DATE : VERSION NR :

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1 DATE : VERSION NR : B

2 Table of contents General instructions 2 Introduction 3 Overview VSI system 4 Approval numbers VSI components 4 The ucer 5 The injector rail 6 The filter unit 7 The VSI computer 7 Instructions rotating the VSI injector rail 8 Hose connections 9 Diagram VSI inlet manifold coupling 0 Diagram 2 VSI inlet manifold coupling with nylon hose Diagram 3 Parallel water connection 2 Diagram 4 Serial water connection 3 The fuel switch 4 Electrical connections on the LPG reservoir 5 Electrical connections VSI wiring harness 6 Electrical connections VSI wiring harness 7 Electrical connections RPM module 09/ Electrical connections Petrol Pressure Simulator 09/ Electrical connections Dual Sensor Interface (DSI) 20 Diagram Base Layout VSI 2 Diagram 2 Base Electrical diagram 22 Diagram 3 Injection module 4cylinder (connector) 23 Diagram 4 Injection module 4cylinder (solder ) 24 Diagram 5 Injection module 6cylinder (connector) 25 Diagram 6 Injection module 6cylinder (solder) 26 Diagram 7 Injection module 8cylinder (connector) 27 Diagram 8 Injection module 8cylinder (solder) 28 Diagram 9 Repair module 48 cylinder 29 Diagram 0 Replacing the injection module 30 Diagram Circuit diagram 4cylinder (connector) 3 Diagram 2 Circuit diagram 4cylinder (solder) 32 Diagram 3 Circuit diagram 6cylinder (connector) 33 Diagram 4 Circuit diagram 6cylinder (solder) 34 Diagram 5 Circuit diagram 8cylinder (connector) 35 Diagram 6 Circuit diagram 8cylinder (solder) 36 Trouble code chart 37 Maintenance instructions 38 Checklist after installation 39

3 General instructions Tools needed for installing the vsi system : PC or laptop VSI serial interface cable VSI Diagnose software EOBD diagnosis equipment Multimeter / Scope Soldering iron / solder / shink sleeves / insulation tape Tubeflaring tool Drilling machine, drill bit set Threading device M6x / M8x / M0x Workshop tools Exhaustemission tester Gas leak detection device Always disconnect the battery when installing the LPG system. Do not place the 7,5 A fuse into the fuse holder before having completed the installation of the VSI system. The VSI computer has to be activated by means of the diagnosis software. In the unlikely event the VSI computer fails, it will automatically switch over to petrol. Never disconnect the VSI computer connector, unless you have removed the 7,5 A fuse. When installing the VSI wiring harness, ensure that it does not run near any of the ignition components. The power supply wire and the ground wire of the VSI system are always to be connected at the battery. The watertight ECM housing is made of aluminium; this material is chosen for its excellent heat dissipation qualities, necessary to cool the injector drivers. Always fix the computer in the coolest place in the engine compartment. Solder and insulate all electrical connections. The wires in the loom are provided with numbers and text. The text on the wire explains the function of the wire. The wire loom is not model specific, therefore is it may be necessary to adjust the length of the wires. Ensure maximum care is taken when connecting wiring. Make professional joints using solder and shrink sleeve. Do not stretch the wiring harness. No component of the LPGsystem shall be located within 00 mm of the exhaust or similar heat source, unless such components are adequately shielded against heat. Remove any internal burrs, after having shortened the LPG hose. (This guarantees the maximum flow through the hose without pollution.) If holes have to be drilled (wear safety glases) in order to facilitate mounting the device frame, the reservoir frame, the LPG cutoff valve, etc., the drilled holes must always be treated with an anticorrosive, after the burrs have been removed ( especcialy when mounting a exterrior filler ). After having completed the installation, check the whole system for gas leakage; use a gas leak detection device. Mount the VSIsystem according to the local LPG regulations (this manual is based on the dutch regulations) the installer is responsible for that. Fitting and maintenance is only allowed by Prins Autogassystemen selected LPG engineers. Prins Autogassystemen is not responsible for any damages to people or objects as a result of changes to Prins products. Check our website regularly for updates, infobulletins and product information. For installing a dedicated VSIsystem download DEDICATED MANUAL ( part 2/2 ) Please fill in the warranty card completely and return it within 8 days after installation. Page 2

4 Introduction VSI stands for vapour sequential injection, it points directly to the most important properties of the system. This secondgeneration gas injection system is based on a vapour LPG injection that is injected sequentially in the engine. Sequential means that the LPG injectors will inject the LPG in the sequence equal to the injection sequence of the petrol injectors, This sequence in most applications is equal to the firing order of the ignition sequence of the engine, for example with a 4cylinder engine this is normally 342. Sequential injection means that the amount of injected fuel per cylinder the can be mete and timed individually. This achieves a much higher level of performance emission and drivability. The VSI system was designed and developed inhouse by Prins Autogassystemen B.V. VSI characterizes itself with a high level of integration into to the petrol management system. The two systems integrate as masterslave system. This means that the original petrol management ECM controls the amount of LPG injected via the LPG injectors into the engine. The VSI ECM only translates the relevant signals coming from the engine management system necessary for MASTER /SLAVE strategy. Following this strategy the petrol management system is the MASTER and the VSI ECM the SLAVE. The advantage of this strategy: while driving on LPG the lambda control and OBD functions keep within the OE parameters, functioning correctly and controlled by the petrol management system. So when operating on LPG it is not necessary to generate simulated signals. There is one exception made for the petrol injector signals, while driving on LPG the petrol injector s are switched off to discontinue the petrol supply. To maintain the injection control signals it is necessary to simulate the petrol injectors to ensure the original ECM does not detect a fault code. Secondly when operating on LPG it is necesarry to maintain a petrol injector control signal to measure the requi fuel demand. The second generation injection system VSI has the ability to inject sequentially making it quicker and more accurate, large benefits can be gained in engine and emission performance. Page 3

5 Overview VSI system Approval numbers VSI components Mark Component LPG CNG Prins VSI Reducer E467R00054 Valtec 6 / 8mm lockoff valve E467R0004 Prins VSI Injector rail E467R00093 E40R00002 Keihin VSI Injector E467R00092 E40R Prins Filter unit E467R00096 E40R Prins ECU E467R00098 E40R Electrical VSI components EMC : E40R Page 4

6 The ucer Mount the ucer to the body of the vehicle in the engine compartment, never on the engine! Mount the ucer so that it is easy to adjust the pressure. Install the supplied 8 mm threaded end in the back cover of the ucer. Mount the ucer as shown in the drawing. Mount the ucer on a bracket and bolt on with a M8x nut. The LPG lockoff valve can be installed in different possisions. Do not dammage the Orings when rotating the lockoff valve. Connect the water connections of the ucer to the interior heating system of the vehicle. Overpressure relief hose : connect with a Tpiece into a vacuum hose connected to the intake manifold. No component of the LPGsystem shall be located within 00 mm of the exhaust or similar heat source, unless such components are adequately shielded against heat. Seal the adjusting screw in the front cover of the ucer after adjusting the pressure. mounting possitions Standard ucer, 6 mm LPG pipe, used for engines with a HP up to 35 kw ( 80 HP ). High Output ucer, 8 mm LPG pipe, used for engines with a HP over 35 kw ( 80 HP ). Use a High Output MAP ucer on blown engines ( turbo / compresssor ) Page 5

7 The injector rail Mount the VSI injector rail as close as possible to the VSI inlet manifold couplings. See instruction how to convert a right rail into a left injector rail. Never mount the VSI injector rail with the LPG outlets facing up. Mounting angle VSI injector rail : mounting angle VSI 4cylinder injector rail 3cylinder rail : 4cylinder rail : 80/30300 = green 32cc 80/30400 = green 32cc 80/3030 = white 42cc 80/3040 = white 42cc 80/30320 = blue 52cc 80/30420 = blue 52cc 80/30330 = orange 63cc 80/30430 = orange 63cc 80/30340 = yellow 73cc 80/30440 = yellow 73cc Guideline VSI injector choise : devide total engine power in Kw up into the amount of cylinders. Injector size Minimum Maximum VSI injector Range in Kw White 42cc 8,5 5 VSI injector Range in Kw Blue 52cc 3,75 2,5 VSI injector Range in Kw Orange 63cc 6,5 27,5 VSI injector Range in Kw Yellow 73cc 20,75 32,5 Page 6

8 The filter unit Mount the filter unit as close as possible to the VSI injector rail. Mount the filter unit so that it is easy to change the filter unit. Use the special round bracket for mounting the filter unit. Check the sensor type : 4 bar = Bosch serial nr. ending with bar = Bosch serial nr. ending with 456 Check the software parameter Press_type[8] to set up the corresponding sensor. Setting 3 for 4 bar reading. Setting 2 for 3.5 bar reading. ( also see Infobulletin 97 ) 345 cylinder engine 68 cylinder engine The VSI computer Mount the computer in the engine compartment. Never install the computer with the connector facing down. Always fix the computer in the coolest area in the engine compartment. Page 7

9 Instructions rotating the VSI injector rail This is a instruction how to convert a right rail into a left injector rail Tools : Ring spanner size 3 mm Torque spanner ( 03 Nm ) Disassambly / assembly :. Unscrew both M8 (4) nuts. 2. Remove the strip (2). 3. Remove the injectors (0) with a rotating movement out of the fuel rail (). 4. Mount the injectors (0) with a rotating movement into the fuel rail (). 5. Mount the strip (2) on the injectors (0). 6. Tighten the strip (2) with two M8 nuts (4). Tightening moment 2.5 Nm. Page 8

10 Hose connections Try to keep the inlet manifold hoses as short as possible. Cut the hoses on length. Use a hose clamp on all the LPG hose connections. Please observe that there is no damage or fouling to the hoses. Page 9

11 VSI injector VSI inlet manifold coupling Hose clamp petrol injector LPG hose inlet manifold exhaust manifold Hose clamp Coupling Lambda sensor Diagram VSI inlet manifold coupling Page 0

12 VSI injector VSI inlet manifold coupling with nylon hose Hose clamp petrol injector LPG hose Hose clamp inlet manifold exhaust manifold Nylon hose Nut Barrel Coupling oxygen sensor Diagram 2 VSI inlet manifold coupling with nylon hose Page

13 injector rail Psys Tlpg sensor filter unit VSI injector petrol injector cylinder overpressure hose vsi coupling inlet manifold ucer lockoff valve exhaust throttle body LPG fuel line Tank in heater valve interior heater with valve oxygen sensor engine coolant Tpiece out Diagram 3 Parallel water connection Page 2

14 injector rail Psys Tlpg sensor filter unit VSI injector petrol injector cylinder overpressure hose vsi coupling inlet manifold ucer lockoff valve exhaust throttle body LPG fuel line Tank in interior heater without valve oxygen sensor engine coolant out Diagram 4 Serial water connection Page 3

15 The fuel switch Mount the switch on a vissible and approachable place for the driver. When mounting the switch, only push on its sides. Pushing the switch in the centre may result in damage to the switch. ELECTRICAL CONNECTION OF THE SWITCH with loose beeper VSI SWITCH partnr. 080/70060 Hall partnr. 080/ Ohm partnr. 080/ Volt POWER FEEDS (5) ARE EXCHANGABLE. 8POLE CONNECTORS BLUE POSITION ON CONNECTOR TANK INDICATOR BEEPER BROWN POSITION 2 ON CONNECTOR YELLOWGREEN POSITION 3 ON CONNECTOR RED POSITION 4 ON CONNECTOR YELLOW POSITION 5 ON CONNECTOR ORANGE POSITION 6 ON CONNECTOR BLACK POSITION 7 ON CONNECTOR RED POSITION 8 ON CONNECTOR GROUND POWER FEED TANKINDICATION POWER FEED SWITCH PULSE FUEL SWITCH DIAGNOSTIC LED GROUND BEEPER POWER FEED BEEPER ELECTRICAL CONNECTION OF THE SWITCH with internal beeper VSI SWITCH WITH INTERNAL BEEPER partnr. 080/70058 POWER FEEDS (5) ARE EXCHANGABLE. 8POLE CONNECTORS BLUE POSITION ON CONNECTOR BROWN POSITION 2 ON CONNECTOR YELLOWGREEN POSITION 3 ON CONNECTOR RED POSITION 4 ON CONNECTOR YELLOW POSITION 5 ON CONNECTOR ORANGE POSITION 6 ON CONNECTOR BLACK POSITION 7 ON CONNECTOR NOT USED TANK INDICATOR GROUND POWER FEED TANKINDICATION POWER FEED SWITCH PULSE FUEL SWITCH DIAGNOSTIC LED GROUND BEEPER POWER FEED BEEPER The new VSI switch with internal beepers is programmable for different types of tank indicators. Standard setting of the switch is 095 Ohm. For reprogramming the switch:. Make sure that the ignition switch is turned off. 2. Place the VSI main fuse. 3. Push the switch for 5 seconds until a signal sounds (beep). 4. Make a choise immediately: push x for 095 Ohm tank indicator push 2 x for Hall tank indicator ( push 3 x preparation VSI2, not used ) 5. The VSI switch will confirm the choise with a beep signal ( or 2 signals ) To change the choise of indicator: remove the VSI main fuse and start with step. Page 4

16 Electrical connections on the LPG reservoir The wire harness contains the wires for connecting the LPG reservoir. Refer to the following diagram when connecting the LPG reservoir. TRIPLE WIRE CABLE VSI COMPUTER FITTING BOX COIL TANK VALVE BLACK RED PRINS BLACK BLUE GROUND SIGNAL TANKINDICATOR RED BLACK BLUE BLACK BLUE SOLDER THE CONNECTIONS IN THE FITTING BOX AND PROTECT THEM WITH A SHRINK SLEEVE. Page 5

17 Electrical connections VSI wiring harness Check and measure the wiring in case of changes in the cars wiring colors. Wire number / code Wire color Connection 50 MAIN GND Connect to the ' ' of the battery; use a ring terminal for this purpose V BAT Connect to the '' of the battery; use a ring terminal for this purpose or solder. Do not place the 7,5 A into the fuse holder before having completed the installation of the LPG system. 50 LPGVLV GND Ground LPG shutoff 2pole connector shutoff valve. 53 LPG VLV yellow / green valve. Power supply LPG 42 ECT GND shutoff valve. Ground ECT sensor. 2pole black connector temperature sensor in the evaporator. 43 ECT ECT measurement. 22 RS232 TxD 4pole black connector diagnosis wire connection. 23 RS232 RxD 50 DIAGNOSE GND 5 2V DIAG 5 T LPG 4pole black connector filter unit connection. 7 Psys pale green 8 5V Psys 42 Psys GND 33 33G INJ OUT White / yellow Connector VSIinjector to cylinder G INJ A PLUS 32 32G INJ OUT 2 Green / yellow Connector VSIinjector to cylinder G INJ A PLUS 3 3G INJ OUT 3 Pink / yellow Connector VSIinjector to cylinder G INJ A PLUS 30 30G INJ OUT 4 Blue / yellow Connector VSIinjector to cylinder G INJ A PLUS 5 5G INJ OUT 5 Grey / yellow Connector VSIinjector to cylinder G INJ A PLUS 4 4G INJ OUT 6 Brown / yellow Connector VSIinjector to cylinder G INJ A PLUS 3 3G INJ OUT 7 Lightblue / Connector VSIinjector to cylinder G INJ A PLUS yellow 2 2G INJ OUT8 Red / yellow Connector VSIinjector to cylinder G INJ A PLUS 44 TPS green For measuring the throttle valve position. Wire not used in this car: insulate. 6 MAP 8 5V MAP 42 MAP GND blue For measuring the inlet manifold pressure (MAP). Wires not used in this car: insulate. Page 6

18 Electrical connections VSI wiring harness Check and measure the wiring in case of changes in the cars wiring colors. 3 IGNITION Greywhite Make a connection to ignition / contact. Make sure that the voltage will not fail during starting the engine. 46 LAMBDA L Orange For the measurement of the lambda signal of cylinder bank. Connect the wire parallel to the lambda sensor signal wire. 45 LAMBDA 2R Orangewhite For the measurement of the lambda signal of cylinder bank 2. Connect the wire parallel to the lambda sensor signal wire. 40 RPM Purplewhite For measuring the engine speed. Connect to a Hallsensor or camshaft sensor, Make sure that the squa signal is not higher then 30 Volt! Never connect to the ignition coil (only with a RPM module)! Injector measure wire ( injection module ) Bicolor / Full color For measuring / interrupting the petrol injectors : Interrupt each petrol injector control wire ( injector min ) Each VSI wire has a cylinder number printed on the wire, connect this wire to the corresponding petrol injector. Connect the bicolo VSI measuring wire to the ecu side, ( wire code: ECU SIDE ). Connect the accompanying full colo VSI wire to the petrol injector side ( wire code: MIN INJ SIDE ). See diagrams in Installation Manual General part / 2. Attention: Each bicolo measuring wire corresponds to a specific LPG injector and cylinder number. Do not interchange the wires. Injection module => VSIecm => VSI injector rail Whiteyellow vsi nr. 39 ( petrol injector cyl. ) =>VSIecm=> Whiteyellow vsi nr.33 ( vsi injector cyl. ) Greenyellow vsi nr. 38 ( petrol injector cyl.2 ) =>VSIecm=> Greenyellow vsi nr.32 ( vsi injector cyl.2 ) Pinkyellow vsi nr. 37 ( petrol injector cyl.3 ) =>VSIecm=> Pinkyellow vsi nr.3 ( vsi injector cyl.3 ) Blueyellow vsi nr. 36 ( petrol injector cyl.4 ) =>VSIecm=> Blueyellow vsi nr.30 ( vsi injector cyl.4 ) Greyyellow vsi nr. ( petrol injector cyl.5 ) =>VSIecm=> Greyyellow vsi nr.05 ( vsi injector cyl.5 ) Bruinyellow vsi nr. 0 ( petrol injector cyl.6 ) =>VSIecm=> Brownyellow vsi nr.04 ( vsi injector cyl.6 ) Light blueyellow vsi nr. 09 ( petrol injector cyl.7 ) =>VSIecm=> Light blueyellow vsi nr.03 ( vsi injector cyl.7 ) Redyellow vsi nr. 08 ( petrol injector cyl.8 ) =>VSIecm=> Redyellow vsi nr.02 ( vsi injector cyl.8 ) Page 7

19 Electrical connections RPM module 09/0236 RPM module rpm 40 ground 50 ignition 3 solder VSI computer ignition battery ignition coil Connect the wire of the RPM module to the wire nr.50 of the VSI wiring loom. Connect the purplewhite wire of the RPM module to the purplewhite wire nr.40 of the VSI wiring loom. Connect the white wire of the RPM module to the white wire nr.3 of the VSI wiring loom. Connect the puple wire of the RPM module to the ignition coil driver wire. Page 8

20 Electrical connections Petrol Pressure Simulator 09/0252 Engines equipped with a return less fuel system. These engines can generate trouble codes and/or have difficulties with the fuel trims(mixture) on both petrol and lpg. Petrol Pressure Simulator 09/ BROWN BLUEWHITE BLUE REDWHITE GREYBLACK 2 Volt Contact VSI wire 3 Sim Low=On VSI wire 26 Ground Battery VSI wire 50 VSI Petrol Pressure signal sensor side Petrol Pressure signal ECU side PETROL PRESSURE SENSOR 05 Volt Interrupt the petrol pressure signal wire PETROL ECU Brands: Mainly brands who are connected with Ford technologies like: * Ford models from 2003/2004 * Jaguar models from 2003/2004 * Some Volvo models from 2003 Connections and Setup Connect the PPS module according the shown schematic. Measure the voltage, on petrol, for the blue wire (pressure sensor signal wire) when the engine is idling. Or read the actual petrol pressure when you have the disposal of a scan tool which can read the actual petrol system pressure. Next we have to setup the same Voltage (pressure) when running on LPG via de pot meter. The pot meter is accessible when you remove the small protection cover of the module. Page 9

21 Electrical connections Dual Sensor Interface (DSI) Dual Sensor Interface 080/70066 Hall level indicator 080/70065 PRINS BLACK BLUE GROUND SIGNAL PRINS BLACK BLUE GROUND SIGNAL Tank lock off valve DSI connection: Connect the interface wiring according to drawing, all blue and black wires are exchangeble since they are internally connected. The DSI makes it possible to connect two level sensors to one lpg switch. The DSI will always show the highest lpg level on the witch. Page 20

22 PRINS Base Layout VSI rev.b ELECTRICAL CONNECTIONS LPG TANK ENGINE ECU LOCK OFF VALVE FUEL LEVEL INDICATOR Psys Tlpg SENSOR INJECTION MODULE FILTER UNIT E467R00096 E40R Partnr 80/800** min injector VSI injector Rail E467R00093 E40R00002 Partnr 80/3****/* PETROL INJECTOR VSI injector E467R00092 INJECTOR RAIL VSI LAMBDA SENSOR WvM LPG TANK R Cil. R Donut R Twin PRESSURE RELIEF HOSE LOCK OFF VALVE E467R0004 Partnr 08/3007 Partnr 08/304 EVAPORATOR E467R00054 Partnr 08/000 Partnr 08/0003 ENGINE ECU FILLER HOSE R ECT SENSOR engine ecu MAIN FUSE BLEEDER 7,5 Amp 5 Amp VSI FILLER R E467R00098 Partnr 080/7000 vsi 4 Partnr 080/70003 vsi 8 IGNITION RPM FUSE LPG INJECTORS BATTERY SWITCH PERSONAL COMPUTER VSI COMPUTER Diagram Base Layout VSI Page 8

23 BLACK GROUND BLUE SIGNAL ENGINE ECU Base Electrical Diagram VSI rev.b INJECTOR RAILS VSI LAMBDA SONDE BANK LAMBDA SONDE BANK 2 INJECTOR SIMULATOR INJECTOR SIMULATOR RPM EVAPORATOR LPG VALVE IGNITION Not used 3 PETROL INJECTORS 2468 Not used Not used cylinder 8 cylinder 6 cylinder 4 cylinder 2 cylinder 7 cylinder 5 cylinder 3 cylinder PETROL INJECTORS 357 ECT SENSOR 8 Not used Amp (58) 5 Amp (4) 7,5 Amp DIAGNOSE CONNECTOR DIAGNOSE CONNECTOR COVER VSI SERIAL INTERFACE CABLE FUSES LPG INJECTORS FILTER UNIT PRINS 2 0 VSI COMPUTER SWITCH CONNECTIONS LPG TANK BATTERY PERSONAL COMPUTER Diagram 2 Base Electrical diagram Page 22

24 4CYLINDER CONNECTOR INJECTION MODULE VSI REV.B blueyellow 36 ecu side 4 blue min inj side 4 injection module 4 cylinder 80/70024 pinkyellow 37 ecu side 3 pink min inj side 3 greenyellow 38 ecu side 2 green min inj side 2 whiteyellow 39 ecu side 26 SIMU LOW=ON 50 MAIN GROUND 39 ecu side 38 ecu side 2 36 ecu side 4 37 ecu side 3 white min inj side PETROL INJECTORS VSI4 computer Make sure that the polarity of the petrol injectors and the VSI connectors are simular! Diagram 3 Injection module 4cylinder (connector) Page 23

25 4CYLINDER SOLDER INJECTION MODULE VSI REV.B blueyellow 36 ecu side 4 blue min inj side 4 injection module 4 cylinder 80/70024 pinkyellow 37 ecu side 3 pink min inj side 3 greenyellow 38 ecu side 2 green min inj side 2 whiteyellow 39 ecu side 26 SIMU LOW=ON 50 MAIN GROUND 39 ecu side 38 ecu side 2 36 ecu side 4 37 ecu side 3 white min inj side VSI4 computer PETROL INJECTORS Diagram 4 Injection module 4cylinder (solder ) Page 24

26 6CYLINDER CONNECTOR INJECTION MODULE VSI REV.B yellow 0 ecu side 6 min inj side 6 yellow ecu side 5 min inj side 5 injection module 6 cylinder 80/70026 blueyellow 36 ecu side 4 blue min inj side 4 pinkyellow 37 ecu side 3 pink min inj side 3 greenyellow 38 ecu side 2 green min inj side 2 whiteyellow 39 ecu side 26 SIMU LOW=ON 50 MAIN GROUND 39 ecu side 38 ecu side 2 36 ecu side 4 37 ecu side 3 0 ecu side 6 ecu side 5 white min inj side PETROL INJECTORS VSI8 computer Make sure that the polarity of the petrol injectors and the VSI connectors are simular! Diagram 5 Injection module 6cylinder (connector) Page 25

27 6CYLINDER SOLDER INJECTION MODULE VSI REV.B yellow 0 ecu side 6 min inj side 6 yellow ecu side 5 injection module 6 cylinder 80/70026 min inj side 5 blueyellow 36 ecu side 4 blue min inj side 4 pinkyellow 37 ecu side 3 pink min inj side 3 greenyellow 38 ecu side 2 green min inj side 2 26 SIMU LOW=ON 50 MAIN GROUND 39 ecu side 38 ecu side 2 37 ecu side 3 36 ecu side 4 ecu side 5 0 ecu side 6 whiteyellow 39 ecu side white min inj side VSI8 computer PETROL INJECTORS Diagram 6 Injection module 6cylinder (solder) Page 26

28 8CYLINDER CONNECTOR INJECTION MODULE VSI REV.B PETROL INJECTORS white min inj side whiteyellow 39 ecu side 8 cylinder injection module 80/70024 pink min inj side 3 pinkyellow 37 ecu side 3 min inj side 5 26 SIMU LOW=ON 50 MAIN GROUND 39 ecu side 37 ecu side 3 ecu side 5 9 ecu side 7 yellow ecu side 5 light blue min inj side 7 light blueyellow 9 ecu side 7 VSI8 computer yellow 8 ecu side 8 26 SIMU LOW=ON 50 MAIN GROUND 38 ecu side 2 36 ecu side 4 0 ecu side 6 8 ecu side 8 yellow 0 ecu side 6 min inj side 8 min inj side 6 blueyellow 36 ecu side 4 8 cylinder injection module 80/70024 blue min inj side 4 greenyellow 38 ecu side 2 green min inj side 2 PETROL INJECTORS Make sure that the polarity of the petrol injectors and the VSI connectors are simular! Diagram 7 Injection module 8cylinder (connector) Page 27

29 8CYLINDER SOLDER INJECTION MODULE VSI REV.B PETROL INJECTORS white min inj side whiteyellow 39 ecu side pink min inj side 3 9 ecu side 7 yellow 8 ecu side 8 min inj side 8 yellow 0 ecu side 6 min inj side 6 blueyellow 36 ecu side 4 blue min inj side 4 greenyellow 38 ecu side 2 green min inj side 2 8 cylinder injection module 80/70024 pinkyellow 37 ecu side 3 min inj side 5 26 simu low=on 50 main ground 37 ecu side 3 39 ecu side ecu side 5 yellow ecu side 5 light blue min inj side 7 light blueyellow 9 ecu side 7 VSI8 computer PETROL ECU 26 simu low=on 50 main ground 36 ecu side 4 38 ecu side 2 0 ecu side 6 8 ecu side 8 8 cylinder injection module 80/70024 PETROL INJECTORS Diagram 8 Injection module 8cylinder (solder) Page 28

30 4 & 8 CYLINDER REPAIR INJECTION MODULE VSI REV.B 80/ cylinder 8 cylinder module A 8 cylinder module B REPAIR MODULE wire A B C D injection module 26 SIMU LOW=ON 50 MAIN GROUND ECU SIDE A ECU SIDE B ECU SIDE C ECU SIDE D INJ SIDE A ECU SIDE A INJ SIDE B ECU SIDE B INJ SIDE C ECU SIDE C INJ SIDE D ECU SIDE D Diagram 9 Repair module 48 cylinder Page 29

31 REPLACING THE INJECTION MODULE VSI REV.B BY OLD TYPE blueyellow 36 ecu side 4 whiteyellow 39 ecu side Black blue min inj side 4 white min inj side Red NEW TYPE pinkyellow 37 ecu side 3 greenyellow 38 ecu side 2 Black OLD TYPE injection module 80/70024 pink min inj side 3 greenyellow 38 ecu side 2 green min inj side 2 pinkyellow 37 ecu side 3 Red Black Injection module 09/045 green min inj side 2 pink min inj side 3 Red whiteyellow 39 ecu side blue min inj side 4 blueyellow 36 ecu side 4 Black Red SIMU LOW=ON 50 MAIN GROUND 39 ecu side 38 ecu side 2 37 ecu side 3 36 ecu side 4 white min inj side INTERRUPT THE POWER FEED OF EACH INJECTOR VSI computer insulate 3 ignition 50 main ground PETROL INJECTORS PETROL INJECTORS 26 SIMU LOW=ON 50 main ground 39 ecu side 38 ecu side 2 36 ecu side 4 37 ecu side VSI computer Change wiring when replacing module 80/30024 into module 09/045. Change VSI wires 26, 27 and 54 and connect the measuring wires to module 09/045 Extend VSI wires 26, 27 and ignition main ground 54 Diagram 0 Replacing the injection module Page 30

32 30 battery 5 ignition switch Circuit diagram 4 cylinder VSI rev. B ( connector ) 80/7004 Engine control relay to LPG tank LPG Beeper LPG Switch LPG injectors Petrol injectors injector simulator 80/70024 Cylinder 234 7,5A fuse 8pole connector blue whiteyellow white greenyellow green pinkyellow pink blueyellow blue Ground blueyellow pinkyellow greenyellow whiteyellow 26 white 27 white white 48 black orange yellow 2 49 yellowgreen 34 blueyellow pinkyellow greenyellow whiteyellow VSI purplewhite orange green Ground Ground black Ground black Ground black LPG yellowgreen LPG injectors 5A fuse ground 2 pulse fuel switch 3 ignition 4 ground 5 T LPG 7 Psys 8 5V Psys 22 TxD 23 RxD 25 2V battery 26 Sim Low=On 27 ignition 29 ground 30 G INJ OUT 4 3 G INJ OUT 3 32 G INJ OUT 2 33 G INJ OUT 34 G INJ A PLUS 35 fused G INJ A 36 B INJ 4 37 B INJ 3 38 B INJ 2 39 B INJ 40 RPM 42 ground psys / Tect 43 Tect 46 Lambda L 48 Beeper ground 49 diagnostic led 50 Ground 5 power feed switch 53 LPG VLV 54 simulator ground Prins Autogassystemen B.V Petrol ECU Lambda sensor t with heater Hall sensor or camshaft sensor Max 30 V 0 V NO Ignition coil signal! U P t Filter unit 2 t TECT sensor in evaporator diagnosis connector 2 Reducer lockoff valve Tank lockoff valve black LPG Tank Hall sensor, tanklevel sensor black 3 Battery direct ground Diagram Circuit diagram 4cylinder (connector) Page 3

33 30 battery 5 ignition switch Circuit diagram 4 cylinder VSI rev. B ( solder ) 80/70004 Engine control relay to LPG tank Petrol injectors LPG Beeper LPG Switch LPG injectors 7,5A fuse pole connector blue white whiteyellow green greenyellow pink pinkyellow blue blueyellow injector simulator 80/70024 Cylinder 234 whiteyellow greenyellow pinkyellow blueyellow white white white black orange yellow yellowgreen whiteyellow greenyellow pinkyellow blueyellow ground purplewhite orange green yellowgreen LPG Ground black Ground black Ground black Ground 35 LPG injectors 5A fuse VSI 4 Petrol ECU ground 2 pulse fuel switch 3 ignition 4 ground 5 T LPG 7 Psys 8 5V Psys 22 TxD 23 RxD 25 2V battery 26 Sim. Low=On 27 ignition 29 ground 30 G INJ OUT 4 3 G INJ OUT 3 32 G INJ OUT 2 33 G INJ OUT 34 G INJ A PLUS 35 fused G INJ A 36 B INJ 4 37 B INJ 3 38 B INJ 2 39 B INJ 40 RPM 42 ground psys / Tect 43 Tect 46 Lambda L 48 Beeper ground 49 diagnostic led 50 Ground 5 power feed switch 53 LPG VLV 54 simulator ground Prins Autogassystemen B.V Lambda sensor t with heater Hall sensor or camshaft sensor Max 30 V 0 V NO Ignition coil signal! U P t Filter unit t TECT sensor in evaporator diagnosis connector Reducer lockoff valve Tank lockoff valve black LPG Tank Hall sensor, tanklevel sensor black 3 Battery direct ground Diagram 2 Circuit diagram 4cylinder (solder) Page 32

34 Circuit diagram 6 cylinder VSI rev. B (connector) 80/ battery 5 ignition switch Engine control relay to LPG tank LPG Beeper LPG Switch LPG injectors (BANK ) LPG injectors (BANK 2) injection module 80/70026 Cylinder ,5A fuse 8pole connector blue white whiteyellow Petrol injectors (Bank ) yellow pink pinkyellow 3 5 ground Petrol injectors (Bank 2) yellow yellow blue blueyellow green greenyellow pinkyellow whiteyellow yellow yellow blueyellow greenyellow white 27 white white 48 black yellowgreen orange yellow yellow blueyellow greenyellow yellow pinkyellow whiteyellow VSI purplewhite orange orangewhite green Ground Ground black Ground black Ground black LPG yellowgreen LPG injectors A 5A fuse LPG injectors B 5A fuse Petrol ECU ground 3 ignition ground 5 T LPG 4 G INJ OUT 6 5 G INJ OUT 5 7 Psys 8 5V Psys 6 G INJ B PLUS 7 fused G INJ B B INJ 6 B INJ 5 2 pulse fuel switch 22 TxD 23 RxD 25 2V battery 26 Sim. Low=On 27 ignition 29 ground 30 G INJ OUT 4 3 G INJ OUT 3 32 G INJ OUT 2 33 G INJ OUT 34 G INJ A PLUS 35 fused G INJ A 36 B INJ 4 37 B INJ 3 38 B INJ 2 39 B INJ 40 RPM 42 ground psys / Tect 43 Tect 45 Lambda 2 L 46 Lambda L 48 Beeper ground 49 diagnostic led 50 Ground 5 power feed switch 53 LPG VLV 54 Simulator Ground Prins Autogassystemen B.V Lambda sensor Lambda sensor t (with heater) B2 t (with heater) B Hall sensor or camshaft sensor Max 30 V 0 V NO Ignition coil signal! U P t Filter unit t TECT sensor in evaporator diagnosis connector Reducer lockoff valve Tank lockoff valve black LPG Tank Hall sensor, tanklevel sensor black 3 Battery direct ground Diagram 3 Circuit diagram 6cylinder (connector) Page 33

35 Circuit diagram 6 cylinder VSI rev. B ( solder ) 80/ battery 5 ignition switch Engine control relay to LPG tank LPG Beeper LPG Switch LPG injectors (BANK ) LPG injectors (BANK 2) white green pink blue 7,5A fuse injection module 80/70026 Cylinder pole connector blue yellowgreen orange yellow black white white white yellow blueyellow greenyellow yellow pinkyellow whiteyellow whiteyellow greenyellow pinkyellow blueyellow yellow yellow ground yellow yellow blueyellow pinkyellow greenyellow whiteyellow VSI purplewhite orange orangewhite green Ground Ground black Ground black Ground black LPG yellowgreen LPG injectors A 5A fuse LPG injectors B 5A fuse Petrol ECU ground 3 ignition ground 5 T LPG 4 G INJ OUT 6 5 G INJ OUT 5 7 Psys 8 5V Psys 6 G INJ B PLUS 7 fused G INJ B ECU SIDE 6 ECU SIDE 5 2 pulse fuel switch 22 TxD 23 RxD 25 2V battery 26 Sim. Low=On 27 ignition 29 ground 30 G INJ OUT 4 3 G INJ OUT 3 32 G INJ OUT 2 33 G INJ OUT 34 G INJ A PLUS 35 fused G INJ A 36 ECU SIDE 4 37 ECU SIDE 3 38 ECU SIDE 2 39 ECU SIDE 40 RPM 42 ground psys / Tect 43 Tect 45 Lambda 2 L 46 Lambda L 48 Beeper ground 49 diagnostic led 50 Ground 5 power feed switch 53 LPG VLV 54 Simulator Ground Prins Autogassystemen B.V Lambda sensor Lambda sensor t (with heater) B2 t (with heater) B Hall sensor or camshaft sensor Max 30 V 0 V NO Ignition coil signal! U P t Filter unit t TECT sensor in evaporator diagnosis connector Reducer lockoff valve Tank lockoff valve black LPG Tank Hall sensor, tanklevel sensor black 3 Battery direct ground Diagram 4 Circuit diagram 6cylinder (solder) Page 34

36 Circuit diagram V8 cylinder VSI rev.b (connector) 80/ battery 5 ignition switch Engine control relay to LPG tank LPG Beeper LPG Switch LPG injectors BANK LPG injectors BANK 2 injector simulator 80/70024 Cylinder 357 7,5A fuse Petrol injectors BANK Petrol injectors BANK 2 injector simulator 80/70024 Cylinder 2468 white yellow yellow blueyellow greenyellow light blueyellow yellow pinkyellow whiteyellow white white white 8pole connector black yellowgreen orange yellow blue whiteyellow pinkyellow yellow light blueyellow greenyellow blueyellow yellow yellow VSI 8 Brownground Brownground orange purplewhite 45 orangewhite green yellowgreen LPG Ground black Ground black Ground black Ground LPG injectors A 5A fuse 35 LPG injectors B 5A fuse 7 Petrol ECU ground 3 ignition 2 G INJ OUT 8 3 G INJ OUT 7 4 ground 5 T LPG 4 G INJ OUT 6 5 G INJ OUT 5 7 Psys 8 5V Psys 6 G INJ B PLUS 7 fused G INJ B 8 ECU SIDE 8 9 ECU SIDE 7 0 ECU SIDE 6 ECU SIDE 5 2 pulse fuel switch 22 TxD 23 RxD 25 2V battery 26 Sim. Low=On 27 ignition 29 ground 30 G INJ OUT 4 3 G INJ OUT 3 32 G INJ OUT 2 33 G INJ OUT 34 G INJ A PLUS 35 fused G INJ A 36 ECU SIDE 4 37 ECU SIDE 3 38 ECU SIDE 2 39 ECU SIDE 40 RPM 42 ground psys / Tect 43 Tect 45 Lambda 2 L 46 Lambda L 48 Beeper ground 49 diagnostic led 50 Ground 5 power feed switch 53 LPG VLV 54 Simulator Ground Prins Autogassystemen B.V Lambda sensor Lambda sensor t (with heater) B2 t (with heater) B Hall sensor or camshaft sensor Max 30 V 0 V NO Ignition coil signal! U P t Filter unit t TECT sensor in evaporator diagnosis connector Reducer lockoff valve Tank lockoff valve black LPG Tank Hall sensor, tanklevel sensor black 3 Battery direct ground Diagram 5 Circuit diagram 8cylinder (connector) Page 35

37 Circuit diagram V8 cylinder VSI rev.b ( solder ) 80/ battery 5 ignition switch Engine control relay Petrol injectors BANK Petrol injectors BANK 2 to LPG tank LPG Beeper LPG Switch LPG injectors BANK LPG injectors BANK 2 7,5A fuse blue green light blue pink white 8pole connector injector simulator 80/70024 blue Cylinder 357 yellowgreen orange yellow black white injector simulator 80/70024 Cylinder 2468 greenyellow blueyellow yellow yellow light blueyellow yellow pinkyellow whiteyellow white white whiteyellow pinkyellow yellow light blueyellow greenyellow blueyellow yellow yellow whiteyellow pinkyellow yellow light blueyellow greenyellow blueyellow yellow yellow VSI 8 6 Brownground Brownground orange purplewhite orangewhite green yellowgreen LPG Ground black Ground black Ground black Ground LPG injectors A 5A fuse 35 LPG injectors B 5A fuse 7 Petrol ECU ground 3 ignition 2 G INJ OUT 8 3 G INJ OUT 7 4 ground 5 T LPG 4 G INJ OUT 6 5 G INJ OUT 5 7 Psys 8 5V Psys 6 G INJ B PLUS 7 fused G INJ B 8 ECU SIDE 8 9 ECU SIDE 7 0 ECU SIDE 6 ECU SIDE 5 2 pulse fuel switch 22 TxD 23 RxD 25 2V battery 26 Sim low=on 27 ignition 29 ground 30 G INJ OUT 4 3 G INJ OUT 3 32 G INJ OUT 2 33 G INJ OUT 34 G INJ A PLUS 35 fused G INJ A 36 ECU SIDE 4 37 ECU SIDE 3 38 ECU SIDE 2 39 ECU SIDE 40 RPM 42 ground psys / Tect 43 Tect 45 Lambda 2 L 46 Lambda L 48 Beeper ground 49 diagnostic led 50 Ground 5 power feed switch 53 LPG VLV 54 Simulator Ground Prins Autogassystemen B.V Max 30 V Hall sensor or camshaft sensor 0 V NO Ignition coil signal! t Lambda sensor (with heater) B2 t Lambda sensor (with heater) B U P t Filter unit t TECT sensor in evaporator diagnosis connector Reducer lockoff valve Tank lockoff valve black LPG Tank Hall sensor, tanklevel sensor black 3 Battery direct ground Diagram 6 Circuit diagram 8cylinder (solder) Page 36

38 Trouble code chart Trouble code Definition Check / solution 00 Lambda to long to rich. Check when operating on petrol and LPG that there is good lambda signal movement. 0 Lambda to long to lean. Check when operating on petrol and LPG that there is good lambda signal movement. 02 Lambda to long to lean during open loop. Check when operating on petrol and LPG that there is good lambda signal movement. 0 TECT>= 7 C Check if the ECT sensor (blue) in the ucer is connector is connected to ground. TECT>= 40 C Check if the ECT sensor (blue) in the ucer has a power connection. 20 TLPG>= 7 C Check the ground connection of the Pressure/temperature sensor in the filter unit. 2 TLPG>= 40 C Check the power connection of the Pressure/temperature sensor in the filter unit. 50 Psys<= Low_Level Based on a pressure drop in the system, this can be caused by an empty LPG tank, incorrect solenoid valve, polluted filter or incorrectly adjusted pressure. 60 ECMVSI not activated Activate the LPG computer with the diagnostic program, using the F function key. 80 TBoard >= 90 C LPG computer circuit board to hot, replace the VSI computer in a cooler area. 8 Battery voltage to high Check board voltage / alternator output and condition of the battery VSI injector Injector current to high, check for short circuiting overload VSI injector Injector current to low, check for bad connections. noload 30 Adjusted pressure on idle out of range Adjust the idle pressure to the value shown by parameter Idle Level 3 Programm error during flahing the Check parameter settings, contact Prins Autogassystemen. memory 320 Psys voltage to low Check the ground connection of the Pressure/temperature sensor in the filter unit. 32 Psys voltage to high Check the power connection of the Pressure/temperature sensor in the filter unit. 322 Psys > 3,5 Bar Check the coolant temperature (Tect) and the evaporator for leakage of the first stage. 330 unexpected parameter change Contact Prins Autogassystemen. 340 ucer warms up to slow Check the water connections / circuit. 34 Gas leakage, system pressure is less then Check the system for gasleakage..25 bar after 4 hours when the engine is not running div. System switches to LPG but engine LPG tank empty? stalls immediately. div. No injection timing on LPG ( 0 Msec.) Check the injection module. div. The LPG system switches constantly Check coolant system for air. div. between LPG and Petrol Engine hesitates on high revs, and not running on all cylinders. Engine runs good on idle. Tect sensor in the evaporator malfunction. Check for kinked or jammed LPG hoses (between VSI injector and couplings). Check for blocked inlet couplings. div. Switch LED s don t lit up Check the main fuse of the VSI system Check ignition (VSI wire 3) div. Fault codes when turning the ignition off ( key out the ignition ) Caused by different switch off times between ignition and injector power. Connect VSI wire 3 to the petrol injector feed instead of ignition. div. The orange LED on the switch flashes Activate the LPG computer with the diagnostic program, using the F function key. div. The LPG system switches to LPG but LPG tank empty? engine stalls immediately div. Not running on all cylinders on lpg Check parameter 0, number of cylinders. div. No injection times on lpg Check the connections of the injection module. div. Injection time falls to 0 msec on Check the injection module. LPG div. Check engine while running on LPG, injector circuit malfunction, no lambda control (limb home) Replace injection module div. Not starting / running on petrol Check the connections of the injection module. Page 37

39 Maintenance instructions MAINTENANCE Compa to driving on petrol, the maintenance of your car is more important if you drive on LPG. Small problems or malfunctioning of the engine may be acceptable when driving on petrol, but may be irritating on LPG, as the engine is more sensible on LPG. For troublefree driving on LPG, you have to follow these maintenance instructions. The general maintenance of the car related to spark plugs, wires, ignition, valves etc. has to be carried out according to the instructions of the manufacturer. There must be evidence of the maintenance work (by means of a completely filled out service booklet) according to the importer's instructions. Maintenance has to be carried out by an authorised dealer appointed by the importer. Adjustments and repairs to your Prins LPG system should only be carried out by an authorised Prins dealer. General * Because of driving on LPG you need to pay extra attention to: valve adjustment spark plugs, ignition wires and, if necessary, distributor cap and rotor idle control, checking the function and for contamination idle speed functioning on petrol, with special attention to O2 sensor cleaning the oneway valve of the negative crankcase ventilation system reading fault codes * Replacement of the filter of the gas valve and filter unit (25,000 km after installation, then periodically every 75,000 km). In case of contamination, check if this contamination persists in evaporator and/or after filter unit and injector rail. * Check hose connections on reliability, for kinks and rubbing. * Check electrical connections. * Check electric connections ( especially battery connections ) * Check the fixing of components. * Check for LPG leakage at the tank, the LPG fuel lock, converter, filter unit and injector rail. * Check for petrol leakage of petrol injector, if VSI couplings are mounted underneath the petrol injectors. * Check for suction of infiltrated air. * Check the emission control with Prins diagnostic equipment and exhaustemission tester. FILTER REGISTRATION Registration of the replacement of the filter from the lock off valve and filter unit (VSI) km km km km Dealerstamp Dealerstamp Dealerstamp Dealerstamp Number of kilometres Date Number of kilometres Date Number of kilometres Date Number of kilometres Date Page 38

40 Checklist after installation. Connect the serial interface wire and run the VSI diagnosis program. Turn the ignitionkey in the accessory position. When working on the car, beware of moving and rotating parts in the engine compartement. 2. When commissioning the LPG system, you must activate the VSI computer with the diagnosis software. When the VSI computer has not been activated, it will keep generating error code 60. To activate the VSI computer, select function F (activate ECM). 3. Check whether the program in the VSI computer matches with the car ( dedicated engine set ): Refer with F2 to the box number and car description in the diagnosis software and compare these with the set number. 4. The system will switch over to LPG as soon as the temperature of the coolant (Tect) becomes higher than the parameter Tmin set and when the TSOcold time is expi. 5. Check all components and connections for any gas or water leakage. Caution for moving and rotating parts in the engine compartment! 6. Let the engine run warm on petrol >80 C. Check if the evaporator heats up. Check the engine signals, petrol injection time, RPM, ECT, lambda Let the engine run idle on LPG. Adjust the evaporator pressure. Refer to the parameter list ( or F2 ) for the idle level value set. Adjust the evaporator pressure in such a way that the pressure measu ( Psys ) equals the idle level value. Turn the sockethead screw at the front of the evaporator to adjust the pressure. An error code will be generated whenever the pressure variation is to high. Seal the evaporator with the sticker included in the delivery after having adjusted the pressure. 7. Use the diagnosis software to check again all input and output signals. 8. Check the system for error codes and solve these, if requi. Check the petrol MMS for EOBD error codes. Place the protection connector on the VSI communication connector. 9. Make a test drive and check the driveability on LPG and petrol. Page 39