Prins VSI LPG Installation manual
Reklama
Reklama
DATE : 2013-09-04
Copyright © Prins Autogassystemen B.V. 2013 VERSION NR : C
Copyright © Prins Autogassystemen B.V. 2013 VERSION NR : C
Table of contents
Required equipment / tools / materials for installing a complete system _______________________ 3
Vehicle check ________________________________________________________________________ 3
General instructions __________________________________________________________________ 4
Introduction _________________________________________________________________________ 5
Approval numbers VSI LPG / CNG components ___________________________________________ 6
The Prins LPG reducer ________________________________________________________________ 7
The Keihin CNG regulator ______________________________________________________________ 8
The injector rail ______________________________________________________________________ 9
The Prins filter unit __________________________________________________________________ 10
The Keihin filter unit _________________________________________________________________ 10
The VSI computer____________________________________________________________________ 11
VSI-I _______________________________________________________________________________ 11
VSI-2.0 computer ____________________________________________________________________ 12
Instructions rotating the Prins VSI injector rail ___________________________________________ 13
The wiring loom._____________________________________________________________________ 14
VSI-I _______________________________________________________________________________ 14
VSI-2.0 _____________________________________________________________________________ 14
Hose connections ___________________________________________________________________ 15
Diagram 1 VSI inlet manifold coupling _________________________________________________ 16
Diagram 2 VSI inlet manifold coupling with nylon hose __________________________________ 17
Diagram 3 Parallel water connection __________________________________________________ 18
Diagram 4 Serial water connection____________________________________________________ 19
Diagram 5 Serial water connection CNG regulator _______________________________________ 20
The VSI-I fuel switch _________________________________________________________________ 21
The VSI-2.0 fuel switch _______________________________________________________________ 22
Electrical connections on the LPG reservoir _____________________________________________ 23
Electrical connections VSI-I wiring harness ______________________________________________ 24
Electrical connections VSI-I wiring harness ______________________________________________ 25
Electrical connections VSI-2.0 wiring harness ____________________________________________ 26
Electrical connections VSI-2.0 wiring harness ____________________________________________ 27
Insulate all not used wires. ____________________________________________________________ 27
Electrical connections VSI-2.0 wiring harness ____________________________________________ 28
Electrical connections VSI-2.0 wiring harness ____________________________________________ 29
Electrical connections RPM module 091/0236 ____________________________________________ 30
Electrical connections Petrol Pressure Simulator 091/0252 _________________________________ 31
Electrical connections Dual Sensor Interface (DSI) ________________________________________ 32
Electrical connections CNG Prins Timing Optimizer (PTO) _________________________________ 33
Diagram CNG PTO wiring Prins Turbo / MAP sensor ______________________________________ 33
Prins Turbo / MAP sensor _____________________________________________________________ 34
Diagram 5 LPG Base layout VSI 4 cylinder connector ____________________________________ 35
Required equipment / tools / materials for installing a complete system _______________________ 3
Vehicle check ________________________________________________________________________ 3
General instructions __________________________________________________________________ 4
Introduction _________________________________________________________________________ 5
Approval numbers VSI LPG / CNG components ___________________________________________ 6
The Prins LPG reducer ________________________________________________________________ 7
The Keihin CNG regulator ______________________________________________________________ 8
The injector rail ______________________________________________________________________ 9
The Prins filter unit __________________________________________________________________ 10
The Keihin filter unit _________________________________________________________________ 10
The VSI computer____________________________________________________________________ 11
VSI-I _______________________________________________________________________________ 11
VSI-2.0 computer ____________________________________________________________________ 12
Instructions rotating the Prins VSI injector rail ___________________________________________ 13
The wiring loom._____________________________________________________________________ 14
VSI-I _______________________________________________________________________________ 14
VSI-2.0 _____________________________________________________________________________ 14
Hose connections ___________________________________________________________________ 15
Diagram 1 VSI inlet manifold coupling _________________________________________________ 16
Diagram 2 VSI inlet manifold coupling with nylon hose __________________________________ 17
Diagram 3 Parallel water connection __________________________________________________ 18
Diagram 4 Serial water connection____________________________________________________ 19
Diagram 5 Serial water connection CNG regulator _______________________________________ 20
The VSI-I fuel switch _________________________________________________________________ 21
The VSI-2.0 fuel switch _______________________________________________________________ 22
Electrical connections on the LPG reservoir _____________________________________________ 23
Electrical connections VSI-I wiring harness ______________________________________________ 24
Electrical connections VSI-I wiring harness ______________________________________________ 25
Electrical connections VSI-2.0 wiring harness ____________________________________________ 26
Electrical connections VSI-2.0 wiring harness ____________________________________________ 27
Insulate all not used wires. ____________________________________________________________ 27
Electrical connections VSI-2.0 wiring harness ____________________________________________ 28
Electrical connections VSI-2.0 wiring harness ____________________________________________ 29
Electrical connections RPM module 091/0236 ____________________________________________ 30
Electrical connections Petrol Pressure Simulator 091/0252 _________________________________ 31
Electrical connections Dual Sensor Interface (DSI) ________________________________________ 32
Electrical connections CNG Prins Timing Optimizer (PTO) _________________________________ 33
Diagram CNG PTO wiring Prins Turbo / MAP sensor ______________________________________ 33
Prins Turbo / MAP sensor _____________________________________________________________ 34
Diagram 5 LPG Base layout VSI 4 cylinder connector ____________________________________ 35
Copyright © Prins Autogassystemen B.V. 2013 Page 2
Diagram 6 LPG Base layout VSI 4 cylinder solder _______________________________________ 36
Diagram 7 LPG Base layout VSI 5 cylinder _____________________________________________ 37
Diagram 8 LPG Base layout VSI 6 cylinder connector ____________________________________ 38
Diagram 9 LPG Base layout VSI 6 cylinder solder _______________________________________ 39
Diagram 10 LPG Base layout VSI 8 cylinder connector ___________________________________ 40
Diagram 11 LPG Base layout VSI 8 cylinder solder ______________________________________ 41
Diagram 12 CNG Base layout ________________________________________________________ 42
Diagram 13 VSI-2.0 LPG Base layout __________________________________________________ 43
Diagram 14 VSI-2.0 MAP LPG Base layout _____________________________________________ 44
Diagram 13 Injection module 4-cylinder ( 180/70024 connector ) ___________________________ 46
Diagram 14 Injection module 4-cylinder ( 180/ 70024 solder ) ______________________________ 47
Diagram 15 Injection module 6-cylinder ( 180/70026 connector ) ___________________________ 48
Diagram 16 Injection module 6-cylinder ( 180/70026 solder ) ______________________________ 49
Diagram 17 Injection module 8-cylinder ( 180/ 70024 connector) ___________________________ 50
Diagram 18 Injection module 8-cylinder ( 180/70024 solder) _______________________________ 51
Diagram 19 Repair module 180/30024 (4-8 cylinder) _____________________________________ 52
Diagram 20 connector injection module 091/71004 ______________________________________ 53
Diagram 21 injection module 091/71006 _______________________________________________ 54
Diagram 22 Replacing the injection module 180/70024 → 091/0145 _________________________ 55
Diagram 23 Replacing the injection module 180/70024 → 091/71004 (4 cylinder) _____________ 56
Diagram 24 Replacing the injection module 180/70026 → 091/71006 (6 cylinder) _____________ 57
Diagram 25 Replacing the injection module 180/70024 → 091/71004 (8 cylinder) _____________ 58
Diagram 26 LPG wiring 180/70014 ____________________________________________________ 59
Diagram 27 LPG wiring 180/70004 ____________________________________________________ 60
Diagram 28 LPG wiring 180/70016 ____________________________________________________ 61
Diagram 29 LPG wiring 180/70006 ____________________________________________________ 62
Diagram 30 LPG wiring 180/70018 ____________________________________________________ 63
Diagram 31 LPG wiring 180/70008 ____________________________________________________ 64
Diagram 32 LPG wiring 080/72040 ____________________________________________________ 65
Diagram 33 LPG wiring 080/72045 ____________________________________________________ 66
Diagram 34 LPG wiring 080/72050 ____________________________________________________ 67
Diagram 35 LPG wiring 080/72055 ____________________________________________________ 68
Diagram 36 LPG wiring 080/72060 ____________________________________________________ 69
Diagram 37 LPG wiring 080/72065 ____________________________________________________ 70
Diagram 38 CNG wiring 095/72045 ____________________________________________________ 71
Diagram 39 VSI-2.0 wiring 191/040002 _________________________________________________ 72
Trouble code chart LPG ______________________________________________________________ 73
Maintenance instructions _____________________________________________________________ 74
Checklist after installation ____________________________________________________________ 76
Diagram 6 LPG Base layout VSI 4 cylinder solder _______________________________________ 36
Diagram 7 LPG Base layout VSI 5 cylinder _____________________________________________ 37
Diagram 8 LPG Base layout VSI 6 cylinder connector ____________________________________ 38
Diagram 9 LPG Base layout VSI 6 cylinder solder _______________________________________ 39
Diagram 10 LPG Base layout VSI 8 cylinder connector ___________________________________ 40
Diagram 11 LPG Base layout VSI 8 cylinder solder ______________________________________ 41
Diagram 12 CNG Base layout ________________________________________________________ 42
Diagram 13 VSI-2.0 LPG Base layout __________________________________________________ 43
Diagram 14 VSI-2.0 MAP LPG Base layout _____________________________________________ 44
Diagram 13 Injection module 4-cylinder ( 180/70024 connector ) ___________________________ 46
Diagram 14 Injection module 4-cylinder ( 180/ 70024 solder ) ______________________________ 47
Diagram 15 Injection module 6-cylinder ( 180/70026 connector ) ___________________________ 48
Diagram 16 Injection module 6-cylinder ( 180/70026 solder ) ______________________________ 49
Diagram 17 Injection module 8-cylinder ( 180/ 70024 connector) ___________________________ 50
Diagram 18 Injection module 8-cylinder ( 180/70024 solder) _______________________________ 51
Diagram 19 Repair module 180/30024 (4-8 cylinder) _____________________________________ 52
Diagram 20 connector injection module 091/71004 ______________________________________ 53
Diagram 21 injection module 091/71006 _______________________________________________ 54
Diagram 22 Replacing the injection module 180/70024 → 091/0145 _________________________ 55
Diagram 23 Replacing the injection module 180/70024 → 091/71004 (4 cylinder) _____________ 56
Diagram 24 Replacing the injection module 180/70026 → 091/71006 (6 cylinder) _____________ 57
Diagram 25 Replacing the injection module 180/70024 → 091/71004 (8 cylinder) _____________ 58
Diagram 26 LPG wiring 180/70014 ____________________________________________________ 59
Diagram 27 LPG wiring 180/70004 ____________________________________________________ 60
Diagram 28 LPG wiring 180/70016 ____________________________________________________ 61
Diagram 29 LPG wiring 180/70006 ____________________________________________________ 62
Diagram 30 LPG wiring 180/70018 ____________________________________________________ 63
Diagram 31 LPG wiring 180/70008 ____________________________________________________ 64
Diagram 32 LPG wiring 080/72040 ____________________________________________________ 65
Diagram 33 LPG wiring 080/72045 ____________________________________________________ 66
Diagram 34 LPG wiring 080/72050 ____________________________________________________ 67
Diagram 35 LPG wiring 080/72055 ____________________________________________________ 68
Diagram 36 LPG wiring 080/72060 ____________________________________________________ 69
Diagram 37 LPG wiring 080/72065 ____________________________________________________ 70
Diagram 38 CNG wiring 095/72045 ____________________________________________________ 71
Diagram 39 VSI-2.0 wiring 191/040002 _________________________________________________ 72
Trouble code chart LPG ______________________________________________________________ 73
Maintenance instructions _____________________________________________________________ 74
Checklist after installation ____________________________________________________________ 76
Copyright © Prins Autogassystemen B.V. 2013 Page 3
Required equipment / tools / materials for installing a complete system
- Complete workshop toolbox ( wrenches, screwdrivers, cutters, pliers, ratchet, sockets )
- Car lift
- Portable computer : operating on Windows 98,W2000 or XP.
Internal memory : 16 Mb or more
Memory HD space : 5MB
Screen : 256 colours, advise colours 16 bits or more
Com port : 1 free COM port 1 or COM port 2 with a 9 or 25 pins connector
or USB
- Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 )
- Exhaust gas analyser
- Multimeter
- Oscilloscope
- Prins VSI diagnostic software
- Prins VSI serial interface
- Prins VSI break out box ( part nr. 080/70090 )
- Torque wrench ( 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
- Threading 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 VSI switch connector ( part nr. 090/9929 )
- Soldering iron, soldering tin
- Wire-stripping pliers
- Adhesive tape
- Adhesive sealant
- Thread locking compound
- Anti-corrosion agent / black body coating
- Gas leak detection device or foam leak spray
- Shrink sleeves
- Engine coolant
Vehicle check
- Check the vehicle drivability on petrol
- Check the fuel system for error codes ( scan tool )
- Check if the catalytic converter is in good condition ( exhaust gas analyzer )
- Check the condition of the ignition system ( spark plugs, cables, coil )
Required equipment / tools / materials for installing a complete system
- Complete workshop toolbox ( wrenches, screwdrivers, cutters, pliers, ratchet, sockets )
- Car lift
- Portable computer : operating on Windows 98,W2000 or XP.
Internal memory : 16 Mb or more
Memory HD space : 5MB
Screen : 256 colours, advise colours 16 bits or more
Com port : 1 free COM port 1 or COM port 2 with a 9 or 25 pins connector
or USB
- Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 )
- Exhaust gas analyser
- Multimeter
- Oscilloscope
- Prins VSI diagnostic software
- Prins VSI serial interface
- Prins VSI break out box ( part nr. 080/70090 )
- Torque wrench ( 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
- Threading 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 VSI switch connector ( part nr. 090/9929 )
- Soldering iron, soldering tin
- Wire-stripping pliers
- Adhesive tape
- Adhesive sealant
- Thread locking compound
- Anti-corrosion agent / black body coating
- Gas leak detection device or foam leak spray
- Shrink sleeves
- Engine coolant
Vehicle check
- Check the vehicle drivability on petrol
- Check the fuel system for error codes ( scan tool )
- Check if the catalytic converter is in good condition ( exhaust gas analyzer )
- Check the condition of the ignition system ( spark plugs, cables, coil )
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