Delphi Pump Test Plans 4 Web

MERLIN S3000 COMMON RAIL TEST SYSTEM
S3000 Common Rail

Test System
TEST DATA
Pump Designation:-9042A0013A-014A
Type Designation:-0.6CC2
Manufacturer I.D.:- RENAULT
Engine:-
Testing Prerequisites
Inlet Feed Pressure - 0.2 BAR
Test Oil Specification- ISO4113
Test Oil Temperature- 40 deg C
Direction of Rotation - Clockwise
Remove injector pipes from test rail and blank off with T031-3005
Fit In line return temperature sensor to return line.
Fit Bosch type Pressure control valve to test rail (ie 0 281 200 872).
Connect Fuel Pump Cable T031-3001 to PCV in test rail.
Set S3000 Test Unit to PCV
1. LEAK TEST
2. RUNNING IN TEST
To be Carried out whenever rollers and shoes have been disturbed or replaced
Test
Bench Speed - RPM Rail Pressure - BAR Conditions Comments
1 350 250 15 Secs No Unusual noise
2 2000 1000 3 Mins No Leaks and
No abnormal
Temperature rise.
Test
Bench Speed - RPM Rail Pressure - BAR Time - Seconds Max Delta
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. TRANSFER PRESSURE
3. PUMP PERFORMANCE
Fit Bosch type PCV to rail (ie 0281002872) and connect lead T031-3001.
4. SCV TEST
Connect pump lead T031-3001 to fuel pump SCV
Leave Bosch type PCV in rail (ie 0281002872)
Set S3000 test unit to SCV.
5. TEMP SENDER / SCV RESISTANCE CHECKS
Test
Bench Speed - RPM Rail Pressure - BAR Comments T.Pressure
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
Bench Speed - RPM SCV DRV % Comments Delivery
CC/1000
1 1000
80
500-600
2 1000
60 0
3 1000
80
500-600
Test
Bench Speed - RPM Temp Sender
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
N/A 5.0-6.0 20
2
-
N/A 5.5-6.5 40
Test
Bench Speed - RPM Rail Pressure
BAR
Comments Delivery
CC/1000
1 2500 1600 440
2 2000 1600 475-525
3 1000 1200 475-525
4 1000 500 560 10%
5 1000 1000 Max 10% less 450-500
6 50 230 450+
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S3000 Common Rail
Test System
TEST DATA
Pump Designation:-9042A021A-023A
Manufacturer I.D.:- PSA
Engine:- DV4 1.4HDi 90HP
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
500-600
2 1000
60 0
3 1000
80
500-600
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
N/A 5.0-6.0 20
2
-
N/A 5.5-6.5 40
Test
BAR
Comments Delivery
CC/1000
1 2500 1600 440
2 2000 1600 475-525
3 1000 1200 475-525
4 1000 500 560 10%
5 1000 1000 Max 10% less 450-500
6 50 230 450+
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S3000 Common Rail
Test System
TEST DATA
Pump Designation:-9042A041A
Manufacturer I.D.:- RENAULT
Engine:-
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
500-600
2 1000
60 0
3 1000
80
500-600
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
N/A 5.0-6.0 20
2
-
N/A 5.5-6.5 40
Test
BAR
Comments Delivery
CC/1000
1 2500 1600 440
2 2000 1600 475-525
3 1000 1200 475-525
4 1000 500 560 10%
5 1000 1000 Max 10% less 450-500
6 50 230 450+
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S3000 Common Rail
Test System
TEST DATA
Manufacturer I.D.:- KIA/HYUNDAI
Engine:- 2.9L
Fit Transfer pressure adaptor T016-697 in place of Temperature sender and
re-connect temperature sender to T.P.adaptor. Connect test bench pressure gauge.
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
130 BAR 1150-1250
2 1000
60 0
3 1000
80
1150-1250
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
2
-
0.9-1.5 5.5-6.5 40
Test
BAR
Comments Delivery
CC/1000
1 2000 1600 760-840
2 1000 1200
3 1000 500 980 10%
4 1000 1000 Max 10% less >900
5 50 230 >1000
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S3000 Common Rail
Test System
TEST DATA
Engine:- 2.9L
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
130 BAR 1150-1250
2 1000
60 0
3 1000
80
1150-1250
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
2
-
0.9-1.5 5.5-6.5 40
Test
BAR
Comments Delivery
CC/1000
1 2000 1600 760-840
2 1000 1200
3 1000 500 980 10%
4 1000 1000 Max 10% less >900
5 50 230 >1000
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S3000 Common Rail
Test System
TEST DATA
Engine:- 2.9L
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
130 BAR 1150-1250
2 1000
60 0
3 1000
80
1150-1250
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
2
-
0.9-1.5 5.5-6.5 40
Test
BAR
Comments Delivery
CC/1000
1 2000 1600 760-840
2 1000 1200
3 1000 500 980 10%
4 1000 1000 Max 10% less >900
5 50 230 >1000
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S3000 Common Rail
Test System
TEST DATA
Pump Designation:-9044Z013A
Manufacturer I.D.:- FORD LYNX
Engine:- 1.8TDCI
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
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2
-
0.9-1.5 5.5-6.5 40
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S3000 Common Rail
Test System
TEST DATA
Engine:- 1.8TDCI
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
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2
-
0.9-1.5 5.5-6.5 40
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S3000 Common Rail
Test System
TEST DATA
Pump Designation:-9044Z016A/B
Engine:- 1.8TDCI FOCUS 115HP
CONNECT 90HP
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
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2
-
0.9-1.5 5.5-6.5 40
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S3000 Common Rail
Test System
TEST DATA
Engine:- 2.9L TCI 149HP
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
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2
-
0.9-1.5 5.5-6.5 40
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S3000 Common Rail
Test System
TEST DATA
Engine:- 2.9L TCI 149HP
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
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2
-
0.9-1.5 5.5-6.5 40
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S3000 Common Rail
Test System
TEST DATA
Manufacturer I.D.:- FORD
Engine:- LYNX 2.0TDCi 16V
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
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2
-
0.9-1.5 5.5-6.5 40
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S3000 Common Rail
Test System
TEST DATA
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
M
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
M
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2
-
0.9-1.5 5.5-6.5 40
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S3000 Common Rail
Test System
TEST DATA
Engine:- PUMA 2.0TDCi 16V
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
M
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
M
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2
-
0.9-1.5 5.5-6.5 40
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S3000 Common Rail
Test System
TEST DATA
Manufacturer I.D.:- FORD/JAGUAR
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
M
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3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
M
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2
-
0.9-1.5 5.5-6.5 40
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S
Y
S
T
E
M
S

L
T
D
S3000 Common Rail
Test System
TEST DATA
Engine:- PUMA 2.4TDCI
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
2
-
0.9-1.5 5.5-6.5 40
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
S3000 Common Rail
Test System
TEST DATA
Engine:- PUMA 2.0TDCi 16V EURO3
2.2TDCi 150HP EURO4
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
2
-
0.9-1.5 5.5-6.5 40
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
S3000 Common Rail
Test System
TEST DATA
Manufacturer I.D.:- Ford
Engine:- Mondeo 2.0 TDCi 150HP Euro4
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
2
-
0.9-1.5 5.5-6.5 40
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
S3000 Common Rail
Test System
TEST DATA
Manufacturer I.D.:- FORD/JAGUAR
Engine:- PUMA 2.0TDCI EURO 4
130/155HP
1. LEAK TEST
2. RUNNING IN TEST
Test
No abnormal
Temperature rise.
Test
T
1 400 400 60 5
2 800 400 60 5
3 1200 400 60 6
4 2000 800 60 8
5 2000 1200 60 9
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
3. PUMP PERFORMANCE
4. SCV TEST
Test
BAR
1 400 230 4.5-5.5
2 1000 1600 5.8-6.2
3 2000 1600 6.5-7.0
Test
CC/1000
1 1000
80
800-900
2 1000
60 0
3 1000
80
800-900
Test
Resistance K
SCV Resistance
INLET FUEL
TEMP C
1
-
2.5-4.0 5.0-6.0 20
Test
BAR
Comments Delivery
CC/1000
1 2500 1600
2 2000 1600 620-700
3 1000 1200 680-760
4 1000 500 780 10%
5 1000 1000 Max 10% less 700
6 50 230 760+
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D
2
-
0.9-1.5 5.5-6.5 40
M
E
R
L
I
N

D
I
E
S
E
L

S
Y
S
T
E
M
S

L
T
D

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Delphi Pump Test Plans 4 Web

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MERLIN S3000 COMMON RAIL TEST SYSTEM

S3000 Common Rail

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