DT-466 JTG DYNAMIC LIQUID PROPANE INJECTION DIESEL INSTALLATION MANUAL P11X AB

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1 DT-466 JTG DYNMIC LIQUID PROPNE INJECTION DIESEL INSTLLTION MNUL P11X B Revision: B - Dated 11/26/12 Replaces: - Dated 10/1/12

2 INTRODUCTION! SFETY WRNING RED BEFORE STRTING THE INSTLLTION OF THE ICOM JTG SYSTEM. ENSURE THT LL PERSONNEL IN THE IMMEDITE RE RE WRE OF THESE REMINDERS.! PROPNE IS NONTOXIC, NONPOISONOUS GS THT IS EXTREMELY FLMMBLE. IF SOMETHING IGNITES IT, YOU COULD BE BDLY BURNED. KEEP SPRKS, OPEN FLMES ND SMOKING MTERIL WY FROM PROPNE.! LIQUID PROPNE IS EXTREMELY COLD (-40 F) ND CUSES SERIOUS BURNS WHEN CONTCTING YOUR SKIN OR EYES. PENT CONTCT WHEN HNDLING LPG BY WERING PPROVED PROTECTIVE GLOVES ND EYE PROTECTION.! PROPNE IS STORED UNDER PRESSURE. THE FUEL SYSTEM OPERTES T PRESSURES OF UP TO 312 PSI. SUDDEN RELESE OF PROPNE CN CUSE SERIOUS INJURIES. THESE INSTRUCTIONS RE INTENDED FOR TECHNICINS WHO RE CERTIFIED BY LL GENCIES THT GOVERN PROPNE INSTLLTIONS ND THE TRNSPORTTION OF PROPNE. THE NTIONL FIRE PROTECTION SSOCITION (NFP) PUBLISHES CODE BOOK OF RULES (NFP 58) THT PPLY TO THE STORGE, HNDLING, TRNSPORTTION ND USE OF LIQUEFIED PETROLEUM GS (LPG). LOCL PROPNE SUPPLIERS SUCH S FERRELGS ND MERIGS, S WELL S SOME GENGIES SUCH S THE TEXS RILROD COMMISION ND PERC (PROPNE EDUCTION & RESERCH COUNCIL) OFFER INFORMTIVE COURSES TO HELP PENT SEVERE INJURY OR DETH TO YOU OR SOMEONE ELSE IF YOU DON'T FULLY UNDERSTND LPG ND ITS PROPERTIES. BEGIN THE INSTLLTION BY PREPRING YOUR WORK SITE. THE RE SHOULD BE CLEN WITH SUFFICIENT LIGHTING. YOU WILL NEED: 1) WORKBENCH 2) TOOLS, INCLUDING SOCKETS, SCREWDRIVERS, WRENCH, METL CUTTING TOOLS (SMLL RECIPROCTING SW, NIBBLERS, DRILLS, ECTC.) 3) SFETY GLSSES, GLOVES ND HERING PROTECTION 4) FUEL PRESSURE GUGE (ICOM # ) ND CLIBRTOR REMOVL TOOL (ICOM # ) 5) SOURCE OF COMPRESSED IR 6) VEHICLE LIFT WITH, PREFERBLY, MODIFIED TRNSMISSION JCK TO SUPPORT THE FUEL TNK DURING FITMENT ND INSTLLTION 7) 'FLUKE 77' MULTIMETER WITH TIME-BSED REDOUT (REQUIRED FOR CLIBRTION & DIGNOSTICS ONLY, NOT NEEDED FOR GENERL INSTLLTION).

3 INTRODUCTION! IMPORTNT IT IS IMPORTNT THT YOU IEW THIS ENTIRE INSTLLTION MNUL BEFORE BEGINNING TO FMILIRIZE YOURSELF WITH THE INSTLLTION PROCESS. THIS WILL HELP MINIMIZE NY POTENTIL ERRORS THT MY OCCUR IF PROCESS IS CONDUCTED OUT OF SEQUENCE.! THREDED FUEL LINE CONNECTORS / FITTINGS THE ICOM FUEL HOSES RE EQUIPPED WITH THREDED END CONNECTORS THT SEL WHEN THE PROPER IS PPLIED. DO NOT USE TEFLON TPE ON NY FITTING S THIS MY GET INTO THE REGULTOR OR FUEL INJECTORS ND CUSE FUEL PRESSURE PROBLEMS. NY WRRNTY RETURNED COMPONENT FOUND CONTMINTED WTH TEFLON TPE WILL BE RETURNED.! BRE METL SURFCES NYTIME THE OEM PINTED SURFCE IS BROKEN BY DRILLING OR REMOVL OF PRTICULR COMPONENT, THE EXPOSED METL SURFCE MUST BE DEBURRED ND COTED WITH PRIMER OR SELER TO PENT RPID CORROSION. THIS IS EXTREMELY IMPORTNT IN RES THT USE ROD SLT DURING THE WINTER MONTHS. FOLLOW THE LBEL INSTRUCTIONS ON THE PRODUCT USED TO ENSURE POSITIVE RESULTS.! PCKGING CREFULLY INSPECT THE CONTENTS OF THE KIT ONCE YOU RECEIVE IT TO ENSURE THT LL OF THE COMPONENTS RE VILBLE BEFORE STRTING THE INSTLLTION. PRTS LIST IS ENCLOSED WITH THIS MNUL. THE LIST OF PRTS MY VRY BSED ON THE PPLICTION.

4 INSTLLTION KIT CONTENTS PRT NUMBERS FOR SOME PRTICULR COMPONENTS WILL CHNGE BSED ON THE PPLICTION. PCKGE D-1 PRT NUMBER COMPONENT QTY ICOM JTG-D WIRE HRNESS SSY 1 PCKGE D ICOM DIESEL ECU MODULE 1 PCKGE D COMMUTTOR STRIGHT BRSS NOZZLE NGLE BRSS NOZZLE FUSE HOLDER MP FUSE MP FUSE " TIE STRP 8 PCKGE D INLINE FUEL FILL FILTER MLE/MLE DPTOR (PI WITH FUEL FILTER) FUEL FILTER MOUNTING CLMP /2" CBLE CLMP /8" CBLE CLMP /2" HOSE CLMP SCREW - SELF TPPING 13 PCKGE D REGULTOR W/FITTINGS TEE FITTING HOLE BRCKET HOLE BRCKET 2 NPN SCREW - MOUNTING BRCKET 10 HOSES P11X RETURN HOSE SSY - RER FUEL RIL TO TEE 1 P11X RETURN HOSE SSY - FRONT FUEL RIL TO TEE 1 P11X RETURN HOSE SSY - REGULTOR TO TEE 1 P11X SUPPLY HOSE SSY - MIDDLE RER FUEL RIL TO RER FUEL RIL 1 P11X SUPPLY HOSE SSY - MIDDLE RER FUEL RIL TO TEE 1 P11X SUPPLY HOSE SSY - MIDDLE FRONT FUEL RIL TO TEE 1 P11X SUPPLY HOSE SSY - MIDDLE FRONT FUEL RIL TO FRONT FUEL RIL 1 VRIES BSED ON ORDER SUPPLY / RETURN CHSSIS HOSE KIT 1 VRIES BSED ON ORDER REMOTE FUEL FILL HOSE KIT 1 VRIES BSED ON ORDER 1-1/2" CORRUGTE HOSE /2" SPLIT CORRUGTE (FOR ENGINE HOSES) 1

5 INSTLLTION MNUL TBLE OF CONTENTS PROCESS # PROCESS NME P11X INSTLL LPG FUEL TNK P11X PREP PSSENGER COMPRTMENT P11X INSTLL FUEL FILL HOSE & FILTER P11X INSTLL FUEL FILL FLOW SWITCH P11X ROUTE CHSSIS SUPPLY / RETURN HOSES & WIRE HRNESS TO LPG TNK P11X TTCH CHSSIS SUPPLY / RETURN HOSES TO MULTIVLVE P11X INTKE MNIFOLD MODIFICTION & NOZZLE INSTLLTION P11X INSTLL FUEL RILS P11X INSTLL ENGINE SUPPLY & RETURN HOSES P11X INSTLL REGULTOR P11X TTCH CHSSIS SUPPLY / RETURN HOSES (ENGINE COMPRTMENT) P11X INSTLL ECU MODULE & TTCH ICOM JTG-D ENGINE WIRE HRNESS P11X INSTLL COMMUTTOR & UDIBLE INDICTOR P11X PERFORM INITIL JTG SYSTEM CHECK P11X PERFORM INITIL LPG FUEL FILL P11X PERFORM PRESSURE CHECK VERIFICTION P11X PERFORM LPG FUEL PUMP POWER SUPPLY VERIFICTION DT466 WIRING DIGRM ICOM JTG-D WIRING DIGRM (SHT 1) ICOM JTG-D WIRING DIGRM (SHT 2)

6 CRITICL PROCESS OPERTION 10) ROTTE THE IGNITION KEY TO THE 'ON' POSITION TO UNLOCK THE STEERING WHEEL; ROTTE THE THE STEERING WHEEL LL THE WY TO THE LEFT TO LLOW FOR MORE ROOM WHEN WORKING INSIDE THE ENGINE BY ON THE DRIVERS SIDE OF THE VEHICLE 20) ROTTE IGNITION KEY BCK TO THE 'OFF' POSITION 30) DISCONNECT THE NEGTIVE CBLE FROM THE BTTERY 40) USING 5/8" DRILL BIT, DRILL HOLES INTO THE VEHICLE T THE SPECIFIC TNK MOUNTING LOCTIONS BSED ON THE TNK USED FOR THE PPLICTION 50) INSTLL 1/2" X 13 X 1.5 GRDE 8 BOLTS INTO THE DRILLED HOLES 60) HNDSTRT NYLOCK NUTS ONTO BOLTS; NUTS TO 108 Nm +/- 10 B PRT NUMBER QTY DESCRIPTION 1/2" x 13 x 1.5 GRDE 8 BOLT 1/2" NYLOCK NUT Nm +/- 10 TOOLS DRILL 5/8" DRILL BIT WRENCH PROCESS NME INSTLL FUEL TNK P11X PGE 1

7 CRITICL PROCESS OPERTION 10) REMOVE THE PSSENGER SIDE SET 10 20) DISCONNECT THE ELECTRICL CONNECTOR FROM THE SHIFTER; REMOVE THE SHIFTER FROM THE ENGINE COVER (KEEP LINKGE TTCHED TO SHIFTER) 20 30) REMOVE THE ENGINE COVER ND PLCE OUTSIDE THE VEHICLE 30 PRT NUMBER QTY DESCRIPTION TOOLS PROCESS NME PREP PSSENGER COMPRTMENT P11X PGE 1 OF 1

CRITICL PROCESS OPERTION 10) OBTIN FUEL FILL FILTER SSY () ND REMOTE FUEL FILL HOSE KIT (B) 20 20) DETERMINE LOCTION FOR THE INLINE FUEL FILL FILTER SSY 30) INSTLL THE REMOTE FUEL FILL VLVE ONTO THE

FILTER TO THE REMOTE FUEL FILL VLVE 30 50) CUT ND SSEMBLE THE FILL HOSES NEEDED PER THE PROVIDED WORK INSTRUCTION FOR SSEMBLY OF THE HOSES (P11X-9203-C) 60) LOCTE FUEL FILL VLVE ON THE TNK 70)

8 CRITICL PROCESS OPERTION 10) OBTIN FUEL FILL FILTER SSY () ND REMOTE FUEL FILL HOSE KIT (B) 20 20) DETERMINE LOCTION FOR THE INLINE FUEL FILL FILTER SSY 30) INSTLL THE REMOTE FUEL FILL VLVE ONTO THE FUEL TNK 40) REMOVE THE CONTENTS FROM THE REMOTE FUEL FILL HOSE KIT; DETERMINE THE LENGTH OF HOSE NEEDED TO GO FROM THE FUEL TNK TO THE INLINE FUEL FILTER ND FROM THE OPPOSITE END OF THE INLINE FUEL FILTER TO THE REMOTE FUEL FILL VLVE 30 50) CUT ND SSEMBLE THE FILL HOSES NEEDED PER THE PROVIDED WORK INSTRUCTION FOR SSEMBLY OF THE HOSES (P11X-9203-C) 60) LOCTE FUEL FILL VLVE ON THE TNK 70) HNDSTRT CRIMPED HOSE FITTING ONTO FILL VLVE FITTING 80) THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/ PRT NUMBER QTY DESCRIPTION TOOLS FUEL FILL FILTER SSY WRENCH 1 25Nm +/- 2.5 B 3702-B 1 HOSE KIT - REMOTE FUEL FILL 19mm OPEN END WRENCH C CORRUGTE - 10' 22mm CROWFOOT D /2" SCREW CLMP PROCESS NME INSTLL FUEL FILL HOSE & FILTER P11X PGE 1 OF 2

CRITICL PROCESS OPERTION 90 1 90) OBTIN FILL HOSE FILTER (B); USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, BOTH END FITTINGS WITH 22mm OPEN END CROWFOOT ND WRENCH TO 45 Nm +/- 4.

9 CRITICL PROCESS OPERTION ) OBTIN FILL HOSE FILTER (B); USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, BOTH END FITTINGS WITH 22mm OPEN END CROWFOOT ND WRENCH TO 45 Nm +/ ) POSITION FUEL FILTER WITH RROW ON FILTER HOUSING POINTING TOWRD THE FUEL TNK ) HNDSTRT FITTING ON HOSE COMING FROM THE FUEL TNK ONTO RROW END OF FILTER HOUSING 120) USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/ ) OBTIN THE SECOND SSEMBLED FILL HOSE FROM STEP ) HNDSTRT HOSE FITTING ONTO FILTER 150) USING 24mm OPEN END WRENCH ON THE FILTER HOUSING, THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/ ) SECURE FILTER HOUSING TO DESIRED LOCTION ON VEHICLE WITH SUPPLIED CLMP & SELF TPPING SCREW DO NOT SCREW DIRECTLY INTO FLOOR, ONLY SCREW INTO SUPPORTS / BRCES FOR FLOOR OR TTCH WITH SUPPLIED CLIPS PRT NUMBER QTY DESCRIPTION TOOLS FUEL FILL FILTER SSY WRENCH 1 45 Nm +/- 4.5 C CORRUGTE - 10' 24mm OPEN END WRENCH D FUEL FILTER CLMP 22mm CROWFOOT 25 Nm +/- 2.5 E SELF TP SCREW 2 PROCESS NME INSTLL FUEL FILL HOSE & FILTER P11X PGE 2 OF 2

CRITICL PROCESS OPERTION 10 10) THE FOLLOWING IS LIST OF THE COMPONENTS THT RE CONTINED WITHIN THE FUEL FILL HOSE FLOW SWITCH KIT (PRT # P11X-4102-) 3/8" FIELD TTCHBLE FERRULE C B 3/8" FIELD TTCHBLE

10 CRITICL PROCESS OPERTION 10 10) THE FOLLOWING IS LIST OF THE COMPONENTS THT RE CONTINED WITHIN THE FUEL FILL HOSE FLOW SWITCH KIT (PRT # P11X-4102-) 3/8" FIELD TTCHBLE FERRULE C B 3/8" FIELD TTCHBLE STRIGHT FITTING C FLOW SWITCH SSEMBLY B 15) DISCONNECT ND REMOVE THE POSITIVE ND NEGTIVE LEDS FROM THE BTTERY 20) THE FLOW SWITCH WILL NEED TO BE INSTLLED ONTO ONE OF THE FILL HOSES IN CLOSE PROXIMITY TO THE FUEL TNK WIRE HRNESS 30) DETERMINE LOCTION FOR FLOW SWITCH ON THE FILL HOSE; CUT THE HOSE WITH N PPROVED HOSE CUTTING TOOL 40) OBTIN (2) 3/8" FIELD TTCHBLE FERRULES () ND (2) 3/8" FIELD TTCHBLE STRIGHT FITTINGS (B) CONTINED IN KIT 50) SSEMBLE FITTINGS ONTO ECH END OF THE CUT HOSE PER ICOM WORK INSTRUCTION P11X-9203-C (FIELD TTCHBLE FITTING SSEMBLY INSTRUCTIONS) 60) OBTIN 10 FOOT SECTION OF CORRUGTE; DETERMINE THE LENGTH OF CORRUGTE NEEDED TO COVER HOSE ON EITHER SIDE OF THE FUEL FILL FILTER ND OVER THE FLOW SWITCH ND CUT TO LENGTH ND INSTLL ONTO HOSES PRT NUMBER QTY DESCRIPTION TOOLS / HRDWRE FERRULE - 3/8" FIELD TTCHBLE HOSE CUTTER B FITTING - 3/8" FIELD TTCHBLE C P11X FLOW SWITCH SSY WITH 3/8" FITTINGS PROCESS NME INSTLL FUEL FILL FLOW SWITCH P11X PGE 1 OF 5

CRITICL PROCESS OPERTION 70 70) OBTIN FLOW SWITCH SSEMBLY (C ); LOCTE FLOW RROW STMPED ONTO FLOW SWITCH POSITION FLOW SWITCH SO THE

CRITICL TO INSURE PROPER OPERTION OF THE SWITCH 80) HNDSTRT THE FILL HOSE FITTINGS SSEMBLED IN STEP 60 ONTO THE FLOW SWITCH

5 80 90 1 100) LOCTE THE 1-1/2" CORRUGTE HOSE TTCHED TO THE FUEL TNK MULTIVLVE COLLR 100 110) IN CLOSE PROXIMITY TO THE FLOW

THE WIRE HRNESS SHETHING (EXERCISE CUTION NOT TO CUT INTO NY WIRES) INSPECT LL WIRES TO VERIFY NONE WERE CUT DURING THIS OPERTION

11 CRITICL PROCESS OPERTION 70 70) OBTIN FLOW SWITCH SSEMBLY (C ); LOCTE FLOW RROW STMPED ONTO FLOW SWITCH POSITION FLOW SWITCH SO THE RROW IS POINTING TOWRD THE FUEL TNK (DIRECTION OF PROPNE GOING INTO THE TNK DURING FILL) IMPORTNT - THE FLOW SWITCH ORIENTTION IS CRITICL TO INSURE PROPER OPERTION OF THE SWITCH 80) HNDSTRT THE FILL HOSE FITTINGS SSEMBLED IN STEP 60 ONTO THE FLOW SWITCH FITTINGS (DO NOT PPLY THRED SELER ON FITTINGS) 90) ECH HOSE FITTING TO 25 Nm +/ ) LOCTE THE 1-1/2" CORRUGTE HOSE TTCHED TO THE FUEL TNK MULTIVLVE COLLR ) IN CLOSE PROXIMITY TO THE FLOW SWITCH, USING RZOR BLDE, CREFULLY INSERT BOUT 3" SLICE LENGTH WISE IN THE CORRUGTE HOSE; CREFULLY INSERT THE SME LENGTH SLICE INTO THE WIRE HRNESS SHETHING (EXERCISE CUTION NOT TO CUT INTO NY WIRES) INSPECT LL WIRES TO VERIFY NONE WERE CUT DURING THIS OPERTION 110 PRT NUMBER QTY DESCRIPTION TOOLS / HRDWRE C P11X FLOW SWITCH SSY WITH 3/8" FITTINGS WRENCH 1 25Nm +/- 2.5 RZOR BLDE PROCESS NME INSTLL FUEL FILL FLOW SWITCH P11X PGE 2 OF 5

CRITICL PROCESS OPERTION FOR VEHICLES EQUIPPED WITH THE LONG FUEL TNK WIRE

SEPRTE FROM THE REST OF THE WIRES 130) USING WIRE CUTTERS, CUT THE WHITE WIRE

BCK INTO THE WIRE LOOM 150) USING WIRE STRIPPERS, CREFULLY REMOVE PPROXIMTELY

ENGINE TO ENGINE 150 140 TO MULTIVLVE PRT NUMBER QTY DESCRIPTION TOOLS / HRDWRE

12 CRITICL PROCESS OPERTION FOR VEHICLES EQUIPPED WITH THE LONG FUEL TNK WIRE HRNESS ) LOCTE THE WHITE ND BLCK WIRES INSIDE THE WIRE HRNESS LOOM ND SEPRTE FROM THE REST OF THE WIRES 130) USING WIRE CUTTERS, CUT THE WHITE WIRE IN HLF ) TUCK THE PORTION OF THE WHITE WIRE THT GOES TO THE MULTIVLVE BCK INTO THE WIRE LOOM 150) USING WIRE STRIPPERS, CREFULLY REMOVE PPROXIMTELY 1/2" OF WIRE INSULTION FROM THE END OF THE WHITE WIRE GOING TO THE ENGINE TO ENGINE TO ENGINE TO MULTIVLVE PRT NUMBER QTY DESCRIPTION TOOLS / HRDWRE WIRE CUTTERS WIRE STRIPPERS PROCESS NME INSTLL FUEL FILL FLOW SWITCH P11X PGE 3 OF 5

CRITICL PROCESS OPERTION 160) CREFULLY REMOVE PPROXIMTELY 1/2" OF WIRE INSULTION

1/2" OF WIRE INSULTION FROM BOTH LEDS COMING FROM THE FLOW SWITCH 170 180) TTCH

CONNECTION TOGETHER ND SEL WITH ELECTRICL TPE 190) TTCH THE REMINING FLOW SWITCH

ELECTRICL TPE 180 190 PRT NUMBER QTY DESCRIPTION TOOLS / HRDWRE WIRE STRIPPERS

13 CRITICL PROCESS OPERTION 160) CREFULLY REMOVE PPROXIMTELY 1/2" OF WIRE INSULTION FROM THE BLCK WIRE S SHOWN (DO NOT CUT WIRE) ) CREFULLY REMOVE PPROXIMTELY 1/2" OF WIRE INSULTION FROM BOTH LEDS COMING FROM THE FLOW SWITCH ) TTCH ONE OF THE FLOW SWITCH WIRE LEDS ONTO THE STRIPPED WHITE WIRE LED; SOLDER CONNECTION TOGETHER ND SEL WITH ELECTRICL TPE 190) TTCH THE REMINING FLOW SWITCH WIRE LED TO THE STRIPPED PORTION OF THE BLCK WIRE; SOLDER CONNECTION ND SEL WITH ELECTRICL TPE PRT NUMBER QTY DESCRIPTION TOOLS / HRDWRE WIRE STRIPPERS SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL FUEL FILL FLOW SWITCH P11X PGE 4 OF 5

CRITICL PROCESS OPERTION 200) INSERT WIRES BCK INTO WIRE HRNESS SHETHING; SEL RE CUT ON SHETHING WITH ELECTRICL TPE; SEL RE CUT ON CORRUGTE WITH ELECTRICL TPE 200 PRT

14 CRITICL PROCESS OPERTION 200) INSERT WIRES BCK INTO WIRE HRNESS SHETHING; SEL RE CUT ON SHETHING WITH ELECTRICL TPE; SEL RE CUT ON CORRUGTE WITH ELECTRICL TPE 200 PRT NUMBER QTY DESCRIPTION TOOLS / HRDWRE WRENCH 1 25Nm +/- 2.5 WIRE STRIPPERS SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL FUEL FILL FLOW SWITCH P11X PGE 5 OF 5

CRITICL PROCESS OPERTION 10) OBTIN THE SUPPLY / RETURN CHSSIS HOSE KIT (), 1-1/2" CORRUGTE HOSE (B), ICOM JTG-D ENGINE WIRE HRNESS SSY (C ), P-CLMPS (D), ND SELF TP SCREWS (E) 20 20) LOCTE THE 'F'

15 CRITICL PROCESS OPERTION 10) OBTIN THE SUPPLY / RETURN CHSSIS HOSE KIT (), 1-1/2" CORRUGTE HOSE (B), ICOM JTG-D ENGINE WIRE HRNESS SSY (C ), P-CLMPS (D), ND SELF TP SCREWS (E) 20 20) LOCTE THE 'F' LOOM ON THE ICOM JTG-D ENGINE WIRE HRNESS; OBTIN THE GREEN SUPPLY ND BLCK RETURN CHSSIS HOSES; GRSP THE ENDS OF BOTH HOSES WITH THE STRIGHT FITTING CRIMPED ON THE END; BUNDLE THE SUPPLY/RETURN CHSSIS HOSES ND THE 'F' LOOM ON THE WIRE HRNESS ND TPE TOGETHER 30) INSERT HOSES ND WIRE LOOM INTO ONE END OF 1-1/2" CORRUGTE HOSE (B) UNTIL HOSES ND WIRE LOOM COME OUT OPPOSITE END OF CORRUGTE 40 40) FROM DRIVER SIDE OF ENGINE COMPRTMENT, ROUTE END OF CORRUGTE WITH HOSE FITTING END & WIRE LOOM END THROUGH CHSSIS TOWRD THE LPG FUEL TNK DO NOT ROUTE OVER MOVING COMPONENTS, DRIVESHFT, STEERING LINKGE OR SUSPENSION COMPONENTS (DO NOT ROUTE WITHIN 8 INCHES OF NY EXHUST SYSTEM COMPONENT WITHOUT PPROVED SHIELDING) 50) OBTIN P-CLMPS (D) ND SELF TP SCREWS (E) LPG FUEL TNK 60) TTCH CORRUGTE TO CHSSIS WITH P-CLMPS S REQUIRED TO SECURE CORRUGTE IN PLCE ND TO ELIMINTE POTENTIL CONTCT WITH CHSSIS COMPONENTS DO NOT SCREW DIRECTLY INTO FLOOR, ONLY SCREW INTO SUPPORTS / BRCES FOR FLOOR OR TTCH WITH SUPPLIED CLIPS 70) PPLY HET SHIELD MTERIL TO RES ON THE CORRUGTE THT RE IN CLOSE PROXIMITY (WITHIN 8 INCHES) FROM NY EXHUST SYSTEM COMPONENT PRT NUMBER QTY DESCRIPTION TOOLS P11X SUPPLY / RETURN CHSSIS HOSE KIT B /2" CORRUGTE HOSE C ICOM JTG-D ENGINE WIRE HRNESS SSY D /8" P-CLMPS E SELF TP SCREW PROCESS NME ROUTE CHSSIS SUPPLY/RETURN HOSES & WIRE HRNESS SSY P11X PGE 1 OF 1

CRITICL PROCESS OPERTION 10) LOCTE THE (SHORT) SUPPLY NOZZLE COMING OUT OF THE MULTIVLVE COLLR BUSHING 20) HNDSTRT THE CRIMPED FITTING ON THE GREEN SUPPLY HOSE ONTO THE SUPPLY NOZZLE 10 20 30 1 30)

16 CRITICL PROCESS OPERTION 10) LOCTE THE (SHORT) SUPPLY NOZZLE COMING OUT OF THE MULTIVLVE COLLR BUSHING 20) HNDSTRT THE CRIMPED FITTING ON THE GREEN SUPPLY HOSE ONTO THE SUPPLY NOZZLE ) USING 14mm OPEN END WRENCH ON THE SUPPLY NOZZLE FROM THE MULTIVLVE, THE FITTING ON THE HOSE WITH 15mm OPEN END CROWFOOT & WRENCH TO 14 Nm +/ ) LOCTE THE (LONG) RETURN NOZZLE COMING OUT OF THE MULTIVLVE COLLR BUSHING 50) HNDSTRT THE CRIMPED FITTING ON THE BLCK RETURN HOSE ONTO THE RETURN NOZZLE 60) USING 14mm OPEN END WRENCH ON THE RETURN NOZZLE FROM THE MULTIVLVE, THE FITTING ON THE HOSE WITH 15mm OPEN END CROWFOOT & WRENCH TO 14 Nm +/ ) LIGN ND SET CONVOLUTE ONTO TNK COLLR BUSHING ) OBTIN (1) 1-1/2" SCREW CLMP (); INSTLL CLMP ONTO CONVOLUTE; POSITION CLMP OVER TNK COLLR BUSHING ND TIGHTEN SET CONVOLUTE ONTO THIS BUSHING ND SECURE WITH CLMP PRT NUMBER QTY DESCRIPTION TOOLS /2" SCREW CLMP 14mm OPEN END WRENCH 1 14 Nm +/- 1.4 B REF 1 1-1/2" CORRUGTE HOSE 15mm CROWFOOT WRENCH PROCESS NME TTCH CHSIS SUPPLY & RETURN HOSES TO MULTIVLVE P11X PGE 1 OF 1

CRITICL PROCESS OPERTION 10 10) FROM THE DRIVERS SIDE OF THE

INLET 20 20) PLCE THE INTKE MNIFOLD ON TBLE WITH THE CENTER IR

TBLE RUNNING PRLLEL LONG THE TOP OF THE INTKE MNIFOLD; POSITION

THE MNIFOLD S SHOWN PRT NUMBER QTY DESCRIPTION TOOLS PROCESS

17 CRITICL PROCESS OPERTION 10 10) FROM THE DRIVERS SIDE OF THE ENGINE COMPRTMENT, REMOVE THE INTKE MNIFOLD FROM THE ENGINE IR INLET 20 20) PLCE THE INTKE MNIFOLD ON TBLE WITH THE CENTER IR INLET PORT FCING WY FROM YOU 30 30) PLCE 3 FOOT SCLE ON THE TBLE RUNNING PRLLEL LONG THE TOP OF THE INTKE MNIFOLD; POSITION THE BEGINNING EDGE OF THE SCLE EVEN TO THE UPPER LEFT EDGE OF THE MNIFOLD S SHOWN PRT NUMBER QTY DESCRIPTION TOOLS PROCESS NME INTKE MNIFOLD MODIFICTION & NOZZLE INSTLLTION P11X PGE 1 OF 4

CRITICL PROCESS OPERTION 40 40) MOVING FROM LEFT TO RIGHT, PLCE MRK ON THE FCING SIDE OF THE INTKE MNIFOLD T THE FOLLOWING INCH INCREMENTS S SHOWN 1 2 3 4 1) 1-1/2" 2) 3-1/2" 3)

POSSIBLE S SHOWN; THE PPROXIMTE MESUREMENTS RE S FOLLOWS: 5) 11-1/2" 6) 13-3/4" 5 6 60 60) THE NEXT TWO MRKS WILL NEED TO BE PLCED ON THE FCING SIDE OF THE IR INLET PORT T THE

18 CRITICL PROCESS OPERTION 40 40) MOVING FROM LEFT TO RIGHT, PLCE MRK ON THE FCING SIDE OF THE INTKE MNIFOLD T THE FOLLOWING INCH INCREMENTS S SHOWN ) 1-1/2" 2) 3-1/2" 3) 6-1/2" 4) 9" 50 50) CONTINUING FROM LEFT TO RIGHT, THE NEXT TWO MRKS WILL NEED TO BE PLCED ON THE TOP SIDE OF THE MNIFOLD S CLOSE TO THE LEFT SIDE OF THE MOUNTING BOSSES S POSSIBLE S SHOWN; THE PPROXIMTE MESUREMENTS RE S FOLLOWS: 5) 11-1/2" 6) 13-3/4" ) THE NEXT TWO MRKS WILL NEED TO BE PLCED ON THE FCING SIDE OF THE IR INLET PORT T THE FOLLOWING MESUREMENT LOCTIONS: 7) 17-1/2" 8) 19-1/2" 7 8 PRT NUMBER QTY DESCRIPTION TOOLS RULER / TPE MESURE PROCESS NME INTKE MNIFOLD MODIFICTION & NOZZLE INSTLLTION P11X PGE 2 OF 4

CRITICL PROCESS OPERTION 70 70) THE FINL FOUR MRKS WILL NEED TO BE PLCED ON THE FCING SIDE OF THE MNIFOLD T THE FOLLOWING MESUREMENT INCREMENTS: 9) 22-1/2" 10) 24-3/4" 11) 28" 12) 30" 9

0 TP 1 2 3 4 100) OBTIN (10) STRIGHT BRSS NOZZLES (); PPLY J-B WELD (OR EQUIVLENT) ONTO THE NOZZLE THREDS; HNDSTRT ND TIGHTEN (1) STRIGHT NOZZLE INTO ECH OF THE TPPED HOLES 7 8 9 10 11 12

19 CRITICL PROCESS OPERTION 70 70) THE FINL FOUR MRKS WILL NEED TO BE PLCED ON THE FCING SIDE OF THE MNIFOLD T THE FOLLOWING MESUREMENT INCREMENTS: 9) 22-1/2" 10) 24-3/4" 11) 28" 12) 30" ) USING 5/32" DRILL BIT, DRILL HOLE THROUGH THE MNIFOLD T ECH OF THE FOLLOWING LOCTIONS: 1, 2, 3, 4, 7, 8, 9, 10, 11, 12 90) TP ECH HOLE USING M6 x 1.0 TP ) OBTIN (10) STRIGHT BRSS NOZZLES (); PPLY J-B WELD (OR EQUIVLENT) ONTO THE NOZZLE THREDS; HNDSTRT ND TIGHTEN (1) STRIGHT NOZZLE INTO ECH OF THE TPPED HOLES PRT NUMBER QTY DESCRIPTION TOOLS STRIGHT BRSS NOZZLE DRILL 5/32" DRILL BIT 15/64" WRENCH M6 x 1.0 TP J-B WELD PROCESS NME INTKE MNIFOLD MODIFICTION & NOZZLE INSTLLTION P11X PGE 3 OF 4

CRITICL PROCESS OPERTION 110 120 110) USING 17/64" DRILL BIT, DRILL HOLE THROUGH THE MNIFOLD T THE REMINING #5 & #6 LOCTIONS 5 6 130 120) TP BOTH HOLES USING M8 x 1.

20 CRITICL PROCESS OPERTION ) USING 17/64" DRILL BIT, DRILL HOLE THROUGH THE MNIFOLD T THE REMINING #5 & #6 LOCTIONS ) TP BOTH HOLES USING M8 x 1.25 TP ) OBTIN (2) NGLE BRSS NOZZLES (B); PPLY J-B WELD (OR EQUIVLENT) ONTO THE NOZZLE THREDS 140) LOCTE THE 'NOTCH' JUST BOVE THE THREDS ON THE NOZZLE (THIS NOTCH SERVES S LOCTOR TO LLOW FOR THE CORRECT ORIENTTION OF THE NOZZLE ONCE IT IS INSTLLED) 150) INSTLL ND HNDSTRT (1) NGLE NOZZLE INTO THE TWO TPPED HOLES; INSERT 4mm LLEN WRENCH INTO THE TOP OF THE NOZZLE TO ROTTE ND SECURE NOZZLE IN PLCE (POSITION THE NOTCH IN BOTH NOZZLES T THE 12 O'CLOCK POSITION) 150 PRT NUMBER QTY DESCRIPTION TOOLS B NGLE BRSS NOZZLE 17/64" DRILL BIT M8 x 1.25 TP J-B- WELD PROCESS NME INTKE MNIFOLD MODIFICTION & NOZZLE INSTLLTION P11X PGE 4 OF 4

CRITICL PROCESS OPERTION #1 - FRONT 10) OBTIN THE FOLLOWING FUEL

FRONT #3 - MIDDLE RER (BRKT MOUNTED INJECTOR CONNECTOR SIDE) #4

MIDDLE FRONT #4 - RER PRT NUMBER QTY DESCRIPTION TOOLS 1

- MIDDLE FRONT 3 P11X4-2010- 1 FUEL RIL SSY - MIDDLE RER 4

21 CRITICL PROCESS OPERTION #1 - FRONT 10) OBTIN THE FOLLOWING FUEL RILS: #1 - FRONT (90 / STRIGHT RIL END FITTINGS) #2 - MIDDLE FRONT #3 - MIDDLE RER (BRKT MOUNTED INJECTOR CONNECTOR SIDE) #4 - RER (STRIGHT / 90 RIL END FITTINGS) #2 - MIDDLE FRONT #3 - MIDDLE FRONT #4 - RER PRT NUMBER QTY DESCRIPTION TOOLS 1 P11X FUEL RIL SSY - FRONT 2 P11X FUEL RIL SSY - MIDDLE FRONT 3 P11X FUEL RIL SSY - MIDDLE RER 4 P11X FUEL RIL SSY - RER PROCESS NME INSTLL FUEL RILS P11X PGE 1 OF 5

22 CRITICL PROCESS OPERTION 10 10) LOCTE THE (4) INJECTOR NOZZLES INSTLLED INTO THE SIDE OF THE INTKE MNIFOLD (#1, #2, #3, #4) T THE FRONT OF THE ENGINE 20) POSITION THE FRONT FUEL RIL SSY (#1) NEXT TO THE INJECTOR NOZZLES WITH THE CONNECTORS ON THE FUEL INJECTORS FCING WY FROM THE ENGINE ) STRTING WITH THE FRONT FUEL INJECTOR (#1), FULLY INSERT THE WHITE RISLN TUBE INTO THE FRONT (#1) INJECTOR NOZZLE ON THE INTKE MNIFOLD 40) FULLY INSERT THE RUBBER HOSE ONTO THE INJECTOR NOZZLE 20 50) USING PLIERS, COMPRESS THE LOWER CONSTNT TENSION CLMP ON THE RUBBER HOSE ND SLIDE THE CLMP DOWN UNTIL IT IS POSITIONED OVER THE INJECTOR NOZZLE; RELESE THE CLMP TO SECURE THE HOSE TO THE NOZZLE 60) REPET STEPS 30 THRU 50 FOR THE REMINING (3) FUEL INJECTORS IN SERIES FROM FRONT TO RER 70) SECURE THE FUEL RIL TO THE ENGINE USING ONE OF THE SUPPLIED HOLED BRCKETS PRT NUMBER QTY DESCRIPTION TOOLS 1 P11X FUEL RIL SSY - FRONT PLIERS PROCESS NME INSTLL FUEL RILS P11X PGE 2 OF 5

CRITICL PROCESS OPERTION 80) LOCTE THE (2) INJECTOR NOZZLES INSTLLED INTO THE TOP OF THE INTKE MNIFOLD (#5 & #6) 80 90) POSITION THE MIDDLE FRONT FUEL RIL SSY (#2) BOVE THE INJECTOR NOZZLES WITH THE

23 CRITICL PROCESS OPERTION 80) LOCTE THE (2) INJECTOR NOZZLES INSTLLED INTO THE TOP OF THE INTKE MNIFOLD (#5 & #6) 80 90) POSITION THE MIDDLE FRONT FUEL RIL SSY (#2) BOVE THE INJECTOR NOZZLES WITH THE CONNECTORS ON THE FUEL INJECTORS FCING WY FROM THE ENGINE ) STRTING WITH THE FRONT FUEL INJECTOR (#5), FULLY INSERT THE WHITE RISLON TUBE INTO THE FRONT (#5) INJECTOR NOZZLE ON THE TOP OF THE INTKE MNIFOLD ) FULLY INSERT THE WHITE RISLON TUBE ON FUEL INJECTOR (#6) INTO THE RER (#6) INJECTOR NOZZLE ON THE TOP OF THE INTKE MNIFOLD 120) FULLY INSERT BOTH RUBBER HOSES ONTO THE INJECTOR NOZZLES 130) USING PLIERS, COMPRESS THE LOWER CONSTNT TENSION CLMP ON ECH RUBBER HOSE ND SLIDE THE CLMP DOWN UNTIL IT IS POSITIONED OVER THE INJECTOR NOZZLE; RELESE THE CLMP TO SECURE THE HOSE TO THE NOZZLE 140) SECURE THE FUEL RIL TO THE ENGINE USING ONE OF THE SUPPLIED HOLED BRCKETS PRT NUMBER QTY DESCRIPTION TOOLS 2 P11X FUEL RIL SSY - MIDDLE FRONT PLIERS PROCESS NME INSTLL FUEL RILS P11X PGE 3 OF 5

CRITICL PROCESS OPERTION 150) LOCTE THE (2) INJECTOR NOZZLES INSTLLED INTO THE INTKE MNIFOLD BY THE IR INLET PORT (#7 & #8) 150 7 8 160) POSITION THE MIDDLE RER FUEL RIL SSY (#3) NEXT TO THE NOZZLES

24 CRITICL PROCESS OPERTION 150) LOCTE THE (2) INJECTOR NOZZLES INSTLLED INTO THE INTKE MNIFOLD BY THE IR INLET PORT (#7 & #8) ) POSITION THE MIDDLE RER FUEL RIL SSY (#3) NEXT TO THE NOZZLES WITH THE CONNECTORS ON THE FUEL INJECTORS FCING UP ) STRTING WITH THE FRONT FUEL INJECTOR (#7), FULLY INSERT THE WHITE RISLN TUBE INTO THE FRONT (#7) INJECTOR NOZZLE ON THE INTKE MNIFOLD 180) FULLY INSERT THE WHITE RISLN TUBE ON FUEL INJECTOR (#6) INTO THE RER (#6) INJECTOR NOZZLE ON THE TOP OF THE INTKE MNIFOLD 190) FULLY INSERT BOTH RUBBER HOSES ONTO THE INJECTOR NOZZLES 200) USING PLIERS, COMPRESS THE LOWER CONSTNT TENSION CLMP ON ECH RUBBER HOSE ND SLIDE THE CLMP DOWN UNTIL IT IS POSITIONED OVER THE INJECTOR NOZZLE; RELESE THE CLMP TO SECURE THE HOSE TO THE NOZZLE ) SECURE THE FUEL RIL TO THE ENGINE USING ONE OF THE SUPPLIED HOLED BRCKETS PRT NUMBER QTY DESCRIPTION TOOLS 3 P11X FUEL RIL SSY - MIDDLE RER PLIERS PROCESS NME INSTLL FUEL RILS P11X PGE 4 OF 5

25 CRITICL PROCESS OPERTION ) LOCTE THE (4) INJECTOR NOZZLES INSTLLED INTO THE SIDE OF THE INTKE MNIFOLD (#9, #10, #11, #12) T THE FRONT OF THE ENGINE ) POSITION THE RER FUEL RIL SSY (#4) NEXT TO THE INJECTOR NOZZLES WITH THE CONNECTORS ON THE FUEL INJECTORS FCING WY FROM THE ENGINE 240) STRTING WITH THE FRONT FUEL INJECTOR (#9), FULLY INSERT THE WHITE RISLN TUBE INTO THE FRONT (#9) INJECTOR NOZZLE ON THE INTKE MNIFOLD 250) FULLY INSERT THE RUBBER HOSE ONTO THE INJECTOR NOZZLE 260) USING PLIERS, COMPRESS THE LOWER CONSTNT TENSION CLMP ON THE RUBBER HOSE ND SLIDE THE CLMP DOWN UNTIL IT IS POSITIONED OVER THE INJECTOR NOZZLE; RELESE THE CLMP TO SECURE THE HOSE TO THE NOZZLE 270) REPET STEPS 30 THRU 50 FOR THE REMINING (3) FUEL INJECTORS IN SERIES FROM FRONT TO RER 280) SECURE THE FUEL RIL TO THE ENGINE USING ONE OF THE SUPPLIED HOLED BRCKETS PRT NUMBER QTY DESCRIPTION TOOLS 4 P11X FUEL RIL SSY - RER PLIERS PROCESS NME INSTLL FUEL RILS P11X PGE 5 OF 5

CRITICL PROCESS OPERTION 10) OBTIN THE FOLLOWING ENGINE HOSES: )

- RER FUEL RIL TO RETURN TEE B C) RETURN HOSE SSY - RETURN TEE TO

E) SUPPLY HOSE SSY - MIDDLE FRT FUEL RIL TO SUPPLY TEE C F)

HOSE SSY - MIDDLE RER FUEL RIL TO RER FUEL RIL D E F G PRT NUMBER

RIL TO TEE B P11X4-2809- 1 RETURN HOSE SSY - RER FUEL RIL TO TEE

D P11X4-2710- 1 SUPPLY HOSE SSY - FRT RIL TO MID FRT RIL E

1 SUPPLY HOSE SSY - MID RR RIL TO TEE PROCESS NME G P11X4-2707- 1

26 CRITICL PROCESS OPERTION 10) OBTIN THE FOLLOWING ENGINE HOSES: ) RETURN HOSE SSY - FRONT FUEL RIL TO RETURN TEE B) RETURN HOSE SSY - RER FUEL RIL TO RETURN TEE B C) RETURN HOSE SSY - RETURN TEE TO REGULTOR D) SUPPLY HOSE SSY - FRT FUEL RIL TO MIDDLE FRT FUEL RIL E) SUPPLY HOSE SSY - MIDDLE FRT FUEL RIL TO SUPPLY TEE C F) SUPPLY HOSE SSY - SUPPLY TEE TO MIDDLE RER FUEL RIL G) SUPPLY HOSE SSY - MIDDLE RER FUEL RIL TO RER FUEL RIL D E F G PRT NUMBER QTY DESCRIPTION TOOLS P11X RETURN HOSE SSY - FRT FUEL RIL TO TEE B P11X RETURN HOSE SSY - RER FUEL RIL TO TEE C P11X RETURN HOSE SSY - RETURN TEE TO REG. D P11X SUPPLY HOSE SSY - FRT RIL TO MID FRT RIL E P11X SUPPLY HOSE SSY - MID FRT RIL TO TEE F P11X SUPPLY HOSE SSY - MID RR RIL TO TEE PROCESS NME G P11X SUPPLY HOSE SSY - MID RR RIL TO RR RIL INSTLL ENGINE SUPPLY / RETURN HOSES P11X PGE 1 OF 7

CRITICL PROCESS OPERTION 20 20) OBTIN (1) TEE FITTING (H) H 30) 40) OBTIN THE RETURN HOSE SSY (B); HNDSTRT HOSE FITTING

THE REGULTOR HOSE IN LTER STEP) 60) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm 4 30 40 1 50 60 1 PRT

27 CRITICL PROCESS OPERTION 20 20) OBTIN (1) TEE FITTING (H) H 30) 40) OBTIN THE RETURN HOSE SSY (B); HNDSTRT HOSE FITTING ONTO THE FRONT 90 RIL END FITTING ON THE FRONT FUEL RIL SSY USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/ ) HNDSTRT THE OPPOSITE FITTING ON THE HOSE ONTO THE TEE FITTING S SHOWN (POSITION THE TEE 'UP' TO LLOW INSTLLTION OF THE REGULTOR HOSE IN LTER STEP) 60) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/ PRT NUMBER QTY DESCRIPTION TOOLS B P11X RETURN HOSE SSY - RER FUEL RIL TO TEE WRENCH H TEE FITTING - RETURN / SUPPLY 1 14 Nm +/ mm CROWFOOT PROCESS NME INSTLL ENGINE SUPPLY / RETURN HOSES P11X PGE 2 OF 7

CRITICL PROCESS OPERTION 70) OBTIN THE SUPPLY HOSE SSY (D); HNDSTRT THE FITTING ON ONE END OF THE HOSE ONTO THE RER FUEL RIL FITTING ON THE FRONT FUEL RIL SSY 80 1 80) USING WRENCH WITH 15mm

28 CRITICL PROCESS OPERTION 70) OBTIN THE SUPPLY HOSE SSY (D); HNDSTRT THE FITTING ON ONE END OF THE HOSE ONTO THE RER FUEL RIL FITTING ON THE FRONT FUEL RIL SSY ) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1.4 WHILE HOLDING THE RIL END FITTING IN PLCE WITH 12mm OPEN END WRENCH (MKE SURE THT THE 45 FITTING IS POINTING DOWN S SHOWN) 90) ROUTE THE OPPOSITE END OF THE HOSE TOWRD THE FRONT OF THE VEHICLE ND THEN UPWRD BETWEEN THE #3 ND #4 INJECTOR HOSES S SHOWN ) HNDSTRT THE OPPOSITE END HOSE FITTING ONTO THE FRONT FUEL RIL FITTING ON THE MIDDLE FRONT FUEL RIL S SHOWN 110) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1.4 WHILE HOLDING THE RIL END FITTING IN PLCE WITH 12mm OPEN END WRENCH 90 PRT NUMBER QTY DESCRIPTION TOOLS D P11X SUPPLY HOSE SSY - FRT RIL TO MID FRT RIL WRENCH 1 14 Nm +/ mm CROWFOOT 12mm OPEN END WRENCH PROCESS NME INSTLL ENGINE SUPPLY / RETURN HOSES P11X PGE 3 OF 7

CRITICL PROCESS OPERTION 120 130 1 120) OBTIN THE SUPPLY HOSE SSY (E); HNDSTRT HOSE FITTING ONTO THE RER END FITTING ON THE MIDDLE FRONT

4 WHILE HOLDING THE RIL END FITTING IN PLCE WITH 12mm OPEN END WRENCH 140 H 140) OBTIN (1) TEE FITTING (H) 150 150) POSITION THE TEE

170 1 170) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1.

29 CRITICL PROCESS OPERTION ) OBTIN THE SUPPLY HOSE SSY (E); HNDSTRT HOSE FITTING ONTO THE RER END FITTING ON THE MIDDLE FRONT FUEL RIL 130) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1.4 WHILE HOLDING THE RIL END FITTING IN PLCE WITH 12mm OPEN END WRENCH 140 H 140) OBTIN (1) TEE FITTING (H) ) POSITION THE TEE 'DOWN' S SHOWN 160) HNDSTRT THE OPPOSITE END HOSE FITTING ON THE SUPPLY HOSE SSY (E) ONTO ONE OF THE THRU FITTINGS ON THE TEE S SHOWN ) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1.4 PRT NUMBER QTY DESCRIPTION TOOLS E P11X SUPPLY HOSE SSY - MID FRT RIL TO TEE WRENCH 1 14 Nm +/- 1.4 H TEE FITTING - RETURN / SUPPLY 15mm CROWFOOT 12mm OPEN END WRENCH PROCESS NME INSTLL ENGINE SUPPLY / RETURN HOSES P11X PGE 4 OF 7

CRITICL PROCESS OPERTION 180) OBTIN THE SUPPLY HOSE SSY (G); HNDSTRT HOSE FITTING ONTO THE TEE FITTING S SHOWN 180 190 1 190) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1.

30 CRITICL PROCESS OPERTION 180) OBTIN THE SUPPLY HOSE SSY (G); HNDSTRT HOSE FITTING ONTO THE TEE FITTING S SHOWN ) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/ ) ROUTE OPPOSITE END OF SUPPLY HOSE SSY (G) DOWN ND LOOP BCK UP; HNDSTRT HOSE FITTING ONTO THE FRONT RIL END FITTING ON THE MIDDLE RER FUEL RIL SSY 210) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1.4 WHILE HOLDING THE RIL END FITTING IN PLCE WITH 12mm OPEN END WRENCH ) OBTIN THE SUPPLY HOSE SSY (F); HNDSTRT HOSE FITTING ON ONE END OF HOSE ONTO THE RER RIL END FITTING ON THE MIDDLE RER FUEL RIL SSY ) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1.4 WHILE HOLDING THE RIL END FITTING IN PLCE WITH 12mm OPEN END WRENCH 240) ROUTE OPPOSITE END OF HOSE DOWN ND TOWRDS THE FRONT OF THE VEHICLE ND THEN BCK UP TO THE FRONT RIL END FITTING ON THE RER FUEL RIL SSY; HNDSTRT HOSE FITTING ONTO RIL END FITTING ) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1.4 WHILE HOLDING THE RIL END FITTING IN PLCE WITH 12mm OPEN END WRENCH PRT NUMBER QTY DESCRIPTION TOOLS F P11X SUPPLY HOSE SSY - MID RR RIL TO TEE WRENCH G P11X SUPPLY HOSE SSY - MID RR RIL TO RR RIL 1 14 Nm +/ mm CROWFOOT 12mm OPEN END WRENCH PROCESS NME INSTLL ENGINE SUPPLY / RETURN HOSES P11X PGE 5 OF 7

CRITICL PROCESS OPERTION 260) OBTIN THE RETURN HOSE SSY (); HNDSTRT HOSE FITTING ON ONE END OF THE HOSE TO THE RER REIL END FITTING ON THE RER FUEL RIL SSY 270) USING WRENCH WITH 15mm CROWFOOT, THE

31 CRITICL PROCESS OPERTION 260) OBTIN THE RETURN HOSE SSY (); HNDSTRT HOSE FITTING ON ONE END OF THE HOSE TO THE RER REIL END FITTING ON THE RER FUEL RIL SSY 270) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/ ) ROUTE OPPOSITE END OF HOSE DOWN ND TOWRD THE FRONT OF THE VEHICLE 290) HNDSTRT OPPOSITE END HOSE FITTING ONTO THE RETURN TEE INSTLLED IN STEP # ) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/ PRT NUMBER QTY DESCRIPTION TOOLS P11X RETURN HOSE SSY - FRT FUEL RIL TO TEE WRENCH 1 14 Nm +/ mm CROWFOOT PROCESS NME INSTLL ENGINE SUPPLY / RETURN HOSES P11X PGE 6 OF 7

32 CRITICL PROCESS OPERTION 310) OBTIN THE RETURN HOSE SSY (C ); HNDSTRT HOSE FITTING ON ONE END OF THE HOSE ONTO THE RETURN TEE S SHOWN 320) USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/ PRT NUMBER QTY DESCRIPTION TOOLS C P11X RETURN HOSE SSY - RETURN TEE TO REG. WRENCH 1 14 Nm +/ mm CROWFOOT PROCESS NME INSTLL ENGINE SUPPLY / RETURN HOSES P11X PGE 7 OF 7

CRITICL PROCESS OPERTION 10 10) OBTIN THE REGULTOR SSY () 20) LOCTE THE RETURN HOSE SSY TTCHED TO THE RETURN TEE

FRONT FUEL RILS) WITH THE SIDE PORT FITTING ON THE REGULTOR FCING WY FROM THE ENGINE 20 30 40) HNDSTRT THE RETURN

FITTING TO 14 Nm +/- 1,4 50) USING SUPPLIED HOLE BRCKET, SECURE REGULTOR IN PLCE 40 1 PRT NUMBER QTY DESCRIPTION

33 CRITICL PROCESS OPERTION 10 10) OBTIN THE REGULTOR SSY () 20) LOCTE THE RETURN HOSE SSY TTCHED TO THE RETURN TEE FUEL FILTER CNISTER 30) POSITION THE REGULTOR SSY IN FRONT OF THE FUEL FILTER CNISTER (BETWEEN THE FRONT ND MIDDLE FRONT FUEL RILS) WITH THE SIDE PORT FITTING ON THE REGULTOR FCING WY FROM THE ENGINE ) HNDSTRT THE RETURN HOSE FITTING ONTO THE FITTING LOCTED ON THE BOTTOM OF THE REGULTOR; USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/- 1,4 50) USING SUPPLIED HOLE BRCKET, SECURE REGULTOR IN PLCE 40 1 PRT NUMBER QTY DESCRIPTION TOOLS REGULTOR WRENCH 14 Nm +/- 1.4 REF 2 DPTOR FITTING 1 15mm CROWFOOT PROCESS NME INSTLL REGULTOR P11X PGE 1 OF 1

CRITICL PROCESS OPERTION 20 10) LOCTE GREEN CHSSIS SUPPLY HOSE INSIDE THE DRIVER SIDE ENGINE COMPRTMENT 20) LOCTE THE SUPPLY TEE BEHIND THE FUEL FILTER CNISTER (BETWEEN THE MIDDLE FRONT ND MIDDLE RER

34 CRITICL PROCESS OPERTION 20 10) LOCTE GREEN CHSSIS SUPPLY HOSE INSIDE THE DRIVER SIDE ENGINE COMPRTMENT 20) LOCTE THE SUPPLY TEE BEHIND THE FUEL FILTER CNISTER (BETWEEN THE MIDDLE FRONT ND MIDDLE RER FUEL RILS) 30) DETERMINE THE LENGTH REQUIRED FOR THE CHSSIS SUPPLY HOSE TTCHMENT TO THE SUPPLY TEE; CUT HOSE WITH PPROVED HOSE CUTTER; SSEMBLE STRIGHT FIELD TTCHBLE FITTING ONTO END OF CHSSIS SUPPLY HOSE PER SSEMBLY INSTRUCTION P11X-9203-C 40) HNDSTRT HOSE FITTING ONTO SUPPLY TEE; USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/ ) LOCTE BLCK CHSSIS RETURN HOSE INSIDE THE DRIVER SIDE ENGINE COMPRTMENT 60) LOCTE THE REGULTOR SSEMBLY MOUNTED IN FRONT OF THE FUEL FILTER CNISTER 60 PRT NUMBER QTY DESCRIPTION TOOLS 1 14 Nm +/- 1.4 WRENCH 15mm CROWFOOT HOSE CUTTER PROCESS NME TTCH CHSSIS SUPPLY / RETURN HOSES (ENGINE COMPRTMENT) P11X PGE 1 OF 2

CRITICL PROCESS OPERTION 70) DETERMINE THE LENGTH REQUIRED FOR THE CHSSIS RETURN HOSE TTCHMENT TO THE REGULTOR; CUT HOSE WITH PPROVED HOSE CUTTER; SSEMBLE 90 DEGREE FIELD TTCHBLE FITTING ONTO END OF

35 CRITICL PROCESS OPERTION 70) DETERMINE THE LENGTH REQUIRED FOR THE CHSSIS RETURN HOSE TTCHMENT TO THE REGULTOR; CUT HOSE WITH PPROVED HOSE CUTTER; SSEMBLE 90 DEGREE FIELD TTCHBLE FITTING ONTO END OF CHSSIS RETURN HOSE PER SSEMBLY INSTRUCTION P11X-9203-C 80) HNDSTRT HOSE FITTING ONTO THE REGULTOR SIDE PORT FITTING; USING WRENCH WITH 15mm CROWFOOT, THE HOSE FITTING TO 14 Nm +/ PRT NUMBER QTY DESCRIPTION TOOLS 1 14 Nm +/- 1.4 WRENCH 15mm CROWFOOT HOSE CUTTER PROCESS NME TTCH CHSSIS SUPPLY / RETURN HOSES (ENGINE COMPRTMENT) P11X PGE 2 OF 2

36 CRITICL PROCESS OPERTION 30 10) OBTIN ICOM ECU MODULE () ND ENGINE WIRE HRNESS SSY (B) 20) INSTLL ECU MODULE BY IR INTKE FILTER OR INSIDE CBIN ON PSSENGER SIDE FLOOR 30) CONNECT MIN PLUG ON ICOM JTG-D ENGINE WIRE HRNESS SSY TO ECU MODULE 40) STRTING T THE FRONT OF THE ENGINE, CONNECT THE LPG FUEL INJECTOR LEDS J2 THRU J13 TO THE LPG FUEL INJECTORS 40 50) LOCTE WIRE LOOM 'E' ON THE ICOM ENGINE WIRE HRNESS (GREEN ND WHITE WIRES); REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF ECH OF THE WIRES 50 PRT NUMBER QTY DESCRIPTION TOOLS ICOM ECU MODULE WIRE STRIPPERS B ICOM JTG-D ENGINE WIRE HRNESS PROCESS NME INSTLL ECU MODULE & TTCH ICOM JTG- D ENGINE WIRE HRNESS P11X PGE 1 OF 13

CRITICL PROCESS OPERTION OPTION 1 60) ROUTE WIRE LOOM 'E' TO THE CRNK SENSOR LOCTED ON THE TOP DRIVER SIDE OF THE TRNSMISSION (GREEN ND WHITE WIRES) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM

37 CRITICL PROCESS OPERTION OPTION 1 60) ROUTE WIRE LOOM 'E' TO THE CRNK SENSOR LOCTED ON THE TOP DRIVER SIDE OF THE TRNSMISSION (GREEN ND WHITE WIRES) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM BOTH WIRES TO THE CRNK SENSOR 60 TTCH THE WHITE WIRE LED FROM WIRE LOOM 'E' ON THE ICOM ENGINE HRNESS TO THE STRIPPED PORTION OF THE WHITE WIRE ON THE CRNK SENSOR LED ON THE FCTORY WIRE HRNESS; SOLDER CONNECTION ND SEL WITH ELECTRICL TPE TTCH THE GREEN WIRE LED FROM WIRE LOOM 'E' ON THE ICOM ENGINE HRNESS TO THE STRIPPED PORTION OF THE GREEN WIRE ON THE CRNK SENSOR LED ON THE FCTORY WIRE HRNESS; SOLDER CONNECTION ND SEL WITH ELECTRICL TPE 60) OPTION 2 ROUTE WIRE LOOM 'E' TO THE CRNK SENSOR LEDS TTCHED TO THE GRY CONNECTOR ON THE FCTORY ECM MODULE CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM BOTH CRNK SENSOR WIRES GOING INTO THE ECM CONNECTOR TTCH THE WHITE WIRE LED FROM WIRE LOOM 'E' ON THE ICOM ENGINE HRNESS TO THE STRIPPED PORTION OF THE WHITE WIRE ON THE CRNK SENSOR LED ON THE FCTORY WIRE HRNESS; SOLDER CONNECTION ND SEL WITH ELECTRICL TPE 60 TTCH THE GREEN WIRE LED FROM WIRE LOOM 'E' ON THE ICOM ENGINE HRNESS TO THE STRIPPED PORTION OF THE GREEN WIRE ON THE CRNK SENSOR LED ON THE FCTORY WIRE HRNESS; SOLDER CONNECTION ND SEL WITH ELECTRICL TPE PRT NUMBER QTY DESCRIPTION TOOLS B ICOM JTG-D ENGINE WIRE HRNESS WIRE STRIPPER SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X B PGE 2 OF 13

38 CRITICL PROCESS OPERTION 70) LOCTE WIRE LOOM 'D' ON THE ICOM ENGINE WIRE HRNESS (GREEN ND WHITE WIRES); REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF ECH OF THE WIRES 80) ON WIRE LOOM 'D', LOCTE THE WIRE LBELED 'LS20' 70 90) LOCTE THE WIRE INSTLLED INTO PIN 'X1-2' ON THE CENTER CONNECTOR TO THE IDM SHOWN IN THE PHOTO BELOW 100) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE WIRE GOING INTO PIN 'X1-2' 110) TTCH THE 'LS20' WIRE FROM WIRE LOOM 'D' ON THE ICOM ENGINE WIRE HRNESS TO THE STRIPPED PORTION OF THE WIRE GOING INTO PIN 'X1-2' ON THE IDM CONNECTOR; SOLDER TTCHMENT ND SEL WITH ELECTRICL TPE PRT NUMBER QTY DESCRIPTION TOOLS B ICOM JTG-D ENGINE WIRE HRNESS WIRE STRIPPER SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 3 OF 13

39 CRITICL PROCESS OPERTION 120) ON WIRE LOOM 'D', LOCTE THE WIRE LBELED 'LS10' 130) LOCTE THE WIRE INSTLLED INTO PIN 'X2-1' ON THE LOWER CONNECTOR TO THE IDM SHOWN IN THE PHOTO BELOW ) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE WIRE GOING INTO PIN 'X2-1' 150) TTCH THE 'LS10' WIRE FROM WIRE LOOM 'D' ON THE ICOM ENGINE WIRE HRNESS TO THE STRIPPED PORTION OF THE WIRE GOING INTO PIN 'X2-1' ON THE IDM CONNECTOR; SOLDER TTCHMENT ND SEL WITH ELECTRICL TPE PRT NUMBER QTY DESCRIPTION TOOLS B ICOM JTG-D ENGINE WIRE HRNESS WIRE STRIPPER SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 4 OF 13

CRITICL PROCESS OPERTION 160) LOCTE WIRE LOOM 'C-1' TTCHED TO WIRE LOOM 'C' ON THE ICOM ENGINE WIRE HRNESS; REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF ECH OF THE WIRES 160 170) ON THE 'C-1'

40 CRITICL PROCESS OPERTION 160) LOCTE WIRE LOOM 'C-1' TTCHED TO WIRE LOOM 'C' ON THE ICOM ENGINE WIRE HRNESS; REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF ECH OF THE WIRES ) ON THE 'C-1' WIRE LOOM, LOCTE THE WIRE LBELED 'CNL-I' (BROWN WIRE) 180) LOCTE THE WIRE INSTLLED INTO PIN 'X2-13' ON THE GRY ECM CONNECTOR 190) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE WIRE GOING INTO PIN 'X2-13' 200) TTCH THE 'CNL-I' WIRE FROM WIRE LOOM 'C-1' ON THE ICOM ENGINE WIRE HRNESS TO THE STRIPPED PORTION OF THE WIRE GOING INTO PIN 'X2-13' ON THE ECM CONNECTOR; SOLDER TTCHMENT ND SEL WITH ELECTRICL TPE PRT NUMBER QTY DESCRIPTION TOOLS B ICOM JTG-D ENGINE WIRE HRNESS WIRE STRIPPER SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 5 OF 13

CRITICL PROCESS OPERTION 210) ON THE 'C-1' WIRE LOOM, LOCTE THE WIRE LBELED 'CNH-I' (WHITE WIRE) 220) LOCTE THE WIRE INSTLLED INTO PIN 'X2-6' ON THE GRY ECM CONNECTOR 210

THE STRIPPED PORTION OF THE WIRE GOING INTO PIN 'X2-6' ON THE ECM CONNECTOR; SOLDER TTCHMENT ND SEL WITH ELECTRICL TPE 220 230 240 PRT NUMBER QTY DESCRIPTION TOOLS B

41 CRITICL PROCESS OPERTION 210) ON THE 'C-1' WIRE LOOM, LOCTE THE WIRE LBELED 'CNH-I' (WHITE WIRE) 220) LOCTE THE WIRE INSTLLED INTO PIN 'X2-6' ON THE GRY ECM CONNECTOR ) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE WIRE GOING INTO PIN 'X2-6' 240) TTCH THE 'CNH-I' WIRE FROM WIRE LOOM 'C-1' ON THE ICOM ENGINE WIRE HRNESS TO THE STRIPPED PORTION OF THE WIRE GOING INTO PIN 'X2-6' ON THE ECM CONNECTOR; SOLDER TTCHMENT ND SEL WITH ELECTRICL TPE PRT NUMBER QTY DESCRIPTION TOOLS B ICOM JTG-D ENGINE WIRE HRNESS WIRE STRIPPER SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 6 OF 13

CRITICL PROCESS OPERTION 250) LOCTE WIRE LOOM 'C-2' TTCHED TO WIRE LOOM 'C' ON THE ICOM ENGINE WIRE HRNESS; REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF ECH OF THE WIRES 250 260) ON THE 'C-2'

42 CRITICL PROCESS OPERTION 250) LOCTE WIRE LOOM 'C-2' TTCHED TO WIRE LOOM 'C' ON THE ICOM ENGINE WIRE HRNESS; REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF ECH OF THE WIRES ) ON THE 'C-2' WIRE LOOM, LOCTE THE WIRE LBELED 'CNL-O' (BROWN WIRE) 270) LOCTE THE WIRE INSTLLED INTO PIN 'X3-31' INTO THE LOWER CONNECTOR ON THE IDM SHOWN IN THE PHOTO BELOW 280) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE WIRE GOING INTO PIN 'X3-31' ) TTCH THE 'CNL-O' WIRE FROM WIRE LOOM 'C-2' ON THE ICOM ENGINE WIRE HRNESS TO THE STRIPPED PORTION OF THE WIRE GOING INTO PIN 'X3-31' ON THE ECM CONNECTOR; SOLDER TTCHMENT ND SEL WITH ELECTRICL TPE PRT NUMBER QTY DESCRIPTION TOOLS B ICOM JTG-D ENGINE WIRE HRNESS WIRE STRIPPER SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 7 OF 13

CRITICL PROCESS OPERTION 300) ON THE 'C-2' WIRE LOOM, LOCTE THE WIRE LBELED 'CNH-O' (WHITE WIRE) 310) LOCTE THE WIRE INSTLLED INTO PIN 'X3-30' INTO THE LOWER CONNECTOR ON THE IDM SHOWN IN THE PHOTO

43 CRITICL PROCESS OPERTION 300) ON THE 'C-2' WIRE LOOM, LOCTE THE WIRE LBELED 'CNH-O' (WHITE WIRE) 310) LOCTE THE WIRE INSTLLED INTO PIN 'X3-30' INTO THE LOWER CONNECTOR ON THE IDM SHOWN IN THE PHOTO BELOW ) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE WIRE GOING INTO PIN 'X3-30' 330) TTCH THE 'CNH-O' WIRE FROM WIRE LOOM 'C-2' ON THE ICOM ENGINE WIRE HRNESS TO THE STRIPPED PORTION OF THE WIRE GOING INTO PIN 'X3-30' ON THE ECM CONNECTOR; SOLDER TTCHMENT ND SEL WITH ELECTRICL TPE PRT NUMBER QTY DESCRIPTION TOOLS B ICOM JTG-D ENGINE WIRE HRNESS WIRE STRIPPER SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 8 OF 13

44 CRITICL PROCESS OPERTION 340) LOCTE WIRE LOOM 'G' ON THE ICOM ENGINE WIRE HRNESS 350) ROUTE WIRE LOOM 'G' INTO THE DRIVER SIDE CBIN RE FOR LTER INSTLLTION TO THE COMMUTTOR 360) LOCTE WIRE LOOM 'F' ON THE ICOM ENGINE WIRE HRNESS ) ROUTE WIRE LOOM 'F' TOWRD THE LPG FUEL TNK 380) CONNECT THE 8-PIN CONNECTOR ON WIRE LOOM 'F' TO THE 8-PIN CONNECTOR ON THE FUEL TNK WIRE HRNESS (PUSH / PULL CONNECTORS TO VERIFY CONNECTORS RE FULLY SETED) 390) CONNECT THE 2-PIN CONNECTOR ON THE WIRE LOOM 'F' TO THE 2-PIN CONNECTOR ON THE FUEL TNK WIRE HRNESS (PUSH / PULL CONNECTORS TO VERIFY CONNECTORS RE FULLY SETED) PRT NUMBER QTY DESCRIPTION TOOLS B ICOM JTG-D ENGINE WIRE HRNESS PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 9 OF 13

45 CRITICL PROCESS OPERTION 400) OBTIN (1) FUSE HOLDER W/5 MP FUSE () ND (1) FUSE HOLDER W/30 MP FUSE (B) 410) LOCTE THE WIRE LOOM 'N' LBELED 'VKEY' (RED WIRE) ON THE ICOM ENGINE WIRE HRNESS 420) DETERMINE LOCTION ON THE 'VKEY' WIRE FOR INSTLLTION OF THE FUSE HOLDER W/5 MP FUSE (); CUT WIRE IN HLF ND INSTLL FUSE HOLDER PER ICOM WORK INSTRUCTION P11X PRT NUMBER QTY DESCRIPTION TOOLS FUSE HOLDER W/5 MP FUSE B FUSE HOLDER W/30 MP FUSE ICOM JTG-D ENGINE WIRE HRNESS PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 10 OF 13

46 CRITICL PROCESS OPERTION 430) LOCTE WIRE LOOM 'J-17' (VBT) TTCHED TO WIRE LOOM '' ON THE ICOM ENGINE WIRE HRNESS 440) DETERMINE LOCTION ON THE 'VBT' WIRE FOR INSTLLTION OF THE FUSE HOLDER W/30 MP FUSE (B); CUT WIRE IN HLF ND INSTLL FUSE HOLDER PER ICOM WORK INSTRUCTION P11X PRT NUMBER QTY DESCRIPTION TOOLS B FUSE HOLDER W/30 MP FUSE ICOM JTG-D ENGINE WIRE HRNESS PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 11 OF 13

47 CRITICL PROCESS OPERTION 450) LOCTE 'KEY ON' SOURCE ON FCTORY WIRE HRNESS; REMOVE PPROXIMTELY 1/2" OF INSULTION FROM WIRE; TTCH 'VKEY' (RED WIRE) FROM ICOM ENGINE WIRE HRNESS ONTO 'KEY ON' SOURCE ON FCTORY WIRE HRNESS; SOLDER ND SEL WITH ELECTRICL TPE 460) DISCONNECT ICOM ENGINE WIRE HRNESS CONNECTOR FROM ICOM ECU MODULE 470) FROM WIRE LOOM '' ON ICOM ENGINE WIRE HRNESS, CONNECT WIRE LOOM 'J-16' (BLCK WIRE) TO NEGTIVE SIDE OF BTTERY 480) FROM WIRE LOOM '' ON ICOM ENGINE WIRE HRNESS, CONNECT WIRE LOOM 'J-17' (RED WIRE W/30 MP FUSE INSTLLED) TO POSITIVE SIDE OF BTTERY PRT NUMBER QTY 1 DESCRIPTION ICOM JTG-D ENGINE WIRE HRNESS TOOLS WIRE STRIPPER SOLDER IRON SOLDER ELECTRICL TPE PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 12 OF 13

48 CRITICL PROCESS OPERTION 490) RE-CONNECT ICOM ENGINE WIRE HRNESS TO ICOM ECU MODULE 500) THE FOLLOWING WIRE LOOM CONNECTORS ON THE ICOM ENGINE WIRE HRNESS WILL NOT BE TTCHED: WIRE LOOM 'H' (4-PIN CONNECTOR) WIRE LOOM 'I' (4-PIN CONNECTOR - ICOM ECU BY-PSS) WIRE LOOM 'K' (4-PIN CONNECTOR) WIRE LOOM 'L' PRT NUMBER QTY DESCRIPTION TOOLS ICOM JTG-D ENGINE WIRE HRNESS PROCESS NME INSTLL ECU MODULE & TTCH ICOM ENGINE WIRE HRNESS P11X PGE 13 OF 13

INSTLL SUPPLIED DOUBLE SIDE DHESIVE TO BCKSIDE OF COMMUTTOR 40 PRT NUMBER QTY DESCRIPTION TOOLS 71301004 1

49 CRITICL PROCESS OPERTION 10 10) OBTIN (1) COMMUTTOR / UDIBLE INDICTOR KIT () 20) DETERMINE LOCTION FOR INSTLLTION OF THE COMMUTTOR ON THE INSTRUMENT PNEL 30) DRILL 3/8" HOLE THROUGH THE INSTRUMENT PNEL ) INSTLL SUPPLIED DOUBLE SIDE DHESIVE TO BCKSIDE OF COMMUTTOR 40 PRT NUMBER QTY DESCRIPTION TOOLS COMMUTTOR / UDIBLE INDICTOR KIT DRILL 3/8" DRILL BIT PROCESS NME INSTLL COMMUTTOR & UDIBLE INDICTOR P11X PGE 1 OF 2

CRITICL PROCESS OPERTION 50) LOCTE WIRE LOOM 'G' ON DRIVER SIDE OF VEHICLE UNDER INSTRUMENT PNEL 60) INSERT COMMUNTTOR LEDS THROUGH DRILLED HOLE; LIGN ND SET COMMUTTOR LED CONNECTOR ONTO CONNECTOR ON

50 CRITICL PROCESS OPERTION 50) LOCTE WIRE LOOM 'G' ON DRIVER SIDE OF VEHICLE UNDER INSTRUMENT PNEL 60) INSERT COMMUNTTOR LEDS THROUGH DRILLED HOLE; LIGN ND SET COMMUTTOR LED CONNECTOR ONTO CONNECTOR ON BCKSIDE OF THE COMMUTTOR (EXERCISE CRE NOT TO DMGE WIRE LEDS DURING INSTLLTION) 70) LIGN ND SET COMMUNTTOR ONTO INSTRUMENT PNEL 70 80) FOLLOW ENCLOSED COLOR SCHEME TO CONNECT COMMUNTTOR LEDS TO WIRE HRNESS LEDS (REFER TO COMMUTTOR KIT INSTRUCTIONS) 90) DETERMINE LOCTION ON BCKSIDE OF INSTRUMENT PNEL FOR UDIBLE INDICTOR (THIS MUST BE INSTLLED TO INFORM OF LOW FUEL CONDITION ND OTHER INFORMTION COMMUNICTED THROUGH THE COMMUNTTOR) UDIBLE INDICTOR 100) INSTLL UDIBLE INDICTOR USING PREFERRED METHOD (TPE / TIE WRP TO HRNESS, DO NOT COVER OPENING ON UDIBLE INDICTOR) PRT NUMBER QTY DESCRIPTION TOOLS COMMUTTOR KIT PROCESS NME INSTLL COMMUTTOR & UDIBLE INDICTOR P11X PGE 2 OF 2

CRITICL PROCESS OPERTION 10) CONNECT NEGTIVE LED TO BTTERY 20) INSPECT LL JTG ELECTRICL ND HOSE CONNECTIONS 40) CYCLE IGNITION TO STRT VEHICLE 50) VERIFY THE COMMUTTOR DOES SWEEP OF GREEN LIGHTS ND

51 CRITICL PROCESS OPERTION 10) CONNECT NEGTIVE LED TO BTTERY 20) INSPECT LL JTG ELECTRICL ND HOSE CONNECTIONS 40) CYCLE IGNITION TO STRT VEHICLE 50) VERIFY THE COMMUTTOR DOES SWEEP OF GREEN LIGHTS ND THE MBER LIGHT TURNS ON ND STYS ON 60) DRIVE VEHICLE TO PROPNE FILLING STTION ND FILL LPG FUEL TNK WITH PROPNE LIGHTS SWEEP 50 MBER LIGHT PRT NUMBER QTY DESCRIPTION TOOLS PROCESS NME PERFORM INITIL JTG SYSTEM CHECK P11X PGE 1 OF 1

CRITICL PROCESS OPERTION 10) T FILLING STTION, TURN VEHICLE OFF 20) TTCH FILL NOZZLE TO FILL VLVE 30) TURN PUMP DISPENSER ON; PUMP PPROXIMTELY 1 GLLON OF PROPNE INTO FUEL TNK 40 50 40) LOCTE BLEEDER

52 CRITICL PROCESS OPERTION 10) T FILLING STTION, TURN VEHICLE OFF 20) TTCH FILL NOZZLE TO FILL VLVE 30) TURN PUMP DISPENSER ON; PUMP PPROXIMTELY 1 GLLON OF PROPNE INTO FUEL TNK ) LOCTE BLEEDER VLVE ON FUEL TNK; LOOSEN BLEEDER VLVE ND PURGE TNK COMPLETELY (PURGE PROCESS IS ONLY DONE ON INITIL INSTLLTION ND NYTIME TNK IS SERVICED) 50) FTER FUEL TNK IS COMPLETELY PURGED, CLOSE BLEEDER VLVE 60) TURN PUMP DISPENSER ON; PUMP PPROXIMTELY 4-5 GLLONS OF PROPNE INTO FUEL TNK 70 70) STRT ENGINE; WHILE THE ENGINE IS RUNNING, THE GREEN LIGHTS ON THE COMMUTTOR WILL ILLUMINTE INDICTING FUEL LEVEL 80) PUSH BUTTON ON COMMUNTTOR; ORNGE LIGHT WILL FLSH FOR PREDETERMINED TIME; WHEN LIGHT STOPS FLSHING (CONTINUOUS ORNGE), THE ENGINE WILL BE RUNNING ON BOTH DIESEL ND PROPNE 90) SHUT ENGINE OFF 80 PRT NUMBER QTY DESCRIPTION TOOLS PROCESS NME PERFORM INITIL LPG FUEL FILL P11X PGE 1 OF 2

CRITICL PROCESS OPERTION 100) CHECK LPG CONNECTIONS FOR LEKS (USE SNOOP

FILLING FUEL TNK; SYSTEM SHOULD STOP FILLING ONCE LIQUID HS RECHED 80%

PUMP OFF; RE-INSTLL FILLER VLVE CP 100 120 PRT NUMBER QTY DESCRIPTION

53 CRITICL PROCESS OPERTION 100) CHECK LPG CONNECTIONS FOR LEKS (USE SNOOP SOLUTION); IF LEKING VERIFY FITTING ND REPIR S NECESSRY 110) CONTINUE FILLING FUEL TNK; SYSTEM SHOULD STOP FILLING ONCE LIQUID HS RECHED 80% INSIDE TNK 120) LOOSEN ND REMOVE FILL NOZZLE FROM FILL VLVE; TURN FILL PUMP OFF; RE-INSTLL FILLER VLVE CP PRT NUMBER QTY DESCRIPTION TOOLS PROCESS NME PERFORM INITIL LPG FUEL FILL P11X PGE 2 OF 2

CRITICL PROCESS OPERTION 10) VERIFY VLVE () IS CLOSED; REMOVE FITTING (B) LOCTED ON THE TOP OF THE PRESSURE REGULTOR 20) OBTIN (1) PRESSURE GUGE (B); INSTLL FITTING ON THE

LPG RUNNING PRESSURE (Pe). THE DIFFERENTIL (DP) BETWEEN THOSE TWO PRESSURES (Pe - P) HVE TO BE 50-70 PSI (FROM 3.4 TO 5.

54 CRITICL PROCESS OPERTION 10) VERIFY VLVE () IS CLOSED; REMOVE FITTING (B) LOCTED ON THE TOP OF THE PRESSURE REGULTOR 20) OBTIN (1) PRESSURE GUGE (B); INSTLL FITTING ON THE GUGE HOSE INTO PORT (B) OF THE REGULTOR TO CHECK LPG PRESSURE 30) OPEN VLVE () ON REGULTOR 40) WHEN INSTLLTION IS COMPLETE, MESURE LPG TNK PRESSURE (P) WITH ENGINE OFF ND LPG RUNNING PRESSURE (Pe). THE DIFFERENTIL (DP) BETWEEN THOSE TWO PRESSURES (Pe - P) HVE TO BE PSI (FROM 3.4 TO 5.0 BR) 10 ROTTE KNOB CLOCKWISE TO CLOSE PORT 'B' B ROTTE KNOB COUNTER CLOCKWISE TO OPEN PORT 'B' PRT NUMBER QTY DESCRIPTION TOOLS PRESSURE GUGE PROCESS NME PERFORM PRESSURE CHECK VERIFICTION P11X PGE 1 OF 2

55 CRITICL PROCESS OPERTION 50) STRT THE ENGINE ND LET THE ENGINE RUN DURING THE LPG 'SWITCHING OPERTION' (55 SECONDS); TURN ENGINE OFF ND MESURE LPG TNK PRESSURE (P) 60) STRT THE ENGINE ND MESURE PURGE PRESSURE (PP) WHILE ORNGE LIGHT IS FLSHING ON COMMUTTOR 70) MESURE THE WORKING PRESSURE (Pe) ONLY FTER THE ORNGE LIGHT ON COMMUNTTOR STYS ON STEDY (WHILE THE ENGINE IS RUNNING ON LPG) DIFFERENTIL PRESSURE (Pe -P) MUST BE BETWEEN 3.4 ND 5.0 BR 80) CLOSE VLVE ON REGULTOR; REMOVE PRESSURE GUGE PRT NUMBER QTY DESCRIPTION TOOLS PRESSURE GUGE PROCESS NME PERFORM PRESSURE CHECK VERIFICTION P11X PGE 2 OF 2

CRITICL PROCESS OPERTION N EXCESSIVE CURRENT MESURED ON THE FUEL PUMP POWER SUPPLY CIRCUIT WILL BE N INDICTION OF N IMPROPER FUNCTION OF THE JTG SYSTEM.

VERIFY MXIMUM CCEPTBLE VLUE IS 9.0 (USE MPROBE OR EQUIVLENT) 20) ON THE SYSTEM REMOVE THE MIN FUSE FROM THE JTG WIRE HRNESS ND CONNECT THE MULTIMETER S SHOWN. VERIFY THE MXIMUM CCEPTBLE VLUE IS 9.

56 CRITICL PROCESS OPERTION N EXCESSIVE CURRENT MESURED ON THE FUEL PUMP POWER SUPPLY CIRCUIT WILL BE N INDICTION OF N IMPROPER FUNCTION OF THE JTG SYSTEM. IT IS VERY IMPORTNT TO MESURE POWER SUPPLY FOR THE FUEL PUMP SYSTEM 10) ON THE FUEL PUMP CONNECT MULTIMETER TO THE FUEL PUMP POWER SUPPLY WIRE LED ON THE FUEL TNK WIRE HRNESS. VERIFY MXIMUM CCEPTBLE VLUE IS 9.0 (USE MPROBE OR EQUIVLENT) 20) ON THE SYSTEM REMOVE THE MIN FUSE FROM THE JTG WIRE HRNESS ND CONNECT THE MULTIMETER S SHOWN. VERIFY THE MXIMUM CCEPTBLE VLUE IS SET METER TO 'MPS' ND TEST IN SERIES MXIMUM POWER SUPPLY ON THE PUMP WIRE: 9.0 mps MXIMUM POWER SUPPLY ON THE SYSTEM: 9.0 TO 10.0 mps PRT NUMBER QTY DESCRIPTION TOOLS MPROBE PROCESS NME PERFORM FUEL PUMP POWER SUPPLY VERIFICTION P11X PGE 1 OF 1

57 Title: JTG-D INSTLLTION MNUL Document I.D.: P11X Page Rev B ISIONS ISION NUMBER ISION LEVEL DESCRIPTION OF CHNGE DTE PPROVED BY #60 WS 'ROUTE LOOM 'E' TO THE CRNK SENSOR P11X B LOCTED IN THE FRONT OF THE ENGINE (GREEN ND 11/26/2012 WHITE WIRES)' M. STEPPEY uthor: Marc Steppey pproval: Date: 11/26/2012 Title: Technical Manager Title: Initials

58 DT-466 WIRE DIGRM

59 ICOM JTG-D ENGINE WIRE HRNESS DIGRM

60 ICOM JTG-D ENGINE WIRE HRNESS DIGRM

E L MONOFUEL ENGINE SYSTEM INSTALLATION MANUAL (UTILIMASTER WALK-IN BODY) P13X AE

E L MONOFUEL ENGINE SYSTEM INSTALLATION MANUAL (UTILIMASTER WALK-IN BODY) P13X AE E450 6.8L MONOFUEL ENGINE SYSTEM INSTLLTION MNUL (UTILIMSTER WLK-IN BODY) P13X4-9229-E Revision: E - Dated 4/9/14 Replaces: D - Dated 9/19/13 INTRODUCTION! SFETY WRNING RED BEFORE STRTING THE INSTLLTION