S5000-1 EUI/EUP

Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 701 005 TEST OIL FEED PRESSURE: 2.0 BAR
TYPE: PDE100S2004 TEST OIL: ISO 4113
O.E.M. REF: SCANIA TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 283 bar SOLENOID RESISTANCE @ 20°C 5-7
EXCHANGE NO. 0 986 441 001/101

ENSURE CORRECT CAM IS FITTED MPU500-13 (13mm Lift)

 Fit Unit Injector to Adaptor kit (MPU500-61). Remove striker pin from Injector. Fit washer
under push rod.
 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER WITH BAR.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

350 005 25 N/A
for Leaks

500 005 030 260-280 Max Torque

Max Power
900 005 038 240-260

MDS16/5/2013 ISSUE1

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 702 010 TEST OIL FEED PRESSURE: 3.0 BAR
TYPE: PDE100/S 3009 TEST OIL: ISO 4113
O.E.M. REF: VOLVO TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 362 bar SOLENOID RESISTANCE @ 20°C 1.6 OHMS
EXCHANGE NO. 0 986 441 006

ENSURE CORRECT CAM IS FITTED MPU500-13 (13mm Lift)

 Fit Nylon washer A12019 over nozzle. Fit Unit Injector to Adaptor kit (MPU500-60).
 Fit Push Rod.
 Fit 2mm &4mm spacer washers on posts.
 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 ENSURE CAMBOX TURNS OVER WITH BAR.
 PURGE THOROUGHLY BEFORE CALIBRATION.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

350 005 25 N/A
for Leaks

400 005 009 Idle Delivery

24-34

500 005 033 274-294 Max Torque

Max Power
800 005 038 250-270

MDS16/10/2013 ISSUE1

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 034/083 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.3/80/360S34 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 288.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 555

 Fit Unit Injector to Adaptor kit (MPU500-62). Note: Remove striker pin from Injector.
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Ensure cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

385 005 011 6-10 Idle Delivery

450 005 016 30-35 Mid Range

750 005 027 49-55 Max Torque

Max Power
900 005 025 35-40

MDS8/3/2013ISSUE1

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 035/085 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.3/80/465S35 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 288.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NUMBER: 0 986 441 501

 Fit Unit Injector to Adaptor kit (MPU500-62).Remove striker pin from Injector.
 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER WITH BAR!

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 012 12-16 Idle Delivery

500 005 017 36-40 Mid Range

700 005 025 58-63 Max Torque

Max Power
900 005 026 42-46

MDS20/03/2013 ISSUE2

MERLIN S5000-1 EUI/EUP TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 036/086 TEST OIL FEED PRESSURE: 3.5 BAR
TYPE: PDE-P1.3/80/350s36 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 288.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 553

 Fit Unit Injector to Adaptor kit (MPU500-62).Note: Remove striker pin from Injector.
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Ensure Cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 16-20 Idle Delivery

39-45
500 005 019 Mid Range

700 005 026 52-60 Max Torque

Max Power
900 005 028 42-50

MDS22/11/2013 ISSUE1

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 037 TEST OIL FEED PRESSURE: 3.5 BAR
TYPE: PDE-P1.3/80/425s37 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 288.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 506/556

 Fit Unit Injector to Adaptor kit (MPU500-62).Note: Remove striker pin from Injector.
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Ensure Cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 012 8.0-12.5 Idle Delivery

35-40
500 005 017 Mid Range

700 005 026 58-64 Max Torque

Max Power
900 005 026 38-43

MDS24/13/2013 ISSUE2

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000 EUI/EUP Test
System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 038/088 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.3/80/465S38 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 288.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 554

 Fit Unit Injector to Adaptor kit (MPU500-62).

 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER WITH BAR

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 011 7.0-11.5 Idle Delivery

500 005 017 36.2-40.5 Mid Range

700 005 024 57.5-63.5 Max Torque

Max Power
900 005 026 44.5-50.5

MDS26/2/2013 ISSUE2

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 039/089 TEST OIL FEED PRESSURE: 3.5 BAR
TYPE: PDE-P1.3/80/550 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 288.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 557

 Fit Unit Injector to Adaptor kit (MPU500-62).Note: Remove striker pin from Injector.
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Ensure Cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 012 12.0-16 Idle Delivery

45-51
500 005 018 Mid Range

700 005 025 68-73 Max Torque

Max Power
900 005 030 67-73

MDS22/11/2013 ISSUE1

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 210/260 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.1/80/520s210 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 2.5L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 292.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 511/561

 Fit Unit Injector to Adaptor kit (MPU500-62). Note: Remove striker pin from Injector.
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Ensure cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 7.0-11.5 Idle Delivery

500 005 019 42-46 Mid Range

700 005 026 62-68 Max Torque

Max Power
900 005 028 49-55

MDS8/3/2013ISSUE2

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000 EUI/EUP Test
System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 215/265 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.1/80/425S215 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 292.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 509/559

 Fit Unit Injector to Adaptor kit (MPU500-62).(Note:Remove striker pin from Injector.)
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER WITH BAR

Pump Beginning
Pulse Width
Speed of Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 10-14 Idle Delivery

500 005 018 34-38 Mid Range

700 005 026 60-66 Max Torque

Max Power
900 005 027 42-48

MDS7/3/2013 ISSUE2

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 216 TEST OIL FEED PRESSURE: 3.5 BAR
TYPE: PDE-P1.1/80/520S216 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 292.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 510/560

 Fit Unit Injector to Adaptor kit (MPU500-62). Note: Remove striker pin from Injector.
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Ensure cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 7.0-11.5 Idle Delivery

500 005 019 38-43 Mid Range

700 005 028 72-78 Max Torque

Max Power
900 005 029 53-58

MDS7/01/2013 ISSUE3

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 221/271 TEST OIL FEED PRESSURE: 3.5 BAR
TYPE: PDE-P1.1/80/400s221 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 292.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 562

 Fit Unit Injector to Adaptor kit (MPU500-62).Note: Remove striker pin from Injector.
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Ensure Cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 9-14 Idle Delivery

32-38
500 005 018 Mid Range

700 005 026 52-59 Max Torque

Max Power
900 005 028 42-50

MDS22/11/2013 ISSUE1

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 222/272 TEST OIL FEED PRESSURE: 3.5 BAR
TYPE: PDE-P1.1/80/520s222 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 292.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 569

 Fit Unit Injector to Adaptor kit (MPU500-62).Note: Remove striker pin from Injector.
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Ensure Cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 7-13 Idle Delivery

40-48
500 005 019 Mid Range

700 005 026 64-72 Max Torque

Max Power
900 005 028 48-56

MDS22/11/2013 ISSUE1

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 228 TEST OIL FEED PRESSURE: 3.5 BAR
TYPE: PDE-P1.1/80/560S228 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 2.5L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 292.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 523/573

 Fit Unit Injector to Adaptor kit (MPU500-62). Remove striker pin from Injector.
 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER WITH BAR

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 9-13 Idle Delivery

500 005 017 32-36 Mid Range

700 005 026 65-72 Max Torque

Max Power
900 005 028 56-62

MDS13/3/2013 ISSUE2

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000 EUI/EUP Test
System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 229 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 292.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 574

 Fit Unit Injector to Adaptor kit (MPU500-62).

 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

420 005 013 10-14 Idle Delivery

500 005 015 18-22 Mid Range

700 005 019 27-33 Max Torque

Max Power
900 005 027 47-54

MDS26/2/2013 ISSUE2

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 230/280 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.1/80/465S230 TEST OIL: ISO 4113
O.E.M. REF: VW/AUDI/SKODA 1.9TDI TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 292.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 525/575

 Fit Unit Injector to Adaptor kit (MPU500-62). Remove striker pin from Injector
 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER WITH BAR.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 11.5-16.5 Idle Delivery

500 005 018 37.5-42.5 Mid Range

700 005 022 43.5-48.5 Max Torque

Max Power
900 005 028 47.5-52.5

MDS08/10/2014 ISSUE1

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000 EUI/EUP Test
System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 232/282 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.1/80/350S232 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 2.0L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 292.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 514/564

 Fit Unit Injector to Adaptor kit (MPU500-62).

 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS WITH BAR

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 6-10 Idle Delivery

500 005 018 26-31 Mid Range

700 005 020 25-30 Max Torque

Max Power
900 005 027 32-37

MDS26/2/2013 ISSUE2

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 309 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.5/75/485S309 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 277.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 578

 Fit Unit Injector to Adaptor kit (MPU500-62). Remove striker pin from Injector
 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER WITH BAR.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

420 005 013 10-14 Idle Delivery

36-43
600 005 018 Mid Range

750 005 026 60-68 Max Torque

Max Power
900 005 028 46-54

MDS19/12/2013 ISSUE1

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 310 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.5/75/380S310 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 277.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 579

 Fit Unit Injector to Adaptor kit (MPU500-62). Remove striker pin from Injector
 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER WITH BAR.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

420 005 013 8-12 Idle Delivery

17-22
600 005 017 Mid Range

750 005 027 45-50 Max Torque

Max Power
900 005 028 42-46

MDS20/3/2013 ISSUE2

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000 EUI/EUP Test
System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 312/362 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.5/75/485s312 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 2.0L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 277.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 517/567

 Fit Unit Injector to Adaptor kit (MPU500-62).Note: Remove striker pin from Injector.
 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe.
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS OVER WITH BAR!

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

420 005 013 7.1-11.5 Idle Delivery

750 005 020 23.5-28.5 Mid Range

750 005 025 43.5-48.5 Max Torque

Max Power
900 005 030 57.5-62.5

MDS26/2/2013 ISSUE2

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 313 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.5/75/350S313 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 277.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 568

 Fit Unit Injector to Adaptor kit (MPU500-62). Note: Remove striker pin from Injector.
 Fit Assembly to Cambox. Tighten grub screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Ensure cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

420 005 014 10-14 Idle Delivery

750 005 021 21-24 Mid Range

750 005 028 42-46 Max Torque

Max Power
900 005 30 40-46

MDS8/3/2013 ISSUE1

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000 EUI/EUP Test
System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 314 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P1.5/75/380S314 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 1.9L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 277.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 527/577

 Fit Unit Injector to Adaptor kit (MPU500-62).

 Fit Assembly to Cambox
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 ENSURE CAMBOX TURNS WITH BAR

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

420 005 013 6.1-10.0 Idle Delivery

750 005 021 23.2-27.5 Mid Range

750 005 028 45.5-50.5 Max Torque

Max Power
900 005 030 46.5-50.5

MDS26/2/2013 ISSUE2

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 720 404 TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: PDE-P2/80/475 s 404 TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 2.0L TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 263.0 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO. 0 986 441 566

 Fit Unit Injector to Adaptor kit (MPU500-63).(Note:Keep striker pin in the Injector.)
 Fit Assembly to Cambox, Tighten Grub screw on plate.
 Fit Inlet/Outlet pipe.
 Attach injector cable.
 Close protective cover.
 Ensure cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

350 005 013 14-18 Idle Delivery

500 005 015 19-25 Mid Range

700 005 023 48-53 Max Torque

Max Power
900 005 030 52-58

MDS28/02/2014 ISSUE2

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: 0 414 755 008 TEST OIL FEED PRESSURE: 2.5 BAR
TYPE: PLD1B100/520/245160 TEST OIL: ISO 4113
O.E.M. REF: DAF TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: SOLENOID RESISTANCE @ 20°C 0.7 Ohms
EXCHANGE NO: 0 986 445 013

ENSURE CORRECT CAM IS FITTED MPU500-16 (16mm Lift)

 Fit MPU500-70 To Cambox. Fit Unit Pump to Adaptor kit with M10 Bolts.
 Remove middle O ring of Unit Pump.
 Fit 2.5 Bar overflow valve.
 Fit Inlet pipe.
 Connect Bosch orifice plate Injector (1 688 901 103) 209Bar
 Fit Injector pipe. (6x1.6x450) T014-085.
 Attach injector cable.
 ENSURE CAMBOX TURNS OVER WITH BAR.
 PURGE THOROUGHLY BEFORE CALIBRATION.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

350 005 20
for Leaks

350 005 008 Idle Delivery

45-55

500 005 020 220-240 Max Torque

Max Power
800 005 025 220-240

MDS27/03/2014 ISSUE1

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA
TEST CONDITIONS
PART No: 03G130073S
TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: SIEMENS/CONTINENTAL
TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 2.0L (140BHP)
TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 150.0 BAR
CAPACITANCE:
EXCHANGE NO.
INSULATION: 1 MEGA OHM

Warning: It is essential Carry out Insulation test and Capacitance test before
connecting Injector, Failure to do so could result in damage to electronics!

 Fit Unit Injector to Adaptor kit (MPU500-63).(Note:Keep striker pin in the Injector.)
 Fit Siemens push rod (B11968).
 Fit O ring (9700213).
 Fit Assembly to Cambox, Tighten Grub screw on plate.
 Fit Inlet/Outlet pipe.
 Attach injector cable.
 Close protective cover.
 Ensure cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 002 20 N/A
for Leaks

350 002 005 7-11 Idle Delivery

500 002 008 20-25 Mid Range

700 002 016 49-55 Max Torque

Max Power
700 002 018 58-62

MDS1-7-2014 ISSUE4

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA
TEST CONDITIONS
PART No: 03G130073T
TEST OIL FEED PRESSURE: 4.0 BAR
TYPE: SIEMENS/CONTINENTAL
TEST OIL: ISO 4113
O.E.M. REF: VOLKSWAGON 2.0L (170BHP)
TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 120.0 BAR
CAPACITANCE:
EXCHANGE NO.
INSULATION: 1 MEGA OHM

Warning: It is essential Carry out Insulation test and Capacitance test before
connecting Injector, Failure to do so could result in damage to electronics!

 Fit Unit Injector to Adaptor kit (MPU500-63).(Note:Keep striker pin in the Injector).
 Fit Siemens push rod (B11968).
 Fit o ring (9700213).
 Fit Assembly to Cambox, Tighten Grub screw on plate.
 Fit Inlet/Outlet pipe.
 Attach injector cable.
 Close protective cover.
 Ensure cambox turns over with bar.

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 002 20 N/A
for Leaks

350 002 008 12-16 Idle Delivery

500 002 010 21-26 Mid Range

700 002 016 45-50 Max Torque

Max Power
700 002 020 54-60

MDS 1/7/2014 ISSUE3

MERLIN S5000 EUI/EUP

TEST SYSTEM
 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: BEBE2A00101 TEST OIL FEED PRESSURE: 3.5 BAR
TYPE: TD5 TEST OIL: ISO 4113
O.E.M. REF: LAND ROVER TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 265 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO.

 Fit Unit Injector to Adaptor kit (MPU500-64 ). Fit O ring over nozzle. (1 460 210 008)
 Fit Packing shims 2mm
 Fit Assembly to Cambox. Tighten hex head screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Crank over manually with tommy bar

Pump Beginig Of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

500 005 010 12-16 Idle Delivery

45-51
750 005 022 Max Torque

76-82 Max Power

1000 005 031

MDS 9/1/2015 ISSUE1

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: BEBE2A01001 TEST OIL FEED PRESSURE: 3.5 BAR
TYPE: TD5 TEST OIL: ISO 4113
O.E.M. REF: LAND ROVER TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 265 BAR SOLENOID RESISTANCE @ 20°C 2-4
EXCHANGE NO.

 Fit Unit Injector to Adaptor kit (MPU500-64 ). Fit O ring over nozzle. (1 460 210 008)
 Fit Packing shims 2mm
 Fit Assembly to Cambox. Tighten hex head screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Crank over manually with tommy bar

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 005 20 N/A
for Leaks

500 005 010 9-13 Idle Delivery

750 005 022 40-45 Max Torque

Max Power
1000 005 031 63-69

MDS19/12/2012 ISSUE1

MERLIN S3000 COMMON RAIL TEST SYSTEM

 S5000-1 EUI/EUP
Test System

TEST DATA

INJECTOR DATA TEST CONDITIONS

PART No: BEBE4C00101/BEBE4C01101 TEST OIL FEED PRESSURE: 1.5 BAR
TYPE: Delphi E1 TEST OIL: ISO 4113
O.E.M. REF: VOLVO D12 20430583/ 20440388 TEST OIL TEMP: 40°C
NOZZLE OPENING PRESSURE: 342 BAR SOLENOID RESISTANCE @ 20°C 3.5-5.1 
EXCHANGE NO.

Note: Purge system before taking measurements.

 Fit Unit Injector to Adaptor kit (MPU500-58). Fit nylon washer over nozzle. (A12019)
 Fit Packing shims 2mm
 Fit Assembly to Cambox. Tighten hex head screw on plate.
 Fit Inlet/Outlet pipe
 Attach injector cable.
 Close protective cover.
 Crank over manually with tommy bar.

Note: To Remove Nozzle Cap nut use tool TO21-093 available from Merlin

Pump Beginning of
Pulse Width
Speed Injection Delivery Comments
(PW)
(RPM) (BOI) cc/1000

Purge System & Check

250 000 20 N/A
for Leaks

500 000 010 37-43 Idle Delivery

500 000 20 130-150 Mid Range

500 000 30 225-245 Max Torque

Max Power
800 005 038 230-250

MDS19-03-2014 ISSUE1

www.merlindiesel.com [email protected]

MERLIN S3000 COMMON RAIL TEST SYSTEM