Prins autogassystemen b.v. Veldhoven

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1 Prins autogassystemen b.v. Veldhoven MOUNTING INSTRUCTION ENGINE CONVERSION SET MAKE OF AUTOMOBILE: TYPE: ASTRA PISTON DISPLACEMENT: 2000 cc MT NUMBER OF VALVES: 16V ENGINE NUMBER: X20XEV INJECTION SYSTEM: MULTI-POINT INJECTION MODEL YEAR: 1998=> NUMBER : 076/ DATE :

2 PAGE 1 076/ GENERAL INSTRUCTIONS Do not place the 15 A 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 (refer to the last page). 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 15 A fuse. When installing the cable harness, ensure that it does not run near any of the ignition components. The power supply cable and the ground cable of the VSI system are always to be connected at the battery. Solder all electrical connections. Remove any internal burrs, after having shortened the LPG hose. (This guarantees the maximum flow through the hose.) If holes have to be drilled in order to facilitate mounting the device frame, the reservoir frame, the LPG cut-off valve, etc., the drilled holes must always be treated with an anti-corrosive, after the burrs have been removed. After having completed the installation, check the whole system for gas leakage; use a gas leak detection device. Mount the VSI-system according to the LPG regulations. Fill the warranty card in completely and return it within 8 days.

3 PAGE 2 076/ BASE VSI LAYOUT MODULE ELECTRICAL CONNECTIONS LPG TANK FILLER LOCK OFF VALVE FUEL LEVEL INDICATOR PETROL INJECTOR INJECTOR RAIL VSI PRESSURE RELIEF HOSE EVAPORATOR + LOCK OFF VALVE ECT SENSOR INJECTION 0 Psys + FILTER UNIT Tlpg SENSOR SWITCH PERSONAL COMPUTER MAIN FUSE 15 Amp ENGINE ECU IGNITION + RPM - + BEEPER ADAPTER BATTERY LAMBDA SENSOR VSI COMPUTER 5 Amp FUSE LPG INJECTORS PRINS

4 PAGE 3 076/ MOUNTING AND CONNECTION POINTS A Evaporator B Filter unit C Injector rail C J K F E G D E Computer Injector module I H F Water connections G Ignition + connection (13) B A D H I J Engine speed signal connection (40) Lambda sonde connection (46) '+' interruption injectors (26+27) K '-' connection injectors

5 PAGE 4 076/ MOUNTING THE EVAPORATOR Mount the evaporator by means of a bracket on the left frontside of the chassis frame. Drill a hole of 8.5 mm under (next to the big original hole) in the chassis. Mount the bracket with a 8mm bolt. Overpressure hose coupling: into the hard plastic hose coming from the leftside of the throttle housing Water connections: Parallel with the heater hoses on the scuttle board. Use thread locking agent when mounting the gas and water line couplings. Do not rotate the couplings after installation. However, you may rotate the gas and water lines, if required. Ensure that the 2 bolts of the gas valve have been fastened.

6 PAGE 5 076/ MOUNTING THE INLET MANIFOLD COUPLINGS Deside where to drill the holes, with the petrol injectors still in the manifold. Remove the petrol injectors and drill 4 holes of 4,8 mm in the inlet manifold. Make sure that the aluminium can not fall into the inlet manifold ). Tap M6 in these holes. Place the couplings with a lock compound in the inlet manifold. Watch out that the lock compound doesn t come inside the couplings. Mount the hoses on the couplings and drill holes into the plastic cable duct and put the hoses through. IMPORTANT Always check the inlet manifold coupling for leakage after installation. Spray brake cleaner onto the couplings and check whether the engine speed and the lambda signal change with the engine running on LPG.

7 PAGE 6 076/ MOUNTING THE INJECTOR RAIL Mount the bracket on the petrolrail, use the original m6 bolt.

8 PAGE 7 076/ MOUNTING THE FILTER UNIT Mount the filter unit by means of a bracket on the frontpanel near the battery.

9 PAGE 8 076/ TUBES Length of hose A, ø 16 mm = 50 cm Length of hose B, ø 6 mm = 130 cm Length of hose C, ø 11 mm = 60 cm Length of hose D, ø 6 mm = 25 cm Length of hose E, ø 6 mm = 20 cm Length of hose F, ø 6 mm = 19 cm Length of hose G, ø 6 mm = 18 cm Use a hose clip on all the connections. C A D E F G B

10 PAGE 9 076/ BASE ELECTRICAL DIAGRAM INJECTOR SIMULATOR 39 cylinder 1 cylinder 2 cylinder 3 cylinder 4 ENGINE ECU EVAPORATOR LAMBDA SONDE 46 FILTER UNIT INJECTOR RAIL VSI LPG VALVE PRINS CONNECTIONS LPG TANK RPM Not used 44 Not used Not used Not used 50 BATTERY PERSONAL COMPUTER 40 ECT SENSOR BEEPER SWITCH - + PETROL INJECTOR VSI COMPUTER IGNITION Amp 53 5 Amp (1-4) FUSE LPG INJECTORS

11 PAGE / MOUNTING THE COMPUTER Mount the computer by means of a bracket in front of the battery. Remove a piece of the plastic battery box.

12 PAGE / Mount the switch. MOUNTING THE FUEL SELECTION SWITCH Attention: 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 VSI SWITCH POWER SUPPLY SWITCH EN BEEPER (51) ARE EXCHANGABLE. VSI COMPUTER 8-POLE CONNECTORS BLUE POSITION 1 ON CONNECTOR TANK INDICATOR BEEPER BROWN POSITION 2 ON CONNECTOR YELLOW-GREEN 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

13 PAGE / ELECTRICAL CONNECTIONS ON THE LPG RESERVOIR The cable 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 PRINS BLACK BLUE GROUND SIGNAL TANKINDICATOR RED RED BLACK BLUE BLACK BLUE SOLDER THE CONNECTIONS IN THE FITTING BOX AND PROTECT THEM WITH A SHRINK SLEEVE.

14 PAGE / ELECTRICAL CONNECTION Cable number / code Cable colour Connection 50 MAIN GND brown Connect to the ' ' of the battery; use a ring terminal for this purpose V BAT red Connect to the '+' of the battery; use a ring terminal for this purpose. Do not place the 15 A into the fuse holder before having completed the installation of the LPG system. 50 LPGVLV GND brown Ground LPG shut-off valve. 2-pole connector shut-off valve LPG VLV yellow / green Power supply LPG shut-off valve. 42 ECT GND brown Ground ECT sensor. 2-pole black connector temperature sensor in the 43 ECT grey ECT measurement. evaporator. 22 RS232 TxD grey 4-pole black connector diagnosis cable connection. 23 RS232 RxD grey 50 DIAGNOSE GND brown V DIAG red 15 T LPG grey 4-pole black connector filter unit connection. 17 Psys pale green V Psys red 42 Psys GND brown 33 33G INJ OUT1 green / white Connector VSI-injector to cylinder G INJ A PLUS red See under 'Mounting the injector rail' for the cylinder numbers G INJ OUT2 green / white Connector VSI-injector to cylinder G INJ A PLUS red See under 'Mounting the injector rail' for the cylinder numbers G INJ OUT3 green / white Connector VSI-injector to cylinder G INJ A PLUS red See under 'Mounting the injector rail' for the cylinder numbers G INJ OUT4 green / white Connector VSI-injector to cylinder G INJ A PLUS red See under 'Mounting the injector rail' for the cylinder numbers. 44 TPS green For measuring the throttle valve position. Cable not used in this car: insulate. 16 MAP V MAP 42 MAP GND blue red brown For measuring the inlet manifold pressure (MAP). Cables not used in this car: insulate.

15 PAGE / ELECTRICAL CONNECTIONS 13 IGNITION + grey / white Make a connection to ignition + / contact +. Cable colour : thin BLACK Cable location : in the relay box, purple relay. 46 LAMBDA 1-L orange For the measurement of the lambda signal of cylinder bank 1. Connect the cable in parallel to the lambda sensor. Cable colour : BROWN-GREY Cable location : 4-pole connector, left side engine. Pos.D 40 RPM purple / white For measuring the engine speed. Cable colour : GREEN Cable location : in wiring harness 10 cm before the ECU connector (back side). 26 +B INJ IN 27 +B INJ OUT red red / white For interrupting injector power supply. Connect cable 26 to the main relay - injector power supply side and cable 27 to the injector side (refer to the injector diagram). Cable colour : RED-BLUE (4X) Cable location : in cable duct above petrol injectors. Cut 4 wires and make two splices. 54 INJ SIMULATOR red / black Power supply for the simulation of the injector(s). Connect the red / black cable (54) to the loose red cable of the injector simulator(s). For the connection of the injector simulator the control cables of the petrol injectors must be interrupted. Connect the red cables of the module to the injector side and the black cables of the module to the computer side. Do not interchange the red and the black cables, but connect those as a pair to each of the injectors (refer to the injector diagram). Module location: inside relay box, behind battery.

16 PAGE / ELECTRICAL CONNECTIONS For measuring the petrol injectors. Connect each yellow / white measuring cable to the position at which the control cables of the petrol injectors have been interrupted (refer to the injector diagram). Injector cable locations: in cable duct above petrol injectors. 39 B INJ IN 1 38 B INJ IN 2 37 B INJ IN 3 36 B INJ IN 4 yellow / white yellow / white yellow / white yellow / white Cylinder cable colour 1 : BROWN-RED Cylinder cable colour 2 : BROWN-WHITE Cylinder cable colour 3 : BROWN-BLACK Cylinder cable colour 4 : BROWN-GREEN Attention: Each yellow / white measuring cable corresponds to a specific LPG injector and cylinder number. Do not interchange the cables. Refer to the page 'mounting the injector rail' for the correct cylinder numbers. RED-BLACK YELLOW-WHITE 54 VSI COMPUTER RED RED INJECTOR SIMULATOR BLACK RED RED-WHITE GREEN-WHITE RED - + VSI INJECTOR PETROL INJECTOR interrupt the power supply of each injector

17 PAGE / CHECKLIST AFTER THE INSTALLATION 1. Connect the serial interface cable and run the VSI diagnosis program. 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 on generating error codes. To activate the VSI computer, select function F11 (activate ECM). 3. Check whether the program in the VSI computer matches with the car: Refer with F2 to the box number and car description in the diagnosis software and compare these with the packer's number. 4. The system will switch over to LPG as soon as the temperature of the coolant (T-ect) becomes higher than the parameter T-min set. 5. Check all components and connections for any gas or water leakage. 6. Let the engine run warm on petrol. Adjust the evaporator pressure: Let the engine run idle on LPG. Refer to the parameter list for the idle level value set. Adjust the evaporator pressure in such a way that the pressure measured ( P-sys ) equals the idle level value. Turn the socket-head 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 all input and output signals. 8. Check the system for error codes and solve these, if required. Check the MMS for EOBD error codes. 9. Make a test drive.

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