010 124
1 688 010 129

MOUNTING FLANGES
MERLIN/HARTRIDGE TEST BENCHES
T012-004 T012-302 T012-303

Mounting Plate 50mm Ø Mounting Plate 50mm Ø Mounting Plate 50mm Ø
For CP3 0 445 020 007 Pump Mercedes Tang Drive Delphi Renault 1.5 dCi
T012-305 T012-305-46 T012-306

Mounting Plate 68mm Ø 46mm Ø insert for T012-305 Mounting Plate 50mm Ø
With 50mm Ø insert T012-305-60 Bosch CP4
Universal including Delphi DFP1 60mm Ø insert for T012-305
T012-307 T012-308 T012-309

Mounting Plate 107mm Ø Mounting Plate Siemens Renault/Nissan 1.5 dCi
With 80mm Ø Insert Siemens Lion V6
Bosch

COMMON RAIL ON-ENGINE
INJECTOR PULLERS
T021-035 T021-036 T021-036A T021-038

Injector Extractor Injector Extractor Injector Extractor Injector Extractor
Iveco Tector Mercedes 'A' Mercedes 'A' Alfa 156, Fiat
Twin Version
T021-048 T021-048A T021-917 T021-923

Injector Extractor Bosch Adaptor Injector Puller Injector Extractor Mercedes
Mercedes 'A' & 'E' M27 x 1 For T021-048 Mercedes Sprinter OM611, 612, 613 Etc
T021-929 T021-932
Injector Puller Siemens Injector Removal &
Rotating Tool
0 986 611 481

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.

GENERAL TOOLS
T016-625 T016-704 T016-705

Puller BMW Rail Plug Socket Drive Gear Puller
CP1 Delphi 3 Pin Delphi Kia/Hyundai
T016-801 T016-802 T016-802n

Timing Kit Timing Kit Timing Kit (New Type)
Fiat/Iveco Multijet 1300-1900 Renault 2.2, 2.5 dCi Renault 2.2, 2.5 dCi
T016-803 T016-804 T016-805

Timing Kit Timing Kit Renault, Mounting Tool Ford
Iveco Peugeot, Citroen Duratorq 2.0, 2.2, 2.4

GENERAL TOOLS
T016-806 T016-807 T016-808

Timing/Tool Kit YDT250 Timing Kit YDT201 Engine & Camshaft Timing Kit YDT202 Camshaft Bar
Peugeot/Citroen Suzuki Pins Renault K9 & Engine Pin Ford Lynx
T016-809 T016-815 T021-916

Pump Puller & Stroke Holding Timing Kit YDT381 Cyl Head Reamer Kit
Tool Renault 2.2 dCi Ssangyong For Delphi/Bosch CR Injectors
T026-027 T016-874 T021-975

Kneeling Pad Rail Pressure Sensor Adaptor Universal Rail Pressure Tester
14” X 21” Available separately: Nipple A11783 Designed to diagnose faults on rail pressure sensors
fitted to Bosch, Delphi and Denso CR systems.
14mm nut 45159104 Can be used on the vehicle or test bench.
12mm nut M001-105

TOOL KITS
T026-001 T026-005
Common Rail Injector Common Rail Injector
Extractor Kit Extractor Kit
3 PC Fitted mainly to Mercedes 9PC Length 350mm Includes

C & E class, Sprinter and Chrysler 17 & 27mm adaptors
Grand Cherokee 2.7CRD (00>)
T026-002 T026-006
Common Rail Injector Common Rail Injector
Extractor Kit Extractor Kit
Suitable for Peugeot and Citroen 7 PC For Mercedes 611, 612, 613
2.0 HDI, 110,135 HP with DW 10 etc engines
engine code
T026-003 T026-007
Common Rail Injector Injector Extractor Kit
Extractor Kit
Heavy duty kit for traditional
VW/Audi truck injectors plus Mercedes
injector-pump system
T026-004 T026-008
Injector Extractor Washer Removal Tool
Short length 230mm with 8, 12 & Collet type for removing copper
14mm adaptors washers. Length 350mm.
Inner hole 7mm.

TOOL KITS
T026-009 T026-016
Injector Socket Kit Injector Seat Cutter
4 PC, 1/2” drive. 25, 27, 29 7 PC 15, 17, 19 & 21mm flat &
& 30mm angled reamers
T026-010 T026-017
Glow Plu Removal Kit Injector Seat Cutter
16 piece kit for removing glow 8 PC 15, 17, 19 & 21mm flat
plugs & angled reamers and 58-600
injector cleaner
T026-011 T026-024
Compression Tester Kit Injector Seat Cutter
37 piece kit for diesel engines 6PC

15, 17, 19 & 21mm flat &
angled reamers
T026-013 T026-026
Common Rail Back-leak Kit Washer Removal Tool
6 cylinder kit for checking back 12 pcs universal terminal

leak flow. (With 24 adaptors for release kit
Bosch, Delphi, Denso & Siemens)
T026-014
COMMON RAIL BACKLEAK KIT
24 adaptors only kit for Bosch,

Delphi, Denso & Siemens)

DELPHI KITS
T016-816 T021-200
False Actuator Kit YDT410 Sealed Rail Diagnostic Kit YDT850
Determines electrical or
mechanical pump problem. Checks pump pressure and
identifies faulty injector.
All-makes compatible: Delphi,
Bosch, Denso & Siemens (VDO). All-makes compatible: Delphi,
Reduces time and cost in Bosch, Denso & Siemens (VDO).
identifying problem part. Reduces time and cost in
identifying problem part.
YDT553 YDT 720

Hand-held, easy to use unit Electronic injector test kit
providing immediate analysis of ‘Buzz Box’.
diesel fuel.
Delphi DS350E YDT 566

Convertible PC Diagnostic Kit Delphi Pico Scope
Delphi DS150E Heavy duty kit for traditional

VCI and software only truck injectors plus Mercedes
injector-pump system.
YDT 586 9109-947

All makes back-leak kit. Quick-fits kit.
10 x all makes back leak
connectors/ adapters. 3 x types of 15 x "Quick-Fit" fittings
protection plugs. all makes. 3 x protection caps
Replacement O- Rings. diameter, (8.0 mm, 9.49mm and
10.0 mm) male and female types.

ELECTRICAL CONNECTORS
T031-3210 T031-3211 T031-3212 T031-3213

Connector Connector Connector Bosch Connector Bosch
Siemens/Bosch Siemens/Bosch CP1 CP1H, CP3 & Piezo
T031-3214 T031-3215 T031-3216 9001-845

Connector Connector 2 Pole Super Connector Connector Kit
2 Pole Super Seal -Male Seal -Female Delphi Euro 3 & 4 Delphi Euro 3 & 4
2001
9001-845NG T031-3217 T031-3218 T031-3219

Connector Kit Delphi Euro Connector Kit (9001-886) Boot Denso Connector
3 & 4 2001 Delphi Euro 5 2 way moisture cover Transit
PSA, Ford 2.0L TDCI

EUI INJECTOR REPAIR
SOCKETS
AUDI/VW
T021-062 T021-063 T021-064 T021-074

VW-AUDI A6 Solenoid Socket VW-AUDI A6 Solenoid socket VW-AUDI A6/nozzle nut socket VW-SIEMENS Piezo ring nut
37mm 12 sides 18 teeth socket 30mm
T021-075 T021-076 T021-087 T021-077

VW-SIEMENS Piezo Solenoid VW-SIEMENS Piezo nozzle nut VW nozzle nut socket 20mm VW-SIEMENS Piezo ring nut
Socket 25mm socket 17mm socket 29mm
LAND ROVER VOLVO (DELPHI) VOLVO/ROVER (DELPHI)
T021-053 T021-054 T021-093

L/ROVER Socket (4 PIN) VOLVO 500 socket 39mm VOLVO ROVER, E1 & E3
dia 2 PIN Nozzle nut clamp
No holes/hex

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

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

EUI INJECTOR TEST
MISCELLANEOUS
LAPPING TOOLS
T021-078 T025-001 EXTRA COURSE

T025-002 COURSE
Lapping Kit T025-003 MEDIUM
T025-004 FINE
T025-005 SUPER FINE
Lapping paste for T021-078
ON-ENGINE TOOLS
T021-042 T021-037
Torx Socket VW Lupo EUI for installation in engine Extractor Adaptor for EUI VW Lupo
used with T021-036, page 20

EUI INJECTOR TEST
TEST ADAPTORS
AUDI/VW
T021-052 T021-057 T021-061 T021-072

VW VW VW-SIEMENS PIEZO VW
24x1.0mm
CATERPILLAR/J.DEERE DETROIT
T021-073 T021-090 T021-081 T021-082

VW 25x0.75mm VW Series 2 CATERPILLAR, J.DEERE DETROIT 32x1.5mm
28x1mm
CUMMINS CUMMINS VOLVO
T021-083 T021-084 T021-094

CUMMINS L10-M11 CUMMINS N14 11/8”x18UNF Injector Test Adaptor
30x1.5mm Volvo 4 pin, E3 (34x1mm)

EUI INJECTOR TEST
TEST ADAPTORS
LAND ROVER NISSAN
T021-050 T021-091
LAND ROVER 24x1mm NISSAN 440
31x1mm
IVECO / SCANIA / VOLVO
T021-058 (DELPHI) T021-059 (DELPHI) T021-079

VOLVO 460 EURO SCANIA, VOLVO 420, VOLVO, CURSOR 350
2 / SCANIA 31x1mm CURSOR 430 31x1mm 28x1mm
T021-080 T021-085 T021-086

VOLVO FH12, 420, 460 VOLVO 520CV IVECO STRALIS
28x1mm 34x1mm 36x1mm

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
T016-872 27mm ring insert
T016-873 Ratchet Head 3/8"
T016-873-1/4 Ratchet Head 1/4"
Digital torque wrench units: N-m/lbf-ft/lbf-in/kgf-m

Digital torque screwdriver units: cNm/lbf-in/ozf-in/kgf-cm

COMMON RAIL & EUI
GENERAL EQUIPMENT
T016-848 T016-851 T016-852

40x Magnifier Tweezers for steel ball Digital External Micrometer Range:
0-25mm Resolution: 0.001mm
T021-958 T021-959 T021-974

Vacuum pen for steel ball Insulation Tester For pre-checking CR Bosch CR injector stripping jig
injectors
T021-978 T021-998 T021-975

USB Magnifier Multimeter 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.

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.
One to three minutes is usually adequate

to clean the parts, which it does without
T021-953 T041-502 2 Litre Capacity damaging any of the surfaces.
Common Rail Pump or Injector T041-505 5 Litre Capacity
Components Tray T041-515 15 Litre Capacity All units are supplied complete with
T041-520 20 Litre Capacity stainless steel baskets and lids.
T041-530 30 Litre Capacity
Larger sizes available,
please contact our office for details.
A range of specialist cleaning

agents are available as follows:
T040-001 T026-025 T042-005

Bench Mounted Wash Tank Brush Cleaning powder for aluminium (1 Kg)
T040-001CR T042-006
As above but fitted with a 2 micron filter, Cleaning powder for steel (1 Kg)
ideal for cleaning common rail components.
STEEL TRAYS & HOLDERS FOR USE IN ULTRASONIC CLEANING TANKS
T021-963 T021-981 T016-862

Multi Steel Tray 240 x 170 x 50mm General purpose common rail injector Filter ball for ultrasonic cleaning of
T021-964 holder stand. small common rail parts.
Single Steel Tray 175 x 125 x 50mm

COMMON RAIL & EUI
GENERAL EQUIPMENT
TOOL CABINETS
AVAILABLE IN 5, 6 & 7 DRAWER COMBINATIONS.

MTC-005
MTC-006
MTC-007
MISCELLANEOUS
T026-200 ISO 4113
Fume extraction aspirator for use 25 litre drum of ISO
when testing injectors. calibration fluid S9365.

COMMON RAIL & EUI
TEST EQUIPMENT
Full details of Merlin test

equipment products
can be found in our
Automotive and Marine
Equipment Catalogues,
S4000 Common Rail Injector Tester S8000 Common Rail Injector Tester
available from our office.
A fully automatic common rail injector test A fully automatic 6 cyl common rail injector
bench designed to test Bosch, Denso, Delphi & pump test bench designed to test Bosch,
and Siemens injectors. Denso, Delphi and Siemens injectors.
S300-1 Common Rail System Tester S3000 Common Rail System Test S300-1 Special Build Injector Testers
For testing the following CR injectors: Bosch, Rail Retro-fit Kit Two injector testers, Merlin S400A and Merlin
Delphi, Denso & Siemens (VDO) plus a Piezo The Merlin S3000 common rail retro-fit kit S400-5 are now available with a built-in a
function. can be mounted on various test benches. Merlin S300-1.
MM815-CR Common Rail Pump & S400A-CRC Common Rail Injector Test Merlin MPU 500 EUI/MUI/EUP
Injector (4cyl) Tester Comparator Cambox Kit
(Can also be a 8cyl standard test bench) Can also be used as a conventional injector Suitable for various applications as follows:
tester. Optional cabinet available. Volvo - Scania - Land Rover - Siemens
Audi/VW Piezo - Cummins Celect

Common Rail
& EUI Tools
TD
SL
EM
ST
SY
EL
ES
DI
LIN
ER
M
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
Distributed By:
ILLUSTRATIONS AND TECHNICAL DATA ARE NON-BINDING.

SUBJECT TO CHANGE AS A RESULT OF TECHNOLOGICAL PROGRESS.
DATA No. 785/CR-EUI/0914 - September 2014 - 2,500 Printed in England.

Merlin Common Rail / EUI Tools and Accessories Catalogue

Uploaded by

Copyright:

Available Formats

You might also like

Merlin Common Rail / EUI Tools and Accessories Catalogue

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Merlin Common Rail / EUI Tools and Accessories Catalogue

Uploaded by

Copyright:

Available Formats

• Fuel Pumps

Merlin Common Rail / EUI Tools

COMMON RAIL INJECTORS

Injector Pullers 20-21

COMMON RAIL & EUI

GENERAL EQUIPMENT 33-36

Pilot Valve Sockets Nozzle Adaptors Window Sockets

Torx Sockets T021-927 T016-704A

Note: Available in kit T021-1002 on page 3.

Please contact 01772 694180 or sales@merlindiesel.com for more detailed information 1

T021-947 T021-948 T021-952

T021-965 T021-968 T021-992

T021-946 Valve Seat Extractor T021-930

2 Please contact 01772 694180 or sales@merlindiesel.com for more detailed information

Fibre Ring Insert Tool CRI Pilot Valve Socket CRI

Please contact 01772 694180 or sales@merlindiesel.com for more detailed information 3

BALL SEAT LAPPING

T021-019 T021-922 T021-925

4 Please contact 01772 694180 or sales@merlindiesel.com for more detailed information

ARMATURE STROKE MEASURING KITS

For Stage 3 Repair (Pilot Valve Replacement)

Merlin Kit for Stage 3 Repair (Pilot Valve Replacement) on all

T016-850 T021-942 T021-960

Please contact 01772 694180 or sales@merlindiesel.com for more detailed information 5

MERLIN P350 STAGE 3 PNEUMATIC PRESS

• 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

6 Please contact 01772 694180 or sales@merlindiesel.com for more detailed information

T021-027 T021-918N T021-920 Denso Injector Test Adaptor

T021-949 T021-950 Quick Test Connector T021-980

T021-994 T031-3050 T031-3051 T031-3053

Please contact 01772 694180 or sales@merlindiesel.com for more detailed information 7

T021-972 T021-1004 T021-202A

BOSCH BACK-LEAK ADAPTORS

M003-502 T021-205 YDT562

DELPHI BACK-LEAK ADAPTORS

T021-201 HK1120 M003-503

8 Please contact 01772 694180 or sales@merlindiesel.com for more detailed information

T021-945A M003-510 M003-512

YDT561 M003-505 M003-506

Please contact 01772 694180 or sales@merlindiesel.com for more detailed information 9

INJECTOR HP 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

T014-108 T014-150 T014-110

10 Please contact 01772 694180 or sales@merlindiesel.com for more detailed information

MERLIN S300-1 COMMON RAIL TEST SYSTEM

REFER TO PAGE 38 FRO DETAILS OF ALL MERLIN CR/EUI TEST EQUIPMENT