MAKE OF AUTOMOBILE: VOLKSWAGEN TYPE: POLO PISTON DISPLACEMENT: 1200 NUMBER OF VALVES: 8V ENGINE NUMBER: BZG TRANSMISSION TYPE ( MT / AT ) MT VEHICLE CATEGORIES M or N M TYPE VSI INJECTOR (COLOUR ) BLUE VERSION CNG INJECTION SYSTEM: SIEMENS VDO MODEL YEAR: 2007 SYSTEM APROVAL NUMBER ( R115 ) R115-0000** LOCATION SYSTEM STICKER If applicable : right side, centre door post ENGINE SET NUMBER 366/1252000 NUMBER : 076/2606800 DATE : 2010-07-15 VERSION NR : 2010-07-15 B
TABLE OF CONTENTS General instructions...2 Required equipment / tools / materials for installing a complete system...3 Vehicle check...3 Diagram...4 VSI approval numbers...5 Overview...6 Tube fittings...7 Regulator connections...8 Mounting the regulator...9 Engine coolant connections...10 Installation of the inlet couplings...11 Mounting the injector rail...12 Mounting the filter unit...13 Mounting computer / PTO / Injection module bracket...14 Wiring loom grommet...15 Fuel selection switch...15 PTO connection to VSI wiring harness...16 Electrical connections 1...17 Electrical connections 2...18 Check list after installation...19 Trouble code chart...20
PAGE 2 076/2606800 General instructions The installation of the system shall be done in accordance with the installation manual provided by Prins Autogassystemen. This manual is based on Dutch regulations, always install the system in accordance to the local regulations. Always download the general manual 1/2 from our website for basic instructions and diagrams. Always disconnect the battery when installing the CNG system. Make sure the ignition key is outside the car. Be aware of central door locking, radio / telephone memory code, alarm system. Do not place the main fuse into the fuse holder before having completed the installation of the VSI system. The VSI computer has to be activated by means of the diagnosis software. In the unlikely event the VSI computer fails, it will automatically switch over to petrol. Never disconnect the VSI computer connector, unless you have removed the main fuse. When installing the VSI wiring harness, ensure that it does not run near any of the ignition components. Solder and insulate all electrical connections. The wires in the loom are provided with numbers and text. The text on the wire explains the function of the wire. The wire harness is not model specific, therefore is it may be necessary to adjust the length of the wires. Ensure maximum care is taken when connecting wiring. Make professional joints using solder and shrink sleeve. Do not stretch the wiring harness. No component of the CNG-system shall be located within 100 mm of the exhaust or similar heat source, unless such components are adequately shielded against heat. Remove any internal burrs, after having shortened the pipe. (This guarantees the maximum flow through the pipe without pollution.) If holes have to be drilled (wear safety glasses) for installing brackets, etc., the drilled holes must always be treated with an anti-corrosion agent, after the chips have been removed ( especially when mounting a exterior filler into body work). After having completed the installation, check the whole system for gas leakage; use a gas leak detection device. Also check for leak of engine coolant, petrol and air. Fitting and maintenance is only allowed by Prins Autogassystemen selected engineers. Failure to follow the instructions in this manual can result in a poor or non-working gas installation or a dangerous situation. For maintenance instructions and filter registration see owner manual. Prins Autogassystemen is not responsible for any damages to people or objects as a result of changes to Prins products. Check our website regularly for diagrams, certificates, updates, info-bulletins and product information. Please fill in the warranty card completely and return it within 8 days after installation. 2
PAGE 3 076/2606800 Required equipment / tools / materials for installing a complete system - Complete workshop toolbox ( wrenches, screwdrivers, cutters, pliers, ratchet, sockets ) - Car lift - Portable computer : operating on Windows 98,W2000 or XP. Internal memory : 16 Mb or more Memory HD space : 5MB Screen : 256 colours, advise colours 16 bits or more Com port : 1 free COM port 1 or COM port 2 with a 9 or 25 pins connector - Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 ) - Exhaust gas analyser - Multimeter - Oscilloscope - Prins VSI diagnostic software - Prins VSI serial interface - Prins VSI break out box ( part nr. 080/70090 ) - Torque wrench ( 25Nm ) - Portable light - Assortment drill bits 4 to 12 mm - Assortment cutters ( ø 20, 30, 50, 70 mm ) - Punching tool ø 70 mm - Threading device M10x1 / M6x1 - Round file - Portable drill or pneumatic drill - Air gun - Vacuum cleaner - Hot air gun - Allan spanner for inlet couplings 3,5mm ( part nr. 099//9970 ) - Molex extraction tool for VSI switch connector ( part nr. 090/9929 ) - Soldering iron, soldering tin - Wire-stripping pliers - Adhesive tape - Adhesive sealant - Thread locking compound - Anti-corrosion agent / black body coating - Gas leak detection device or foam leak spray - Shrink sleeves - Engine coolant Vehicle check - Check the vehicle drivability on petrol - Check the fuel system for error codes ( scan tool ) - Check if the catalytic converter is in good condition ( exhaust gas analyzer ) - Check the condition of the ignition system ( spark plugs, cables, coil ) 3
PAGE 4 076/2606800 Diagram 4
PAGE 5 076/2606800 VSI approval numbers Reducer VSI CNG Keihin : E4-110R-000092 Injector rail Prins : CNG E4-110R-000021 Filter unit T1 / T2 Prins : CNG E4-110R-000028 Filter unit Keihin : CNG E4-110R-000091 Injector Keihin : CNG E4-110R-000020 Computer VSI- 4 / 8 / 10 Prins:CNG E4-110R-000083 CNG hoses Tubithor : CNG E13-110R-000017 Rubia : CNG E4-110R-000003 5
PAGE 6 076/2606800 Overview A : Regulator I : RPM ( 40 ) B : Filter unit J : Lambda-signal ( 46 ) C : Injector rail K : - interruption petrol injector D : Lock-off valve / manometer gauge L : Crank signal E : VSI Computer M : Approval sticker F : Injection module N : Grommet G : Water connection P : PTO module H : Ignition+ ( 13 ) Q : T-ect signal. R115 approval sticker : Right side centre door post 6
PAGE 7 076/2606800 Tube fittings 7
PAGE 8 076/2606800 Regulator connections water connections mounting points cng in cng out 8
PAGE 9 076/2606800 Mounting the regulator Mount the regulator with bracket below the original bolt from the engine mounting Mount the bracket on the second hole (see picture) Mount the bracket with the original M8 bolt 9
PAGE 10 076/2606800 Engine coolant connections Remove the 8mm water hose from the coolant reservoir and extend this hose with an extension pipe. Mount on the coolant reservoir and on the extension pipe 2x 75cm water hose. The waterhose routing from the coolant reservoir is running below and the extended hose is running on top of the coolant reservoir Extension pipe 8x8 Extension pipe 8x8 Temperature sensor 16x16 10
PAGE 11 076/2606800 Installation of the inlet couplings Remove the inlet manifold. Drill 3 holes of 5 mm into the inlet manifold (see picture). Cut M6x1 thread in these holes. Place the VSI couplings with a lock compound. Watch out that the lock compound doesn t come inside the VSI couplings. Mount the CNG-hoses on the VSI couplings. Mount the inlet manifold back on the engine The first cylinder on the distribution site is considered as cylinder 1. 11
PAGE 12 076/2606800 Mounting the injector rail The injector rail bracket with filter unit is mounted on the fixation from the petrol injector rail 12
PAGE 13 076/2606800 Mounting the filter unit Mount the filter unit with the original bracket on the rail bracket Hose length, ø 16 mm Regulator -> filter unit Prins = ± 105 cm Hose length, ø 11 mm filter unit Prins -> injector rail = ± 6 cm Hose length, ø 5 mm VSI-injector 1 -> inlet coupling = ± 15 cm Hose length, ø 5 mm VSI-injector 2 -> inlet coupling = ± 15 cm Hose length, ø 5 mm VSI-injector 3 -> inlet coupling = ± 15 cm Cut the CNG hoses on length Make sure that the hoses aren t stuck and/or kinked 13
PAGE 14 076/2606800 Mounting computer / PTO / Injection module bracket Mount the computer against the firewall on the 2 existing threaded rods. Mount on the threaded rods 2x an extension nut M6x18 Mount the bracket with modules and VSI ecu on the 2 extension nuts. 14
PAGE 15 076/2606800 Wiring loom grommet Fuel selection switch When mounting the switch, only push on its sides. Pushing the switch in the centre may result in damage to the switch. 15
PAGE 16 076/2606800 PTO connection to VSI wiring harness. PTO wiring loop: under the VSI connector. Use to connect the PTO wiring. 16
PAGE 17 076/2606800 Electrical connections 1 Check and measure the wiring in case of changes in the cars wiring colours. Wire number / code Wire colour 50 MAIN GND brown (-31) Connection Mount with a ring terminal on the negative connection from the battery or on the original grounding point on the suspension strut 25-51 +12V BAT (+30) red Mount with a ring terminal on the positive connection from the battery. Do not place the fuse in the holder before having completed the installation of the CNG system. 33 33G INJ OUT 1 34 34 G INJ A PLUS 32 32G INJ OUT 2 34 34 G INJ A PLUS 31 31G INJ OUT 3 34 34 G INJ A PLUS 30 30G INJ OUT 4 34 34 G INJ A PLUS 13 IGNITION + (+15) White-yellow red Green-yellow red Pink-yellow red Blue-yellow red Grey-white Connector VSI-injector to cylinder 1. ( timing belt side ) Connector VSI-injector to cylinder 2. Connector VSI-injector to cylinder 3. Connector VSI-injector to cylinder 4. Make a connection to + 15 petrol ecu. Wire colour : Zwart/geel Wire location : Petrol ecu pos. 27 46 LAMBDA1 Orange For measuring lambda on cylinder bank 1 Wire colour : Grey/red Wire location : Petrol ecu pos. 46 40 RPM Purple-white For measuring the engine speed. Wire colour : White/yellow Wire location : Petrol ecu pos. 60 16 / PTO MAP Blue For measuring the intake manifold air pressure. Wire colour : Brown/white Wire location : Petrol ecu pos. 70 PTO CRANK- signal (optional) Purple / Purple-yellow For interrupting the crank signal. For measuring the engine coolant. Purple directing sensor and purple-yellow directing ecu Wire colour : White Wire location : Petrol ecu pos. 53 17
PAGE 18 076/2606800 Electrical connections 2 Check and measure the wiring in case of changes in the cars wiring colours. For measuring the petrol injectors : Interrupt each petrol injector control wire (injector min) Each VSI wire has a petrol injector / cylinder number printed on the wire, connect this wire to the corresponding petrol injector / cylinder. Connect the bicoloured VSI measuring wire to the ecu side, ( wire code: ECU SIDE ). Connect the corresponding full coloured VSI wire to the petrol injector side ( wire code: MIN INJ SIDE ) See diagrams: Installation manual general part 1 / 2. Attention: Each bicoloured measuring wire corresponds to a specific CNG injector and petrol injector / cylinder number. Do not interchange the wires. VSI measure wire nr. : Full coloured / Bicoloured To interrupt petrol injector wire colour / location VSI wire nr. 39 Petrol injector / cyl. 1 White / White-yellow Wire colour : Purple/brown Wire location : petrol ecu pos. 79 VSI wire nr. 38 Petrol injector / cyl. 2 Green / Green-yellow Wire colour : Purple/green Wire location : petrol ecu pos. 73 VSI wire nr. 37 Petrol injector / cyl. 3 Pink / pink-yellow Wire colour : Purple/yellow Wire location : petrol ecu pos. 65 Cylinder / petrol injector nr. 1 is the cylinder on the timing belt side. 18
PAGE 19 076/2606800 Check list after installation GENERAL WARNING When working on the car, beware of moving / rotating parts in the engine compartment! Beware of the pressure! See manometer! 1. Remove the protection connector from the diagnosis connector and connect the serial interface wire and run the VSI diagnosis program. Turn the ignition key in the accessory position. 2. When commissioning the CNG system, you must activate the VSI computer with the diagnosis software. When the VSI computer has not been activated, it will keep generating error code 160.To activate the VSI computer, select function F11 (activate ECM). 3. Check whether the program in the VSI computer matches with the vehicle. Refer with F2 to the box number and car description in the diagnosis software and compare this. Also check PTO signals. 4. Let the engine run warm on petrol >80 C. Check if the regulator heats up. Check the incoming signals: 4*injection in (Inj1_in, Inj2_in, Inj3_in, Inj4_in), Engine speed signal (RPM), Engine coolant temperature (T-ECT), Gas temperature (T-CNG), Lambda sensor signal (Lambda1), Manifold Absolute Pressure signal (MAP) System pressure (P-sys). Push the switch and let the engine switch over to CNG. Check in idle P-sys, this should be in between 2,9 & 3,5 bar. 5. The system will switch over to CNG as soon as the temperature of the coolant (T-ECT) becomes higher than the parameter T-min set and when the TSO-cold time is expired. 6. Check all components and connections for any gas leakage from cylinder to filler and from cylinder to injector coupling. (use a CNG leak detector device or a detection fluid). 7. Check the petrol MMS for (OBD) error codes and solve these, if required. Check the VSI-CNG system for error codes and solve these, if required. Remove the diagnosis cable and place the protection connector on the VSI communication connector. 8. Make a test drive and check the driveability on CNG and petrol. NOTE : remember the manual valve onto CNG cylinder! NEVER replace CNG part when there s system pressure! 19
PAGE 20 076/2606800 Trouble code chart Trouble code Definition Check / solution 100 Lambda to long to rich. Check when operating on petrol and CNG that there is good lambda signal movement. 101 Lambda to long to lean. Check when operating on petrol and CNG that there is good lambda signal movement. 102 Lambda to long to lean during open loop. Check when operating on petrol and CNG that there is good lambda signal movement. 110 T_ECT Voltage too low Check if the ECT sensor from the engine is connected to ground. 111 T_ECT Voltage too high Check if the ECT sensor from the engine has power supply. 120 T-CNG>= 171 C Voltage too low. Check the ground connection of the P/T-sensor in the filter unit. 121 T-CNG>= -40 C Voltage too high. Check the power connection of the P/T-sensor in the filter unit. 140 MAP> 5 bits or 0,01 bar Check MAP signal is connected correctly and not connected to ground 141 MAP> 250 bits or 1.00 bar Check MAP signal is connected correctly and powered. 150 Psys<= Low-Level Based on a pressure drop in the system. This can be caused by an empty CNG tank, incorrect solenoid valve, polluted filter or incorrect Psys, kinked cng fuel pipe. 160 ECM-VSI not activated Activate the VSI-CNG computer with the diagnostic program, using the F11 function key. 180 T-Board >= 91 C CNG computer circuit board to hot, See location instruction. 181 Battery voltage to high Check board voltage / alternator output and condition of the battery. 210-220-230-240-250-260-270- VSI injector Injector current to high, check for short circuiting 280 overload 211-221-231-241-251-261-271-281 VSI injector no load Injector current to low, check for bad connections. 310 Adjusted pressure on idle out of Psys: min.2.9 & max.3.5bar, RPM: 500 950RPM, T_ECT: >70 C range 311 Program error during flashing the Check parameter settings, contact Prins Autogassystemen. memory 320 Psys voltage to low Check the ground connection of the P/T-sensor in the filter unit. 321 Psys voltage to high Check the power connection of the P/T- sensor in the filter unit. 322 Psys > 3,9 Bar Check the reducer temperature and the reducer for leakage. 330 unexpected parameter change Contact Prins Autogassystemen. 341 Gas leakage, system pressure Check the gas connections and the system for gas leakage. dropped with more then 0.4bar in 15 min, after switching of the engine. 360 Supply voltage too low, lower than 7.5V Check supply lines 50 / 51 of the VSI-CNG system and check the condition of the battery. - System switches to CNG but engine stalls immediately. CNG tank empty? Lock-off valve, cylinder or main open? Manual cylinder tap opened? - No injection timing on CNG Check the injection module connector and main connector X1 & X2. ( 0 Msec.) - The CNG system switches constantly between CNG and Petrol - Check coolant system for air. - T-ECT sensor malfunction - Engine hesitates on high revs, and not running on all cylinders. Engine runs good on idle. Check for kinked or jammed CNG hoses (between VSI injector and couplings). Check for blocked inlet couplings. - Switch LED s don t lit up Check the main fuse of the VSI system Check ignition+ (VSI wire 13) & connector X3 pos.b - The orange LED on the switch flashes Activate the CNG computer with the diagnostic program, using the F11 function key. 20