MAKE OF AUTOMOBILE: TYPE: V 70 PISTON DISPLACEMENT: 2521 NUMBER OF VALVES: 20V ENGINE NUMBER: B5254T TRANSMISSION TYPE ( MT / AT ) AT VEHICLE CATEGORIES M or N PASSENGER CAR ( M ) TYPE VSI INJECTOR (COLOUR ) YELLOW VERSION CNG INJECTION SYSTEM: BOSCH MOTRONIC MODEL YEAR: 2010 SYSTEM APROVAL NUMBER ( R115 ) R115-0000** LOCATION SYSTEM STICKER RIGHT CENTRE DOOR POST ENGINE SET NUMBER 367/1770600 NUMBER : 076/2705100 DATE : 2010-09-08 Copyright Prins Autogassystemen B.V. 2010 VERSION NR : 2010-09-08 B
TABLE OF CONTENTS Required equipment / tools / materials for installing a complete system... 2 VEHICLE CHECK... 2 DIAGRAM... 3 OVERVIEW... 4 INSTALLATION OF THE INLET COUPLINGS and MAP / Overpressure... 5 MOUNTING THE PRE-ASSEMBLE REGULATOR... 6 WATER CONNECTIONS... 7 MOUNTING THE INJECTOR RAIL... 8 TUBES... 9 PRE-ASSEMBLE ECU / PTO / INJECTION MODULE... 10 WIRING LOOM GROMMET... 11 MOUNTING THE FUEL SELECTION SWITCH 1... 12 MOUNTING THE FUEL SELECTION SWITCH 2... 13 REMOVING THE REAR SEAT (for can-bus solder points)... 14 ELECTRICAL CONNECTIONS 1... 15 ELECTRICAL CONNECTIONS 2... 16 ELECTRICAL CONNECTIONS 3... 18 ELECTRICAL CONNECTIONS 4... 19 ELECTRICAL CONNECTIONS 5... 20 CHECK LIST AFTER INSTALLATION.... 21 TROUBLE CODE CHART... 22
PAGE 2 076/2705100 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 /USB : 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 ) 2
PAGE 3 076/2705100 DIAGRAM 3
PAGE 4 076/2705100 OVERVIEW A : Pre-assembly Regulator / Lock-off valve / Manometer gauge / MAP-sensor B : Pre-assembly ECU / PTO / IM module C : Injector rail D : Water connections 2x E : MAP / Overpressure coupling F : Battery +30 ( 25-51 ) G : 15+ ignition+ ( 13 ) H : - interruption petrol injector Approval sticker I : Crank signal J : T-ect signal K : Petrol pressure sensor L : Approval sticker M : Diagnose connector / Fuse N : Ground (-) O : Can-bus Can-bus P : Grommet Q : Fuel selection switch / Can bus / Tank lock-off valve 4
PAGE 5 076/2705100 INSTALLATION OF THE INLET COUPLINGS and MAP / Overpressure Remove the inlet plastic manifold and the petrol injector rail. Do not remove the aluminium manifold! Drill 1 hole ( Ø5mm) in the plastic manifold (see picture) and cut M6x1 thread in the hole. Drill 5 holes (Ø5mm) into the inlet aluminium manifold. Cut M6x1 thread in the holes. Clean manifold with vacuum cleaner. Place the VSI couplings with a lock compound. Watch out that the lock compound doesn t locking inside the VSI couplings. MAP / Overpressure coupling 5
PAGE 6 076/2705100 MOUNTING THE PRE-ASSEMBLE REGULATOR Regulator / Lock-off valve / Manometer gauge / MAP-sensor / Filter unit Pre-assembly. Install the pre-assembly with the two original nuts ( see picture ) Connect the water hoses to the water T-pieces ( see page 7 ). 6
PAGE 7 076/2705100 WATER CONNECTIONS Remove battery and battery holder for easy mounting. The regulator water hoses are connected with the T-pieces in the heater hoses. Install the T-pieces (16x8x16) Connect the water hoses from the regulator pre-assembly to the T-pieces. 7
PAGE 8 076/2705100 MOUNTING THE INJECTOR RAIL Cylinder / petrol injector nr. 1 is the cylinder on the timing belt side. Remove the two valve cover bolts. Bolt on the rail bracket with the original valve cover bolts. 1 2 3 4 5 Assemble the VSI injector rail onto the rail bracket and tighten with 3 lock nuts and 3 washers. 13 Squeeze on the hose clamps with the special pliers. 8
PAGE 9 076/2705100 TUBES Length of hose, ø 16 mm regulator -> filter unit = ± 9 cm Length of hose, ø 11 mm filter unit -> rail = ± 78 cm Length of hose, ø 5 mm VSI-injector 1 -> coupling = ± 29 cm Length of hose, ø 5 mm VSI-injector 2 -> coupling = ± 24 cm Length of hose, ø 5 mm VSI-injector 3 -> coupling = ± 24 cm Length of hose, ø 5 mm VSI-injector 4 -> coupling = ± 24 cm Length of hose, ø 5 mm VSI-injector 5 -> coupling = ± 24 cm Length of hose, ø 5 mm regulator -> T-pieces = ± 10 cm Length of hose, ø 5 mm MAP-sensor -> T-pieces = ± 18 cm Length of hose, ø 5 mm T-pieces -> Inlet manifold = ± 42.5cm Please observe that there is no damage or fouling to the hoses. 9
PAGE 10 076/2705100 PRE-ASSEMBLE ECU / PTO / INJECTION MODULE Before installing the pre-assembly into wiper box, first install the wiring harness (switch / can bus and tank lock-off valve) to interior room. Remove glove box for easy installation on the inside of the car. Pre-assembly ECU / PTO / IM module Loosen the 2 nuts but do not remove them. 10 10
PAGE 11 076/2705100 WIRING LOOM GROMMET Grommet for wiring harness switch / can-bus and tank lock-off valve to interior room: (remove glove box for easy installation on the inside of the car) Grommet engine room: punch a hole of Ø20mm: 11
PAGE 12 076/2705100 MOUNTING THE FUEL SELECTION SWITCH 1 Mount the switch into the centre console. * When mounting the switch, only push on its sides. * Pushing the switch in the centre may result in damage to the switch. 12
PAGE 13 076/2705100 MOUNTING THE FUEL SELECTION SWITCH 2 Before drilling the 8mm hole for the fuel switch, remove the control panel 13
PAGE 14 076/2705100 REMOVING THE REAR SEAT (for can-bus solder points) 14
PAGE 15 076/2705100 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 Volvo Wire colour : Brown with a Ø6mm ring terminal. Wire location : Ground point is located on the left chassis beam underneath the regulator. 25-51 +12V BAT (+30) Red Wire colour : Grey - purple Wire location : in fuse box (left side under hood) big socket 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 White-yellow red Green-yellow red Pink-yellow red Blue-yellow red Isolated wire connection with vulcanizing tape. 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. 15
PAGE 16 076/2705100 5 5G INJ OUT 5 6 6 G INJ A PLUS Grey-yellow Connector VSI-injector to cylinder 5. red ELECTRICAL CONNECTIONS 2 * Check and measure the wiring in case of changes in the cars wiring colours. Wire number / code Wire colour Connection Volvo 13 IGNITION + (+15) Grey-white Make a connection to ignition + / contact +. Wire colour : Red Wire location : Fuse box (left side under hood) little socket Do not place the fuse in the holder before having completed the installation of the CNG system. Isolated wire connection with vulcanizing tape. 16
PAGE 17 076/2705100 16 Canbus Blue-black Green-black Blue-black Pos.3 Green-black Pos.4 Wire location : left side under the rear seat. Grey 22 pin connector : 17
PAGE 18 076/2705100 ELECTRICAL CONNECTIONS 3 * Check and measure the wiring in case of changes in the cars wiring colours. Wire number / code Wire colour Connection Volvo PTO CRANK-D Pink Grey Pink-yellow To be connected in between the original crank shaft sensor / connector. Wire colour : Black connector, plug and play. 2-P connector Grey-yellow Connector location :see picture 43 T-ect 2-P connector Grey To be connected in between the original coolant sensor / connector. Connector colour : Grey connector, Plug and Play Sensor location : thermostat housing, beneath the inlet manifold on the left side. 18
PAGE 19 076/2705100 ELECTRICAL CONNECTIONS 4 * Check and measure the wiring in case of changes in the cars wiring colours. Wire number/ code Wire colour Connection Volvo Injection module Pin A8 Yellow-Green Make a parallel connection to Lamda sensor signal wire : yellow - green pin 1. Wire colour : yellow-green Wire location : left side engine. Connect the yellow-green Isolated wire connection with vulcanizing tape. 19
PAGE 20 076/2705100 ELECTRICAL CONNECTIONS 5 * 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 bi-coloured 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 bi-coloured measuring wire corresponds to a specific CNG injector and petrol injector / cylinder number. Do not interchange the wires. Wire number / code Wire colour Connection Volvo 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 To be connected in between the petrol injector and connector. VSI wire nr. 38 Petrol injector / cyl. 2 VSI wire nr. 37 Petrol injector / cyl. 3 VSI wire nr. 36 Petrol injector / cyl. 4 VSI wire nr. 11 Petrol injector / cyl. 5 Green / Green-yellow Pink / Pink-yellow Blue / Blue-yellow Grey / Grey-yellow Wire location : Petrol injector cylinder 1 To be connected in between the petrol injector and connector. Wire location : Petrol injector cylinder 2 To be connected in between the petrol injector and connector. Wire location : Petrol injector cylinder 3 To be connected in between the petrol injector and connector. Wire location : Petrol injector cylinder 4 To be connected in between the petrol injector and connector. Wire location : Petrol injector cylinder 5 Cylinder / petrol injector nr. 1 is the cylinder on the timing belt side. 20
PAGE 21 076/2705100 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 the CNG pipe connections for leakage with a gas leak detection device or foam leak spray. After the test open the manual valve on CNG cylinder. 4. 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. 5. Check the coolant level. 6. Let the engine run warm on petrol >80 C. Check if the regulator heats up. Check the incoming signals: * 5x injection in (Inj1_in, Inj2_in, Inj3_in, Inj4, Inj5_incomming signals), * Engine speed signal (RPM), * Engine coolant temperature (T-ECT), * Gas temperature (T-CNG), * 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. 7. 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. 8. 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). 9. 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. 10. Make a test drive and check the driveability on CNG and petrol. 21
PAGE 22 076/2705100 TROUBLE CODE CHART Trouble code Définition 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. 22