E450 6.8L MONOFUEL ENGINE SYSTEM INSTLLTION MNUL (UTILIMSTER WLK-IN BODY) P13X4-9229-E Revision: E - Dated 4/9/14 Replaces: D - Dated 9/19/13
INTRODUCTION! SFETY WRNING RED BEFORE STRTING THE INSTLLTION OF THE ICOM JTG SYSTEM. ENSURE THT LL PERSONNEL IN THE IMMEDITE RE RE WRE OF THESE REMINDERS.! PROPNE IS NONTOXIC, NONPOISONOUS GS THT IS EXTREMELY FLMMBLE. IF SOMETHING IGNITES IT, YOU COULD BE BDLY BURNED. KEEP SPRKS, OPEN FLMES ND SMOKING MTERIL WY FROM PROPNE.! LIQUID PROPNE IS EXTREMELY COLD (-40 F) ND CUSES SERIOUS BURNS WHEN CONTCTING YOUR SKIN OR EYES. PENT CONTCT WHEN HNDLING LPG BY WERING PPROVED PROTECTIVE GLOVES ND EYE PROTECTION.! PROPNE IS STORED UNDER PRESSURE. THE FUEL SYSTEM OPERTES T PRESSURES OF UP TO 312 PSI. SUDDEN RELESE OF PROPNE CN CUSE SERIOUS INJURIES. THESE INSTRUCTIONS RE INTENDED FOR TECHNICINS WHO RE CERTIFIED BY LL GENCIES THT GOVERN PROPNE INSTLLTIONS ND THE TRNSPORTTION OF PROPNE. THE NTIONL FIRE PROTECTION SSOCITION (NFP) PUBLISHES CODE BOOK OF RULES (NFP 58) THT PPLY TO THE STORGE, HNDLING, TRNSPORTTION ND USE OF LIQUEFIED PETROLEUM GS (LPG). LOCL PROPNE SUPPLIERS SUCH S FERRELGS ND MERIGS, S WELL S SOME GENGIES SUCH S THE TEXS RILROD COMMISION ND PERC (PROPNE EDUCTION & RESERCH COUNCIL) OFFER INFORMTIVE COURSES TO HELP PENT SEVERE INJURY OR DETH TO YOU OR SOMEONE ELSE IF YOU DON'T FULLY UNDERSTND LPG ND ITS PROPERTIES. BEGIN THE INSTLLTION BY PREPRING YOUR WORK SITE. THE RE SHOULD BE CLEN WITH SUFFICIENT LIGHTING. YOU WILL NEED: 1) WORKBENCH 2) TOOLS, INCLUDING SOCKETS, SCREWDRIVERS, WRENCH, METL CUTTING TOOLS (SMLL RECIPROCTING SW, NIBBLERS, DRILLS, ECTC.) 3) SFETY GLSSES, GLOVES ND HERING PROTECTION 4) FUEL PRESSURE GUGE (ICOM # 88500001) ND CLIBRTOR REMOVL TOOL (ICOM # 90005400) 5) SOURCE OF COMPRESSED IR 6) VEHICLE LIFT WITH, PREFERBLY, MODIFIED TRNSMISSION JCK TO SUPPORT THE FUEL TNK DURING FITMENT ND INSTLLTION 7) 'FLUKE 77' MULTIMETER WITH TIME-BSED REDOUT (REQUIRED FOR CLIBRTION & DIGNOSTICS ONLY, NOT NEEDED FOR GENERL INSTLLTION).
INTRODUCTION! IMPORTNT IT IS IMPORTNT THT YOU IEW THIS ENTIRE INSTLLTION MNUL BEFORE BEGINNING TO FMILIRIZE YOURSELF WITH THE INSTLLTION PROCESS. THIS WILL HELP MINIMIZE NY POTENTIL ERRORS THT MY OCCUR IF PROCESS IS CONDUCTED OUT OF SEQUENCE.! THREDED FUEL LINE CONNECTORS / FITTINGS THE ICOM FUEL HOSES RE EQUIPPED WITH THREDED END CONNECTORS THT SEL WHEN THE PROPER IS PPLIED. DO NOT USE TEFLON TPE OR THRED SELER ON NY FITTING (UNLESS OTHERWISE INSTRUCTED) S THIS MY GET INTO THE REGULTOR OR FUEL INJECTORS ND CUSE FUEL PRESSURE PROBLEMS. NY WRRNTY RETURNED COMPONENT FOUND CONTMINTED WITH TEFLON TPE WILL BE RETURNED.! BRE METL SURFCES NYTIME THE OEM PINTED SURFCE IS BROKEN BY DRILLING OR REMOVL OF PRTICULR COMPONENT, THE EXPOSED METL SURFCE MUST BE DEBURRED ND COTED WITH PRIMER OR SELER TO PENT RPID CORROSION. THIS IS EXTREMELY IMPORTNT IN RES THT USE ROD SLT DURING THE WINTER MONTHS. FOLLOW THE LBEL INSTRUCTIONS ON THE PRODUCT USED TO ENSURE POSITIVE RESULTS.! PCKGING CREFULLY INSPECT THE CONTENTS OF THE KIT ONCE YOU RECEIVE IT TO ENSURE THT LL OF THE COMPONENTS RE VILBLE BEFORE STRTING THE INSTLLTION. PRTS LIST IS ENCLOSED WITH THIS MNUL. THE LIST OF PRTS MY VRY BSED ON THE PPLICTION.
INSTLLTION KIT CONTENTS THE CONTENTS IN THE INSTLLTION KIT LISTED BELOW IS BSED ON 6.8L MONOFUEL PPLICTION. PRT NUMBERS FOR SOME PRTICULR COMPONENTS WILL CHNGE BSED ON THE PPLICTION. PCKGE PRT NUMBER COMPONENT QTY P11X4-4218-F WIRE HRNESS SSY - ENGINE 1 110000 GROMMET - ENGINE WIRE HRNESS 1 70306602 MONO FUEL ICU MODULE 1 8808000 UXILIRY FUEL PUMP 1 90004208 FITTING - UXILIRY FUEL PUMP (PI) 2 320001 HET SHIELD 1 200006 BRCKET - UXILIRY FUEL PUMP 1 950000 SELF TP SCREW 1 700002 M6 FLT WSHER 1 90009100 ICOM NTC SENSOR 1 19299100 DPTOR - NTC SENSOR 1 440000 3/16" SHRINK TUBE 1 71301100 BUZZER 1 495000 LED LIGHT 1 P11X4-4219- WIRE HRNESS SSY - EV6 TO EV1 9 P11X4-4220- WIRE HRNESS SSY - EV6 TO EV1 W/KEY ON & RPM 1 19318100 EVP SENSOR ORIFICE 1 480000 RING TERMINL 2 150000 8" TIE STRP 8 12103784 CONNECTOR 1 12124581 TERMINL 2 15324980 SEL 2 P13X4-9426- LBEL - STRTING INSTRUCTIONS PCKGE B PCKGE C PCKGE D PCKGE E 27036000 BRCKET - MONO FUEL ICU MODULE 1 800002 M4 NYLOCK NUT 4 900003 M4 x 60 SCREW 4 PCKGE F (FUEL RILS) P13X4-2022L- FUEL RIL SSY - 6.8L MONO FUEL ENGINE LH 1 P13X4-2022R- FUEL RIL SSY - 6.8L MONO FUEL ENGINE RH 1 PCKGE G P11X4-2300-B REGULTOR W/TEE SSY 1 P11X4-9302- BRCKET SSY - REGULTOR 1 P11X4-2301- NON-RETURN VLVE W/TEE SSY 1 P11X4-9303- BRCKET SSY - NON RETURN VLVE 1 PCKGE H P12X4-7002- FUEL FILL FILTER 1 330009 CLMP - FUEL FILTER MOUNTING 1 330002 1/2" CBLE CLMP 4 330005 1-3/8" CBLE CLMP 4 330006 1-1/2" HOSE CLMP 2 950000 SELF TP SCREW 13
INSTLLTION KIT CONTENTS PCKGE I PRT NUMBER COMPONENT QTY P11X4-9301- ICOM LUMINUM FILL HOUSING 1 650000 FILL VLVE 1 900004 M6 x 30 PHILLIPS HED SCREW 4 800004 M6 X 1.0 NYLOCK NUT 4 700002 M6 FLT WSHER 4 PCKGE J 90009000 ICOM EMBLEM 1 P11X-9420- DIMOND PROPNE DECL 1 P13X4-9225- ICOM MONO FUEL OWNERS MNUL 1 PCKGE K P13X4-4110- UXILIRY FUEL PUMP SWITCH KIT 1 FUEL RIL HRDWRE 90003502 MODIFIED 5-HOLE BRCKET 4 800004 M6 X 1.0 NYLOCK NUT 4 900006 M4 X 10mm SCREW 4 800002 M4 X 0.7 NYLOCK NUT 4 ENGINE HOSES P13X4-2711- ENGINE HOSE - SUPPLY PSSENGER SIDE 1 P13X4-2712- ENGINE HOSE - SUPPLY DRIVER SIDE 1 P13X4-2812- ENGINE HOSE - RETURN PSSENGER SIDE 1 P13X4-2813- ENGINE HOSE - RETURN DRIVER SIDE 1 UXILIRY FUEL PUMP HOSE P13X4-3314- HOSE SSY - UXILIRY FUEL PUMP 1 FUEL FILL HOSE KIT P11X4-3702- HOSE KIT - REMOTE FUEL FILL (10 FT.) 1 REMOTE BLEEDER HOSE KIT P11X4-3109- HOSE KIT - REMOTE BLEEDER VLVE (10 FT.) 1 EVP HOSE KIT P13X4-3120- HOSE KIT - EVP RELOCTION 1 CHSSIS HOSE KIT P11X4-3110- HOSE KIT - CHSSIS (25 FT.) (13 x 92 FUEL TNK) 1 P11X4-3119- HOSE KIT - CHSSIS (30 FT.) (14 x 14 x 47 FUEL TNK) 1 CORRUGTE 350031 CORRUGTE HOSE - 1/2" SPLIT (10 FT.) 1 350024 CORRUGTE HOSE - 1-1/2" SOLID (10 FT.) (FUEL FILL HOSE) 1 350027 CORRUGTE HOSE - 1-1/2" SOLID (25 FT.) (13 x 92 FUEL TNK) 1 350041 CORRUGTE HOSE - 1-1/2" SOLID (30 FT.) (14 x 14 x 47 FUEL TNK) 1 320000 HET SHIELD TUBE 1 350042 / 350043 1/4" SPLIT CORRUGTE (13 x 92 TNK L=36" - 14 x 14 x 47 TNK L=10') 1
INSTLLTION MNUL TBLE OF CONTENTS PROCESS # PROCESS NME P13X4-9229-0010 RELOCTE EVP CNNISTER (13 X 92 TNK INSTLLS ONLY) P13X4-9229-0015 INSTLL EVP SENSOR BY-PSS E P13X4-9229-0020 INSTLL FUEL TNK BRCKETS (13 x 92 FUEL TNK) P13X4-9229-0030 INSTLL CHSSIS SUPPLY & RETURN HOSES ONTO FUEL TNK B P13X4-9229-0040 INSTLL FUEL TNK (13 x 92 FUEL TNK) P13X4-9229-0045 INSTLL FUEL TNK (14 x 14 x 47 FUEL TNK) P13X4-9229-0050 INSTLL ICOM FUEL FILL HOUSING (13 x 92 FUEL TNK ONLY) P13X4-9229-0055 INSTLL ICOM FUEL FILL HOUSING (14 x 14 x 47 FUEL TNK ONLY) P13X4-9229-0060 INSTLL REMOTE BLEEDER VLVE HOSE P13X4-9229-0070 INSTLL FUEL FILL HOSES & FILTER TO FUEL TNK P13X4-9229-0080 INSTLL LPG FUEL RILS P13X4-9229-0090 INSTLL LPG FUEL INJECTOR WIRE HRNESS LEDS P13X4-9229-0100 INSTLL LPG REGULTOR ND NON-RETURN VLVE P13X4-9229-0110 INSTLL LPG ENGINE SUPPLY/RETURN HOSES P13X4-9229-0120 INSTLL UXILIRY FUEL PUMP ND HOSE SSY P13X4-9229-0130 TTCH CHSSIS SUPPLY / RETURN HOSES P13X4-9229-0140 INSTLL LPG ENGINE WIRE HRNESS SSY D P13X4-9229-0150 INSTLL ICOM NTC SENSOR P13X4-9229-0160 INSTLL MONO FUEL ICU MODULE P13X4-9229-0165 MODIFY EVP PURGE VLVE SENSOR E P13X4-9229-0170 INSTLL LED LIGHT P13X4-9229-0180 INSTLL ENGINE STRT INSTRUCTION DECL P13X4-9229-0190 INSTLL UDIBLE INDICTOR (BUZZER) P13X4-9229-0200 PLUG GSOLINE SUPPLY HOSE INSIDE ENGINE COMPRTMENT P13X4-9229-0210 CONNECT FUEL PUMP & FUEL LEVEL WIRE LEDS C P13X4-9229-0220 INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0230 INSTLL ENGINE HRDWRE ND TTCH BTTERY LEDS P13X4-9229-0240 INSTLL PROPNE DIMOND DECL P13X4-9229-0250 INSTLL VEHICLE EMISSION LBEL P13X4-9229-0260 FINL INSPECTION ND SYSTEM CHECK P13X4-9229-0270 TROUBLESHOOTING
NUMBER 10 10) FROM THE DRIVERS SIDE OF THE VEHICLE, LOCTE THE EVP CNNISTER TTCHED TO THE INBORD SIDE OF THE FRME 20 20) LOCTE THE (2) HOSES TTCHED TO THE FRONT INBORD SIDE OF THE CNNISTER 30) CREFULLY DISCONNECT BOTH HOSES FROM THE EVP CNNISTER 30 DESCRIPTION TOOLS PROCESS NME RELOCTE EVP CNNISTER (13 x 92 TNK ONLY) P13X4-9229-0010 1 OF 9
NUMBER 40) LOCTE THE EVP MODULE MOUNTED ON THE FRONT OF THE CNNISTER 40 CREFULLY DISCONNECT THE WIRE HRNESS LED CONNECTOR FROM THE MODULE 50) LOCTE THE HOSE TTCHED T THE FRONT FCING SIDE OF THE EVP MODULE CREFULLY DISCONNECT THE HOSE FROM THE MODULE 60) LOCTE THE (3) SCREWS THT TTCH THE EVP CNNISTER TO THE VEHICLE REMOVE THE SCREWS ND LOWER THE EVP CNNISTER FROM THE FRME 50 SET SCREWS SIDE FOR LTER RE-INSTLLTION 60 DESCRIPTION TOOLS PROCESS NME RELOCTE EVP CNNISTER (13 x 92 TNK ONLY) P13X4-9229-0010 2 OF 9
NUMBER 70) POSITION THE EVP CNNISTER TO THE OUTBORD DRIVER SIDE OF THE FRME LIGN ND SET THE (2) LEGS ON THE CNNISTER MOUNTING BRCKET TO THE ORIGINL MOUNTING HOLES ON THE OUTBORD SIDE OF THE FRME 80) OBTIN (2) OF THE ORIGINL MOUNTING SCREWS INSERT SCREWS FROM THE INBORD SIDE OF THE FRME INTO THE U-NUTS ON THE CNNISTER BRCKETS 70 80 FULLY TIGHTEN SCREWS TO SECURE CNNISTER TO THE OUTBORD SIDE OF THE FRME S SHOWN 90) OBTIN 2" x 9" PIECE OF LUMINUM; FORM THE LUMINUM INTO 'Z-SHPE' S SHOWN DRILL 3/8" HOLE INTO ONE OF THE FORMED TBS S SHOWN 100) SECURE THE LUMINUM BRCKET TO THE TOP EVP CNNISTER BRCKET 90 USING SELF TPPING SCREW, SECURE THE LUMINUM BRCKET TO THE FLOOR PN BRCE S SHOWN 100 DESCRIPTION TOOLS 950000 1 SELF TP SCREW DRILL 3/8" DRILL BIT 2" x 9" LUMINUM PROCESS NME RELOCTE EVP CNNISTER (13 x 92 TNK ONLY) P13X4-9229-0010 3 OF 9
NUMBER 110) LOCTE ND GRSP THE HOSE THT WS TTCHED TO THE EVP MODULE ROUTE THE HOSE TO THE RER FCING SIDE OF THE CNNISTER 110 120 120) LIGN ND SET THE HOSE CONNECTOR ONTO THE EVP MODULE NOZZLE S SHOWN 130) LOCTE THE EVP CNNISTER HOSE WITH THE STRIGHT FITTING ON THE END OF THE HOSE 140) USING PIR OF HOSE CUTTERS, CUT THE SMOOTH PORTION OF EVP HOSE S SHOWN; KEEP THE CUT PORTION OF THE HOSE FOR RE-INSTLLTION IN STEP #190 130 140 DESCRIPTION TOOLS HOSE CUTTER PROCESS NME RELOCTE EVP CNNISTER (13 x 92 TNK ONLY) P13X4-9229-0010 4 OF 9
NUMBER 150 B 150) OBTIN THE EVP RELOCTION HOSE KIT () 160) OBTIN THE SMLLER DIMETER RUBBER HOSE FROM THE KIT ND (2) OF THE SMLLER HOSE CLMPS 160 170) INSTLL (1) HOSE CLMP ONTO END OF HOSE; INSERT HOSE ONTO THE END OF THE CUT EVP HOSE; POSITION CLMP OVER EVP HOSE ND FULLY TIGHTEN CLMP 170 180) ROUTE OPPOSITE END OF HOSE BETWEEN DRIVER SIDE FRME ND BODY S SHOWN 190) OBTIN THE CUT PORTION OF THE EVP HOSE FROM STEP #140; INSTLL HOSE CLMP ONTO OPPOSITE END OF RUBBER HOSE; INSERT RUBBER HOSE ONTO THE SMOOTH END OF THE CUT EVP HOSE; POSION CLMP OVER EVP HOSE ND FULLY TIGHTEN CLMP 200) LIGN ND SET THE EVP HOSE CONNECTOR ONTO THE LOWER NOZZLE ON THE EVP CNNISTER S SHOWN 180 190 200 DESCRIPTION TOOLS B P13X4-3120- 1 EVP RELOCTION HOSE KIT PROCESS NME RELOCTE EVP CNNISTER (13 x 92 TNK ONLY) P13X4-9229-0010 5 OF 9
NUMBER 210 210) LOCTE THE EVP CNNISTER HOSE WITH THE 90 DEGREE FITTING ON THE END OF THE HOSE 220) USING PIR OF HOSE CUTTERS, CUT THE HOSE S SHOWN; KEEP THE CUT PORTION OF THE HOSE FOR LTER RE-INSTLLTION IN STEP #260 220 230) OBTIN THE LRGE DIMETER RUBBER HOSE FROM THE KIT ND THE (2) LRGE HOSE CLMPS 240) INSTLL (1) HOSE CLMP ONTO END OF HOSE; INSERT HOSE ONTO THE END OF THE CUT EVP HOSE; POSITION CLMP OVER EVP HOSE ND FULLY TIGHTEN CLMP 240 230 DESCRIPTION TOOLS PROCESS NME RELOCTE EVP CNNISTER (13 x 92 TNK ONLY) P13X4-9229-0010 6 OF 9
NUMBER 250) ROUTE OPPOSITE END OF HOSE BETWEEN DRIVER SIDE FRME ND BODY S SHOWN 250 260 260) OBTIN THE CUT PORTION OF THE EVP HOSE FROM STEP #220; INSTLL HOSE CLMP ONTO OPPOSITE END OF RUBBER HOSE; INSERT RUBBER HOSE ONTO THE SMOOTH END OF THE CUT EVP HOSE; POSION CLMP OVER EVP HOSE ND FULLY TIGHTEN CLMP 270) LIGN ND SET THE EVP HOSE CONNECTOR ONTO THE LOWER NOZZLE ON THE EVP CNNISTER S SHOWN 280) LOCTE THE EVP MODULE WIRE HRNESS LED 270 280 DESCRIPTION TOOLS PROCESS NME RELOCTE EVP CNNISTER (13 x 92 TNK ONLY) P13X4-9229-0010 7 OF 9
NUMBER 290 290) USING WIRE CUTTERS, REMOVE THE CONNECTOR FROM THE END OF THE WIRE HRNESS LED 300 300) OBTIN THE WHITE/RED WIRE, GREEN WIRE, SHRINK TUBE ND 1/4" SPLIT CORRUGTE FROM KIT 310) CREFULLY REMOVE PPROXIMTELY 1/2" OF WIRE INSULTION FROM BOTH EVP MODULE WIRES CREFULLY REMOVE PPROXIMTELY 1/2" OF WIRE INSULTION FROM BOTH ENDS OF THE WHITE/RED WIRE ND GREEN WIRE; CUT SHRINK TUBE IN HLF ND INSTLL BOTH HLFS ONTO BOTH WIRES 320) TTCH THE WHITE/RED WIRE TO THE CORRESPONDING EVP MODULE LED ND THE GREEN WIRE THE CORRESPONDING EVP MODULE LED SOLDER CONNECTIONS TOGETHER ND SEL SOLDERED CONNECTIONS WITH SHRINK TUBE 310 320 DESCRIPTION TOOLS WIRE CUTTERS WIRE STRIPPERS SOLDER IRON ROSIN CORE SOLDER PROCESS NME RELOCTE EVP CNNISTER (13 x 92 TNK ONLY) P13X4-9229-0010 8 OF 9
NUMBER 330) ROUTE OPPOSITE END OF WIRES BETWEEN DRIVER SIDE FRME ND BODY S SHOWN 330 340) CREFULLY REMOVE PPROXIMTELY 1/2" OF WIRE INSULTION FROM BOTH EVP MODULE WIRES TTCHED TO THE CONNECTOR 340 350 350) TTCH THE WHITE/RED WIRE TO THE CORRESPONDING EVP MODULE CONNECTOR LED ND THE GREEN WIRE THE CORRESPONDING EVP MODULE CONNECTOR LED SOLDER CONNECTIONS TOGETHER ND SEL SOLDERED CONNECTIONS WITH SHRINK TUBE 360) LIGN ND SET CONNECTOR INTO EVP MODULE (PUSH / PULL CONNECTOR TO VERIFY FULLY SETED) 370) INSTLL 1/4" SPLIT CORRUGTE ONTO THE EXPOSED WHITE/RED ND GREEN WIRES; TRIM CORRUGTE S NECESSRY 360 DESCRIPTION TOOLS SOLDER IRON ROSIN CORE SOLDER PROCESS NME RELOCTE EVP CNNISTER (13 x 92 TNK ONLY) P13X4-9229-0010 9 OF 9
NUMBER 10 05) REMOVE THE GSOLINE FUEL TNK FROM THE VEHICLE 10) REMOVE THE EVP SENSOR FROM THE GSOLINE FUEL TNK 20) OBTIN THE EVP SENSOR CP () FROM THE EVP HOSE KIT 30 30) INSTLL THE EVP SENSOR CP () ONTO ONE END OF THE EVP SENSOR HOSE BRB S SHOWN 40) CONNECT THE EVP HOSE GOING TO THE EVP CNISTER ONTO THE UNCPPED NOZZLE ON THE EVP SENSOR 40 50) LOCTE THE EVP SENSOR WIRE LED CONNECTOR LOCTED BOVE THE DRIVER SIDE FRME RIL; LIGN ND SET THE WIRE CONNECTOR INTO THE EVP SENSOR (PUSH / PULL CONNECTOR TO VERIFY FULLY SETED) 50 DESCRIPTION TOOLS 100001 1 CP - EVP SENSOR PROCESS NME INSTLL EVP SENSOR BY-PSS P13X4-9229-0015 1 OF 1
NUMBER 10 FRONT BRCKETS RER BRCKETS 10) REMOVE & SEPRTE THE FUEL TNK TTCHMENT BRCKETS FROM THE FUEL TNK S SHOWN; SET FSTENERS SIDE FOR LTER RE-INSTLLTION FRONT CROSSMEMBER 20) FROM UNDERNETH THE DRIVERS SIDE OF THE VEHICLE, LOCTE THE FRONT ND RER CROSSMEMBERS 30) OBTIN THE UPPER FRONT FUEL TNK BRCKET 20 30 RER CROSSMEMBER DESCRIPTION TOOLS PI 1 FRONT UPPER FUEL TNK BRCKET B PI 1 RER UPPER FUEL TNK BRCKET PROCESS NME INSTLL FUEL TNK BRCKETS (13 x 92 TNK ONLY) P13X4-9229-0020 1 OF 5
NUMBER 40 40) LIGN ND SET THE UPPER FRONT BRCKET INTO THE CHNNEL OF THE FRONT CROSSMEMBER S SHOWN 50 50) MRK THE BRCKET TTCHMENT HOLES ONTO THE UNDERSIDE OF THE FRONT CROSSMEMBER S SHOWN 60 60) USING DRILL WITH 1/2" DRILL BIT, CREFULLY DRILL THE (2) MRKED HOLES IN THE FRONT CROSSMEMBER DESCRIPTION TOOLS PI 1 FRONT UPPER FUEL TNK BRCKET DRILL 1/2" DRILL BIT PROCESS NME INSTLL FUEL TNK BRCKETS (13 x 92 TNK ONLY) P13X4-9229-0020 2 OF 5
NUMBER 70 70) OBTIN THE UPPER RER FUEL TNK BRCKET 80) LIGN ND SET THE UPPER RER BRCKET INTO THE CHNNEL OF THE RER CROSSMEMBER S SHOWN 80 90) MRK THE BRCKET TTCHMENT HOLES ONTO THE UNDERSIDE OF THE RER CROSSMEMBER S SHOWN 100) USING DRILL WITH 1/2" DRILL BIT, CREFULLY DRILL THE (2) MRKED HOLES IN THE RER CROSSMEMBER 90 100 DESCRIPTION TOOLS B PI 1 RER UPPER FUEL TNK BRCKET DRILL 1/2" DRILL BIT PROCESS NME INSTLL FUEL TNK BRCKETS (13 x 92 TNK ONLY) P13X4-9229-0020 3 OF 5
NUMBER 120 110) OBTIN (4) GRDE 8 BOLTS - 1/2" x 2", (4) GRDE 8 1/2" WSHERS ND (4) 1/2" GRDE 8 NYLOCK NUTS (NOT INCLUDED WITH KIT) 120) LIGN ND SET THE UPPER FRONT FUEL TNK BRCKET INTO THE CHNNEL OF THE FRONT CROSSMEMBER 130 130) LIGN MOUNTING HOLES ND INSERT (2) 1/2" x 2" BOLTS DOWNWRD THROUGH CROSSMEMBER ND INTO MOUNTING BRCKET; INSTLL 1/2" WSHER ONTO ECH BOLT; HNDSTRT 1/2" NYLOCK NUT ONTO ECH BOLT 140) LIGN ND SET THE UPPER RER FUEL TNK BRCKET INTO THE CHNNEL OF THE RER CROSSMEMBER 150) LIGN MOUNTING HOLES ND INSERT (2) 1/2" x 2" BOLTS DOWNWRD THROUGH CROSSMEMBER ND INTO MOUNTING BRCKET; INSTLL 1/2" WSHER ONTO ECH BOLT; HNDSTRT 1/2" NYLOCK NUT ONTO ECH BOLT 140 150 DESCRIPTION TOOLS PI 1 FRONT UPPER FUEL TNK BRCKET B PI 1 RER UPPER FUEL TNK BRCKET PROCESS NME INSTLL FUEL TNK BRCKETS (13 x 92 TNK ONLY) P13X4-9229-0020 4 OF 5
NUMBER 160) LL (4) BOLTS/NUTS TO 100 Nm +/- 10 160 1 DESCRIPTION TOOLS WRENCH 1 100 Nm +/-10 PROCESS NME INSTLL FUEL TNK BRCKETS (13 x 92 TNK ONLY) P13X4-9229-0020 5 OF 5
NUMBER 10) OBTIN THE SUPPLY / RETURN CHSSIS HOSE KIT () OR (B) ( KIT () 13 x 92 FUEL TNK - KIT (B) 14 x 14 x 47 FUEL TNK) 20) LOCTE THE (SHORT) SUPPLY NOZZLE COMING OUT OF THE MULTIVLVE COLLR BUSHING 30) HNDSTRT THE CRIMPED FITTING ON THE GREEN SUPPLY HOSE ONTO THE SUPPLY NOZZLE 50 60 70 1 20 30 40 1 40) 50) USING 14mm OPEN END WRENCH ON THE SUPPLY NOZZLE FROM THE MULTIVLVE, THE FITTING ON THE HOSE WITH 15mm OPEN END CROWFOOT & WRENCH TO 14 Nm +/- 1.4 LOCTE THE (LONG) RETURN NOZZLE COMING OUT OF THE MULTIVLVE COLLR BUSHING 60) HNDSTRT THE CRIMPED FITTING ON THE BLCK RETURN HOSE ONTO THE RETURN NOZZLE 80 90 100 70) 80) USING 14mm OPEN END WRENCH ON THE RETURN NOZZLE FROM THE MULTIVLVE, THE FITTING ON THE HOSE WITH 15mm OPEN END CROWFOOT & WRENCH TO 14 Nm +/- 1.4 OBTIN THE 1-1/2" CORRUGTE HOSE (C ) OR (D) ( 13 x 92 FUEL TNK - HOSE (C ) - 14 x 14 x 47 FUEL TNK - HOSE (D)) 90) FROM PCKGE 'H', OBTIN (1) 1-1/2" SCREW CLMP; INSTLL CLMP ONTO END OF CORRUGTE THT WILL BE INSTLLED ONTO THE MULTIVLVE COLLR BUSHING 110 100) TPE THE GREEN SUPPLY HOSE, BLCK RETURN HOSE ND FUEL TNK WIRE HRNESS TOGETHER TOWRDS THE END; INSERT THE HOSES ND HRNESS INTO ND COMPLETELY THROUGH THE CORRUGTE 110) INSERT CORRUGTE HOSE ONTO TNK BUSHING; POSITION CLMP OVER BUSHING ND FULLY TIGHTEN DESCRIPTION TOOLS P11X4-3110- 1 SUPPLY / RETURN CHSSIS HOSE KIT (25 FT) 14mm OPEN END WRENCH 1 14 Nm +/- 1.4 B P11X4-3119- 1 SUPPLY / RETURN CHSSIS HOSE KIT (30 FT) 15mm CROWFOOT C 350027 1 CORRUGTE HOSE - 1-1/2" SOLID (25 FT) WRENCH D 350041 1 CORRUGTE HOSE - 1-1/2" SOLID (30 FT) E 330006 2 1-1/2" HOSE CLMP (PKG H) PROCESS NME INSTLL CHSSIS SUPPLY & RETURN HOSES TO FUEL TNK B P13X4-9229-0030 1 OF 2
NUMBER 120 120) MESURE 30" FROM THE FUEL TNK BUSHING ON THE CORRUGTE HOSE 130) USING RZOR BLDE, CREFULLY SLICE OPEN THE CORRUGTE HOSE ND LOCTE THE FUEL LEVEL SENDING UNIT LED; REMOVE LED THROUGH OPENING 140) LOCTE THE RED ND BLCK FUEL PUMP WIRES; REMOVE LEDS THROUGH OPENING; MESURE TO THE SME LENGTH S THE FUEL LEVEL SENDING UNIT LEDS ND CUT 130 140 150 OBTIN 1/4" SPILT CORRUGTE FROM KIT; INSTLL CORRUGTE ONTO EXPOSED WIRE LEDS ND CUT TO REQUIRED LENGTH 160 SEL CUT OPENING ON 1-1/2" CORRUGTE WITH ELECTRICL TPE S SHOWN 150 F 160 DESCRIPTION TOOLS F 1 1/4" SPLIT CORRUGTE ELECTRICL TPE PROCESS NME INSTLL CHSSIS SUPPLY & RETURN HOSES TO FUEL TNK P13X4-9229-0030 B 2 OF 2
NUMBER 10 10) OBTIN THE (2) LOWER FUEL TNK BRCKETS & FSTENERS REMOVED IN 0020 STEP #10 20) POSITION THE FUEL TNK TO THE DRIVER SIDE OF THE VEHICLE WITH THE MULTIVLVE ON THE END OF THE FUEL TNK FCING TOWRD THE RER OF THE VEHICLE 30) USING N PPROPRITE LIFTING DEVICE, LIGN ND CENTER FUEL TNK TO THE FRONT ND RER UPPER FUEL TNK BRCKETS MOUNTED TO THE VEHICLE CROSSMEMBERS; CREFULLY LIFT TNK ND SET INTO THE UPPER BRCKETS 30 40) LIGN ND SET (1) OF THE LOWER FUEL TNK BRCKETS TO THE UPPER RER BRCKET MOUNTED TO THE RER CROSSMEMBER; LOOSELY SECURE THE UPPER ND LOWER BRCKETS TOGETHER WITH THE REMOVED FSTENERS 40 DESCRIPTION TOOLS PI 2 LOWER FUEL TNK BRCKETS PROCESS NME INSTLL FUEL TNK (13 x 92 TNK ONLY) P13X4-9229-0040 1 OF 4
NUMBER 50) LIGN ND SET THE REMINING LOWER FUEL TNK BRCKET TO THE UPPER FRONT BRCKET MOUNTED TO THE FRONT CROSSMEMBER; LOOSELY SECURE THE UPPER ND LOWER BRCKETS TOGETHER WITH THE REMOVED FSTENERS 50 60) MOVE THE TNK S NEEDED TO CENTER THE TNK FRONT TO RER INSIDE THE BRCKETS ND ROTTE THE TNK TO POSITION THE 'TOP' DECL T TOP CENTER 70) ONCE TNK IS POSITIONED CORRECTLY, THE (4) FSTENERS TO 100 Nm +/- 10 TO SECURE THE FUEL TNK IN PLCE 70 1 80) 90) GRSP THE CORRUGTE HOSE MOUNTED TO THE FUEL TNK BUSHING; ROUTE THE CORRUGTE THROUGH THE OPENING IN THE BODY REINFORCEMENT TOWRD THE OUTBORD SIDE OF THE FRME ROUTE CORRUGTE TOWRD FRONT OF VEHICLE 90 80 FRONT OF VEHICLE DESCRIPTION TOOLS WRENCH 1 100 Nm +/-10 PROCESS NME INSTLL FUEL TNK (13 x 92 TNK ONLY) P13X4-9229-0040 2 OF 4
NUMBER 100 100) OBTIN (1) 1-3/8" CBLE CLMP (B) ND (1) SELF TP SCREW (C ) INSTLL CBLE CLMP (B) ONTO CORRUGTE HOSE ND SECURE CLMP TO BODY REINFORCEMENT WITH SELF TP SCREW (C ) S SHOWN 110 110) CONTINUE ROUTING THE CORRUGTE TOWRD THE FRONT OF THE VEHICLE LONG THE OUTBORD SIDE OF THE BODY FRME S SHOWN 120) OBTIN (1) 1-3/8" CBLE CLMP (B) ND (1) SELF TP SCREW (C ) INSTLL CBLE CLMP (B) ONTO CORRUGTE HOSE ND SECURE CLMP TO BODY REINFORCEMENT WITH SELF TP SCREW (C ) S SHOWN 130) OBTIN (1) 1-3/8" CBLE CLMP (B) ND (1) SELF TP SCREW (C ) INSTLL CBLE CLMP (B) ONTO CORRUGTE HOSE ND SECURE CLMP TO BODY REINFORCEMENT WITH SELF TP SCREW (C ) S SHOWN JUST IN FRONT OF THE EVP CNNISTER 130 120 DESCRIPTION TOOLS B 330005 3 1-3/8" CBLE CLMP (PKG H) CORDLESS DRILL C 950000 3 SELF TP SCREW (PKG H) 9mm SOCKET PROCESS NME INSTLL FUEL TNK (13 x 92 TNK ONLY) P13X4-9229-0040 3 OF 4
NUMBER 140) CONTINUE ROUTING THE CORRUGTE TOWRD THE FRONT OF VEHICLE S SHOWN 140 150) OBTIN (1) 1-3/8" CBLE CLMP (B) ND (1) SELF TP SCREW (C ) INSTLL CBLE CLMP (B) ONTO CORRUGTE HOSE ND SECURE CLMP TO BODY REINFORCEMENT WITH SELF TP SCREW (C ) S SHOWN 160) ROUTE CORRUGTE UPWRD INTO THE ENGINE COMPRTMENT RE S SHOWN 160 150 DESCRIPTION TOOLS B 330005 1 1-3/8" CBLE CLMP (PKG H) CORDLESS DRILL C 950000 1 SELF TP SCREW (PKG H) 9mm SOCKET PROCESS NME INSTLL FUEL TNK (13 x 92 TNK ONLY) P13X4-9229-0040 4 OF 4
NUMBER 10 10) FROM THE RER UNDERSIDE OF THE VEHICLE, LOCTE THE FRME CROSSMEMBER WITH THE HOLES 20) USING N PPROPRITE CUTTING TOOL, CUT THE CROSSMEMBER FLUSH TO THE INBORD SIDE OF THE DRIVER & PSSENGER FRME ND REMOVE 30) CUT ND REMOVE THE STUDS FROM THE BOTTOMSIDE OF THE DRIVER & PSSENGER FRME RILS (THESE RE THE STUDS THT SECURE THE REMINING PORTION OF THE REMOVED CROSSMEMBER) 20 30 DESCRIPTION TOOLS PROCESS NME INSTLL FUEL TNK (14 x 14 x 47 TNK ONLY) P13X4-9229-0045 1 OF 6
NUMBER 40 40) FROM THE RER UNDERSIDE OF THE VEHICLE, LOCTE THE RER BUMPER FRME SECTION MRK THE RER BUMPER FRME SECTION S SHOWN (PPROXIMTELY 2-1/2" x 5" SECTION) ON BOTH THE DRIVER ND PSSENGER SIDE NOTE - HORIZONTL LINE IS FLUSH TO THE BOTTOMSIDE OF THE VEHICLE FRME 50) USING THE PPROPRITE CUTTING TOOL, REMOVED THE MRKED SECTION ON BOTH THE DRIVER ND PSSENGER SIDE S SHOWN 50 60) POSITION THE FUEL TNK T THE RER OF THE VEHICLE WITH THE MULTIVLVE ON THE FUEL TNK POINTING TOWRD THE DRIVER SIDE OF THE VEHICLE 70) USING N PPROPRITE LIFTING DEVICE, LIGN ND CENTER FUEL TNK BETWEEN THE DRIVER / PSSENGER SIDE VEHICLE FRME RILS ND THE REMOVED CROSSMEMBER / RER BUMPER FRME SECTION; CREFULLY LIFT TNK UNTIL TNK BRCKETS RE NESTED TO THE BOTTOMSIDE OF THE DRIVER/PSSENGER FRME RILS S SHOWN 60 70 DESCRIPTION TOOLS PROCESS NME INSTLL FUEL TNK (14 x 14 x 47 TNK ONLY) P13X4-9229-0045 2 OF 6
NUMBER 80) MRK THE (3) DRIVER / PSSENGER SIDE FUEL TNK TTCHMENT HOLES TO THE UNDERSIDE OF THE DRIVER/PSSENGER FRME RILS 80 USING DRILL WITH 1/2" DRILL BIT, CREFULLY DRILL THE MRKED HOLES IN THE DRIVER/PSSENGER FRME RILS 90) OBTIN (6) GRDE 8 BOLTS - 1/2" x 2", (6) GRDE 8 1/2" WSHERS ND (6) 1/2" GRDE 8 NYLOCK NUTS (NOT INCLUDED WITH KIT) LIGN MOUNTING HOLES ND INSERT (6) 1/2" x 2" BOLTS DOWNWRD THROUGH FRME ND INTO MOUNTING BRCKET; INSTLL 1/2" WSHER ONTO ECH BOLT; HNDSTRT 1/2" NYLOCK NUT ONTO ECH BOLT 100) LL (6) BOLTS/NUTS TO 100 Nm +/- 10 90 100 1 DESCRIPTION TOOLS 1 100 Nm +/-10 DRILL 1/2" DRILL BIT WRENCH PROCESS NME INSTLL FUEL TNK (14 x 14 x 47 TNK ONLY) P13X4-9229-0045 3 OF 6
NUMBER 110) GRSP THE CORRUGTE HOSE MOUNTED TO THE BUSHING ON THE MULTIVLVE COLLR ND ROUTE TOWRD THE FRON OF THE VEHICLE S SHOWN 120) OBTIN (1) 1-3/8" CBLE CLMP (B) ND (1) SELF TP SCREW (C ) 120 110 INSTLL CBLE CLMP (B) ONTO CORRUGTE HOSE ND SECURE CLMP TO THE UNDERSIDE OF THE DRIVER SIDE FRME WITH SELF TP SCREW (C ) S SHOWN 130) CONTINUE ROUTING CORRUGTE BOVE THE GSOLINE TNK ND LONG THE DRIVER INBORD SIDE OF THE BODY FRME S SHOWN 140) ROUTE THE CORRUGTE THROUGH THE OPENING IN THE BODY REINFORCEMENT TOWRD THE OUTBORD SIDE OF THE FRME GSOLINE TNK 150) ROUTE CORRUGTE TOWRD FRONT OF VEHICLE 130 140 150 FRONT OF VEHICLE DESCRIPTION TOOLS B 330005 1 1-3/8" CBLE CLMP (PKG H) CORDLESS DRILL C 950000 1 SELF TP SCREW (PKG H) 9mm SOCKET PROCESS NME INSTLL FUEL TNK (14 x 14 x 47 TNK ONLY) P13X4-9229-0045 4 OF 6
NUMBER 160 160) OBTIN (1) 1-3/8" CBLE CLMP (B) ND (1) SELF TP SCREW (C ) INSTLL CBLE CLMP (B) ONTO CORRUGTE HOSE ND SECURE CLMP TO BODY REINFORCEMENT WITH SELF TP SCREW (C ) S SHOWN 170 170) CONTINUE ROUTING THE CORRUGTE TOWRD THE FRONT OF THE VEHICLE LONG THE OUTBORD SIDE OF THE BODY FRME S SHOWN 180) OBTIN (1) 1-3/8" CBLE CLMP (B) ND (1) SELF TP SCREW (C ) INSTLL CBLE CLMP (B) ONTO CORRUGTE HOSE ND SECURE CLMP TO BODY REINFORCEMENT WITH SELF TP SCREW (C ) S SHOWN 190) OBTIN (1) 1-3/8" CBLE CLMP (B) ND (1) SELF TP SCREW (C ) INSTLL CBLE CLMP (B) ONTO CORRUGTE HOSE ND SECURE CLMP TO BODY REINFORCEMENT WITH SELF TP SCREW (C ) S SHOWN JUST IN FRONT OF THE EVP CNNISTER 190 180 DESCRIPTION TOOLS B 330005 3 1-3/8" CBLE CLMP (PKG H) CORDLESS DRILL C 950000 3 SELF TP SCREW (PKG H) 9mm SOCKET PROCESS NME INSTLL FUEL TNK (14 x 14 x 47 TNK ONLY) P13X4-9229-0045 5 OF 6
NUMBER 200) CONTINUE ROUTING THE CORRUGTE TOWRD THE FRONT OF VEHICLE S SHOWN 200 210) OBTIN (1) 1-3/8" CBLE CLMP (B) ND (1) SELF TP SCREW (C ) INSTLL CBLE CLMP (B) ONTO CORRUGTE HOSE ND SECURE CLMP TO BODY REINFORCEMENT WITH SELF TP SCREW (C ) S SHOWN 220) ROUTE CORRUGTE UPWRD INTO THE ENGINE COMPRTMENT RE S SHOWN 220 210 DESCRIPTION TOOLS B 330005 1 1-3/8" CBLE CLMP (PKG H) CORDLESS DRILL C 950000 1 SELF TP SCREW (PKG H) 9mm SOCKET PROCESS NME INSTLL FUEL TNK (14 x 14 x 47 TNK ONLY) P13X4-9229-0045 6 OF 6
NUMBER 10 10) OBTIN PCKGE I (FUEL FILL HOUSING & HRDWRE) 20) OBTIN THE REMOTE BLEEDER VLVE ND DPTOR FROM THE REMOTE BLEEDER VLVE HOSE KIT (P11X4-3109-) 20 B 30) INSTLL THE REMOTE BLEEDER VLVE INTO THE FUEL FILL HOUSING S SHOWN 40) PPLY THRED SELER ONTO THE BLEEDER VLVE THREDS INSTLL ND FULLY TIGHTEN DPTOR ONTO REMOTE S SHOWN 30 40 DESCRIPTION TOOLS 1 PCKGE I THRED SELER B P11X4-3109- 1 REMOTE BLEEDER VLVE HOSE KIT PROCESS NME INSTLL ICOM FUEL FILL HOUSING (13 x 92 FUEL TNK ONLY) P13X4-9229-0050 1 OF 4
NUMBER 50 50) OBTIN THE FUEL FILL VLVE FROM PCKGE 'I'; REMOVE THE LOCK NUT ND WSHER FROM THE VLVE ND SET SIDE 60 60) LIGN ND SET THE FUEL FILL VLVE INTO THE FUEL FILL HOUSING S SHOWN 70 70) INSTLL LOCK WSHER ONTO FILL VLVE; HNDSTRT ND FULLY SECURE NUT ONTO FILL VLVE USING 1-1/4" WRENCH DESCRIPTION TOOLS C 650000 1 FUEL FILL VLVE SSY 1-1/4" WRENCH PROCESS NME INSTLL ICOM FUEL FILL HOUSING (13 x 92 FUEL TNK ONLY) P13X4-9229-0050 2 OF 4
NUMBER 80) LOCTE THE VERTICL BODY REINFORCEMENT ON THE DRIVER SIDE OF THE VEHICLE JUST BEHIND THE PSSENGER COMPRTMENT MESURE 11-1/2" FROM THE RER EDGE OF THE REINFORCEMENT ND 10-1/2" FROM THE BOTTOM EDGE OF THE BODY TO LOCTE THE CENTER OF THE HOLE FOR THE FUEL FILL HOUSING 90) USING DRILL WITH 4-3/8" HOLE SW, DRILL HOLE INTO THE VEHICLE BODY S SHOWN 11-1/2" 80 90 10-1/2" DESCRIPTION TOOLS MESURING TPE DRILL 4-3/8" HOLE SW PROCESS NME INSTLL ICOM FUEL FILL HOUSING (13 x 92 FUEL TNK ONLY) P13X4-9229-0050 3 OF 4
NUMBER 100 100) USING DREMEL, CREFULLY GRIND WY SMLL PORTION OF THE RIGHT SIDE OF THE HOLE TO LLOW FLUSH FIT OF THE FUEL FILL HOUSING 110) REMOVE THE (4) SCREWS, WSHERS ND NUTS FROM THE FUEL FILL HOUSING ND SET SIDE 120) INSTLL THE FUEL FILL HOUSING ONTO THE VEHICLE; VERIFY HOUSING IS CENTERED ND FITS FLUSH TO THE VEHICLE 110 MRK THE (4) TTCHMENT HOLES ONTO THE VEHICLE PNEL USING DRILL WITH 1/4" DRILL BIT, DRILL OUT THE (4) TTCHMENT HOLES 130) INSERT THE )4) SCREWS INTO THE FUEL FILL HOUSING; FROM THE BCKSIDE OF THE VEHICLE PNEL, INSTLL THE (4) WSHERS & NUTS ONTO THE SCREWS ND SECURELY TIGHTEN WITH PHILLIPS SCREWDRIVER ND 10mm SOCKET WRENCH 120 130 DESCRIPTION TOOLS D 900004 4 M6 x 30 PHILLIPS HED SCREW (PKG I) DREMEL E 700002 4 M6 FLT WSHER (PKG I) DRILL F 800004 4 M6 x 1.0 NYLOCK NUT (PKG I) 1/4" DRILL BIT PHILLIPS SCREWDRIVER 10mm SOCKET WRENCH PROCESS NME INSTLL ICOM FUEL FILL HOUSING (13 x 92 FUEL TNK ONLY) P13X4-9229-0050 4 OF 4
NUMBER 10 10) OBTIN PCKGE I (FUEL FILL HOUSING & HRDWRE) 20) OBTIN THE REMOTE BLEEDER VLVE ND DPTOR FROM THE REMOTE BLEEDER VLVE HOSE KIT (P11X4-3109-) 20 B 30) INSTLL THE REMOTE BLEEDER VLVE INTO THE FUEL FILL HOUSING S SHOWN 40) PPLY THRED SELER ONTO THE BLEEDER VLVE THREDS INSTLL ND FULLY TIGHTEN DPTOR ONTO REMOTE S SHOWN 30 40 DESCRIPTION TOOLS 1 PCKGE I THRED SELER B P11X4-3109- 1 REMOTE BLEEDER VLVE HOSE KIT PROCESS NME INSTLL ICOM FUEL FILL HOUSING (14 x 14 x 47 FUEL TNK ONLY) P13X4-9229-0055 1 OF 4
NUMBER 50 50) OBTIN THE FUEL FILL VLVE FROM PCKGE 'I'; REMOVE THE LOCK NUT ND WSHER FROM THE VLVE ND SET SIDE 60 60) LIGN ND SET THE FUEL FILL VLVE INTO THE FUEL FILL HOUSING S SHOWN 70 70) INSTLL LOCK WSHER ONTO FILL VLVE; HNDSTRT ND FULLY SECURE NUT ONTO FILL VLVE USING 1-1/4" WRENCH DESCRIPTION TOOLS C 650000 1 FUEL FILL VLVE SSY 1-1/4" WRENCH PROCESS NME INSTLL ICOM FUEL FILL HOUSING (14 x 14 x 47 FUEL TNK ONLY) P13X4-9229-0055 2 OF 4
NUMBER 80) LOCTE THE VERTICL BODY REINFORCEMENT ON THE DRIVER SIDE OF THE VEHICLE JUST BEHIND THE PSSENGER COMPRTMENT MESURE 11-1/2" FROM THE RER EDGE OF THE REINFORCEMENT ND 10-1/2" FROM THE BOTTOM EDGE OF THE BODY TO LOCTE THE CENTER OF THE HOLE FOR THE FUEL FILL HOUSING 90) USING DRILL WITH 4-3/8" HOLE SW, DRILL HOLE INTO THE VEHICLE BODY S SHOWN 13" 80 90 9" DESCRIPTION TOOLS MESURING TPE DRILL 4-3/8" HOLE SW PROCESS NME INSTLL ICOM FUEL FILL HOUSING (14 x 14 x 47 FUEL TNK ONLY) P13X4-9229-0055 3 OF 4
NUMBER 100 100) USING DREMEL, CREFULLY GRIND WY SMLL PORTION OF THE RIGHT SIDE OF THE HOLE TO LLOW FLUSH FIT OF THE FUEL FILL HOUSING 110) REMOVE THE (4) SCREWS, WSHERS ND NUTS FROM THE FUEL FILL HOUSING ND SET SIDE 120) INSTLL THE FUEL FILL HOUSING ONTO THE VEHICLE; VERIFY HOUSING IS CENTERED ND FITS FLUSH TO THE VEHICLE 110 MRK THE (4) TTCHMENT HOLES ONTO THE VEHICLE PNEL USING DRILL WITH 1/4" DRILL BIT, DRILL OUT THE (4) TTCHMENT HOLES 130) INSERT THE )4) SCREWS INTO THE FUEL FILL HOUSING; FROM THE BCKSIDE OF THE VEHICLE PNEL, INSTLL THE (4) WSHERS & NUTS ONTO THE SCREWS ND SECURELY TIGHTEN WITH PHILLIPS SCREWDRIVER ND 10mm SOCKET WRENCH 120 130 DESCRIPTION TOOLS D 900004 4 M6 x 30 PHILLIPS HED SCREW (PKG I) DREMEL E 700002 4 M6 FLT WSHER (PKG I) DRILL F 800004 4 M6 x 1.0 NYLOCK NUT (PKG I) 1/4" DRILL BIT PHILLIPS SCREWDRIVER 10mm SOCKET WRENCH PROCESS NME INSTLL ICOM FUEL FILL HOUSING (14 x 14 x 47 FUEL TNK ONLY) P13X4-9229-0055 4 OF 4
NUMBER 10 10) OBTIN THE BLEEDER HOSE SSY FROM THE REMOTE BLEEDER VLVE HOSE KIT (P11X4-3109-) 20) LOCTE THE REMOTE BLEEDER VLVE TTCHED TO THE FUEL FILL HOUSING 20 30) INSTLL ND HNDSTRT THE FITTING TTCHED TO THE HOSE ONTO THE BLEEDER VLVE; THE HOSE FITTING WITH N OPEN END 15mm CROWFOOT & WRENCH TO 14 Nm +/- 1.4 40) ROUTE THE REMOTE BLEEDER HOSE BETWEEN THE DRIVER SIDE VEHICLE FRME ND BODY TOWRD THE FRONT OF THE FUEL TNK 30 1 40 DESCRIPTION TOOLS P11X4-3109- 1 REMOTE BLEEDER VLVE HOSE KIT WRENCH 1 14 Nm +/- 1.4 15mm CROWFOOT PROCESS NME INSTLL REMOTE BLEEDER VLVE HOSE P13X4-9229-0060 1 OF 2
NUMBER 50) USING 11mm SOCKET WRENCH & OPEN END WRENCH, LOOSEN ND REMOVE ONE OF THE BOLTS/NUTS FROM THE VLVE GURD ON THE FRONT OF THE TNK; ROTTE BRCKET TO GIN CCESS TO THE BLEEDER VLVE 50 60) CUT THE HOSE TO THE REQUIRED LENGTH; INSERT PROVIDED SPRING INTO END OF HOSE; SSEMBLE THE STRIGHT FIELD TTCHBLE FITTING ONTO THE END OF THE HOSE PER THE HOSE SSEMBLY INSTRUCTION (P11X-9203-C) 60 70) INSTLL ND HNDSTRT THE HOSE FITTING ONTO FUEL TNK BLEEDER VLVE; THE HOSE FITTING WITH 15mm OPEN END CROWFOOT & WRENCH TO 14 Nm +/- 1.4 80) OBTIN THE PROVIDED 1/2" SPLIT CORRUGTE; INSTLL CORRUGTE ONTO BLEEDER HOSE ND TRIM TO THE REQUIRED LENGTH 70 1 80 B DESCRIPTION TOOLS B 350031 1 CORRUGTE HOSE - 1/2" SPLIT 11mm SOCKET WRENCH 1 14Nm +/- 1.4 11mm OPEN END WRENCH WRENCH 15mm CROWFOOT PROCESS NME INSTLL REMOTE BLEEDER VLVE HOSE P13X4-9229-0060 2 OF 2
NUMBER 10 10) OBTIN THE REMOTE FUEL FILL HOSE KIT (), CORRUGTE HOSE (B), INLINE FUEL FILTER (C ), FILTER CLMP (D) ND (1) SELF TP SCREW (E) B C D E DESCRIPTION TOOLS P11X4-3702- 1 HOSE KIT - REMOTE FUEL FILL (10 FT.) B 350024 1 CORRUGTE HOSE (10 FT.) C P12X4-7002- 1 INLINE FUEL FILTER (PKG. H) D 330009 1 FUEL FILTER MOUNTING CLMP (PKG. H) E 950000 1 SELF TPPING SCREW (PKG. H) PROCESS NME INSTLL FUEL FILL HOSES & FILTER TO FUEL TNK P13X4-9229-0070 1 OF 5
NUMBER 20 20) LOCTE THE OPENING BETWEEN THE VEHICLE BODY ND DRIVER SIDE FRME IN CLOSE PROXIMITY TO THE FUEL FILL HOUSING 30) POSITION THE FUEL FILTER WITH THE RROWS ON THE FILTER POINTING TOWRD THE TNK 30 40) INSTLL CLMP (C ) ONTO FILTER ND SECURE CLMP TO BODY REINFORCEMENT WITH SELF TP SCREW (D) S SHOWN 40 DESCRIPTION TOOLS C P12X4-7002- 1 INLINE FUEL FILTER (PKG. H) CORDLESS DRILL D 330009 1 FUEL FILTER MOUNTING CLMP (PKG. H) 9mm SOCKET E 950000 1 SELF TPPING SCREW (PKG. H) PROCESS NME INSTLL FUEL FILL HOSES & FILTER TO FUEL TNK P13X4-9229-0070 2 OF 5
NUMBER 50 1 50) OBTIN FUEL FILL HOSE; INSTLL ND HNDTIGHTEN THE STRIGHT FITTING CRIMPED ON THE HOSE ONTO THE REMOTE FUEL FILL VLVE THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT & WRENCH TO 25 Nm +/- 2.5 60) ROUTE HOSE TO FILTER; CUT THE HOSE TO THE REQUIRED LENGTH; OBTIN CORRUGTE & DETERMINE LENGTH NEEDED TO COVER HOSE; CUT CORRUGTE TO REQUIRED LENGTH ND INSTLL ONTO HOSE CORRUGTE CUT ONE OF THE PROVIDED SPRINGS IN HLF ND INSERT INTO END OF HOSE; SSEMBLE THE 90 FIELD TTCHBLE FITTING ONTO THE END OF THE HOSE PER THE HOSE SSEMBLY INSTRUCTION (P11X-9203-C) 60 70 1 70) HNDSTRT HOSE FITTING ONTO FILTER; USING 3/4" OPEN END WRENCH ON THE FILTER HOUSING, THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 DESCRIPTION TOOLS REF 1 FUEL FILL HOSE (P11X4-3702-) WRENCH REF 1 NTI-KINK SPRING (P11X4-3702-) 1 25Nm +/- 2.5 3/4" OPEN END WRENCH REF 1 90 FITTING (P11X4-3702-) 22mm CROWFOOT REF 1 FERRULE (P11X4-3702-) B 350024 1 CORRUGTE HOSE (10 FT.) PROCESS NME INSTLL FUEL FILL HOSES & FILTER TO FUEL TNK P13X4-9229-0070 3 OF 5
NUMBER 80) USING THE REMINING FUEL HOSE, INSERT THE OTHER HLF OF THE CUT SPRING FROM STEP #60 INTO ONE END OF THE HOSE; SSEMBLE THE STRIGHT FIELD TTCHBLE FITTING ONTO THE END OF THE HOSE PER THE HOSE SSEMBLY INSTRUCTION (P11X-9203-C) 90) HNDSTRT HOSE FITTING ONTO FILTER; USING 3/4" OPEN END WRENCH ON THE FILTER HOUSING, THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 80 90 1 100) INSERT HOSE INTO OPENING BETWEEN THE DRIVER SIDE FRME ND BODY S SHOWN 110) ROUTE HOSE TO FUEL TNK FILL VLVE; CUT THE HOSE TO THE REQUIRED LENGTH; OBTIN CORRUGTE & DETERMINE LENGTH NEEDED TO COVER HOSE; CUT CORRUGTE TO REQUIRED LENGTH ND INSTLL ONTO HOSE 110 100 DESCRIPTION TOOLS REF 1 FUEL FILL HOSE (P11X4-3702-) WRENCH 1 25Nm +/- 2.5 REF 1 NTI-KINK SPRING (P11X4-3702-) 3/4" OPEN END WRENCH REF REF 1 1 STRIGHT FITTING (P11X4-3702-) FERRULE (P11X4-3702-) 22mm CROWFOOT PROCESS NME INSTLL FUEL FILL HOSES & FILTER TO FUEL TNK P13X4-9229-0070 4 OF 5
NUMBER 120) CUT ONE OF THE PROVIDED SPRINGS IN HLF ND INSERT INTO END OF HOSE; SSEMBLE THE STRIGHT FIELD TTCHBLE FITTING ONTO THE END OF THE HOSE PER THE HOSE SSEMBLY INSTRUCTION (P11X-9203-C) 120 130 1 130) HNDSTRT HOSE FITTING ONTO FUEL TNK FILL VLVE; THE FITTING ON THE HOSE WITH 22mm OPEN END CROWFOOT ND WRENCH TO 25 Nm +/- 2.5 140) ROTTE THE VLVE GURD BCK INTO POSITION; INSTLL REMOVED BOLT/NUT ND SECURE USING 11mm SOCKET WRENCH & OPEN END WRENCH 140 DESCRIPTION TOOLS REF 1 FUEL FILL HOSE (P11X4-3702-) WRENCH 1 25Nm +/- 2.5 REF 1 NTI-KINK SPRING (P11X4-3702-) 3/4" OPEN END WRENCH REF 1 STRIGHT FITTING (P11X4-3702-) 22mm CROWFOOT REF 1 FERRULE (P11X4-3702-) B 350024 1 CORRUGTE HOSE (10 FT.) PROCESS NME INSTLL FUEL FILL HOSES & FILTER TO FUEL TNK P13X4-9229-0070 5 OF 5
NUMBER 10 10) OPEN HOOD ON VEHICLE; FROM THE FRONT OF THE VEHICLE, DISCONNECT THE NEGTIVE CBLE FROM THE BTTERY 20) LOOSEN & REMOVE THE IR INLET TUBE ND SET SIDE 20 30) FROM INSIDE THE VEHICLE, LOOSEN THE CLMP THT SECURES THE INLET TUBE TO THE THROTTLE BODY; REMOVE THE INLET TUBE FROM THE THROTTLE BODY S SHOWN 40) REMOVE THE EVP HOSE FROM THE INLET TUBE S SHOWN 30 40 DESCRIPTION TOOLS PROCESS NME INSTLL LPG FUEL RILS P13X4-9229-0080 1 OF 5
NUMBER 50 50) FROM THE FRONT OF THE VEHICLE, REMOVE THE THROTTLE BODY IR INLET TUBE 60) FROM INSIDE THE VEHICLE, DISCONNECT THE OEM WIRE HRNESS LEDS FROM LL (10) GSOLINE FUEL INJECTORS 70) DISCONNECT THE OEM GSOLINE SUPPLY LINE TTCHED TO THE DRIVER SIDE GSOLINE FUEL RIL 60 80) LOOSEN ND REMOVE THE (4) SCREWS THT SECURE THE DRIVER ND PSSENGER SIDE FUEL RILS TO THE INTKE MNIFOLD 80 70 DESCRIPTION TOOLS PROCESS NME INSTLL LPG FUEL RILS P13X4-9229-0080 2 OF 5
NUMBER 90 90) ON THE PSSENGER SIDE OF THE ENGINE, LOOSEN ND REMOVE THE NUT THT SECURES THE TRNSMISSION FILL TUBE TO THE INTKE MNIFOLD; REMOVE TRNSMISSION FILL TUBE FROM STUD 100) USING PIR OF HOSE CUTTERS, CUT THE FUEL RIL CROSSOVER HOSE IN HLF 100 110) CREFULLY REMOVE THE DRIVER & PSSENGER SIDE GSOLINE FUEL RILS FROM THE ENGINE 120) OBTIN THE DRIVER/PSSENGER FUEL RILS () ND FUEL RIL HRDWRE (B) 120 B 110 DESCRIPTION TOOLS 1 1 DRIVER SIDE LPG FUEL RIL SSY (PKG F) PSSENGER SIDE LPG FUEL RIL SSY (PKG F) HOSE CUTTER B 90003502 800004 900006 800002 4 4 4 4 5-HOLE BRCKET M6 X 1.0 NYLOCK NUT M4 X 10mm SCREW M4 X 0.7 NYLOCK NUT PROCESS NME INSTLL LPG FUEL RILS P13X4-9229-0080 3 OF 5
NUMBER 130 130) OBTIN THE PSSENGER SIDE LPG FUEL RIL SSY (SHOWN WITH THE NON-RETURN VLVE ON THE LEFT SIDE OF THE RIL), (2) 5-HOLE BRCKETS, (2) M4 SCREWS, (2) M4 NYLOCK NUTS ND (2) M6 NYLOCK NUTS 140) LOOSLY INSTLL THE 5-HOLE BRCKET TO THE FRONT ND RER UPPER FUEL RIL BRCKET SLOT S SHOWN 150) ON THE PSSENGER SIDE OF THE ENGINE, POSITION THE LPG FUEL RIL WITH THE BRCKET ON THE RIL FCING TOWRD THE CENTER OF THE VEHICLE; LIGN ND SET ECH LPG INJECTOR NOZZLE INTO ECH GSOLINE INJECTOR PORT 140 150 DESCRIPTION TOOLS 1 PSSENGER SIDE LPG FUEL RIL SSY (PKG F) B 90003502 800004 900006 800002 2 2 2 2 5-HOLE BRCKET M6 X 1.0 NYLOCK NUT M4 X 10mm SCREW M4 X 0.7 NYLOCK NUT PROCESS NME INSTLL LPG FUEL RILS P13X4-9229-0080 4 OF 5
NUMBER 160) POSITION THE FRONT & RER 5-HOLE BRCKETS TO THE STUDS TTCHED TO THE INTKE MNIFOLD; LIGN ND SET THE LRGE HOLE ON THE BRCKET ONTO THE STUD 160 INSTLL THE M6 NYLOCK NUT ONTO ECH STUD ND TIGHTEN SECURELY SECURELY TIGHTEN BOTH SCREWS/NUTS THT TTCH THE 5-HOLE BRCKET TO THE FUEL RIL 170 170) OBTIN THE DRIVER SIDE LPG FUEL RIL SSY (SHOWN WITH THE NON-RETURN VLVE ON THE RIGHT SIDE OF THE RIL), (2) 5-HOLE BRCKETS, (2) M4 SCREWS, (2) M4 NYLOCK NUTS ND (2) M6 NYLOCK NUTS 180) REPET STEPS 140 THROUGH 160 FOR THE DRIVER SIDE LPG FUEL RIL 190 190) ON THE PSSENGER SIDE OF THE ENGINE, RE-INSTLL THE TRNSMISSION FILL TUBE ONTO THE STUD TTCHED TO THE MNIFOLD; RE-INSTLL NUT ND SECURE DESCRIPTION TOOLS 1 DRIVER SIDE LPG FUEL RIL SSY (PKG F) B 90003502 800004 900006 800002 2 2 2 2 5-HOLE BRCKET M6 X 1.0 NYLOCK NUT M4 X 10mm SCREW M4 X 0.7 NYLOCK NUT PROCESS NME INSTLL LPG FUEL RILS P13X4-9229-0080 5 OF 5
NUMBER 10 10) FROM PCKGE 'D', OBTIN THE (9) EV6 TO EV1 WIRE HRNESS LEDS () ND (1) EV6 TO EV1 WIRE HRNESS LED WITH KEY-ON & RPM B 20 20) STRTING WITH THE RER PSSENGER SIDE LPG FUEL INJECTOR, LIGN ND SET THE EV1 CONNECTOR ON THE WIRE HRNESS SSY () ONTO THE LPG FUEL INJECTOR S SHOWN 30 30) LIGN ND SET THE EV6 CONNECTOR ON THE WIRE HRNESS SSY () INTO THE DJCENT OEM EV6 GSOLINE INJECTOR LED CONNECTOR S SHOWN 40) REPET STEPS 20 ND 30 FOR THE REMINING (4) LPG FUEL INJECTORS ON THE PSSENGER SIDE FUEL RIL 40 DESCRIPTION TOOLS P11X4-4219- 9 WIRE HRNESS SSY - EV6 TO EV1 B P11X4-4220- 1 WIRE HRNESS SSY - EV6 TO EV1 W/KEY ON & RPM PROCESS NME INSTLL LPG FUEL INJECTOR WIRE HRNESS LEDS P13X4-9229-0090 1 OF 2
NUMBER 50 60 50) STRTING WITH THE FRONT DRIVER SIDE LPG FUEL INJECTOR, LIGN ND SET THE EV1 CONNECTOR ON THE WIRE HRNESS SSY () ONTO THE LPG FUEL INJECTOR S SHOWN 60) LIGN ND SET THE EV6 CONNECTOR ON THE WIRE HRNESS SSY () INTO THE DJCENT OEM EV6 GSOLINE INJECTOR LED CONNECTOR S SHOWN 70) REPET STEPS 50 ND 60 FOR THE NEXT (3) LPG FUEL INJECTORS ON THE DRIVER SIDE FUEL RIL 70 80) LIGN ND SET THE EV1 CONNECTOR ON THE WIRE HRNESS SSY (B) (WIRE HRNESS LED W/KEY ON & RPM) ONTO THE RER DRIVER SIDE LPG FUEL INJECTOR S SHOWN 80 90) LIGN ND SET THE EV6 CONNECTOR ON THE WIRE HRNESS SSY (B) INTO THE DJCENT OEM EV6 GSOLINE INJECTOR LED CONNECTOR S SHOWN 90 DESCRIPTION TOOLS PROCESS NME INSTLL LPG FUEL INJECTOR WIRE HRNESS LEDS P13X4-9229-0090 2 OF 2
NUMBER 10 B D 10) OBTIN THE FOLLOWING S FROM PCKGE 'G' (1) NON-RETURN VLVE SSY () (1) NON-RETURN VLVE BRCKET SSY (B) (1) REGULTOR SSY (C ) (1) REGULTOR BRCKET SSY (D) C 20) TTCH THE REGULTOR BRCKET (D) TO THE REGULTOR (C ) USING THE SCREWS PROVIDED WITH THE REGULTOR S SHOWN 20 30) FROM INSIDE THE VEHICLE, LOCTE THE BRCKET TTCHED TO THE TOP OF THE TRNSMISSION HOUSING; DISCONNECT THE WIRE HRNESS CLIP FROM THIS BRCKET 40) POSITION THE REGULTOR WITH THE BRNCH TEE POINTING 'UP' USING THE TTCHING HRDWRE PROVIDED WITH THE REGULTOR BRCKET SSY, TTCHED THE REGULTOR TO THE BRCKET ON THE TRNSMISSION HOUSING S SHOWN 30 40 DESCRIPTION TOOLS P11X4-2301- 1 NON-RETURN VLVE SSY M4 TEE HNDLE B P11X4-9303- 1 NON-RETURN VLVE BRCKET M6 TEE HNDLE C P11X4-2300- 1 REGULTOR SSY D P11X4-9302- 1 REGULTOR BRCKET PROCESS NME INSTLL LPG REGULTOR ND NON-RETURN VLVE P13X4-9229-0100 1 OF 2
NUMBER 50) TTCH THE NON-RETURN VLVE BRCKET (B) TO THE NON-RETURN VLVE () USING THE SCREWS PROVIDED WITH THE NON-RETURN VLVE 50 60) LOCTE THE THREDED BOSS ON THE PSSENGER FRONT SIDE OF THE INTKE MNIFOLD BY THE HETER HOSE 60 70) POSITION THE NON-RETURN VLVE WITH THE INLET PORT ON THE VLVE POINTING TOWRD THE RER OF THE VEHICLE INSTLL THE NON-RETURN VLVE SSY ONTO THE MNIFOLD BOSS S SHOWN (TTCHMENT SCREW NOT INCLUDED WITH KIT) 70 DESCRIPTION TOOLS PROCESS NME INSTLL LPG REGULTOR ND NON-RETURN VLVE P13X4-9229-0100 2 OF 2
NUMBER 10 B C 10) OBTIN THE FOLLOWING S: (1) - ENGINE HOSE - SUPPLY PSSENGER SIDE () (1) - ENGINE HOSE - SUPPLY DRIVER SIDE (B) (1) - ENGINE HOSE - RETURN PSSENGER SIDE (C ) (1) - ENGINE HOSE - RETURN DRIVER SIDE (D) D 20 30 1 20) OBTIN THE ENGINE HOSE - SUPPLY PSSENGER SIDE () (GREEN HOSE WITH TWO 90 DEGREE FITTINGS) 40 FROM THE FRONT OF THE VEHICLE, INSTLL ND HNDTIGHTEN ONE OF THE 90 FITTINGS ON THE HOSE ONTO THE SUPPLY FITTING LOCTED ON THE FRONT OF THE PSSENGER SIDE FUEL RIL 30) USING 12mm WRENCH TO HOLD THE RIL FITTING, THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 50 60 1 40) ROUTE THE HOSE LONG THE OUTBORD SIDE OF THE PSSENGER SIDE FUEL RIL TOWRDS THE RER OF THE VEHICLE S SHOWN 50) FROM INSIDE THE VEHICLE, LOCTE ND GRSP THE OPPOSITE END OF THE PSSENGER SIDE SUPPLY HOSE; INSTLL ND HNDTIGHTEN THE HOSE FITTING ONTO THE RER FCING NON-RETURN VLVE TEE FITTING S SHOWN 60) THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 DESCRIPTION TOOLS P13X4-2711- 1 ENGINE HOSE - SUPPLY PSSENGER SIDE 12mm WRENCH B P13X4-2712- 1 ENGINE HOSE - SUPPLY DRIVER SIDE 1 14 Nm +/- 1.4 15mm CROWFOOT C P13X4-2812- 1 ENGINE HOSE - RETURN PSSENGER SIDE WRENCH D P13X4-2813- 1 ENGINE HOSE - RETURN DRIVER SIDE PROCESS NME INSTLL LPG ENGINE SUPPLY/RETURN HOSES P13X4-9229-0110 1 OF 5
NUMBER 70) OBTIN THE ENGINE HOSE - SUPPLY DRIVER SIDE (B) (GREEN HOSE WITH STRIGHT & 90 DEGREE FITTINGS) B 100 80) 90) FROM THE FRONT OF THE VEHICLE, INSTLL ND HNDTIGHTEN THE STRIGHT FITTING ON THE HOSE ONTO THE SUPPLY FITTING LOCTED ON THE FRONT OF THE DRIVER SIDE FUEL RIL USING 12mm WRENCH TO HOLD THE RIL FITTING, THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 80 90 1 100) ROUTE THE HOSE TOWRDS THE PSSENGER SIDE OF THE ENGINE S SHOWN 110 120 1 110) FROM INSIDE THE VEHICLE, LOCTE ND GRSP THE OPPOSITE END OF THE DRIVER SIDE SUPPLY HOSE; INSTLL ND HNDTIGHTEN THE HOSE FITTING ONTO THE FRONT FCING NON-RETURN VLVE TEE FITTING S SHOWN 120) THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 DESCRIPTION TOOLS B P13X4-2712- 1 ENGINE HOSE - SUPPLY DRIVER SIDE 12mm WRENCH 1 14 Nm +/- 1.4 15mm CROWFOOT WRENCH PROCESS NME INSTLL LPG ENGINE SUPPLY/RETURN HOSES P13X4-9229-0110 2 OF 5
NUMBER 130 130) OBTIN THE ENGINE HOSE - RETURN PSSENGER SIDE (C ) (LONGER BLCK HOSE WITH STRIGHT & 90 DEGREE FITTINGS) C 140 150 1 140) FROM INSIDE THE VEHICLE, INSTLL ND HNDTIGHTEN THE 90 FITTING ON THE HOSE ONTO THE RETURN FITTING LOCTED ON THE RER OF THE PSSENGER SIDE FUEL RIL 160 150) USING 12mm WRENCH TO HOLD THE RIL FITTING, THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 160) ROUTE THE HOSE TOWRD THE REGULTOR S SHOWN 170 180 1 170) INSTLL ND HNDTIGHTEN THE OPPOSITE END OF THE PSSENGER SIDE RETURN HOSE ONTO THE PSSENGER SIDE OF THE REGULTOR TEE S SHOWN 180) THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 DESCRIPTION TOOLS C P13X4-2812- 1 ENGINE HOSE - RETURN PSSENGER SIDE 12mm WRENCH 1 14 Nm +/- 1.4 15mm CROWFOOT WRENCH PROCESS NME INSTLL LPG ENGINE SUPPLY/RETURN HOSES P13X4-9229-0110 3 OF 5
NUMBER 190 190) OBTIN THE ENGINE HOSE - RETURN DRIVER SIDE (D) (SHORTER BLCK HOSE WITH STRIGHT & 90 DEGREE FITTINGS) D 200 210 1 200) FROM INSIDE THE VEHICLE, INSTLL ND HNDTIGHTEN THE 90 FITTING ON THE HOSE ONTO THE RETURN FITTING LOCTED ON THE RER OF THE DRIVER SIDE FUEL RIL 210) USING 12mm WRENCH TO HOLD THE RIL FITTING, THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 220) ROUTE THE HOSE TOWRD THE REGULTOR S SHOWN 220 230) INSTLL ND HNDTIGHTEN THE OPPOSITE END OF THE DRIVER SIDE RETURN HOSE ONTO THE DRIVER SIDE OF THE REGULTOR TEE S SHOWN 240) THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 230 240 1 DESCRIPTION TOOLS D P13X4-2813- 1 ENGINE HOSE - RETURN DRIVER SIDE 12mm WRENCH 1 14 Nm +/- 1.4 15mm CROWFOOT WRENCH PROCESS NME INSTLL LPG ENGINE SUPPLY/RETURN HOSES P13X4-9229-0110 4 OF 5
NUMBER 250 E 250) OBTIN THE 1/2" SPLIT CORRUGTE (E) FROM THE ENGINE KIT 260) INSTLL CORRUGTE ONTO THE ENGINE SUPPLY / RETURN HOSES ND TRIM TO THE REQUIRED LENGTH 260 DESCRIPTION TOOLS E 350031 1 1/2" SPLIT CORRUGTE RZOR BLDE PROCESS NME INSTLL LPG ENGINE SUPPLY/RETURN HOSES P13X4-9229-0110 5 OF 5
NUMBER 10 B C 10) FROM PCKGE 'C', OBTIN THE FOLLOWING S: - UXILIRY FUEL PUMP SSY B - UXILIRY FUEL PUMP BRCKET C - HET SHIELD PDDING D - SELF TP SCREW E - M6 FLT WSHER D E 20) REMOVE ND DISCRD THE DHESIVE BCKING FROM THE HET SHIELD PDDING (C ); INSTLL PDDING ROUND THE PUMP HOUSING; TRIM ND DISCRD NY EXCESS PDDING OUT 30 40 30) POSITION THE FUEL PUMP WITH THE 'OUT' PORT T THE BOTTOM ND THE PUMP FITTINGS POINTING TO THE LEFT S SHOWN 40) INSTLL THE FUEL PUMP BRCKET (B) ONTO THE FUEL PUMP HOUSING WITH THE TTCHMENT POINT T THE TOP S SHOWN DESCRIPTION TOOLS 88080000 1 UXILIRY FUEL PUMP B 200006 1 BRCKET - UXILIRY FUEL PUMP C 320001 1 HET SHIELD PDDING D 950000 1 SELF TP SCREW E 700002 1 M6 FLT WSHER PROCESS NME INSTLL UXILIRY FUEL PUMP ND HOSE SSY P13X4-9229-0120 1 OF 4
NUMBER 50 50) WITH THE HOOD OPEN FROM THE FRONT OF THE VEHICLE, LOCTE THE MIN OEM WIRE HRNESS JUNCTION BLOCK ON THE DRIVER SIDE ENGINE COMPRTMENT PNEL 60 60) POSITION THE UXILIRY FUEL PUMP ONTO THE ENGINE COMPRTMENT PNEL S SHOWN WITH THE MOUNTING TB ON THE FUEL PUMP BRCKET T THE TOP ND THE FUEL PUMP FITTINGS POINTING INBORD TO THE CENTERLINE OF THE VEHICLE 70) INSTLL THE M6 FLT WSHER (E) ONTO THE SELF TPPING SCREW (D) 70 80 80) SET THE UXILIRY FUEL PUMP ND BRCKET ONTO THE ENGINE COMPRTMENT PNEL; INSERT SCREW ND WSHER INTO TTCHMENT HOLE ON THE PUMP BRCKET; USING CORDLESS DRILL WITH 9mm SOCKET, SECURE PUMP ND BRCKET TO THE ENGINE COMPRTMENT PNEL S SHOWN DESCRIPTION TOOLS D 950000 1 SELF TP SCREW CORDLESS DRILL E 700002 1 M6 FLT WSHER 9mm SOCKET PROCESS NME INSTLL UXILIRY FUEL PUMP ND HOSE SSY P13X4-9229-0120 2 OF 4
NUMBER 90 F 90) OBTIN THE UXILIRY FUEL PUMP HOSE SSY (F) ND 1/2" SPLIT CORRUGTE (G) 100) INSTLL CORRUGTE ONTO THE UXILIRY FUEL PUMP HOSE ND TRIM TO THE REQUIRED LENGTH G 110) INSTLL ND HNDTIGHTEN THE STRIGHT FITTING ON THE HOSE ONTO THE LOWER 'OUT' PORT FITTING ON THE UXILIRY FUEL PUMP S SHOWN 120) USING 15mm WRENCH TO HOLD THE FITTING ON THE UXILIRY FUEL PUMP, THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 130) ROUTE THE HOSE TOWRD THE SUPPLY ELECTROVLVE MOUNTED ON THE PSSENGER SIDE OF THE INTKE MNIFOLD 130 110 120 1 DESCRIPTION TOOLS F P13X4-3314- 1 HOSE SSY - UXILIRY FUEL PUMP 15mm WRENCH 1 14 Nm +/- 1.4 15mm CROWFOOT WRENCH PROCESS NME INSTLL UXILIRY FUEL PUMP ND HOSE SSY P13X4-9229-0120 3 OF 4
NUMBER 140 150 1 140) FROM INSIDE THE VEHICLE, LOCTE ND GRSP THE OPPOSITE END OF THE UXILIRY FUEL PUMP HOSE; INSTLL ND HNDTIGHTEN THE HOSE FITTING ONTO THE RER FCING NON-RETURN VLVE FITTING S SHOWN 150) THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 DESCRIPTION TOOLS F P13X4-3314- 1 HOSE SSY - UXILIRY FUEL PUMP 15mm CROWFOOT 1 14 Nm +/- 1.4 WRENCH PROCESS NME INSTLL UXILIRY FUEL PUMP ND HOSE SSY P13X4-9229-0120 4 OF 4
NUMBER 10 10) FROM THE FRONT OF THE VEHICLE, INSIDE THE ENGINE COMPRTMENT, LOCTE THE CHSSIS SUPPLY / RETURN HOSES ND FUEL TNK WIRE HRNESS CORRUGTE 20) OBTIN THE HET SHIELD TUBE () ND (1) 8" TIE STRP (FROM PKG D) 20 30) INSTLL HET SHIELD TUBE () ONTO CHSSIS HOSE CORRUGTE ND POSITION ON CORRUGTE S SHOWN; INSTLL TIE STRP HET SHIELD ND TIGHTEN TO SECURE HET SHIELD IN PLCE; CUT EXCESS FROM TIE STRP ND DISCRD 30 DESCRIPTION TOOLS PROCESS NME TTCH CHSSIS SUPPLY / RETURN HOSES P13X4-9229-0130 1 OF 4
NUMBER 40 40) REMOVE TPE FROM THE END OF THE HOSES ND WIRE HRNESS ND SEPRTE 50 50) ROUTE THE GREEN CHSSIS SUPPLY HOSE TOWRD THE UXILIRY FUEL PUMP S SHOWN 60 60) OBTIN (1) 1/4" FERRULE, (1) 1/4" STRIGHT FIELD TTCHBLE FITTING ND (1) 1/4" SPRING FROM THE CHSSIS HOSE KIT DESCRIPTION TOOLS P11X4-3110- P11X4-3119- REF REF REF REF 1 1 1 1 2 1 CHSSIS HOSE KIT (25') (13 x 92 TNK) CHSSIS HOSE KIT (30') (14 x 14 x 47 TNK) 1/4" 90 FIELD TTCHBLE FITTING 1/4" STRIGHT FIELD TTCHBLE FITTING 1/4" FERRULE 1/4" SPRING PROCESS NME 3/16" HOSE SSY TOOL 1/4" HOSE SSY TOOL WIRE CUTTERS REF 1 3/16" 90 FIELD TTCHBLE FITTING REF 1 3/16" STRIGHT FIELD TTCHBLE FITTING TTCH CHSSIS SUPPLY / RETURN HOSES REF 1 3/16" FERRULE REF 1 3/16" SPRING P13X4-9229-0130 2 OF 4
NUMBER 70 80 70) POSITION THE HOSE TO THE TOP FITTING ON THE UXILIRY FUEL PUMP ND CUT HOSE TO THE REQUIRED LENGTH 80) CUT THE 1/4" SPRING IN HLF ND INSERT THE SPRING INTO THE END OF THE HOSE; SSEMBLE 1/4" STRIGHT FIELD TTCHBLE FITTING ONTO THE END OF THE HOSE PER THE HOSE SSEMBLY INSTRUCTION (P11X-9203-C) 90 100 1 90) INSTLL ND HNDTIGHTEN THE STRIGHT FITTING ON THE HOSE ONTO THE UPPER 'IN' PORT FITTING ON THE UXILIRY FUEL PUMP S SHOWN 100) USING 15mm WRENCH TO HOLD THE FITTING ON THE UXILIRY FUEL PUMP, THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 110) ROUTE THE BLCK CHSSIS HOSE TOWRD THE RER OF THE VEHICLE LONG THE DRIVER SIDE OF THE ENGINE 110 DESCRIPTION TOOLS REF 1 1/4" STRIGHT FIELD TTCHBLE FITTING HOSE CUTTER REF 1 1/4" FERRULE 1 14 Nm +/- 1.4 1/4" HOSE SSY TOOL REF 1 1/4" SPRING 15mm WRENCH 15mm CROWFOOT WRENCH PROCESS NME TTCH CHSSIS SUPPLY / RETURN HOSES P13X4-9229-0130 3 OF 4
NUMBER 120 120) OBTIN (1) 3/16" FERRULE, (1) 3/16" STRIGHT FIELD TTCHBLE FITTING ND (1) 3/16" SPRING FROM THE CHSSIS HOSE KIT 130) POSITION THE HOSE TO THE FITTING ON THE REGULTOR ND CUT THE HOSE TO THE REQUIRED LENGTH 140) INSERT THE SPRING INTO THE END OF THE HOSE; SSEMBLE THE 3/16" STRIGHT TTCHBLE FITTING ONTO THE END OF THE HOSE PER THE HOSE SSEMBLY INSTRUCTION (P11X-9203-C) 130 140 150) INSTLL ND HNDTIGHTEN THE STRIGHT FITTING ON THE HOSE ONTO THE REGULTOR FITTING S SHOWN 160) THE HOSE FITTING WITH 15mm CROWFOOT ND WRENCH TO 14 Nm +/- 1.4 150 160 1 DESCRIPTION TOOLS REF 1 3/16" STRIGHT FIELD TTCHBLE FITTING 3/16" HOSE SSY TOOL REF 1 3/16" FERRULE 1 14 Nm +/- 1.4 15mm CROWFOOT REF 1 3/16" SPRING WRENCH PROCESS NME TTCH CHSSIS SUPPLY / RETURN HOSES P13X4-9229-0130 4 OF 4
NUMBER 10 10) USING 2-1/2" HOLE SW, DRILL HOLE INTO THE LOCTION SHOWN IN THE ENGINE COMPRTMENT PNEL JUST BOVE THE UXILIRY FUEL PUMP 20) OBTIN THE LPG ENGINE WIRE HRNESS SSY () ND THE WIRE HRNESS GROMMET (B) FROM THE ENGINE KIT 20 B 30) FROM THE FRONT OF THE VEHICLE, INSERT THE MIN CONNECTOR, UDIBLE INDICTOR, DOOR SWITCH ND LED LMP LEDS THROUGH THE DRILLED HOLE ND INTO THE DRIVERS COMPRTMENT S SHOWN 40) INSERT THE WIRE HRNESS GROMMET (B) ONTO THE MIN WIRE HRNESS LED S SHOWN 40 30 DESCRIPTION TOOLS P11X4-4218-F 1 WIRE HRNESS SSY - LPG ENGINE CORDLESS DRILL B 110000 1 GROMMET - WIRE HRNESS 2-1/2" HOLE SW PROCESS NME INSTLL LPG ENGINE WIRE HRNESS SSY P13X4-9229-0140 D 1 OF 7
NUMBER 50 50) LIGN ND SET THE GROMMET INTO THE DRILLED HOLE S SHOWN 60) ROUTE THE REMINDER OF THE LPG ENGINE WIRE HRNESS BEHIND THE COOLNT RESERVOIR BOTTLE ND BRCKET ND TOWRD THE PSSENGER SIDE OF THE VEHICLE S SHOWN 70) ROUTE THE LPG ENGINE WIRE HRNESS BOVE THE BRKE FLUID RESERVOIR; OBTIN (1) TIE STRP (C ) FROM PCKGE 'D'; SECURE THE LPG ENGINE WIRE HRNESS TO THE OEM WIRE HRNESS JUST BOVE THE BRKE FLUID RESERVOIR S SHOWN 60 70 DESCRIPTION TOOLS PROCESS NME INSTLL LPG ENGINE WIRE HRNESS SSY P13X4-9229-0140 D 2 OF 7
NUMBER 80 80) CONTINUE ROUTING THE LPG ENGINE WIRE HRNESS LONG SIDE THE OEM WIRE HRNESS ND TOWRD THE PSSENGER SIDE OF THE VEHICLE OBTIN (1) TIE STRP (C ) FROM PCKGE 'D'; SECURE THE LPG ENGINE WIRE HRNESS TO THE OEM WIRE HRNESS JUST BOVE THE ENGINE COMPRTMENT BRCE S SHOWN 90 90) CONTINUE ROUTING THE LPG ENGINE WIRE HRNESS OVER TOP OF THE WTER SHIELD TTCHED TO THE COWL PNEL OBTIN (1) TIE STRP (C ) FROM PCKGE 'D'; SECURE THE LPG ENGINE WIRE HRNESS TO THE OEM WIRE HRNESS JUST TO THE INBORD SIDE OF THE WTER SHIELD S SHOWN 100 100) CONTINUE ROUTING THE LPG ENGINE WIRE HRNESS TOWRD THE WINDSHIELD WSHER RESERVOIR OBTIN (1) TIE STRP (C ) FROM PCKGE 'D'; SECURE THE LPG ENGINE WIRE HRNESS TO THE OEM WIRE HRNESS JUST TO THE INBORD SIDE OF THE WINDSHIELD WSHER RESERVOIR S SHOWN DESCRIPTION TOOLS C 150000 3 8" TIE STRP PROCESS NME INSTLL LPG ENGINE WIRE HRNESS SSY P13X4-9229-0140 D 3 OF 7
NUMBER CHSSIS RETURN HOSE CHSSIS SUPPLY HOSE 110) LOCTE ND GRSP THE BROWN WIRE TTCHED TO THE FUEL TNK HRNESS COMING OUT OF THE SUPPLY / RETURN CHSSIS HOSE CORRUGTE 110 120) OBTIN THE 1-PIN CONNECTOR, TERMINL ND SEL THT COMES TTCHED TO THE FUEL TNK WIRE HRNESS 120 130) TTCH THE SEL, TERMINL ND 1-PIN CONNECTOR ONTO THE END OF THE BROWN WIRE S SHOWN 140) LOCTE ND GRSP THE BLCK 1-PIN CONNECTOR ND LED TTCHED TO THE LPG ENGINE WIRE HRNESS 150) LIGN ND SET THE BROWN WIRE LED CONNECTOR ON THE FUEL TNK WIRE HRNESS TO THE BROWN WIRE LED CONNECTOR ON THE LPG ENGINE WIRE HRNESS (PUSH/PULL CONNECTORS TO VERIFY FULLY SETED) 130 140 150 DESCRIPTION TOOLS PROCESS NME INSTLL LPG ENGINE WIRE HRNESS SSY P13X4-9229-0140 D 4 OF 7
NUMBER 160) LOCTE ND GRSP THE LPG WIRE HRNESS LED LBELED 'UXILIRY FUEL PUMP' 180 170) CREFULLY ROUTE THE WIRE HRNESS TO THE UXILIRY FUEL PUMP MOUNTED ON THE DRIVER SIDE ENGINE COMPRTMENT PNEL 180) LIGN ND SET THE WIRE HRNESS CONNECTOR TO THE UXILIRY FUEL PUMP CONNECTOR (PUSH/PULL CONNECTORS TO VERIFY FULLY SETED) 190) LOCTE THE OEM TEMPERTURE SENSOR WIRE LED LOCTED ON THE PSSENGER SIDE OF THE ENGINE BY THE LTERNTOR (TWO WIRE LED - BLUE WIRE & GREEN/WHITE WIRE) 200) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM BOTH WIRES (DO NOT CUT WIRES) 200 210) LOCTE ND GRSP THE LPG ENGINE WIRE HRNESS LED LBELED 'TEMP SENSOR OEM' 230 220) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF BOTH WIRES ON THE 'TEMP SENSOR OEM' LED 230) TTCH THE WHITE/GREEN WIRE FROM THE 'TEMP SENSOR OEM' LED ON THE LPG ENGINE HRNESS TO THE STRIPPED GREEN/WHITE OEM TEMP SENSOR WIRE; SOLDER CONNECTION TOGETHER ND SEL WITH ELECTRICL TPE DESCRIPTION TOOLS WIRE STRIPPERS SOLDER IRON ROSIN CORE SOLDER ELECTRICL TPE PROCESS NME INSTLL LPG ENGINE WIRE HRNESS SSY P13X4-9229-0140 D 5 OF 7
NUMBER 240) TTCH THE GREEN WIRE FROM THE 'TEMP SENSOR OEM' LED ON THE LPG ENGINE HRNESS TO THE STRIPPED BLUE OEM TEMP SENSOR WIRE; SOLDER CONNECTION TOGETHER ND SEL WITH ELECTRICL TPE 240 250) LOCTE ND GRSP THE LPG ENGINE WIRE HRNESS LED LBELED 'IRIS'; ROUTE LED TO THE SUPPLY ELECTROVLVE MOUNTED ON THE PSSENGER FRONT SIDE OF THE INTKE MNIFOLD 270 260) LOCTE ND GRSP THE LPG ENGINE WIRE HRNESS LED LBELED 'FUEL INJ. / KEY ON SIGNL'; ROUTE LED TOWRD THE RER OF THE VEHICLE LONG THE DRIVER SIDE OF THE ENGINE 270) FROM INSIDE THE VEHICLE, LOCTE ND GRSP THE 'IRIS' LED; LIGN ND SET THE WIRE LED CONNECTOR INTO THE SOLENOID ON THE SUPPLY ELECTROVLVE (PUSH/PULL CONNECTOR TO VERIFY FULLY SETED) 280 280) LOCTE ND GRSP THE 'FUEL INJ. / KEY ON SIGNL' LED; ROUTE LED TOWRD THE RER DRIVER SIDE LPG FUEL INJECTOR; LOCTE ND GRSP THE LED ND CONNECTOR TTCHED TO THE EV1 TO EV6 WIRE HRNESS ON THE DRIVER SIDE RER LPG FUEL INJECTOR; LIGN ND SET THE 'FUEL INJECTOR SIGNL / KEY ON' CONNECTOR TO THE CONNECTOR ON THE EV1 TO EV6 LED (PUSH/PULL CONNECTORS TO VERIFY FULLY SETED) DESCRIPTION TOOLS WIRE STRIPPERS SOLDER IRON ROSIN CORE SOLDER ELECTRICL TPE PROCESS NME INSTLL LPG ENGINE WIRE HRNESS SSY P13X4-9229-0140 D 6 OF 7
NUMBER 290) LOCTE ND GRSP THE LPG WIRE HRNESS LED LBELED 'RPM' 300 300) DISCONNECT THE OEM WIRE HRNESS LED TO THE RER DRIVER SIDE IGNITION COIL (ECH IGNITION COIL HS (2) WIRES - ONE OF THE WIRES IS THE SME COLOR FROM COIL TO COIL (POWER) - THE OTHER WIRE IS DIFFERENT COLOR FROM COIL TO COIL - THIS IS THE RPM SIGNL) 330 310) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE DIFFERENT COLOR WIRE (DO NOT CUT WIRE) 320) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF THE 'RPM' WIRE LED 330) TTCH THE 'RPM' WIRE LED TO THE STRIPPED IGNITION COIL WIRE; SOLDER CONNECTION TOGETHER ND SEL WITH ELECTRICL TPE DESCRIPTION TOOLS WIRE STRIPPERS SOLDER IRON ROSIN CORE SOLDER ELECTRICL TPE PROCESS NME INSTLL LPG ENGINE WIRE HRNESS SSY P13X4-9229-0140 D 7 OF 7
NUMBER 10 10) OBTIN THE ICOM NTC SENSOR () ND DPTOR - NTC SENSOR(B) FROM PCKGE 'D' 20 30 20) FROM THE FRONT OF THE VEHICLE, LOCTE THE STNCHION WITH THREDED HOLE ON THE DRIVER SIDE FRONT OF THE INTKE MNIFOLD BY THE UPPER RDITOR HOSE INLET 30) INSTLL ND TIGHTEN THE SENSOR DPTOR FITTING (B) ONTO THE ICOM NTC SENSOR (); INSTLL ND TIGHTEN THE DPTOR FITTING INTO THE STNCHION 40) LOCTE ND GRSP THE LPG ENGINE WIRE HRNESS LED LBELED 'SENSOR NTC'; LIGN ND SET THE WIRE LED CONNECTOR INTO THE ICOM NTC SENSOR LED CONNECTOR (PUSH/PULL CONNECTORS TO VERIFY FULLY SETED) 40 DESCRIPTION TOOLS 90009100 1 ICOM NTC SENSOR B 19299100 DPTOR - NTC SENSOR PROCESS NME INSTLL ICOM NTC SENSOR P13X4-9229-0150 1 OF 1
NUMBER 10 10) OBTIN THE FOLLOWING S: (1) MONO FUEL ICU MODULE () (1) BRCKET - ICU MODULE (B) (4) M4 x 60 SCREW (C ) (4) M4 NYLOCK NUT (D) (2) SELF TP SCREW (E) B C D 20) POSITION THE ICU BRCKET (B) WITH THE MOUNTING TB T THE TOP POINTING UP; LIGN ND SET THE ICU MODULE () ONTO THE BRCKET WITH THE CONNECTOR OPENING ON THE MODULE POSITIONED TO THE RIGHT; SECURE THE MODULE TO THE BRCKET WITH THE (4) M4 x 60 SCREWS (C ) ND (4) M4 NYLOCK NUTS (D) MOUNTING TB E 20 DESCRIPTION TOOLS 70306602 1 MONO FUEL ICU MODULE B 27036000 1 BRCKET - ICU MODULE C 900003 4 M4 x 60 SCREW D 800002 4 M4 NYLOCK NUT E 950000 2 SELF TP SCREW PROCESS NME INSTLL MONO FUEL ICU MODULE P13X4-9229-0160 1 OF 2
NUMBER 30) FROM INSIDE THE DRIVERS SIDE OF THE VEHICLE, POSITION THE ICU MODULE WITH THE MOUNTING TB ON THE BRCKET POINTING 'DOWN' 40) SET THE MOUNTING TB ON THE BRCKET TO THE ENGINE COMPRTMENT PNEL JUST BOVE ND TO THE LEFT OF THE ICOM LPG WIRE HRNESS GROMMET S SHOWN 50) INSERT THE (2) SELF TP SCREWS (E) INTO THE BRCKET MOUNTING TB; SECURE BRCKET TO ENGINE COMPRTMENT PNEL S SHOWN 60) LOCTE ND GRSP THE GREY LPG ENGINE WIRE HRNESS CONNECTOR; LIGN ND SET THE CONNECTOR INTO THE ICU MODULE S SHOWN (PUSH/PULL CONNECTOR TO VERIFY FULLY SETED) 30 40 60 50 WIRE HRNESS GROMMET DESCRIPTION TOOLS E 950000 2 SELF TP SCREW CORDLESS DRILL 9mm SOCKET PROCESS NME INSTLL MONO FUEL ICU MODULE P13X4-9229-0160 2 OF 2
NUMBER 10 10) OBTIN THE EVP SENSOR ORIFICE () FROM PCKGE D 20 20) LOCTE THE EVP PURGE VLVE SENSOR MOUNTED TO THE TOP OF THE INTKE MNIFOLD T THE RER OF THE ENGINE 30) CREFULLY DISCONNECT ND REMOVE THE EVP HOSES ND WIRE HRNESS CONNECTION FROM THE SENSOR; REMOVE THE SENSOR FROM THE ENGINE 30 DESCRIPTION TOOLS 19318100 1 EVP SENSOR ORIFICE PROCESS NME MODIFY EVP PURGE VLVE SENSOR P13X4-9229-0165 E 1 OF 2
NUMBER 40) CREFULLY LIGN ND SET THE EVP ORIFICE () INTO THE NOZZLE NEXT TO THE ELECTRICL CONNECTOR ON THE EVP SENSOR S SHOWN 40 50) REINSTLL THE EVP SENSOR ONTO THE ENGINE; RECONNECT THE EVP HOSES ND ELECTRICL CONNECTION 50 DESCRIPTION TOOLS 19318100 1 EVP SENSOR ORIFICE PROCESS NME MODIFY EVP PURGE VLVE SENSOR P13X4-9229-0165 E 2 OF 2
NUMBER 10 10) FROM PCKGE 'D', OBTIN THE FOLLOWING S: - LED LMP - QTY (1) B - SPDE CONNECTOR - QTY (2) B 20 20) LOCTE THE FUSE CCESS PNEL ON THE LOWER DRIVER SIDE OF THE INSTRUMENT PNEL; LOOSEN ND REMOVE THE TTCHMENT NUT FROM THE FUSE CCESS PNEL 30) REMOVE THE FUSE CCESS PNEL FROM THE INSTRUMENT PNEL 30 DESCRIPTION TOOLS 495000 1 LED LIGHT (PKG D) B PI 2 SPDE CONNECTOR (PKG D) PROCESS NME INSTLL LED LIGHT P13X4-9229-0170 1 OF 4
NUMBER 40 40) USING 5/16" DRILL BIT, CREFULLY DRILL HOLE INTO THE FUSE CCESS PNEL S SHOWN ICU MODULE 50) LOCTE THE WIRE HRNESS LEDS LBELED 'LED LIGHT' ON THE DRIVERS SIDE PSSENGER COMPRTMENT BY THE ICOM ENGINE WIRE HRNESS MIN CONNECTOR MIN CONNECTOR 50 60) FROM THE BCKSIDE OF THE FUSE CCESS PNEL, INSERT THE 'LED LIGHT' LEDS INTO ND THRU THE DRILLED HOLE 70 70) REMOVE LED TTCHMENT NUT ON BCK OF LED LIGHT; INSTLL NUT ONTO THE 'LED LIGHT' LEDS DESCRIPTION TOOLS 495000 1 LED LIGHT (PKG D) CORDLESS DRILL 5/16" DRILL BIT PROCESS NME INSTLL LED LIGHT P13X4-9229-0170 2 OF 4
NUMBER 80) INSTLL THE (2) SPDE CONNECTORS (B) ONTO THE 'LED LIGHT' LEDS 70 90) LOCTE THE '+' SYMBOL ON THE END OF THE LED LIGHT NEXT TO THE LONG SPDE 100) LIGN ND SET THE ORNGE LED WIRE CONNECTOR ONTO THE LONG (+) SPDE ON THE LED LIGHT 90 100 110) LIGN ND SET THE BLCK LED LED WIRE CONNECTOR ONTO THE SHORT SPDE ON THE LED LIGHT 110 120) INSERT LED LIGHT INTO THE DRILLED HOLE; FROM BCKSIDE OF THE FUSE CCESS PNEL, SLIDE TTCHMENT NUT FROM LED WIRES ONTO THE LED LIGHT HOUSING ND HNDTIGHTEN ONTO BCKSIDE OF LED LIGHT BEZEL DESCRIPTION TOOLS B PI 2 SPDE CONNECTOR (PKG D) WIRE STRIPPERS WIRE CRIMPERS PROCESS NME INSTLL LED LIGHT P13X4-9229-0170 3 OF 4
NUMBER 130) RE-INSTLL THE FUSE CCESS PNEL INTO THE INSTRUMENT PNEL RE-INSTLL THE TTCHMENT NUT 130 DESCRIPTION TOOLS PROCESS NME INSTLL LED LIGHT P13X4-9229-0170 4 OF 4
NUMBER 10 10) OBTIN THE STRTING INSTRUCTION LBEL () FROM PCKGE 'D' 20) REMOVE ND DISCRD THE DHESIVE BCKING FROM THE STRTING INSTRUCTION LBEL 30 30) POSITION ND CENTER THE LBEL BOVE THE LED LIGHT; LIGN ND SET THE LBEL ONTO THE FUSE CCESS PNEL S SHOWN DESCRIPTION TOOLS P13X4-9426- 1 LBEL - STRTING INSTRUCTIONS (PKG D) PROCESS NME INSTLL ENGINE STRT INSTRUCTION LBEL P13X4-9229-0180 1 OF 1
NUMBER 10 10) OBTIN THE FOLLOWING S FROM PCKGE 'D'; - UDIBLE INDICTOR B - 8" ZIP TIE ICU MODULE MIN CONNECTOR 20) LOCTE THE WIRE HRNESS LEDS LBELED 'UDIBLE INDICTOR' ON THE DRIVERS SIDE PSSENGER COMPRTMENT BY THE ICOM ENGINE WIRE HRNESS MIN CONNECTOR 20 30) LIGN ND SET THE UDIBLE INDICTOR CONNECTOR ND THE WIRE HRNESS LED CONNECTOR TOGETHER (PUSH/PULL CONNECTORS TO VERIFY FULLY SETED) 30 40) BUNDLE THE 'UDIBLE INDICTOR' LEDS TOGETHER; TIE STRP THE UDIBLE INDICTOR TO THE UDIBLE INDICTOR LEDS 40 DESCRIPTION TOOLS PROCESS NME INSTLL UDIBLE INDICTOR (BUZZER) P13X4-9229-0190 1 OF 1
NUMBER 10) OBTIN THE DRIVER SIDE OEM GSOLINE FUEL RIL (REMOVED IN SECTION 0080) 20) LOCTE THE GSOLINE FUEL SUPPLY NOZZLE TTCHED TO THE FUEL RIL 20 30 30) CREFULLY CUT & REMOVE THE FUEL SUPPLY NOZZLE FROM THE FUEL RIL S SHOWN 40) CREFULLY FOLD OVER THE CUT END OF THE NOZZLE TO SEL THE END SHUT S SHOWN 50) FROM INSIDE THE VEHICLE, LOCTE ND GRSP THE GSOLINE FUEL SUPPLY HOSE ON THE DRIVER SIDE RER OF THE ENGINE COMPRTMENT 40 60) LIGN ND SET THE MODIFIED NOZZLE INTO THE GSOLINE FUEL SUPPLY HOSE CONNECTOR; LOCK THE RED TB ON THE CONNECTOR S SHOWN (PUSH / PULL NOZZLE TO VERIFY LOCKED INTO CONNECTOR) 50 60 DESCRIPTION TOOLS METL SW WELDER PROCESS NME PLUG GSOLINE SUPPLY HOSE INSIDE ENGINE COMPRTMENT P13X4-9229-0200 1 OF 1
NUMBER 10 B C 10) OBTIN THE FOLLOWING S: - CONNECTOR - QTY (1) (PCKGE 'D') B - TERMINL - QTY (2) (PCKGE 'D') C - SEL - QTY (2) (PCKGE 'D') D - CONNECTOR - QTY (1) (TTCHED TO THE FUEL TNK WIRE HRNESS) E - TERMINL - QTY (2) (TTCHED TO THE FUEL TNK WIRE HRNESS) F - SEL - QTY (2) (TTCHED TO THE FUEL TNK WIRE HRNESS) D E F 20) FROM THE UNDERSIDE OF THE VEHICLE DRIVER SIDE, LOCTE THE FUEL LEVEL SENDING UNIT & FUEL PUMP LEDS TTCHED TO THE CORRUGTE HOSE COMING FROM THE LPG FUEL TNK 20 30) LONG THE INBORD SIDE OF THE DRIVER SIDE FUEL RIL, LOCTE THE OEM WIRE HRNESS LOOM FOR THE GSOLINE FUEL TNK 30 CREFULLY USING RZOR BLDE, OPEN THE CORRUGTE IN CLOSE PROXIMITY TO THE FUEL LEVEL SENDING UNIT & FUEL PUMP LEDS DESCRIPTION TOOLS 12103784 1 CONNECTOR (PKG D) RZOR BLDE B 12124581 2 TERMINL (PKG D) C 15324980 2 SEL (PKG D) D REF 1 CONNECTOR (PI TO WIRE HRNESS) E REF 2 TERMINL (PI TO WIRE HRNESS) F REF 2 SEL (PI TO WIRE HRNESS) PROCESS NME CONNECT FUEL PUMP ND FUEL LEVEL WIRE LEDS C P13X4-9229-0210 1 OF 5
NUMBER 50 40) LOCTE THE GREEN / LT GREEN SENDING UNIT WIRE INSIDE THE OEM WIRE HRNESS LOOM CUT THE GREEN / LT WIRE IN HLF ND SEPRTE THE FRONT HLF FROM THE RER 40 50) LOCTE THE YELLOW / PURPLE SENDING UNIT WIRE INSIDE THE OEM WIRE HRNESS LOOM (NOTE - THERE RE (2) YELLOW / PURPLE WIRES INSIDE THE OEM WIRE HRNESS LOOM - Ohm CHECK BOTH WIRES TO LOCTE THE SENDING UNIT LED - CORRECT WIRE WILL RED 10-180 Ohms) 80 60 CUT THE YELLOW / PURPLE WIRE IN HLF ND SEPRTE THE FRONT HLF FROM THE RER 60) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF THE GREEN / LT GREEN OEM WIRE (FRONT HLF) 70 70) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF THE GREEN WIRE COMING FROM THE LPG FUEL TNK WIRE HRNESS; INSTLL 1-1/2" PIECE OF SHRINK TUBE ONTO WIRE 80) TTCH THE OEM GREEN / LT GREEN LED ND GREEN WIRE LED FROM THE LPG FUEL TNK HRNESS TOGETHER SHOWN 110 90) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF THE YELLOW / PURPLE OEM WIRE (FRONT HLF) 90 100) CREFULLY REMOVE PPROXIMTELY 1/2" OF INSULTION FROM THE END OF THE YELLOW WIRE COMING FROM THE LPG FUEL TNK WIRE HRNESS; INSTLL 1-1/2" PIECE OF SHRINK TUBE ONTO WIRE 100 110) TTCH THE OEM YELLOW / PURPLE LED ND YELLOW WIRE LED FROM THE LPG FUEL TNK HRNESS TOGETHER SHOWN DESCRIPTION TOOLS WIRE CUTTERS WIRE STRIPPERS PROCESS NME CONNECT FUEL PUMP ND FUEL LEVEL WIRE LEDS P13X4-9229-0210 C 2 OF 5
NUMBER 120) SOLDER CONNECTIONS TOGETHER ND SEL WITH SHRINK TUBE S SHOWN 120 130) LOCTE THE WHITE / BROWN ND YELLOW / GREEN WIRES FOR THE OEM FUEL PUMP (THE WIRES RE WRPPED IN LUMINUM INSIDE THE WIRE LOOM) 140) CUT BOTH WIRES IN HLF ND SEPRTE THE FRONT HLF FROM THE RER 130 DESCRIPTION TOOLS SOLDER IRON ROSIN CORE SOLDER SHRINK TUBE PROCESS NME CONNECT FUEL PUMP ND FUEL LEVEL WIRE LEDS P13X4-9229-0210 C 3 OF 5
NUMBER 150 150) OBTIN (1) FEMLE CONNECTOR (D), (2) TERMINLS (E) ND (2) SEL (F) THT WERE TTCHED TO THE LPG FUEL TNK WIRE HRNESS D E F 160) INSTLL THE (2) SELS & (2) TERMINLS ONTO THE RED & BLCK WIRE LEDS COMING FROM THE LPG FUEL TNK WIRE HRNESS 170 180 190 170) INSERT ND SET THE TERMINL TTCHED TO THE RED WIRE INTO POSITION '' ON THE FEMLE CONNECTOR (PUSH/PULL WIRE TO VERIFY FULLY SETED) 180) INSERT ND SET THE TERMINL TTCHED TO THE BLCK WIRE INTO POSITION 'B' ON THE FEMLE CONNECTOR (PUSH/PULL WIRE TO VERIFY FULLY SETED) 190) SET LOCKING TB ON CONNECTOR 200 B C 200) OBTIN (1) MLE CONNECTOR (), (2) TERMINL (B) ND (2) SEL (C ) THT WERE INSIDE PCKGE 'D' DESCRIPTION TOOLS 12103784 1 CONNECTOR (PKG D) WIRE STRIPPERS B 12124581 2 TERMINL (PKG D) WIRE CRIMPERS C 15324980 2 SEL (PKG D) D REF 1 CONNECTOR (PI TO WIRE HRNESS) E REF 2 TERMINL (PI TO WIRE HRNESS) F REF 2 SEL (PI TO WIRE HRNESS) PROCESS NME CONNECT FUEL PUMP ND FUEL LEVEL WIRE LEDS C P13X4-9229-0210 4 OF 5
NUMBER 220 230 240 210) INSTLL THE (2) SELS & (2) TERMINLS ONTO THE WHITE / BROWN ND YELLOW / GREEN WIRE LEDS COMING FROM THE OEM WIRE HRNESS 220) INSERT ND SET THE TERMINL TTCHED TO THE YELLOW / GREEN WIRE INTO POSITION '' ON THE MLE CONNECTOR (PUSH/PULL WIRE TO VERIFY FULLY SETED) 230) INSERT ND SET THE TERMINL TTCHED TO THE WHITE / BROWN WIRE INTO POSITION 'B' ON THE MLE CONNECTOR (PUSH/PULL WIRE TO VERIFY FULLY SETED) 240) SET LOCKING TB ON CONNECTOR 250 250) LIGN ND SET THE LPG FUEL PUMP LED CONNECTOR (FEMLE) TO THE CONNECTOR (MLE) ON THE OEM WIRE HRNESS LED (PUSH/PULL CONNECTORS TO VERIFY FULLY SETED) 260 260) INSERT WIRES BCK INTO CORRUGTE ND SEL WITH ELECTRICL TPE DESCRIPTION TOOLS 12103784 1 CONNECTOR (PKG D) WIRE STRIPPERS B 12124581 2 TERMINL (PKG D) WIRE CRIMPERS C 15324980 2 SEL (PKG D) ELECTRICL TPE PROCESS NME CONNECT FUEL PUMP ND FUEL LEVEL WIRE LEDS P13X4-9229-0210 C 5 OF 5
NUMBER 10 10) OBTIN THE UXILIRY FUEL PUMP SWITCH KIT () 30 20) FROM THE FRONT OF THE VEHICLE, INSIDE THE ENGINE COMPRTMENT, LOCTE THE HETER HOSE 30) INSTLL (2) HOSE PLIERS, SPCED PPROXIMTELY 6" PRT, ONTO THE HETER HOSE S SHOWN 40 40) USING PIR OF HOSE CUTTERS, CUT THE HETER HOSE IN HLF IN THE MIDDLE BETWEEN THE HOSE PLIERS S SHOWN DESCRIPTION TOOLS P13X4-4110- 1 SWITCH KIT - UXILIRY FUEL PUMP HOSE PLIERS HOSE CUTTER PROCESS NME INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0220 1 OF 9
NUMBER 50 50) OBTIN THE HOSE DPTOR ND (2) HOSE CLMPS FROM THE UXILIRY FUEL PUMP SWITCH KIT 60 SWITCH 60) INSTLL (1) HOSE CLMP ONTO CUT HOSE; INSERT ND FULLY SET THE HOSE DPTOR INTO THE HOSE WITH THE INSTLLED CLMP; POSITION HOSE DPTOR WITH THE TTCHED SWITCH POINTING TOWRD YOU S SHOWN 70 70) INSTLL (1) HOSE CLMP ONTO THE OPPOSITE CUT HOSE; INSERT ND FULLY SET HOSE THE HOSE DPTOR INTO THE HOSE REMOVE BOTH HOSE PLIERS FROM HETER HOSE DESCRIPTION TOOLS REF 1 HOSE DPTOR HOSE PLIERS REF 2 HOSE CLMP PROCESS NME INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0220 2 OF 9
NUMBER 80 80) POSITION BOTH HOSE CLMPS OVER BRBS T BOTH ENDS OF THE HOSE DPTOR; FULLY TIGHTEN CLMPS TO SEL HOSE TO DPTOR 90 90) OBTIN THE RELY SSY, (2) SELF TP SCREW ND (1) RING TERMINL FROM THE UXILIRY FUEL PUMP SWITCH KIT 100) FROM INSIDE THE VEHICLE, DRIVER SIDE PSSENGER COMPRTMENT, POSITION THE RELY SSY JUST BELOW ND LEFT OF THE ICU MODULE S SHOWN 110) SECURE THE RELY TO THE ENGINE COMPRTMENT PNEL BELOW THE ICU MODULE WITH THE SELF TP SCREW 100 110 PRT NUMBER REF REF REF QTY 1 2 1 DESCRIPTION RELY SSY SELF TP SCREW RING TERMINL TOOLS CORDLESS DRILL 9mm SOCKET PROCESS NME INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0220 3 OF 9
NUMBER 120 130 120) INSTLL THE RING TERMINL ONTO THE BLCK WIRE LED TTCHED TO THE RELY SSY 130) OBTIN (1) SELF TP SCREW; SECURE THE RING TERMINL TO THE ENGINE ENGINE COMPRTMENT PNEL JUST TO THE LEFT OF THE RELY SSY S SHOWN 140) INSERT THE YELLOW, GREEN ND PINK WIRES FROM THE RELY SSY INTO ND THROUGH THE WIRE HRNESS GROMMET ON THE ENGINE COMPRTMENT PNEL S SHOWN 150) FROM THE FRONT OF THE VEHICLE, INSIDE THE ENGINE COMPRTMENT, LOCTE ND GRSP THE GREEN WIRE FROM THE RELY SSY; ROUTE THE WIRE TOWRD THE HOSE DPTOR S SHOWN 140 160) LIGN ND SET THE SPDE CONNECTOR ON THE END OF THE GREEN WIRE ONTO ONE OF THE SPDES ON THE SWITCH TTCHED TO THE HOSE DPTOR S SHOWN (PUSH/PULL CONNECTOR TO VERIFY FULLY SETED) 150 160 DESCRIPTION TOOLS REF 1 RING TERMINL WIRE STRIPPER WIRE CRIMPER PROCESS NME INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0220 4 OF 9
NUMBER 170 170) REMOVE THE BLCK WIRE FROM INSIDE THE UXILIRY FUEL PUMP WIRE LED CORRUGTE 180 180) USING WIRE CUTTERS, CUT THE BLCK WIRE IN HLF 190) REMOVE PPROXIMTELY 1" OF INSULTION FROM THE END OF THE BLCK WIRE GOING TO THE UXILIRY FUEL PUMP 190 200) LOCTE ND GRSP THE YELLOW WIRE COMING FROM THE RELY SSY; REMOVE PPROXIMTELY 1" OF INSULTION FROM THE END OF THE YELLOW WIRE 200 DESCRIPTION TOOLS WIRE CUTTERS WIRE STRIPPER PROCESS NME INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0220 5 OF 9
NUMBER 210 210) INSTLL 1-1/2" PIECE OF SHRINK TUBE ONTO THE YELLOW WIRE TTCH THE YELLOW WIRE LED FROM THE RELY SSY TO THE BLCK WIRE LED FROM THE UXILIRY FUEL PUMP SOLDER CONNECTIONS TOGETHER ND SEL WITH SHRINK TUBE S SHOWN 220 220) OBTIN THE BLCK WIRE W/SPDE CONNECTOR TTCHED FROM THE UXILIRY FUEL PUMP SWITCH KIT REMOVE PPROXIMTELY 1" OF INSULTION FROM THE END OF THE BLCK WIRE 230 230) REMOVE PPROXIMTELY 1" OF INSULTION FROM THE END OF THE BLCK WIRE TTCHED TO THE UXILIRY FUEL PUMP WIRE HRNESS LED PRT NUMBER REF QTY 1 DESCRIPTION BLCK WIRE W/SPDE CONNECTOR TOOLS SOLDER IRON ROSIN CORE SOLDER WIRE STRIPPERS PROCESS NME INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0220 6 OF 9
NUMBER 240 240) INSTLL 1-1/2" PIECE OF SHRINK TUBE ONTO THE SEPRTE BLCK WIRE TTCH THE BLCK WIRES TOGETHER; SOLDER CONNECTIONS TOGETHER ND SEL WITH SHRINK TUBE S SHOWN 250) ROUTE THE BLCK WIRE TOWRD THE HOSE DPTOR; LIGN ND SET THE SPDE CONNECTOR ON THE END OF THE BLCK WIRE ONTO THE REMINING SPDE ON THE SWITCH TTCHED TO THE HOSE DPTOR S SHOWN (PUSH/PULL CONNECTOR TO VERIFY FULLY SETED) 250 270 260) LOCTE ND GRSP THE PINK WIRE FROM THE RELY SSY; ROUTE THE WIRE TOWRD LONG THE COWL PNEL ND TOWRD THE BTTERY 260 270) USING WIRE CUTTERS, CUT THE PINK WIRE IN HLF IN CLOSE PROXIMITY TO THE BTTERY DESCRIPTION TOOLS WIRE CUTTERS PROCESS NME INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0220 7 OF 9
NUMBER 280 280) OBTIN THE FUSE HOLDER FROM THE UXILIRY FUEL PUMP SWITCH KIT 290) SSEMBLE THE FUSE HOLDER ONTO THE ENDS OF THE CUT PINK WIRE PER THE ICOM INSTRUCTION P11X-9208-290 300) OBTIN (1) RING TERMINL FROM THE UXILIRY FUEL PUMP SWITCH KIT 310) INSTLL THE RING TERMINL ONTO THE PINK WIRE LED TTCHED TO THE RELY SSY 300 310 DESCRIPTION TOOLS REF 1 FUSE HOLDER WIRE STRIPPER REF 1 RING TERMINL WIRE CRIMPER PROCESS NME INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0220 8 OF 9
NUMBER 320) CONNECT THE PINK WIRE WITH THE RING TERMINL TO THE POSITIVE SIDE OF THE BTTERY S SHOWN 320 330 330) OBTIN THE 1/4" SPLIT CORRUGTE FROM THE UXILIRY FUEL PUMP SWITCH KIT 340) INSTLL CORRUGTE ONTO THE EXPOSED WIRES ND CUT TO THE REQUIRED LENGTH 350) TIE STRP THE WIRE LEDS TO THE MIN WIRE HRNESS LOOM TO KEEP THE WIRE LEDS WY FROM THE ENGINE 330 340 DESCRIPTION TOOLS REF 1 1/4" SPLIT CORRUGTE PROCESS NME INSTLL UXILIRY FUEL PUMP SWITCH KIT P13X4-9229-0220 9 OF 9
NUMBER 10 10) OBTIN THE THROTTLE BODY IR INLET TUBE & CLMP REMOVED IN SECTION 0080; FROM INSIDE THE VEHICLE, TTCH THE IR INLET TUBE TO THE THROTTLE BODY; SECURE WITH CLMP 20 20) LOCTE ND GRSP THE EVP TUBE ON THE DRIVER SIDE OF THE ENGINE; LIGN ND SET THE EVP TUBE TO THE NOZZLE ON THE THROTTLE BODY IR INLET TUBE 30 30) REINSTLL THE ENGINE COVER ND SECURE WITH THE (4) RUBBER STRPS S SHOWN DESCRIPTION TOOLS PROCESS NME INSTLL ENGINE HRDWRE ND TTCH BTTERY LEDS P13X4-9229-0230 1 OF 3
NUMBER 40 40) OBTIN THE IR INLET TUBE REMOVED IN SECTION 0080 FROM THE FRONT OF THE VEHICLE, REINSTLL THE IR INLET TUBE 50 50) OBTIN (2) RING TERMINLS FROM PCKGE D 60 60) TTCH THE NEGTIVE CBLE TO THE BTTERY 70) OBTIN ND GRSP THE (2) BLCK NEGTIVE WIRE LEDS ON THE LPG ENGINE WIRE HRNESS 70 TTCH LEDS TOGETHER ND INSTLL (1) RING TERMINL INSTLL NEGTIVE LEDS TO THE NEGTIVE BTTERY TERMINL S SHOWN DESCRIPTION TOOLS REF 2 RING TERMINL (PCKGE D) PROCESS NME INSTLL ENGINE HRDWRE ND TTCH BTTERY LEDS P13X4-9229-0230 2 OF 3
NUMBER 80) OBTIN ND GRSP THE RED POSITIVE WIRE LED ON THE LPG ENGINE WIRE HRNESS 90 90) INSTLL (1) RING TERMINL ONTO THE RED POSITIVE LED INSTLL THE RED POSITIVE LED TO THE POSITIVE BTTERY TERMINL S SHOWN DESCRIPTION TOOLS PROCESS NME INSTLL ENGINE HRDWRE ND TTCH BTTERY LEDS P13X4-9229-0230 3 OF 3
NUMBER 10 10) OBTIN THE DIMOND PROPNE DECL FROM PCKGE J 20) REMOVE ND DISCRD THE DHESIVE BCKING FROM THE DIMOND PROPNE DECL 20 CLEN THE RE BOVE THE RER BUMPER ON THE PSSENGER SIDE OF THE VEHICLE; LIGN ND CENTER THE DIMOND PROPNE DECL BOVE THE RER BUMPER; SET DECL ONTO THE VEHICLE S SHOWN DESCRIPTION TOOLS P11X-9420-1 DIMOND PROPNE DECL PROCESS NME INSTLL PROPNE DIMOND DECL P13X4-9229-0240 1 OF 1
NUMBER 10 10) OBTIN THE VEHICLE EMISSION LBEL 20) OPEN HOOD ON VEHICLE 30) CLEN THE ENGINE COMPRTMENT PNEL JUST BOVE THE BRKE MSTER CYLINDER 50 40) REMOVE ND DISCRD THE DHESIVE BCKING FROM THE EMISSION LBEL 50) LIGN ND SET THE EMISSION LBEL ONTO THE ENGINE COMPRTMENT PNEL S SHOWN DESCRIPTION TOOLS REF 1 VEHICLE EMISSION LBEL PROCESS NME INSTLL VEHICLE EMISSION LBEL P13X4-9229-0250 1 OF 1
NUMBER PLESE RED THE INTRODUCTION SECTION OF THIS MNUL BEFORE BEGINNING THIS PROCEDURE 30 UNDER VEHICLE INSTLLTION INSPECTION 10) POSITION ND RISE VEHICLE UP ON SUITBLE LIFT 20) INSPECT HOSE ROUTING ND VERIFY PROPER CLERNCE ND SHIELDING BY HET SOURCES 30) VERIFY PROPER RETENTION OF HOSES (FRONT ND RER) 50 BLEEDER VLVE 40) VERIFY PROPER OF TNK FSTENERS 50) VERIFY BLEEDER VLVE IS FULLY CLOSED (ROTTE KNOB CLOCKWISE TO CLOSE) (ONLY FOR SYSTEMS THT RE NOT EQUIPPED WITH REMOTE BLEEDER VLVE HOSE KIT) 60) VERIFY MNUL SHUT-OFF KNOB IS FULLY OPEN (ROTTE KNOB COUNTERCLOCKWISE TO OPEN) 60 70) VERIFY TNK LBEL IS INSTLLED 80) RECORD TNK SERIL # ON INSPECTION FORM MNUL SHUT- OFF KNOB DESCRIPTION TOOLS PROCESS NME FINL INSPECTION ND SYSTEM CHECK P13X4-9229-0260 1 OF 4
NUMBER ENGINE COMPRTMENT INSTLLTION INSPECTION 90) VERIFY ENGINE HOSES RE PROTECTED WITH CORRUGTE 100) INSPECT HOSES FOR PROPER ROUTING 110) VERIFY EMISSION LBEL INSTLLED ONTO ENGINE COMPRTMENT PNEL JUST BOVE THE BRKE MSTER CYLINDER 120) INSPECT LPG WIRE HRNESSES FOR PROPER ROUTING 110 130) HET SHIELDING INSTLLED WHERE PPLICBLE 140) CHSSIS HOSE CORRUGTE ROUTED TO PENT WTER INGRESS 150) BTTERY CBLES PROPERLY TIGHTENED 150 DESCRIPTION TOOLS PROCESS NME FINL INSPECTION ND SYSTEM CHECK P13X4-9229-0260 2 OF 4
NUMBER SYSTEM FUNCTION / ROD TEST 160) FILL FUEL TNK WITH PROPNE - RECORD GLLONS INSTLLED ON INSPECTION FORM 170) VERIFY FUEL LEVEL INDICTION ON OEM FUEL GUGE ND RECORD RESULTS ON INSPECTION FORM 180 180) INSERT IGNITION KEY ND CYCLE TO THE 'ON' POSITION; WIT TO VERIFY GREEN LED LIGHT ON DSH PNEL ILLUMINTES FTER SHORT PERIOD OF TIME 190) CYCLE THE KEY TO STRT THE VEHICLE; VERIFY VEHICLE STRTS ND RUNS 200) LLOW VEHICLE TO RUN FOR FEW MINUTES THEN SHUT VEHICLE OFF 210) POSITION ND RISE VEHICLE UP ON SUITBLE LIFT 220) USING N PPROVED LEK DETECTION SOLUTION, SPRY FILL HOSE FITTINGS ND CHECK FOR LEKS ND REPIR IF NEEDED 240 230) REMOVE CORRUGTE FROM TNK; SPRY THE CHSSIS RETURN ND SUPPLY HOSE FITTINGS T THE TNK ND CHECK FOR LEKS; REPIR IF NEEDED 240) REINSTLL CORRUGTE ONTO TNK BUSHING; POSITION HOSE CLMP OVER BUSHING ND TIGHTEN CLMP TO SECURE CORRUGTE DESCRIPTION TOOLS PROCESS NME FINL INSPECTION ND SYSTEM CHECK P13X4-9229-0260 3 OF 4