Prins SilverLine LPG system General instruction
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Copyright © Prins Autogassystemen B.V.
2010 VERSION : 2010-14-09
TABLE OF CONTENTS
FOR EXPLANATION AND CIRCUIT DIAGRAMS SEE : INSTALLATION MANUAL GENERAL PART 1 / 2
EXPLANATION OF SYMBOLS :
= IMPORTANT, CAUTION
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
General instructions
The installation of the system shall be done in accordance with the installation manual provided by Prins
Autogassystemen.
This manual is based on Dutch regulations, always install the system in accordance to the local regulations.
Always download the “general manual 1/2 “ from our website for basic instructions and diagrams.
Always disconnect the battery when installing the LPG system. Make sure the ignition key is outside the car.
Be aware of central door locking, radio / telephone memory code, alarm system.
Do not place the main fuse into the fuse holder before having completed the installation of the SilverLine system.
The SilverLine computer has to be activated by means of the diagnosis software.
In the unlikely event the SilverLine computer fails, it will automatically switch over to petrol.
Never disconnect the SilverLine computer connector, unless you have removed the main fuse.
When installing the SilverLine wiring harness, ensure that it does not run near any of the ignition components.
Solder and insulate all electrical connections.
The wires in the loom are provided with numbers and text. The text on the wire explains the function of the wire. The wire harness is not model specific, therefore is it may be necessary to adjust the length of the wires. Ensure maximum care is taken when connecting wiring.
Make professional joints using solder and shrink sleeve. Do not stretch the wiring harness.
No component of the LPG-system shall be located within 100 mm of the exhaust or similar heat source,
unless such components are adequately shielded against heat.
Remove any internal burrs, after having shortened the LPG pipe. (This guarantees the maximum flow through the pipe without pollution.)
If holes have to be drilled (wear safety glasses) for installing brackets, etc., the drilled holes must always be treated with an anti-corrosion agent, after the chips have been removed ( especially when mounting a exterior filler into body work).
After having completed the installation, check the whole system for gas leakage; use a gas leak detection device. Also check for leak of engine coolant, petrol and air.
Fitting and maintenance is only allowed by Prins Autogassystemen selected LPG engineers.
Failure to follow the instructions in this manual can result in a poor or non-working gas installation or a dangerous situation.
For maintenance instructions and filter registration see owner manual.
Prins Autogassystemen is not responsible for any damages to people or objects as a result of changes to
Prins products.
Check our website regularly for diagrams, certificates, updates, info-bulletins and product information.
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Required equipment / tools / materials for installing a complete system
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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
Com port
Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 )
Exhaust gas analyser
Multi meter
: 256 colours, advise colours 16 bits or more
: 1 free COM port 1 or COM port 2 with a 9 or 25 pins connector
Oscilloscope
Prins SilverLine diagnostic software
Prins SilverLine serial interface
Prins SilverLine break out box ( part nr. 080/70090 )
Torque wrench ( 10Nm )
Portable light
Assortment drill bits 4 to 12 mm
Assortment cutters ( ø 20, 30, 50, 70 mm )
Punching tool ø 70 mm
Round file
Portable drill or pneumatic drill
Thread cutting device ( male M6x1, M8x1, M10x1 )
Pipe-flaring tool ( for 6 and 8 mm copper pipe )
Air gun
Vacuum cleaner
Hot air gun
Allan spanner for inlet couplings 3,5mm ( part nr. 099//9970 )
Reducer adjustment tool ( part nr. 099/9960 )
Molex extraction tool for SilverLine 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 )
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Copyright © Prins Autogassystemen B.V.
2010
Base diagram
General SilverLine mounting instruction
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Copyright © Prins Autogassystemen B.V.
2010
Approval numbers
General SilverLine mounting instruction
Reducer SilverLine LPG Prins : E4-67R-010054
Lock-off valve OMB
Lock-off valve Valtek
: E8-67R-014327
: E4-67R-010041
Injector rail OMB : LPG E8-67R-014303
CNG E4-110R-004304
Filter unit Prins : LPG E4-67R-010096
CNG E4-110R-000028
Computer SilverLine Prins: LPG E4-67R-010098
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Copyright © Prins Autogassystemen B.V.
2010
Mounting the reducer
General SilverLine mounting instruction
Filter replacement must be recorded in the service book supplied
The only two correct mounting positions of the reducer.
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Copyright © Prins Autogassystemen B.V.
2010
Water connections
General SilverLine mounting instruction
Parallel
injector rail
filter unit
Psys + Tlpg sensor exhaust oxygen sensor
VSI injector 1 2 3 4 petrol injector cylinder 1
vsi coupling inlet manifold overpressure hose
throttle body reducer
+ lock-off valve
LPG fuel line Tank heater valve interior heater with valve in engine coolant out
T-piece
Serial
exhaust injector rail filter unit
VSI injector 1
2 3 4 petrol injector cylinder 1
vsi coupling inlet manifold overpressure hose
throttle body
Psys + Tlpg sensor reducer
+ lock-off valve
LPG fuel line Tank interior heater without valve oxygen sensor engine coolant out
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Overpressure and vacuum connection
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Turbo / MAP sensor
When no original MAP sensor ( inlet manifold pressure sensor ) is available on the engine for connecting the blue MAP sensor wire, use the Prins Turbo/MAP sensor kit part nr. 180/70250.
Connect the hose for engine vacuum by means of an original vacuum connection or install a coupling into the manifold.
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Mounting the inlet manifold couplings
Remove the inlet manifold. Try to install the couplings as close as possible near the petrol injectors.
Drill x holes of 5 mm in the inlet manifold.
Cut M6x1 thread in these holes.
Place the inlet couplings with a lock compound in the inlet manifold.
Watch out that the lock compound doesn’t come inside the inlet couplings and place the inlet manifold back on the engine.
Coupling 3.5mm Allan key Lock compound
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Injector nozzle modification 1
Remove the locking clips and remove the nozzles.
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Injector nozzle modification 2
Drilling diagram
Injector size Nozzle
Diameter Ø mm
1.6
1.9
2.1
2.3
2.6
32cc / stroke
42cc / stroke
52cc / stroke
63cc / stroke
73cc / stroke
Minimum power per cylinder ( LPG ) kW
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9
HP
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12
13
18
25
17.4
24
33.5
Maximum power per cylinder ( LPG ) kW
13
15
HP
18
20
20
27
35
27
36
47
Choose a drill size from the drilling diagram and insert the drill into the drilling machine
Carefully clamp in the nozzle.
Be sure to drill straight into the nozzle.
Be sure to drill all the way through the nozzle.
Check if the drilled hole has the correct diameter.
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Injector nozzle modification 3
Thoroughly clean the nozzle with compressed air.
Check thoroughly if the nozzle is clean.
Check if the O-rings are not damaged before installation.
Carefully re-install the nozzle.
Push the nozzle with a rotating movement into the rail.
Use the locking clips the secure the nozzles.
Install the 14mm end plug.
Torque moment 7Nm.
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Copyright © Prins Autogassystemen B.V.
2010
Rail mounting points
General SilverLine mounting instruction
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Filter unit
The filter unit filters the LPG and is also used to measure the gas temperature (T_gas) and gas pressure (Psys) in the SilverLine system, by means of a combination sensor.
The filter unit has a single outlet of 11mm.
The filter unit has a single inlet of 16 mm.
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Copyright © Prins Autogassystemen B.V.
2010
LPG hoses
Hose
(Ø..mm)
From component
16
11
5
5
Reducer
Prins filter unit
General SilverLine mounting instruction
To component
Prins filter unit
SilverLine injector rail
Reducer overpressure Inlet manifold coupling ( vacuum )
Reducer MAP connection Inlet manifold coupling ( vacuum )
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5
5
SilverLine injector 1
SilverLine injector 2
SilverLine injector 3
Inlet manifold coupling cyl.1
Inlet manifold coupling cyl.2
Inlet manifold coupling cyl.3
5
5
SilverLine injector 4 Inlet manifold coupling cyl.4
Optional:
Prins MAP / Turbo sensor Inlet manifold coupling ( vacuum )
Please observe that there is no damage or fouling to the hoses.
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Mounting the computer
Never mount the computer upside down or near a heat source
Mounting the fuel selection switch
Drill a hole of Ø8mm for mounting the switch.
When mounting the switch, only push on its sides.
Pushing the switch in the centre may result in damage to the switch.
Program the selection switch for correct level indication.
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Electrical connections
Check and measure the wiring in case of changes in the cars wiring colours.
Insulate not used wires.
Wire number / code Wire colour
50 MAIN GND
25-51 +12V BAT brown red
Connection
Connect to the '
–' of the battery; use a ring terminal for this purpose or solder:
Wire colour :
Wire location :
Connect to the '+' of the battery; use a ring terminal for this purpose or solder.
Do not place the fuse in the holder before having completed the installation of the LPG system.
Wire colour :
Wire location :
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
18 5V MAP
42 ground MAP
16 signal MAP kit part nr. 180/70250
16 signal MAP
13 fused IGNITION +
46 LAMBDA 1-L
40 RPM
White - yellow
red
Green - yellow
red
Pink - yellow
red
Blue - yellow
red
Red
Brown
Blue
Blue extend this wire grey-white orange
Purple-white
Connector injector to cylinder 1.
Connector injector to cylinder 2.
Connector injector to cylinder 3.
Connector injector to cylinder 4.
For measuring the inlet manifold pressure (MAP).
Connect the 3-pole connector to the Prins MAP sensor.
For measuring the inlet manifold pressure (MAP).
Connect to original engine MAP sensor.
Wire colour :
Wire location :
Make a connection to ignition + / contact +.
Do not place the fuse in the holder before having completed the installation of the LPG system.
Wire colour :
Wire location :
For the measurement of the lambda signal of cylinder bank 1.
Connect the wire in parallel to the lambda sensor.
Wire colour :
Wire location :
For measuring the engine speed.
Wire colour :
Wire location :
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Electrical connections
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 SilverLine wire has a petrol injector / cylinder number printed on the wire, connect this wire to the corresponding petrol injector / cylinder.
Connect the bicoloured SilverLine measuring wire to the ecu side, ( wire code: ECU SIDE ).
Connect the corresponding full coloured SilverLine wire to the petrol injector side ( wire code: MIN
INJ SIDE ).
See diagrams: Installation manual general part 1 / 2.
Attention:
Each bicoloured measuring wire corresponds to a specific LPG injector and petrol injector /
cylinder number. Do not interchange the wires.
SilverLine
measure wire nr. :
Full coloured / Bicoloured
Module position
Interrupt petrol injector wire
wire nr. 39
Petrol injector cyl. 1 wire nr. 38
Petrol injector cyl. 2 wire nr. 37
Petrol injector cyl. 3 wire nr. 36
Petrol injector cyl. 4 white / white-yellow green / green-yellow pink / pink-yellow blue / blue-yellow
Colour :
Location :
Colour :
Location :
Colour :
Location :
Colour :
Location :
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Checklist after installation
1. Connect the serial interface wire and run the SilverLine diagnosis program.
Install the main fuse, and program the SilverLine switch.
Turn the ignition key in the accessory position.
When working on the car, beware of moving and rotating parts in the engine compartment.
2. When commissioning the LPG system, you must activate the SilverLine computer with the diagnosis software. When the SilverLine computer has not been activated, it will keep generating error code 160. To activate the SilverLine computer, select function F11 (activate
ECM).
3. Check whether the program in the SilverLine computer matches with the car (dedicated engine set ):
Refer with F2 to the box number and car description in the diagnosis software and compare these with the set number.
4. The system will switch over to LPG as soon as the temperature of the coolant (T-ect) becomes higher than the parameter T-min set and when the TSO-cold time is expired.
5. Check all components and connections for any gas leakage ( use a LPG leak detector device or a fluid detection like soap. Caution for moving and rotating parts in the engine compartment !
6. Let the engine run warm on petrol >80°C.
Check if the evaporator heats up.
Check the engine signals, petrol injection time, RPM, ECT, lambda, MAP signal, petrol pressure signal.
Let the engine run idle on LPG.
Adjust the evaporator pressure.
Adjust the evaporator pressure in such a way that the pressure measured ( P-sys ) equals the idle level value.
Turn the socket-head screw at the front of the evaporator to adjust the pressure.
An error code will be generated whenever the pressure variation is to high.
Seal the evaporator with the sticker included in the delivery after having adjusted the pressure.
7. Use the diagnosis software to check again all input and output signals.
8. Check the system for error codes and solve these, if required.
Check the petrol MMS for EOBD error codes.
Place the protection connector on the SilverLine communication connector.
9. Make a test drive and check the drivability on LPG and petrol.
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Copyright © Prins Autogassystemen B.V.
2010 General SilverLine mounting instruction
Trouble code Definition
100
101
102
110
111
120
121
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Lambda to long to rich.
Lambda to long to lean. loop.
T-ECT>= 171°C
T-ECT>= -40°C
T-LPG>= 171°C
T-LPG>= -40°C
Trouble code chart
Lambda to long to lean during open
Check / solution
Check when operating on petrol and LPG that there is good lambda signal movement.
Check when operating on petrol and LPG that there is good lambda signal movement.
Check when operating on petrol and LPG that there is good lambda signal movement.
Check if the ECT sensor (blue) in the reducer is connector is connected to ground.
Check if the ECT sensor (blue) in the reducer has a power connection.
Check the ground connection of the Pressure/temperature sensor in the filter unit.
Check the power connection of the Pressure/temperature sensor in the filter unit.
150
160
180
Based on a pressure drop in the system, this can be caused by an empty
LPG tank, incorrect solenoid valve, polluted filter or incorrectly adjusted pressure.
Activate the LPG computer with the diagnostic program, using the F11 function key.
LPG computer circuit board to hot, replace the SilverLine computer in a cooler area.
Check board voltage / alternator output and condition of the battery. 181 Battery voltage to high
210-220-230-240-250-260-270-
280
SilverLine injector overload
Injector current to high, check for short circuiting
211-221-231-241-251-261-271-
281
310
SilverLine injector noload
Injector current to low, check for bad connections.
Adjusted pressure on idle out of
Adjust the idle pressure to the value shown by parameter “ Idle Level “ range
311 Check parameter settings, contact Prins Autogassystemen.
320
Psys<= Low_Level
ECM-SILVERLINE not activated
T-Board >= 90°C
Programm error during flahing the memory
Psys voltage to low Check the ground connection of the Pressure/temperature sensor in the filter unit.
321
322
Psys voltage to high
Psys > 3,5 Bar
Check the power connection of the Pressure/temperature sensor in the filter unit.
Check the coolant temperature (T-ect) and the evaporator for leakage of the first stage.
330
340
341 unexpected parameter change reducer warms up to slow
Gas leakage, system pressure is less then 1.25 bar after 4 hours when the engine is not running
System switches to LPG but engine stalls immediately.
Contact Prins Autogassystemen.
Check the water connections / circuit.
Check the system for gasleakage.
No injection timing on LPG ( 0
Msec.)
The LPG system switches constantly between LPG and Petrol
Engine hesitates on high revs, and not running on all cylinders. Engine runs good on idle.
Switch LED’s don’t lit up
LPG tank empty ?
Lock-off valves open ?
Check the injection module.
- Check coolant system for air.
- T-ect sensor in the evaporator malfunction.
Check for kinked or jammed LPG hoses (between SilverLine injector and couplings).
Check for blocked inlet couplings.
Fault codes when turning the ignition off ( key out the ignition )
The orange LED on the switch flashes
The LPG system switches to LPG but engine stalls immediately
Check the main fuse of the SilverLine system
Check ignition+ (SilverLine wire 13)
Caused by different switch off times between ignition+ and injector power.
Connect SilverLine wire 13 to the petrol injector feed instead of ignition+.
Activate the LPG computer with the diagnostic program, using the F11 function key.
LPG tank empty?
Not running on all cylinders on lpg Check parameter 10, number of cylinders.
No injection times on lpg
Injection time “falls” to 0 mSec on
Check the connections of the injection module.
Check the injection module.
LPG
Check engine while running on Replace injection module
LPG, injector circuit malfunction, no lambda control (limb home)
Not starting / running on petrol Check the connections of the injection module.
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