ICOM JTG-II LIQUID PROPANE INJECTION INSTALLATION MANUAL P11X AD

Transcription

1 ICOM JTG-II LIQUID PROPANE INJECTION INSTALLATION MANUAL PX AD Revision: D - Dated 9/30/6 Replaces: C - Dated 2/5/5

2 INTRODUCTION! SAFETY WARNING READ BEFORE STARTING THE INSTALLATION OF THE ICOM JTG SYSTEM. ENSURE THAT ALL PERSONNEL IN THE IMMEDIATE AREA ARE AWARE OF THESE REMINDERS.! PROPANE IS A NONTOXIC, NONPOISONOUS GAS THAT IS EXTREMELY FLAMMABLE. IF SOMETHING IGNITES IT, YOU COULD BE BADLY BURNED. KEEP SPARKS, OPEN FLAMES AND SMOKING MATERIAL AWAY FROM PROPANE.! LIQUID PROPANE IS EXTREMELY COLD (-40 F) AND CAUSE SERIOUS BURNS WHEN CONTACTING YOUR SKIN OR EYES. PENT CONTACT WHEN HANDLING LPG BY WEARING APPROVED PROTECTIVE GLOVES AND EYE PROTECTION.! PROPANE IS STORED UNDER PRESSURE. THE FUEL SYSTEM OPERATES AT PRESSURES OF UP TO 32 PSI. A SUDDEN RELEASE OF PROPANE CAN CAUSE SERIOUS INJURIES. THESE INSTRUCTIONS ARE INTENDED FOR TECHNICIANS WHO ARE CERTIFIED BY ALL AGENCIES THAT GOVERN PROPANE INSTALLATIONS AND THE TRANSPORTATION OF PROPANE. THE NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) PUBLISHES A CODE BOOK OF RULES (NFPA 58) THAT APPLY TO THE STORAGE, HANDLING, TRANSPORTATION AND USE OF LIQUEFIED PETROLEUM GAS (LPG). LOCAL PROPANE SUPPLIERS SUCH AS FERRELGAS AND AMERIGAS, AS WELL AS SOME AGENGIES SUCH AS THE TEXAS RAILROAD COMMISION AND PERC (PROPANE EDUCATION & RESEARCH COUNCIL) OFFER INFORMATIVE COURSES TO HELP PENT SEVERE INJURY OR DEATH TO YOU OR SOMEONE ELSE IF YOU DON'T FULLY UNDERSTAND LPG AND ITS PROPERTIES. BEGIN THE INSTALLATION BY PREPARING YOUR WORK SITE. THE AREA SHOULD BE CLEAN WITH SUFFICIENT LIGHTING. YOU WILL NEED: ) A WORKBENCH 2) TOOLS, INCLUDING SOCKETS, SCREWDRIVERS, WRENCH, METAL CUTTING TOOLS (SMALL RECIPROCATING SAW, NIBBLERS, DRILLS, ECTC.) 3) SAFETY GLASSES, GLOVES AND HEARING PROTECTION 4) FUEL PRESSURE GAUGE (ICOM # ) AND CALIBRATOR REMOVAL TOOL (ICOM # ) 5) SOURCE OF COMPRESSED AIR 6) VEHICLE LIFT WITH, PREFERABLY, A MODIFIED TRANSMISSION JACK TO SUPPORT THE FUEL TANK DURING FITMENT AND INSTALLATION 7) A 'FLUKE 77' MULTIMETER WITH TIME-BASED READOUT (REQUIRED FOR CALIBRATION & DIAGNOSTICS ONLY, NOT NEEDED FOR GENERAL INSTALLATION). 8) METRIC TAP (8 x.25) AND DRILL INDEX

3 INTRODUCTION! IMPORTANT IT IS IMPORTANT THAT YOU IEW THIS ENTIRE INSTALLATION MANUAL BEFORE BEGINNING TO FAMILIARIZE YOURSELF WITH THE INSTALLATION PROCESS. THIS WILL HELP MINIMIZE ANY POTENTIAL ERRORS THAT MAY OCCUR IF A PROCESS IS CONDUCTED OUT OF SEQUENCE.! INSTALLATION PLEASE REFERENCE THE APPLICABLE STANDARDS WITHIN NFPA 58, FMVSS AND CSA (CANADA ONLY) TO INSURE THE FUEL TANK AND LPG COMPONENTS ARE INSTALLED PROPERLY. IN ADDITION, FOR EXTERNALLY MOUNTED TANKS, PLEASE REFERENCE SAE J689 (CURBSIDE CLEARANCE, APPROACH, DEPARTURE, AND RAMP BREAKOVER ANGLES) AS A GUIDELINE.! THREADED FUEL LINE CONNECTORS / FITTINGS THE ICOM FUEL HOSES ARE EQUIPPED WITH THREADED END CONNECTORS THAT SEAL WHEN THE PROPER IS APPLIED. DO NOT USE TEFLON TAPE ON ANY FITTING AS THIS MAY GET INTO THE REGULATOR OR FUEL INJECTORS AND CAUSE FUEL PRESSURE PROBLEMS. ANY WARRANTY RETURNED COMPONENT FOUND CONTAMINATED WTH TEFLON TAPE WILL BE RETURNED.! BARE METAL SURFACES ANYTIME THE OEM PAINTED SURFACE IS BROKEN BY DRILLING OR REMOVAL OF A PARTICULAR COMPONENT, THE EXPOSED METAL SURFACE MUST BE DEBURRED AND COATED WITH A PRIMER OR SEALER TO PENT RAPID CORROSION. THIS IS EXTREMELY IMPORTANT IN AREAS THAT USE ROAD SALT DURING THE WINTER MONTHS. FOLLOW THE LABEL INSTRUCTIONS ON THE PRODUCT USED TO ENSURE POSITIVE RESULTS.! HEAT SHIELDING EXERCISE CAUTION WHEN ROUTING HOSES AND WIRE HARNESSES TO AVOID DAMAGE DUE TO CHAFFING, CUTTING OR EXTREME HEAT. USE CORRUGATED CONDUIT OR HEAT SHIELDING MATERIAL AS REQUIRED TO PENT ANY POTENTIAL DAMAGE TO THESE COMPONENTS. HEAT SHIELDING MAY ALSO BE REQUIRED BY THE FUEL TANK TO PENT EXCESSIVE HEATING OF THE LPG INSIDE THE TANK. (NOTE - INSTALLER TO PROVIDE HEAT SHIELDING IF NECESSARY) NFPA 58 CONTAINERS LOCATED LESS THAN 8 IN. (460mm) FROM THE EXHAUST SYSTEM, THE TRANSMISSION, OR A HEAT PRODUCING COMPONENT SHALL BE SHIELDED BY A VEHICLE FRAME MEMBER OR BY A NONCOMBUSTIBLE BAFFLE.7..3 WITH AN AIR SPACE ON BOTH SIDES OF THE FRAME OR BAFFLE.! PACKAGING CAREFULLY INSPECT THE CONTENTS OF THE KIT ONCE YOU RECEIVE IT TO ENSURE THAT ALL OF THE COMPONENTS ARE AVAILABLE BEFORE STARTING THE INSTALLATION. A PARTS LIST IS ENCLOSED WITH THIS MANUAL. THE LIST OF PARTS MAY VARY BASED ON THE APPLICATION.

4 INSTALLATION KIT CONTENTS THE INSTALLATION KIT CONTENTS LISTED BELOW IS A GENERAL OVERVIEW AND MAY VARY BASED ON THE APPLICATION. PLEASE REFER TO THE PACKING SLIP ENCLOSED WITH THE KIT FOR THE LATEST KIT CONTENT FOR THE APPLICATION. PACKAGE A PART NUMBER COMPONENT QTY PX4-422 ICOM JTG ENGINE WIRE HARNESS ASSY (4-CYLINDER ENGINE) P3X ICOM JTG ENGINE WIRE HARNESS ASSY (6-CYLINDER ENGINE) PX ICOM JTG ENGINE WIRE HARNESS ASSY (8-CYLINDER ENGINE) PX ICOM JTG ENGINE WIRE HARNESS ASSY (0-CYLINDER ENGINE) 0000 GROMMET - WIRE HARNESS PACKAGE B PART NUMBER COMPONENT QTY UNIT 'B' MODULE PACKAGE C PART NUMBER COMPONENT QTY UNIT 'A' MODULE PACKAGE D PART NUMBER COMPONENT QTY COMMUTATOR INJECTOR HOSE NOZZLE (4-CYLINDER ENGINE) INJECTOR HOSE NOZZLE (6-CYLINDER ENGINE) INJECTOR HOSE NOZZLE (8-CYLINDER ENGINE) INJECTOR HOSE NOZZLE (0-CYLINDER ENGINE) NTC SENSOR ICOM TEMPERATURE SENSOR HOSE ADAPTOR (LARGE) ICOM TEMPERATURE SENSOR HOSE ADAPTOR (SMALL) #8 HOSE CLAMP /6" HEAT SHRINK TUBE ( FOOT) RING TERMINAL (SMALL) RING TERMINAL (LARGE) " TIE STRAP ADD-A-CIRCUIT FUSE HOLDER (2.0L ENGINE ONLY) AMP MINI FUSE (2.0L ENGINE ONLY) 8 PACKAGE E PART NUMBER COMPONENT QTY BRACKET - ICU MODULE NUT - M4 NYLOCK SCREW - M4-0.7 x SCREW - M4-0.7 x 60 2 PACKAGE F PART NUMBER COMPONENT QTY FUEL RAIL ASSEMBLY (ENGINE & VEHICLE SPECIFIC) OR 2

5 INSTALLATION KIT CONTENTS PACKAGE G PART NUMBER COMPONENT QTY PX REGULATOR ASSY PX BRACKET ASSY - REGULATOR P3X NON-RETURN VALVE ASSY P4X4-939 BRACKET ASSY - NON-RETURN VALVE PACKAGE H INLINE FUEL FILL FILTER /4" REUSABLE FERRULE /4" REUSABLE STRAIGHT FITTING " CABLE CLAMP /2" CABLE CLAMP /8" CABLE CLAMP SCREW - SELF TAPPING 7 PACKAGE I PART NUMBER COMPONENT QTY (-PER) P6X ICOM BLACK FILL HOUSING W/ACME FILL VALVE P6X ICOM BLACK FILL HOUSING W/EURO FILL VALVE P6X4-933 ICOM CHROME FILL HOUSING W/ACME FILL VALVE P6X ICOM CHROME FIL HOUSING W/EURO FILL VALVE P6X ACME FILL VALVE W/BRACKET (F250/F350) P6X EURO VILL VALVE W/BRACKET (F250/F350) REMOTE FUEL FILL VALVE (ACME) REMOTE FUEL FILL VALVE (EURO) PACKAGE J PART NUMBER COMPONENT QTY ICOM NAMEPLATE PX-9420 DIAMOND PROPANE LABEL PX-920 ICOM OWNERS MANUAL HOSES (ENGINE) PART NUMBER COMPONENT QTY (-PER) PX4-3 HOSE KIT - ENGINE P4X4-324 HOSE KIT - ENGINE (3.7L TRANSIT ONLY) P5X4-334 HOSE KIT - ENGINE (3.7L EXPLORER & F50 ONLY) HOSES (CHASSIS) PART NUMBER COMPONENT QTY (-PER) PX4-308 HOSE KIT - CHASSIS (L=20') PX4-30 HOSE KIT - CHASSIS (L=25') PX4-39 HOSE KIT - CHASSIS (L=30') 000 GROMMET (IN BED AND INTERNAL MOUNT TANKS ONLY) 2

6 INSTALLATION KIT CONTENTS HOSES (FUEL FILL) PART NUMBER COMPONENT QTY (-PER) PX HOSE KIT - REMOTE FUEL FILL (L=0') PX HOSE KIT - REMOTE FUEL FILL (L=5') PX HOSE KIT - REMOTE FUEL FILL (L=20') PX HOSE KIT - REMOTE FUEL FILL (L=25') HOSES (REMOTE BLEEDER) - OPTIONAL PART NUMBER COMPONENT QTY (-PER) PX4-309 HOSE KIT - REMOTE BLEEDER (L=0') PX4-32 HOSE KIT - REMOTE BLEEDER (L=5') PX4-33 HOSE KIT - REMOTE BLEEDER (L=20') PX4-34 HOSE KIT - REMOTE BLEEDER (L=25') CORRUGATE PART NUMBER COMPONENT QTY /2" SPLIT CORRUGATE (L=0') (ENGINE HOSES) /4" SOLID CORRUGATE (L=0') (FILL HOSE) /4" SOLID CORRUGATE (L=5') (FILL HOSE) /4" SOLID CORRUGATE (L=20') (CHASSIS / FILL HOSE) /4" SOLID CORRUGATE (L=25') (CHASSIS / FILL HOSE) /4" SOLID CORRUGATE (L=30') (CHASSIS) HEAT SHIELD TUBING - 2 ACCESSORIES PART NUMBER COMPONENT QTY PX4-205 GM FUEL PRESSURE SENSOR BY-PASS KIT (GM 4.8L & 5.3L) (OPTIONAL) P3X4-320 EVAP RELOCATION KIT (E-SERIES 3x60, 3x80 & 3x92 TANKS ONLY) P3X4-405 PROPANE OPTOMIZATION PROGRAM (POP) (EMERGENCY VEHICLES) P3X4-406 PROPANE OPTOMIZATION PROGRAM (POP) (FLEET VEHICLES) P3X4-409 FORD FUEL GAUGE RESET MODULE (203 & OLDER) P6X4-424 FORD FUEL GAUGE RESET MODULE (204 & NEWER) P6X4-704 FUEL FILL FILTER KIT (OPTIONAL) PX4-93 ICOM VAPOR SEAL KIT (OPTIONAL) P5X ICOM VAPOR SEAL KIT (EXPLORER ONLY) (OPTIONAL) P6X ICOM VAPOR SEAL KIT (TRANSIT ONLY) (OPTIONAL) P3X ICOM SYSTEM TOOL KIT (OPTIONAL)

7 TABLE OF CONTENTS PROCESS # PX INSTALL FUEL TANK C PX INSTALL ICOM FUEL FILL HOUSING C PX INSTALL ICOM FUEL FILL HOSE D PX INTAKE MANIFOLD MODIFICATION & NOZZLE INSTALLATION C PX INSTALL LPG FUEL RAIL ASSEMBLY C PX INSTALL INLINE FUEL FILTER D PX INSTALL NON-RETURN VALVE & ENGINE SUPPLY HOSES D PX INSTALL REGULATOR & ENGINE RETURN HOSES D PX INSTALL ICU MODULES D PX INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY D PX INSTALL ICOM TEMPERATURE SENSOR D PX INSTALL COMMUTATOR & AUDIBLE INDICATOR C PX INSTALL PROPANE OPTIMIZATION PROGRAM (POP) SWITCH (OPTIONAL) D PX INSTALL VEHICLE / MODEL SPECIFIC MODULES D PX ATTACH NEGATIVE CABLE TO BATTERY D PX CONNECT ICOM JTG ENGINE WIRE HARNESS ASSY TO BATTERY D PX PERFORM INITIAL ICOM JTG SYSTEM CHECK C PX PERFORM INITIAL LPG FUEL FILL AND SYSTEM ACTIVATION C PX PERFORM PRESSURE CHECK VERIFICATION C PX FINAL INSPECTION AND SYSTEM CHECK C PX TROUBLESHOOTING D

8 NUMBER REFERENCE THE ICOM FUEL TANK INSTALLATION INSTRUCTION 5X LOCATED ON THE ICOM WEBSITE DESCRIPTION TOOLS INSTALL FUEL TANK PX C OF

9 NUMBER REFERENCE THE ICOM FUEL FILL HOUSING INSTALLATION INSTRUCTION 5X LOCATED ON THE ICOM WEBSITE DESCRIPTION TOOLS INSTALL FUEL FILL HOUSING PX C OF

10 NUMBER REFERENCE THE ICOM FUEL FILL HOSE INSTALLATION INSTRUCTION 5X LOCATED ON THE ICOM WEBSITE DESCRIPTION TOOLS INSTALL FUEL FILL HOSE PX D OF

11 NUMBER 0 0) OPEN HOOD ON VEHICLE; FROM THE FRONT OF THE VEHICLE, DISCONNECT THE NEGATIVE CABLE FROM THE BATTERY 20 20) LOOSEN & REMOVE THE AIR INLET TUBE AND SET ASIDE 30) REMOVE THE EVAP HOSE FROM THE INLET AS SHOWN 40) LOOSEN AND REMOVE THE CLAMP THAT SECURES THE INLET HOSE TO THE THROTTLE BODY; REMOVE THE INLET HOSE FROM THE THROTTLE AND SET ASIDE DESCRIPTION TOOLS INTAKE MANIFOLD MODIFICATION & NOZZLE INSTALLATION PX C OF 7

12 NUMBER 50 50) DISCONNECT THE OEM WIRE HARNESS LEADS FROM ALL GASOLINE FUEL INJECTORS 60 60) DISCONNECT THE OEM GASOLINE SUPPLY LINE ATTACHED TO THE DRIVER SIDE GASOLINE FUEL RAIL 70) DRAIN COOLING SYSTEM 80) REMOVE INTAKE MANIFOLD FROM ENGINE DESCRIPTION TOOLS INTAKE MANIFOLD MODIFICATION & NOZZLE INSTALLATION PX C 2 OF 7

13 NUMBER THE ANGULAR NOZZLE IN THE PICTURE ALLOWS FLEXIBILITY TO ORIENTATE THE LPG FLOW IN THE SAME DIRECTION OF THE GASOLINE FLOW 0 90) A HOLE MUST BE DRILLED INTO EACH INLET ON THE INTAKE MANIFOLD INSURING PROPER POSITIONING OF THE HOLES IN THE SAME DIRECTION AS THE GASOLINE INJECTOR (REFERENCE EXAMPLES ON S 5 & 6 OF THIS SECTION) 00) DRILL A /4" HOLE INTO THE (8) INTAKE PORTS ON THE MANIFOLD; TAP EACH HOLE WITH A M8 X.25 TAP THREAD SEALER PLASTIC MANIFOLD - EPOXY METAL MANIFOLD - J & B WELD 0) OBTAIN (8) ANGULAR NOZZLES (A); APPLY APPROPRIATE SEALER TO THREADS (SEE THREAD SEALER NOTE) 20) INSERT AND HANDTIGHTEN NOZZLES INTO DRILLED HOLES IN INTAKE MANIFOLD J & B WELD OR EQUIVALENT 0 METAL INTAKE MANIFOLD DESCRIPTION TOOLS A ANGULAR NOZZLE - 29mm 4mm ALLEN WRENCH INTAKE MANIFOLD MODIFICATION & NOZZLE INSTALLATION PX C 3 OF 7

14 NUMBER 30) USING A 4MM ALLEN WRENCH, SECURE NOZZLES INTO INTAKE MANIFOLD (POSITION ANGLE ON NOZZLE TOWARD THE GASOLINE INJECTOR - INSURE THE LPG SPRAY DOES NOT SPRAY THE INTAKE MANIFOLD WALLS) METAL INTAKE MANIFOLD 30 0 METAL INTAKE MANIFOLD DESCRIPTION TOOLS A ANGULAR NOZZLE - 29mm 4mm ALLEN WRENCH INTAKE MANIFOLD MODIFICATION & NOZZLE INSTALLATION PX C 4 0F 7

15 NUMBER ICOM INJECTOR NOZZLE INSTALLATION LOCATIONS FORD 3.7L ENGINE FORD 5.4L ENGINE DESCRIPTION TOOLS INTAKE MANIFOLD MODIFICATION & NOZZLE INSTALLATION PX C 5 OF 7

16 NUMBER ICOM INJECTOR NOZZLE INSTALLATION LOCATIONS FORD 6.8L ENGINE DESCRIPTION TOOLS INTAKE MANIFOLD MODIFICATION & NOZZLE INSTALLATION PX C 6 OF 7

17 NUMBER ICOM INJECTOR NOZZLE INSTALLATION LOCATIONS FORD 6.2L ENGINE DESCRIPTION TOOLS INTAKE MANIFOLD MODIFICATION & NOZZLE INSTALLATION PX C 7 OF 7

18 NUMBER 0) OBTAIN () FUEL RAIL ASSEMBLY (A); LOCATE THE CHECK VALVE LOCATED ON THE END OF THE FUEL RAIL (THE RETURN HOSE WILL BE ATTACHED TO THE CHECK VALVE DURING FINAL ASSEMBLY - VERIFY RAIL IS POSITIONED TO ALLOW INSTALLATION OF THE RETURN HOSE) 0 20) POSITION FUEL RAIL WITH INJECTOR CONNECTORS FACING 'DOWN'; DETERMINE BEST MOUNTING POSITION FOR FUEL RAIL AND DETERMINE LENGTH FOR BLACK INJECTOR HOSES 30) LOCATE CONSTANT TENSION CLAMPS SECURED TO INJECTOR HOSES JUST BELOW THE INJECTOR HOUSING 40) USING PLIERS, DEPRESS TABS ON CLAMPS TO LOOSEN AND REPOSITION CLAMPS AWAY FROM INJECTOR HOUSING FLOW INJECTOR HOUSING CONSTANT TENSION CLAMP INJECTOR HOSE DESCRIPTION TOOLS A REF 2 FUEL RAIL ASSEMBLY B REF INTAKE MANIFOLD INSTALL LPG FUEL RAIL ASSEMBLY PX C OF 4

19 NUMBER 50) REMOVE BLACK HOSES FROM INJECTOR HOUSINGS; USING HOSE CUTTER, CUT HOSES TO LENGTH DETERMINED IN STEP ) CAREFULLY INSERT HOSES BACK ONTO RISLAN TUBES; FULLY SEAT HOSES BACK ONTO INJECTOR HOUSING NOZZLES; ALIGN AND SEAT CONSTANT TENSION CLAMPS THAT WERE REPOSITIONED IN STEP 40 BACK INTO ORIGINAL POSITION UNDER THE INJECTOR HOUSING 70) CUT THE TIP OF THE RISLAN TUBE AT A SHARP ANGLE TO EASE THE INSTALLATION OF THE RISLAN TUBE INTO NOZZLES INSTALLED ON THE INTAKE MANIFOLD (THESE WILL BE CUT TO LENGTH IN A LATER ) 70 DESCRIPTION TOOLS A REF 2 FUEL RAIL ASSEMBLY RAZOR KNIFE B REF INTAKE MANIFOLD INSTALL LPG FUEL RAIL ASSEMBLY PX C 2 OF 4

20 NUMBER 80 80) CAREFULLY INSERT RISLAN TUBES INTO NOZZLES INSTALLED ON INTAKE MANIFOLD; ALIGN AND FULLY SEAT BLACK HOSES ONTO NOZZLES (RISLAN TUBES SHOULD PROTRUDE BEYOND END OF NOZZLE AS SHOWN IN PHOTO) 90) USING PLIERS, DEPRESS TABS ON THE LOWER CONSTANT TENSION CLAMPS TO LOOSEN; POSITION CLAMPS ON BLACK HOSE OVER NOZZLE AND RELEASE TO SECURE HOSE IN PLACE 00) USING A RAZOR KNIFE, CUT THE RISLAN TUBE APPROXIMATELY APPROXIMATELY INCH DOWN FROM THE END OF THE NOZZLE MAKING SURE THE RISLAN TUBE POINTS AT THE INTAKE VALVE (VERIFY HOLE IN RISLAN TUBE IS NOT DISTORTED AFTER THE TUBE HAS BEEN CUT) PLASTIC INTAKE MANIFOLD VERIFY HOLE IN RISLAN TUBE IS NOT DISTORTED AFTER THE TUBE HAS BEEN CUT 90 POSITION THIS CLAMP OVER INTAKE MANIFOLD NOZZLE 00 DESCRIPTION TOOLS A REF 2 FUEL RAIL ASSEMBLY PLIERS B REF INTAKE MANIFOLD RAZOR KNIFE INSTALL LPG FUEL RAIL ASSEMBLY PX C 3 OF 4

21 NUMBER 0) INSTALL THE FUEL RAIL INTO FINAL POSITION USING THE PROVIDED BRACKETS (VERIFY CHECK VALVE IS POSITIONED TO ALLOW ATTACHMENT OF THE RETURN HOSE) 20) REPEAT STEPS 0 THROUGH 0 FOR SECOND FUEL RAIL ASSEMBLY 30) REINSTALL INTAKE MANIFOLD ONTO ENGINE 40) REFILL COOLANT SYSTEM (PRESSURE TEST COOLING SYSTEM TO CHECK FOR LEAKS) 0 DESCRIPTION TOOLS A REF 2 FUEL RAIL ASSEMBLY COOLING SYSTEM B REF INTAKE MANIFOLD PRESSURE TESTER INSTALL LPG FUEL RAIL ASSEMBLY PX C 4 OF 4

22 NUMBER 0) FROM INSIDE THE ENGINE COMPARTMENT, LOCATE THE GREEN CHASSIS SUPPLY HOSE COMING FROM THE LPG FUEL TANK 0 20) OBTAIN THE INLINE FUEL FILTER (A), (2) /4" REUSABLE FITTINGS WITH FERRULES (B), (2) -7/8" CABLE CLAMPS (C ) AND (2) SELF TAP SCREWS (D) 20 A 30) DETERMINE LOCATION AWAY FROM ANY HEAT SOURCE FOR FILTER LOCATION ON THE CHASSIS SUPPLY HOSE 40) INSTALL THE (2) /4" REUSABLE FITTINGS WITH FERRULES (B) ONTO THE GREEN CHASSIS SUPPLY HOSE (REFERENCE ICOM INSTRUCTION PX-9203 OR PX-9209 FOR FITTING INSTALLATION) B 50) INSTALL INLINE FUEL FILTER (A) ONTO CHASSIS SUPPLY HOSE WITH THE ARROW ON THE FILTER POINTING TOWARD THE ICOM LPG FUEL RAILS; USING A WRENCH WITH A 5mm CROWFOOT, THE HOSE FITTNG TO 4 Nm +/ ) SECURE FILTER IF NEEDED USING THE (2) -7/8" CABLE CLAMPS (C ) AND (2) SELF TAP SCREWS (D) C D DESCRIPTION TOOLS A INLINE FUEL FILTER WRENCH B /4" REUSABLE FERRULE 4 Nm +/-.4 5mm CROWFOOT /4" STRAIGHT REUSABLE FITTING C /8" CABLE CLAMP D SCREW - SELF TAPPING INSTALL INLINE FUEL FILTER PX D OF

23 NUMBER 0 A 0) OBTAIN () NON-RETURN VALVE ASSY (A) AND BRACKET ASSY (B) FROM PACKAGE 'G' B 20) MOUNT THE NON-RETURN VALVE IN CLOSE PROXIMITY TO THE SUPPLY END FITTNGS ON THE FUEL RAILS TO MINIMIZE THE LENGTH OF THE SUPPLY HOSES NOTE - DO NOT MOUNT ON ENGINE OR BY ANY HEAT SOURCE - MOUNT TO 3 FEET FROM FUEL RAIL(S) 20 30) LOCATE AND GRASP THE GREEN CHASSIS SUPPLY HOSE COMING FROM FUEL TANK; CUT THE HOSE TO THE REQUIRED LENGTH AND ASSEMBLE THE REQUIRED FIELD ATTACHABLE FITTING ONTO THE HOSE PER THE HOSE ASSEMBLY INSTRUCTION (PX-9203) 40) LOCATE THE PORT ON THE NON-RETURN VALVE MARKED 'IN' 50) HAND START FITTING ON GREEN CHASSIS SUPPLY HOSE ONTO THE 'IN' PORT FITTING ON THE NON-RETURN VALVE; USING A WRENCH WITH A 5mm CROWFOOT, THE HOSE FITTING TO 4 Nm +/ DESCRIPTION TOOLS A P3X NON RETURN VALVE ASSY WRENCH 4 Nm +/-.4 B P4X4-93 KIT - NON RETURN VALVE BRACKET 5mm CROWFOOT INSTALL NON-RETURN VALVE ASSY & ENGINE SUPPLY HOSES PX D OF 2

24 NUMBER 60 C THE FOLLOWING STEPS ONLY APPLY TO 8 & 0 CYLINDER SYSTEMS 60) OBTAIN THE ENGINE HOSE KIT (C ); OBTAIN THE GREEN HOSE AND FITTINGS FROM THE KIT 70) DETERMINE WHAT LENGTH HOSES ARE NEEDED TO GO FROM THE NON-RETURN VALVE ASSY TO THE SUPPLY FITTING (MARKED GREEN) ON DRIVER / PASSENGER SIDE FUEL RAILS 80) CUT AND ASSEMBLE THE ENGINE SUPPLY HOSES PER THE WORK INSTRUCTION FOR ASSEMBLY OF THE HOSES (PX-9203) 90) INSTALL & HAND TIGHTEN ENGINE HOSE FITTINGS ONTO THE TEE ATTACHED TO THE NON-RETURN VALVE ASSY 00) CAREFULLY ROUTE HOSES TO THE SUPPLY FITTINGS (MARKED GREEN) ON THE DRIVER / PASSENGER SIDE FUEL RAILS; INSTALL & HAND TIGHTEN HOSE FITTINGS ONTO FUEL RAIL FITTINGS 90 0) USING A WRENCH WITH A 5mm CROWFOOT, EACH OF THE HOSE FITTINGS TO THE FUEL RAILS & NON-RETURN VALVE TEE TO 4 Nm +/-.4 20) OBTAIN /2" SPLIT CORRUGATE FROM ENGINE KIT; INSTALL CORRUGATE ONTO EXPOSED ENGINE SUPPLY HOSES AND TRIM TO FIT 20 0 DESCRIPTION TOOLS C PX4-3 ENGINE HOSE KIT WRENCH 4 Nm +/-.4 5mm CROWFOOT INSTALL NON-RETURN VALVE ASSY & ENGINE SUPPLY HOSES PX D 2 OF 2

25 NUMBER A 0) OBTAIN () REGULATOR ASSY (A) AND () REGULATOR BRACKET (B) 20) ATTACH THE REGULATOR BRACKET TO THE REGULATOR USING THE SCREWS PROVIDED WITH THE REGULATOR AS SHOWN B 0 30) INSTALL THE REGULATOR ASSY INSIDE THE ENGINE COMPARTMENT IN CLOSE PROXIMITY TO THE FUEL RAILS (NOTE - DO NOT INSTALL REGULATOR ONTO THE DASH PANEL - THE FLUID TRANSFER NOISE INSIDE THE REGULATOR WILL BE TRANSMITTED INTO THE PASSENGER COMPARTMENT) 20 SYSTEMS EQUIPPED WITH 4 OR 6 CYLINDER ENGINE PROCEED TO STEP # 0 40) OBTAIN THE ENGINE HOSE KIT (C ); OBTAIN THE BLACK HOSE AND FITTINGS FROM THE KIT 50) DETERMINE WHAT LENGTH HOSES ARE NEEDED TO GO FROM THE REGULATOR TEE FITTING TO THE RETURN FITTING (MARKED BLACK) ON THE DRIVER / PASSENGER SIDE FUEL RAILS DESCRIPTION TOOLS A PX REGULATOR TEE ASSY B PX REGULATOR BRACKET INSTALL REGULATOR & ENGINE RETURN HOSES PX D OF 3

26 NUMBER 70 60) CUT AND ASSEMBLE THE ENGINE RETURN HOSES PER THE WORK INSTRUCTION FOR THE ASSEMBLY OF THE HOSES (PX-9203) 70) INSTALL & HAND TIGHTEN HOSE FITTINGS ONTO THE TEE ATTACHED TO THE REGULATOR ASSY 80 80) CAREFULLY ROUTE HOSES TO THE RETURN FITTINGS (MARKED BLACK) ON THE DRIVER / PASSENGER SIDE FUEL RAILS; INSTALL & HAND TIGHTEN HOSE FITTINGS ONTO THE FUEL RAIL FITTINGS 90) USING A WRENCH WITH A 5mm CROWFOOT, EACH OF THE HOSE FITTINGS TO THE FUEL RAILS & REGULATOR TEE TO 4 Nm +/ ) OBTAIN /2" SPLIT CORRUGATE FROM THE ENGINE KIT; INSTALL CORRUGATE ONTO EXPOSED ENGINE RETURN HOSES AND TRIM TO FIT 00 DESCRIPTION TOOLS C PX4-3 ENGINE HOSE KIT WRENCH 4Nm +/-.4 5mm CROWFOOT INSTALL REGULATOR & ENGINE RETURN HOSES PX D 2 OF 3

27 NUMBER 0) LOCATE AND GRASP THE BLACK CHASSIS RETURN HOSE COMING FROM FUEL TANK; CUT THE HOSE TO THE REQUIRED LENGTH AND ASSEMBLE THE REQUIRED FIELD ATTACHABLE FITTING ONTO THE HOSE PER THE HOSE ASSEMBLY INSTRUCTION (PX-9203) 0 0 0) HAND START FITTING ON BLACK CHASSIS RETURN HOSE ONTO THE 'IN' PORT FITTING ON THE SIDE OF THE REGULATOR; USING A WRENCH WITH A 5mm CROWFOOT, THE HOSE FITTING TO 4 Nm +/-.4 DESCRIPTION TOOLS WRENCH 4Nm +/-.4 5mm CROWFOOT INSTALL REGULATOR & ENGINE RETURN HOSES PX D 3 OF 3

28 NUMBER 0 A B C 0) OBTAIN () PACKAGE 'E' (CONSISTS OF () ICU MODULE BRACKET (A), (2) M4 x 30 SCREWS (B), (2) M4 X 60 SCREWS (C ), (4) M4 NUTS (D)) FROM INSIDE THE ENGINE KIT D 20) OBTAIN () UNIT 'A' MODULE (E) AND () UNIT 'B' MODULE (F) FROM THE ENGINE KIT (NOTE - 4-CYLINDER AND 6-CYLINDER ENGINES WILL ONLY REQUIRE THE UNIT 'A' MODULE) 20 E F 30) ATTACH MODULE(S) TO THE BRACKET ALLOWING ACCESS TO THE CONNECTOR END OF THE MODULES 40) FROM INSIDE THE PASSENGER COMPARTMENT, SECURE THE BRACKET UNDER THE DRIVER SIDE INSTRUMENT PANEL (USE (2) SELF TAPPING SCREWS PROVIDED INSIDE PACKAGE 'H') 20 PART NUMBER PX4-803-A QTY DESCRIPTION PACKAGE 'E' TOOLS E ICU MODULE UNIT 'A' F ICU MODULE UNIT 'B' INSTALL ICU MODULES PX D OF

29 NUMBER 0 A 0) OBTAIN THE ICOM JTG BI-FUEL ENGINE WIRE HARNESS (A) AND () GROMMET (B) FROM THE ENGINE KIT 20) INSTALL THE GROMMET ONTO THE MAIN LOOM OF THE WIRE HARNESS IN CLOSE PROXIMITY TO THE (2) GRAY MODULE CONNECTORS AS SHOWN B 30) FROM INSIDE THE ENGINE COMPARTMENT, LOCATE AN AREA ON THE DRIVER SIDE OF THE DASH PANEL THAT WILL BE IN CLOSE PROXIMITY TO THE MODULES MOUNTED INSIDE THE VEHICLE; USING A 2.5" HOLE SAW OR KNOCKOUT HOLE PUNCH, INSTALL A HOLE IN THE DASH PANEL AS SHOWN (NOTE - BE CAREFUL NOT TO CONTACT ANY WIRE HARNESSES OR COMPONENTS INSIDE THE PASSENGER COMPARTMENT WHEN INSTALLING THE HOLE) 20 GREY 30 DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE DRILL 2-/2" HOLE SAW B 0000 GROMMET - WIRE HARNESS INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY D PX OF

30 NUMBER 40) PLACE ICOM ENGINE WIRE HARNESS INSIDE ENGINE COMPARTMENT; LOCATE AND GRASP THE (2) LARGE GRAY CONNECTORS, DIAGNOSTIC LEAD, COMMUTATOR LEAD AND AUDIBLE INDICATOR LEAD (NOTE - 4 & 6 CYLINDER ENGINES WILL ONLY HAVE () LARGE GRAY CONNECTOR) 40 50) CAREFULLY INSERT LEADS INTO THE DRILLED HOLE IN THE DASH PANEL; ALIGN AND SEAT GROMMET ON THE WIRE HARNESS INTO THE DRILLED HOLE IN THE DASH PANEL AS SHOWN 60) FROM INSIDE THE PASSENGER COMPARTMENT, LOCATE AND GRASP THE GRAY CONNECTOR ATTACHED TO THE LARGER DIAMETER WIRE LOOM; ALIGN AND FULLY SEAT THE CONNECTOR INTO THE MODULE LABELED 'UNIT A' PUSH / PULL CONNECTOR TO VERIFY FULLY SEATED COMMUTATOR AUDIBLE INDICATOR 70) LOCATE AND GRASP THE GRAY CONNECTOR ATTACHED TO THE SMALLER DIAMETER WIRE LOOM; ALIGN AND FULLY SEAT CONNECTOR INTO THE MODULE LABELED 'UNIT B' ONLY APPLICABLE FOR 8 & 0 CYLINDER ENGINES - PUSH / PULL CONNECTOR TO VERIFY FULLY SEATED DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE B 0000 GROMMET - WIRE HARNESS REF UNIT 'A' MODULE REF UNIT 'B' MODULE (IF EQUIPPED) INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D 2 OF

31 NUMBER ) FROM INSIDE THE ENGINE COMPARTMENT, ROUTE THE REMAINDER OF THE ICOM ENGINE WIRE HARNESS ALONG THE DASH PANEL JUST BELOW THE COWL SCREEN TOWARD THE PASSENGER SIDE OF THE VEHICLE 90) SECURE THE ICOM ENGINE WIRE HARNESS TO THE DASH PANEL BY USING EITHER TIE STRAPS PROVIDED INSIDE PACKAGE 'D' OR /2" CABLE CLAMPS PROVIDED INSIDE PACKAGE 'H' 00) LOCATE AND GRASP THE FUEL PUMP RELAY AND KEY-ON RELAY ATTACHED TO THE ICOM ENGINE WIRE HARNESS; SECURE THE RELAYS TO THE DASH PANEL USING A SELF TAPPING SCREW PROVIDED INSIDE PACKAGE 'H' 00 0) ROUTE THE REMAINDER OF THE ICOM ENGINE WIRE HARNESS WITH THE '-' BATTERY AND '+' BATTERY LEADS TOWARD THE VEHICLE BATTERY 0 DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D 3 OF

32 NUMBER 20 20) LOCATE THE FUEL TANK CONNECTOR LEADS NEXT TO THE FUEL PUMP AND KEY ON LEADS ON THE ICOM ENGINE WIRE HARNESS 30) LOCATE AND GRASP THE (2) LEADS ATTACHED TO THE FUEL TANK WIRE HARNESS BY THE CHASSIS SUPPLY AND RETURN HOSES COMING FROM THE FUEL TANK 30 40) ALIGN AND FULLY SEAT THE WHITE (5) PIN CONNECTOR ON THE FUEL TANK HARNESS INTO THE WHITE (5) PIN CONNECTOR ON THE ICOM ENGINE WIRE HARNESS PUSH / PULL CONNECTOR TO VERIFY FULLY SEATED 50) ALIGN AND FULLY SEAT THE BLACK (2) PIN CONNECTOR ON THE FUEL TANK HARNESS INTO THE BLACK (2) PIN CONNECTOR ON THE ICOM ENGINE WIRE HARNESS PUSH / PULL CONNECTOR TO VERIFY FULLY SEATED DESCRIPTION TOOLS A PX PX P3X PX4-422 REF WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE WIRE HARNESS ASSY - FUEL TANK INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D 4 OF

33 NUMBER 60) LOCATE AND GRASP THE (2) FUEL INJECTOR WIRE LEAD BRANCHES ON THE ICOM ENGINE WIRE HARNESS; ROUTE THE WIRE LEAD BRANCHES ALONG EITHER SIDE OF THE ENGINE BY THE ICOM FUEL RAILS (NOTE - 4 & 6 CYLINDER ENGINES WILL ONLY HAVE () FUEL INJECTOR WIRE LEAD BRANCH) 60 70) STARTING FROM THE FRONT OF THE ENGINE ON THE PASSENGER SIDE, GRASP THE GREEN CONNECTOR LEAD AT THE END OF THE WIRE LEAD BRANCH; ALIGN AND SEAT THE CONNECTOR ONTO THE LPG FUEL RAIL INJECTOR AT THE FRONT OF THE ENGINE; ATTACH IN ORDER FROM FRONT TO REAR FOR THE REMAINING LPG INJECTOR LEADS AS SHOWN AN AUDIBLE 'CLICK' SHOULD BE HEARD WHEN THE CONNECTORS ARE INSTALLED CORRECTLY ONTO THE FUEL INJECTOR 70 DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D 5 OF

34 NUMBER 80 80) STARTING FROM THE FRONT OF THE ENGINE ON THE PASSENGER SIDE, DISCONNECT THE OEM WIRE HARNESS CONNECTORS FROM THE GASOLINE FUEL INJECTORS 90) GRASP THE GRAY CONNECTOR LEAD AT THE END OF THE ICOM ENGINE WIRE HARNESS AND INSTALL CONNECTOR ONTO THE GASOLINE FUEL INJECTOR AT THE FRONT OF THE ENGINE AN AUDIBLE 'CLICK' SHOULD BE HEARD WHEN THE CONNECTOR IS INSTALLED CORRECTLY 80 DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D 6 OF

35 NUMBER 200) ATTACH IN ORDER FROM FRONT TO REAR THE REMAINING GRAY GASOLINE INJECTOR LEADS AN AUDIBLE 'CLICK' SHOULD BE HEARD WHEN THE CONNECTORS ARE INSTALLED CORRECTLY 200 DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D 7 OF

36 NUMBER 20) GRASP THE BLACK CONNECTOR LEAD AT THE END OF THE ICOM ENGINE WIRE HARNESS AND INSTALL THE CONNECTOR INTO THE OEM GASOLINE FUEL INJECTOR CONNECTOR AT THE FRON OF THE ENGINE AN AUDIBLE 'CLICK' SHOULD BE HEARD WHEN THE CONNECTORS ARE INSTALLED CORRECTLY 20 ICOM ENGINE WIRE HARNESS BLACK CONNECTOR OEM GASOLINE FUEL INJECTOR CONNECTOR OEM GASOLINE FUEL INJECTOR WIRE HARNESS DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D 8 OF

37 NUMBER 220) ATTACH IN ORDER FROM FRONT TO BACK THE REMAINING BLACK ICOM ENGINE WIRE HARNESS LEADS TO THE OEM GASOLINE INJECTOR CONNECTOR LEADS AN AUDIBLE 'CLICK' SHOULD BE HEARD WHEN THE CONNECTORS ARE INSTALLED CORRECTLY 230) REPEAT STEPS 70 THROUGH 220 FOR THE DRIVERS SIDE OF THE ENGINE ) LOCATE AND GRASP THE ICOM JTG ENGINE WIRE HARNESS LEAD LABELED 'RPM' 250) DISCONNECT THE OEM WIRE HARNESS LEAD TO THE REAR PASSENGER SIDE IGNITION COIL (EACH IGNITION COIL HAS (4) WIRES - TWO OF THE WIRES ARE GROUNDS (BLACK/BROWN) - ONE OF THE WIRES IS THE SAME COLOR FROM COIL TO COIL (POWER) - THE OTHER WIRE IS A DIFFERENT COLOR FROM COIL TO COIL - THIS IS THE RPM SIGNAL) DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D 9 OF

38 NUMBER ) CAREFULLY REMOVE APPROXIMATELY /2" OF INSULATION FROM THE DIFFERENT COLOR WIRE (DO NOT CUT WIRE) CAREFULLY REMOVE APPROXIMATELY /2" OF INSULATION FROM THE END OF THE 'RPM' WIRE LEAD 270) ATTACH THE 'RPM' WIRE LEAD TO THE STRIPPED IGNITION COIL WIRE; SOLDER CONNECTION TOGETHER 280) SEAL SOLDERED CONNECTION WITH ELECTRICAL TAPE 290) RECONNECT THE OEM WIRE HARNESS LEAD TO THE IGNITION COIL DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE RAZOR BLADE SOLDER IRON ROSIN CORE SOLDER ELECTRICAL TAPE INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D 0 OF

39 NUMBER ) FROM INSIDE THE ENGINE COMPARTMENT, LOCATE AND GRASP THE WIRE LEAD LABELED 'IRIS' OR 'NON-RETURN VALVE' ATTACHED TO THE ICOM JTG ENGINE WIRE HARNESS ASSY 30) LOCATE AND GRASP THE WIRE LEAD ATTACHED TO THE NON RETURN VALVE; ALIGN AND SEAT THE CONNECTORS TOGETHER PUSH / PULL CONNECTORS TO VERIFY CONNECTORS ARE FULLY SEATED NON RETURN VALVE 30 DESCRIPTION TOOLS A PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE REF P3X NON RETURN VALVE INSTALL ICOM JTG ENGINE WIRE HARNESS ASSY PX D OF

40 NUMBER 0 A B 0) OBTAIN () ICOM TEMPERATURE SENSOR (A), () ICOM TEMPERATURE SENSOR HOSE ADAPTOR (B) (CORRECT SIZE TO BE DETERMINED BASED ON HEATER HOSE SIZE) AND (2) #8 HOSE CLAMPS (C ) FROM PACKAGE 'D' C 20) FROM INSIDE THE ENGINE COMPARTMENT, LOCATE THE HEATER HOSE THAT SUPPLIES COOLANT FROM THE ENGINE TO THE HEATER CORE LARGE SMALL APPLY JB WELD TO THE THREADS ON THE TEMPERATURE SENSOR ADAPTOR 30) DETERMINE THE CORRECT SIZE TEMPERATURE SENSOR ADAPTOR TO USE BASED ON THE HEATER HOSE SIZE; APPLY JB WELD TO THE THREADS ON THE ICOM TEMPERATURE SENSOR ADAPTOR; INSTALL AND FULLY TIGHTEN THE ADAPTOR ON THE ICOM TEMPERATURE SENSOR INTO THE THREADED HOLE IN THE HOSE ADAPTOR 40) INSTALL (2) HOSE PLIERS, SPACED APPROXIMATELY 6" APART, ONTO THE HEATER HOSE AS SHOWN DESCRIPTION TOOLS A ICOM TEMPERATURE SENSOR JB WELD B HOSE ADAPTOR - TEMP SENSOR (LARGE) HOSE ADAPTOR - TEMP SENSOR (SMALL) HOSE PLIERS (2) C #8 HOSE CLAMP INSTALL ICOM TEMPERATURE SENSOR PX D OF 3

41 NUMBER 50 50) USING A PAIR OF HOSE CUTTERS, CUT THE HEATER HOSE IN HALF BETWEEN THE HOSE PLIERS AS SHOWN 60) INSTALL () HOSE CLAMP ONTO ONE END OF THE CUT HOSE; INSERT AND FULLY SEAT THE HOSE ADAPTOR WITH THE TEMPERATURE SENSOR INSTALLED INTO THE END OF THE HOSE WITH THE INSTALLED CLAMP AS SHOWN 60 70) INSTALL () HOSE CLAMP ONTO THE OPPOSITE CUT HOSE; INSERT AND FULLY SEAT THE HOSE ADAPTOR INTO THE HOSE AS SHOWN REMOVE BOTH HOSE PLIERS FROM THE HEATER HOSE 80) POSITION BOTH HOSE CLAMPS OVER BARBS AT BOTH ENDS OF THE HOSE ADAPTOR; FULLY TIGHTEN CLAMPS TO SEAL HOSE TO ADAPTOR DESCRIPTION TOOLS A ICOM TEMPERATURE SENSOR HOSE CUTTER B HOSE ADAPTOR - TEMP SENSOR (LARGE) HOSE ADAPTOR - TEMP SENSOR (SMALL) C #8 HOSE CLAMP INSTALL ICOM TEMPERATURE SENSOR PX D 2 OF 3

42 NUMBER 90 90) LOCATE AND GRASP THE WIRE LEAD LABELED 'TEMP SENSOR' ATTACHED TO THE ICOM JTG ENGINE WIRE HARNESS 00) LOCATE AND GRASP THE WIRE CONNECTOR ATTACHED TO THE ICOM TEMPERATURE SENSOR; ALIGN AND FULLY SEAT CONNECTORS TOGETHER PUSH / PULL CONNECTORS TO VERIFY CONNECTORS ARE FULLY SEATED 00 DESCRIPTION TOOLS A ICOM TEMPERATURE SENSOR REF PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE INSTALL ICOM TEMPERATURE SENSOR PX D 3 OF 3

43 NUMBER 0 A 0) OBTAIN () COMMUTATOR / AUDIBLE INDICATOR (A) FROM INSIDE 'PACKAGE D' 20) DETERMINE LOCATION FOR INSTALLATION OF THE COMMUTATOR ON THE INSTRUMENT PANEL; USING A DRILL WITH A 3/8" DRILL BIT, CAREFULLY DRILL A HOLE INTO THE INSTRUMENT PANEL (VERIFY DRILL BIT WILL NOT CONTACT ANY WIRES OR COMPONENTS WHILE DRILLING THE HOLE) 30) OBTAIN THE 5-WIRE LEAD FROM INSIDE THE COMMUTATOR PACKAGE 20 40) FROM THE BACKSIDE OF THE INSTRUMENT PANEL, INSERT THE SMALL CONNECTOR END OF THE 5-PIN WIRE LEAD THROUGH THE DRILLED HOLE IN THE INSTRUMENT PANEL AS SHOWN DESCRIPTION TOOLS A COMMUTATOR / AUDIBLE INDICATOR KIT DRILL 3/8" DRILL BIT INSTALL COMMUTATOR & AUDIBLE INDICATOR PX C OF 4

44 NUMBER 50) OBTAIN THE DOUBLE SIDE ADHESIVE MOUNTING PAD FROM INSIDE THE COMMUTATOR PACKAGE; REMOVE AND DISCARD THE ADHESIVE BACKING FROM THE ONE SIDE OF THE MOUNTING PAD; ALIGN AND SEAT THE PAD ONTO THE BACKSIDE OF THE COMMUTATOR; REMOVE AND DISCARD THE SECOND ADHESIVE BACKING FROM THE MOUNTING PAD 50 60) ALIGN AND SEAT THE SMALL CONNECTOR ON THE END OF THE 5-WIRE LEAD INTO THE CONNECTOR ON THE BACKSIDE OF THE COMMUTATOR AS SHOWN 60 70) ALIGN AND SEAT COMMUTATOR ONTO THE INSTRUMENT PANEL 80) FROM THE UNDERSIDE OF THE INSTRUMENT PANEL, LOCATE AND GRASP THE COMMUTATOR WIRE LEAD ATTACHED TO THE ICOM JTG ENGINE WIRE HARNESS BY THE ICU MODULE CONNECTOR(S) 70 ICOM ENGINE WIRE HARNESS COMMUTATOR LEAD DESCRIPTION TOOLS A COMMUTATOR KIT INSTALL COMMUTATOR & AUDIBLE INDICATOR PX C 2 OF 4

45 NUMBER 90 COMMUTATOR LEAD 90) LOCATE AND GRASP THE LARGE CONNECTOR ATTACHED TO THE 5-WIRE LEAD COMING FROM THE COMMUTATOR; ALIGN AND SEAT THE CONNECTORS TOGETHER PUSH / PULL CONNECTORS TO VERIFY FULLY SEATED ICOM ENGINE WIRE HARNESS COMMUTATOR LEAD 00 00) OBTAIN THE AUDIBLE INDICATOR FROM INSIDE THE COMMUTATOR PACKAGE 0) FROM THE UNDERSIDE OF THE INSTRUMENT PANEL, LOCATE AND GRASP THE AUDIBLE INDICATOR WIRE LEAD ATTACHED TO THE ICOM JTG ENGINE WIRE HARNESS BY THE ICU MODULE CONNECTOR(S) 20) LOCATE AND GRASP THE CONNECTOR ATTACHED TO THE AUDIBLE INDICATOR WIRE LEAD; ALIGN AND SEAT THE CONNECTORS TOGETHER AS SHOWN PUSH / PULL CONNECTORS TO VERIFY FULLY SEATED 0 ICOM ENGINE WIRE HARNESS AUDIBLE INDICATOR LEAD DESCRIPTION TOOLS INSTALL COMMUTATOR & AUDIBLE INDICATOR PX C 3 OF 4

46 NUMBER 30 30) BUNDLE THE EXCESS COMMUTATOR AND AUDIBLE INDICATOR WIRE LEADS TOGETHER AND SECURE WITH TIE STRAPS AS SHOWN (DO NOT COVER OPENING ON THE AUDIBLE INDICATOR) DESCRIPTION TOOLS INSTALL COMMUTATOR & AUDIBLE INDICATOR PX C 4 OF 4

47 NUMBER FOR SYSTEMS THAT WILL BE EQUIPPED WITH THE OPTIONAL ICOM PROPANE OPTIMIZATION PROGRAM (POP) REFER TO THE FOLLOWING ICOM INSTALLATION INSTRUCTIONS: P3X EMERGENCY VEHICLE POP SWITCH P3X FLEET VEHICLE POP SWITCH DESCRIPTION TOOLS INSTALL PROPANE OPTIMIZATION PROGRAM (POP) SWITCH (OPTIONAL) PX D OF

48 NUMBER GM MODEL VEHICLES FOR GM VEHICLES EQUIPPED WITH A NORMALLY ASPIRATED 4.8L OR 5.3L ENGINE, THE ICOM GM FUEL PRESSURE SENSOR BY- PASS KIT NUST BE INSTALLED REFER TO ICOM INSTALLATION INSTRUCTION PX4-924 FORD MODEL VEHICLES ALL FORD MODEL VEHICLES (EXCEPT F-SERIES VEHICLES EQUIPPED WITH THE 6.8L ENGINE) MUST HAVE A FUEL GAUGE RESET MODULE INSTALLED REFER TO ICOM INSTALLATION INSTRUCTION P3X DESCRIPTION TOOLS INSTALL VEHICLE / MODEL SPECIFIC MODULES PX D OF

49 NUMBER 0) ATTACH AND FULLY TIGHTEN NEGATIVE CABLE TO BATTERY 0 DESCRIPTION TOOLS ATTACH NEGATIVE CABLE TO BATTERY PX D OF

50 NUMBER ) FROM INSIDE THE ENGINE COMPARTMENT, LOCATE AND GRASP THE ICOM JTG ENGINE WIRE HARNESS LEADS LABELED 'BAT -' AND 'BAT +' 20) USING WIRE STRIPPERS, CAREFULLY REMOVE APPROXIMATELY /2" OF WIRE INSULATION FROM THE END OF THE RED WIRE AND PINK WIRE LABELED 'BAT +' 30 30) OBTAIN THE APPROPRIATE SIZE RING TERMINAL (A) FROM PACKAGE 'D' BASED ON THE SIZE OF THE POSITIVE TERMINAL STUD ON THE BATTERY 40) ATTACH THE ENDS OF THE RED AND PINK WIRE LEADS TOGETHER; FULLY INSERT WIRE ENDS INTO BARREL OF RING TERMINAL 50) USING WIRE CRIMPERS, INSTALL THE RING TERMINAL ONTO THE END OF THE RED AND PINK WIRES 60) USING A TORCH WITH A LOW FLAME, CAREFULLY HEAT THE TUBING ON THE BARREL OF THE RING TERMINAL TO ALLOW THE SOLDER INSIDE THE RING TERMINAL TO FLOW AROUND THE STRIPPED WIRE ENDS DESCRIPTION TOOLS A RING TERMINAL (SMALL) RING TERMINAL (LARGE) WIRE STRIPPERS WIRE CRIMPERS REF PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE TORCH CONNECT ICOM JTG ENGINE WIRE HARNESS TO BATTERY PX D OF 3

51 NUMBER 70 70) LOOSEN AND REMOVE THE NUT FROM THE POSITIVE TERMINAL STUD ON THE BATTERY 80) INSTALL THE RING TERMINAL ATTACHED TO THE RED AND PINK WIRES ONTO THE POSITIVE TERMINAL STUD; REINSTALL NUT AND FULLY TIGHTEN 80 90) USING WIRE STRIPPERS, CAREFULLY REMOVE APPROXIMATELY /2" OF WIRE INSULATION FROM THE ENDS OF THE (2) BLACK WIRES LABELED 'BAT -' 00) OBTAIN THE APPROPRIATE SIZE RING TERMINAL (A) FROM PACKAGE 'D' BASED ON THE SIZE OF THE NEGATIVE TERMINAL STUD ON THE BATTERY DESCRIPTION TOOLS A RING TERMINAL (SMALL) RING TERMINAL (LARGE) WIRE STRIPPERS REF PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE CONNECT ICOM JTG ENGINE WIRE HARNESS TO BATTERY PX D 2 OF 3

52 NUMBER 0) ATTACH THE ENDS OF THE (2) BLACK WIRE LEADS TOGETHER; FULLY INSERT WIRE ENDS INTO THE BARREL OF THE RING TERMINAL ) USING WIRE CRIMPERS, INSTALL THE RING TERMINAL ONTO THE ENDS OF THE BLACK WIRES 30) USING A TORCH WITH A LOW FLAME, CAREFULLY HEAT THE TUBING ON THE RING TERMINAL TO ALLOW THE SOLDER INSIDE THE RING TERMINAL TO FLOW AROUND THE STRIPPED WIRE ENDS 40) LOOSEN AND REMOVE THE NUT FROM THE NEGATIVE TERMINAL STUD ON THE BATTERY ) INSTALL THE RING TERMINAL ATTACHED TO THE BLACK WIRES ONTO THE NEGATIVE CABLE STUD; REINSTALL NUT AND FULLY TIGHTEN 50 DESCRIPTION TOOLS A RING TERMINAL (SMALL) RING TERMINAL (LARGE) WIRE CRIMPERS TORCH REF PX PX P3X PX4-422 WIRE HARNESS ASSY - V0 ENGINE WIRE HARNESS ASSY - V8 ENGINE WIRE HARNESS ASSY - V6 ENGINE WIRE HARNESS ASSY - 4 CYL. ENGINE CONNECT ICOM JTG ENGINE WIRE HARNESS TO BATTERY PX D 3 OF 3

53 NUMBER 0) INSPECT ALL ICOM JTG LPG ELECTRICAL AND HOSE CONNECTIONS 20) CYCLE IGNITION TO START VEHICLE; VEHICLE SHOULD START ON GASOLINE 30) VERIFY RED LIGHT ILLUMINATES ON COMMUTATOR INDICATING THE LPG FUEL TANK IS EMPTY 40) DRIVE VEHICLE TO PROPANE FILLING STATION; VERIFY PROPER OF OEM FUEL SYSTEM DURING DRIVE 50 DESCRIPTION TOOLS PERFORM INITIAL ICOM JTG SYSTEM CHECK PX C OF

54 NUMBER 0) AT FILLING STATION, TURN VEHICLE 'OFF' 20 20) ATTACH FILL NOZZLE TO FILL VALVE 30) TURN PUMP DISPENSER 'ON'; PUMP APPROXIMATELY 3 GALLONS OF PROPANE INTO THE FUEL TANK 40) LOCATE BLEEDER VALVE ON FUEL TANK; LOOSEN BLEEDER VALVE AND COMPLETELY PURGE THE FUEL TANK 40 50) AFTER THE FUEL TANK IS COMPLETELY PURGED, CLOSE THE BLEEDER VALVE (PURGE PROCESS IS ONLY DONE ON INITIAL INSTALLATION OR ANYTIME THE FUEL TANK IS SERVICED) 50 DESCRIPTION TOOLS PERFORM INITIAL LPG FUEL FILL AND SYSTEM ACTIVATION PX C OF 2

55 NUMBER 60) CONTINUE FILLING FUEL TANK; SYSTEM WILL STOP FILLING ONCE LIQUID HAS REACHED 80% INSIDE FUEL TANK 70 70) LOOSEN AND REMOVE FILL NOOZLE FROM THE FILL VALVE; TURN FILL PUMP 'OFF'; REINSTALL FILLER VALVE CAP 80) START ENGINE (ENGINE WILL START ON GASOLINE); VERIFY ALL FOUR LIGHTS ON COMMUTATOR ILLUMINATE INDICATION THE FUEL TANK FULL 90) PUSH THE CENTER 'JTG' BUTTON ON THE COMMUTATOR; THE ORANGE LIGHT WILL BEGIN FLASHING ON THE LOWER RH CORNER OF THE COMMUTATOR (THIS WILL OCCUR FOR AT LEAST 45 SECONDS OR UNTIL THE ENGINES REACHES THE PROPER TEMPERATURE FOR CHANGE OVER, WHICHEVER HAPPENS FIRST, BEFORE SWITCHING OVER TO PROPANE) 00) TURN ENGINE OFF ONCE VEHICLE SWITCHES OVER TO PROPANE DESCRIPTION TOOLS PERFORM INITIAL LPG FUEL FILL AND SYSTEM ACTIVATION PX C 2 OF 2

56 NUMBER 0) USING A 6mm WRENCH, CAREFULLY LOOSEN AND REMOVE THE PRESSURE GAUGE PORT FITTING FROM THE REGULATOR; SETT FITTING ASIDE FOR LATER RE-INSTALLATION 0 20) SLOWLY ROTATE THE KNOB ON THE TOP OF THE REGULATOR 'COUNTER CLOCKWISE' TO OPEN THE VALVE TO THE PRESSURE GAUGE PORT AND CAREFULLY RELIEVE THE PROPANE PRESSURE IN THE RETURN HOSES 30) AFTER ALL OF THE PROPANE PRESSURE HAS BEEN RELIEVED, INSTALL AND FULLY TIGHTEN THE FITTING ON THE END OF THE PRESSURE GAUGE HOSE INTO THE PRESSURE GAUGE PORT OF THE REGULATOR AS SHOWN 20 40) CYCLE THE IGNITION KEY TO THE 'ON' POSITION FOR A FEW SECONDS AND THEN CYCLE THE KEY BACK TO 'OFF' TO PRESSURIZE THE SYSTEM NOTE THE TANK PRESSURE READING ON THE GAUGE DESCRIPTION TOOLS REF PX PRESSURE REGULATOR ASSY 6mm WRENCH ICOM PRESSURE GAUGE PERFORM PRESSURE CHECK VERIFICATION PX C OF 3

57 NUMBER ) START THE ENGINE AND CHECK THE PROPANE PRESSURE ON THE GAUGE NOTE - THE PRESSURE ON THE GAUGE SHOULD BE 3.5 BAR ABOVE THE STARTING TANK PRESSURE THAT WAS NOTED IN THE PIOUS STEP #40 60) IF THE PROPANE PRESSURE IS READING 3.5 BAR ABOVE THE TANK PRESSURE, PROCEED TO STEP #90 65) IF THE PROPANE PRESSURE IS ABOVE OR BELOW 3.5 BAR ABOVE TANK PRESSURE, PROCEED TO NEXT STEP 70) OBTAIN THE FOLLOWING TOOLS: - 8mm WRENCH - 2.5mm ALLEN WRENCH 80 80) WHILE THE ENGINE IS STILL RUNNING, USING THE 8mm WRENCH, CAREFULLY LOOSEN THE NUT ON THE REGULATOR ADJUSTER; USING THE 2.5mm ALLEN WRENCH, SLOWLY LOOSEN OR TIGHTEN THE SET SCREW ON THE REGULATOR ADJUSTER UNTIL THE PRESSURE GAUGE READING IS 3.5 BAR ABOVE THE STARTING TANK PRESSURE; TIGHTEN THE NUT TO LOCK THE SET SCREW IN PLACE DESCRIPTION TOOLS REF PX PRESSURE REGULATOR ASSY 8mm WRENCH 2.5mm ALLEN WRENCH PERFORM PRESSURE CHECK VERIFICATION PX C 2 OF 3

58 NUMBER 90) TURN ENGINE 'OFF' - ROTATE KNOB ON THE TOP OF THE REGULATOR 'CLOCKWISE' TO CLOSE THE VALVE TO THE PRESSURE GAUGE PORT - REMOVE THE PRESSURE GAUGE FROM THE REGULATOR - INSTALL AND FULLY TIGHTEN THE PRESSURE GAUGE PORT FITTING INTO THE REGULATOR 90 PRESSURE GAUGE PORT VALVE PRESSURE GAUGE PORT FITTING DESCRIPTION TOOLS REF PX PRESSURE REGULATOR ASSY 6mm WRENCH PERFORM PRESSURE CHECK VERIFICATION PX C 3 OF 3

59 NUMBER 30 PLEASE READ THE INTRODUCTION SECTION OF THIS MANUAL BEFORE BEGINNING THIS PROCEDURE THE ICOM INSTALLTION INSPECTION FORM MUST BE COMPLETED FOR EACH SYSTEM INSTALLATION AND SUBMITTED TO YOUR AUTHORIZED ICOM DISTRIBUTOR UNDER VEHICLE INSTALLATION INSPECTION 0) POSITION AND RAISE VEHICLE UP ON SUITABLE LIFT 20) INSPECT HOSE ROUTING AND VERIFY PROPER CLEARANCE AND SHIELDING BY HEAT SOURCES 30) VERIFY PROPER RETENTION OF HOSES (FRONT AND REAR) 40) VERIFY PROPER OF TANK FASTENERS 50 50) 60) VERIFY PROPER CLEARANCE AND SHIELDING OF FUEL TANK BY SOURCES OF HEAT CHECK LPG CONNECTIONS FOR LEAKS (USE SNOOP SOLUTION) AND REPAIR AS NEEDED 60 DESCRIPTION TOOLS FINAL INSPECTION AND SYSTEM CHECK PX C OF 5

60 NUMBER 70 BLEEDER VALVE 70) VERIFY BLEEDER VALVE ON FUEL TANK IS FULLY CLOSED (ROTATE KNOB CLOCKWISE) (ONLY FOR SYSTEMS THAT ARE NOT EQUIPPED WITH REMOTE BLEEDER VALVE HOSE KIT) 80) VERIFY MANUAL SHUT-OFF KNOB ON FUEL TANK MULTIVALVE IS FULLY OPE (ROTATE KNOB COUNTERCLOCKWISE TO OPEN) 90) VERIFY FUEL TANK LABEL IS INSTALLED 80 00) RECORD FUEL TANK SERIAL # ON INSPECTION FORM MANUAL SHUT- OFF KNOB DESCRIPTION TOOLS FINAL INSPECTION AND SYSTEM CHECK PX C 2 OF 5

61 NUMBER 0 ENGINE COMPARTMENT INSTALLATION INSPECTION 0) VERIFY ENGINE HOSES ARE PROTECTED WITH CORRUGATE 20) INSPECT HOSE ROUTING AND VERIFY PROPER CLEARANCE AND SHIELDING BY SOURCES OF HEAT 30) VERIFY ICOM EMISSION LABEL INSTALLED ON UNDERSIDE OF HOOD 30 40) INSPECT LPG WIRE HARNESSES FOR PROPER ROUTING 50) INSPECT LPG CONNECTIONS FOR LEAKS (USE SNOOP SOLUTION) AND REPAIR AS NEEDED 60) CHASSIS HOSE CORRUGATE ROUTED TO PENT WATER INGRESS 70) VERIFY ENGINE COOLANT IS AT CORRECT LEVEL 50 DESCRIPTION TOOLS FINAL INSPECTION AND SYSTEM CHECK PX C 3 OF 5

62 NUMBER 80 80) VERIFY NEGATIVE BATTERY CABLE IS PROPERLY TIGHTENED SYSTEM FUNCTION 90) CYCLE THE KEY TO START THE ENGINE; VERIFY ENGINE STARTS AND RUNS 200) VERIFY FUEL LEVEL INDICATION ON COMMUTATOR AND RECORD RESULTS ONTO INSPECTION FORM ) WHILE THE ENGINE IS RUNNING, VERIFY THE ORANGE LIGHT ON THE LOWER RH CORNER OF THE COMMUTATOR IS FLASHING (INDICATING THE PROPANE SYSTEM IS ON AND PURGING) ) THE ORANGE LIGHT ON THE COMMUTATOR WILL TURN SOLID FOLLOWED BY A BEEP FROM THE AUDIBLE INDICATOR WHEN: - AFTER 45 SECONDS AND THE ENGINE IS AT OPERATING TEMPERATURE - AFTER THE ENGINE REACHES OPERATING TEMPERATURE AT SUCH TIME THE VEHICLE WILL BE RUNNING ON PROPANE DESCRIPTION TOOLS FINAL INSPECTION AND SYSTEM CHECK PX C 4 OF 5

63 NUMBER DRIVEABILITY INSPECTION 230) VERIFY VEHICLE DOES NOT EXHIBIT AN EXTENDED CRANK TIME WHEN STARTING 240) DRIVE THE VEHICLE AND VERIFY NO HESITATION, STUMBLE OR SURGING IS EXHIBITED 250) VERIFY NO ENGINE LIGHT COMES ON DURING THIS TIME VEHICLE BADGING 260) VERIFY THE PROPANE DIAMOND LABEL IS INSTALLED ON THE LOWER PASSENGER SIDE OF THE TAILGATE / DECKLID 270) VERIFY THE ICOM BADGE IS INSTALLED ON THE DRIVER SIDE OF THE TAILGATE / DECKLID DESCRIPTION TOOLS FINAL INSPECTION AND SYSTEM CHECK PX C 5 OF 5

64 JTG II TROUBLESHOOTING AFTER THE SWITCHING PERIOD (40 SECONDS), THE SYSTEM DOES NOT SWITCH TO LPG AND REMAINS ON GASOLINE WHEN LPG IS IN THE TANK. POSSIBLE CAUSES: A) LPG FUEL PUMP B) ICU MODULE C) SUPPLY PRESSURE SWITCH (BLACK) A) LPG FUEL PUMP - THE DIFFERENTIAL PRESSURE IS TOO LOW - IF THE PUMP PRESSURE IS LESS THAN.4 BAR, REPLACE THE PUMP. - THE DIFFERENTIAL PRESSURE IS 0 (ZERO) BAR - VERIFY THAT THE LPG FUEL PUMP TURNED ON. IF THE PUMP IS NOT RUNNING, PROCEED WITH THE REPLACEMENT OF THE PUMP. - IF THE LPG PUMP IS RUNNING BUT NOT GENERATING ANY PRESSURE, CHECK TO SEE IF A SUPPLY HOSE IS DISCONNECTED OR SEVERED REPAIR AS NECESSARY B) ICU MODULE - CHECK THE CONTINUITY OF THE LPG FUEL PUMP SUPPLY WIRE FROM PIN 34 AND 35 ON THE MAIN ICU CONNECTOR TO PIN 'A' TO THE LPG FUEL PUMP CONNECTOR AT THE TANK (SEE DIAGRAM BELOW) - IF CONNECTIONS ARE GOOD, REPLACE THE ICU MODULE C) SUPPLY PRESSURE SWITCH - IF THE LPG FUEL PUMP PRESSURE IS GOOD (DIFFERENTIAL PRESSURE BETWEEN 2.5 BAR AND 3.5 BAR), PROCEED TO CHECK THE SUPPLY PRESSURE SWITCH GROUNDING (PIN 30 ON THE ICU MODULE CONNECTOR AND PIN 7 ON THE TANK HARNESS CONNECTOR). WHILE GROUNDING IF THE SYSTEM SWITCHES, CHECK THE CONTINUITY ON THE WIRE FROM PIN 30 (AT THE ICU MODULE) TO PIN 7 (AT THE TANK CONNECTOR) - IF CONTINUITY CHECKS 'OK', REPLACE THE SUPPLY PRESSURE SWITCH JTG TROUBLESHOOTING PX D OF 4

65 JTG II TROUBLESHOOTING FAILURE TO FILL THE SYSTEM - THE SYSTEM DOES NOT ALLOW THE REFUELING OF LPG POSSIBLE CAUSES: A) REMOTE FILL HOSE BENT / KINKED A) REMOTE FILL HOSE BENT / KINKED - PROCEED TO CHECK IF ANY OF THE FILL HOSES ARE BENT/KINKED PENTING LPG TO PASS THROUGH THE HOSE - IF A HOSE IS FOUND TO BE BENT/KINKED, REPLACE IT. THE COMMUTATOR (LPG LEVEL DISPLAY) DOES NOT INDICATE THE CORRECT LPG - LIGHTS ON THE COMMUTATOR FLASH CONTINUOUSLY WHEN THE IGNITION IS 'ON' POSSIBLE CAUSES: A) FAILURE TO COMMUNICATE BETWEEN THE LEVEL SENSOR AND THE COMMUTATOR - IF THE COMMUTATOR FLASHES CONTINUOUSLY WHEN THE IGNITION IS 'ON', THIS INDICATES A COMMUNICATION FAILURE BETWEEN THE LEVEL SENSOR AND THE COMMUTATOR. PROCEED TO VERIFY THE ELECTRICAL CONNECTION BETWEEN THE FUEL TANK AND THE COMMUTATOR. MAKE SURE THE DIODES ARE NOT INTERRUPTED AND/OR ISOLATED. THE SYSTEM DOES NOT ALLOW THE REFUELING OF LPG - THE COMMUTATOR (LPG LEVEL DISPLAY) DOES NOT FLASH CONTINUOUSLY WHEN THE IGNITION IS ON AND DOES LIGHT DURING THE FILL POSSIBLE CAUSES: A) FUEL FILL SOLENOID - WITH THE ENGINE OFF BEGIN THE 'FORCE FILL' PROCEDURE (REFER TO THE OWNERS MANUAL FOR THIS PROCEDURE) - ONCE THIS STARTS, THE ICU SHOULD EMIT (2) TWO BEEPS FROM THE AUDIBLE INDICATOR AND OPEN THE FUEL FILL SOLENOID. IF THE ICU EMITS (2) TWO BEEPS BUT LPG DOES NOT ENTER INTO THE TANK, PROCEED TO CHECK THE FUEL FILL SOLENOID (SEE THE FOLLOWING INSTRUCTIONS) TO VERIFY THE SOLENOID IS DEFECTIVE - ONCE THE FUEL FILL PUMP AT THE DISTRIBUTOR STARTS, CONNECT +2V OF POWER TO PIN 6 ON THE FUEL TANK CONNECTOR. IF LPG DOES NOT ENTER THE TANK, REPLACE THE FUEL FILL SOLENOID. JTG TROUBLESHOOTING PX D 2 OF 4

66 JTG II TROUBLESHOOTING THE SYSTEM SWITCHES AUTOMATICALLY TO GASOLINE - AUDIBLE BEEPS ARE HEARD FROM THE AUDIBLE INDICATOR - LPG IS PRESENT IN THE TANK POSSIBLE CAUSES: A) ICU MODULE B) SUPPLY PRESSURE SWITCH (BLACK) A) ICU MODULE - CHECK THE CONTINUITY OF THE LPG FUEL PUMP SUPPLY WIRE FROM PIN 34 AND 35 ON THE MAIN ICU CONNECTOR TO PIN 'A' TO THE LPG FUEL PUMP CONNECTOR AT THE TANK (SEE DIAGRAM BELOW) - IF CONNECTIONS ARE GOOD, REPLACE THE ICU MODULE B) SUPPLY PRESSURE SWITCH - IF THE LPG FUEL PUMP PRESSURE IS GOOD (DIFFERENTIAL PRESSURE BETWEEN 2.5 BAR AND 3.5 BAR), PROCEED TO CHECK THE SUPPLY PRESSURE SWITCH GROUNDING (PIN 30 ON THE ICU MODULE CONNECTOR AND PIN 7 ON THE TANK HARNESS CONNECTOR). WHILE GROUNDING IF THE SYSTEM SWITCHES, CHECK THE CONTINUITY ON THE WIRE FROM PIN 30 (AT THE ICU MODULE) TO PIN 7 (AT THE TANK CONNECTOR) - IF CONTINUITY CHECKS 'OK', REPLACE THE SUPPLY PRESSURE SWITCH ENGINE IS HARD TO START IN COLD OUTSIDE TEMPERATURES POSSIBLE CAUSES: A) ONE OR MORE LPG FUEL INJECTORS ARE LEAKING B) LPG CALIBRATION IS EITHER TOO RICH OR TOO LEAN COMPARED TO GASOLINE WHILE DRIVING AT A CONSTANT SPEED (IN LPG MODE), THE ENGINE HESITATES (JERKS) POSSIBLE CAUSES: A) INCORRECT DRILLING OF THE INTAKE MANIFOLD - THE LPG NOZZLES ARE POSITIONED INCORRECTLY B) DIFFERENTIAL PRESSURE IS LESS THAN THE MINIMUM VALUE JTG TROUBLESHOOTING PX D 3 OF 4

67 JTG II TROUBLESHOOTING THE DIFFERENTIAL PRESSURE (LPG FUEL PUMP PRESSURE) IS LESS THAN THE MINIMUM VALUE POSSIBLE CAUSES: A) LPG FUEL PUMP DEFECTIVE B) PRESSURE REGULATOR DEFECTIVE THE DIFFERENTIAL PRESSURE (LPG FUEL PUMP PRESSURE) IS HIGHER THAN THE MAXIMUM VALUE POSSIBLE CAUSES: A) PRESSURE REGULATOR DEFECTIVE B) LPG RETURN HOSE (BLACK HOSE FROM THE REGULATOR TO THE TANK) IS BENT/KINKED C) NON-RETURN VALVE BLOCKED ON JTG 8/0/2 CYLINDER SYSTEMS, ONE CYLINDER BANK INJECTS LPG AND THE OTHER CYLINDER BANK INJECTS GASOLINE POSSIBLE CAUSES: A) 3-PIN CONNECTORS I AND M (SEE DIAGRAM BELOW) DISCONNECTED B) ERSED WIRE ON THE 3-PIN CONNECTORS I OR M C) ICU FOLLOWER MODULE DEFECTIVE D) ICU MODULE DEFECTIVE - VERIFY PROPER CONNECTION OF THE I AND M 3-PIN CONNECTORS - VERIFY THE CORRECT POSITIONING AND SEQUENCE OF THE WIRES BETWEEN THE CONNECTORS PER THE DIAGRAM BELOW - REPLACE THEE ICU FOLLOWER MODULE - REPLACE THE ICU MODULE JTG TROUBLESHOOTING PX D 4 OF 4

68 ICOM JTG II INSTALLATION INSPECTION FORM VIN # Date: Vehicle: Installer: UNDER VEHICLE INSTALLATION / SERVICE INSPECTION Inspect hose routing and verify proper clearance Verify bleeder valve closed on fuel tank (only and shielding by heat sources for systems that are not equipped with remote Verify proper retention of hoses (front to rear) bleeder valve hose kit Verify proper torque of tank fasteners Tank Label Installed Verify proper clearance and shielding of fuel Manual Supply Shut-Off Operates (leave fully open) tank by heat sources Tank Serial # COMMENTS ENGINE COMPARTMENT INSTALLATION / SERVICE INSPECTION ICU Module mounted securely and protected from water intrusion Engine hoses protected with corrugate Emission Label installed Inspect hoses / wire harness for proper routing Heat shielding installed where applicable Chassis hose corrugate routed to prevent water ingress Engine coolant correct level COMMENTS SYSTEM FUNCTION / ROAD TEST INSPECTION Propane fill complete OVERALL DRIVEABILITY Gallons installed Starting Crank Time - Stalls - Stumbles Yes No Commutator Level Operation (circle one:) Hesitations - Surging - Stability Yes No F 3/4 /2 /4 E Check Engine Lights Yes No Commutator LPG/Gasoline Switch Yes No Injector times acceptable Yes No Correct Purge Time (45 seconds when Injector times engine is at operating temperature) Yes No Pulse widths acceptable Yes No Correct Temp Sensor function Yes No Pulse widths LED lamp function (monofuel only) Yes No Auxiliary pump function (monofuel only verify pump comes on when driver door is open) Yes No COMMENTS Technician: Approved By: THIS FORM MUST BE COMPLETED FOR EACH INSTALLATION AND SUBMITTED TO YOUR AUTHORIZED ICOM DISTRIBUTOR