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AC S.A. all rights reserved. Under penalty of law and/or liability claims it is forbidden to copy, publish, distribute, make available and/or use in any way all or any part of information contained 

within this document, in particular photographs, drawings, illustrations, trademarks, etc 

16 

 

FORD KUGA 

Engi

ne 

Year of 

manufac

ture 

Petrol ECM harness 

Installation notes

 

Conne

ctor 

Pin 
No. 

Wire colour 

Signal 

2.5T 

2008 

÷ 

2012 

„B” 

21 

blue-yellow 

Fuel pump control signal 

 

ECM location 

 

„A” 

89 

white-blue 

Fuel pressure sensor signal 

 

View of the pins in the connector of the petrol controller. 

 

Summary of Contents for STAG-4 QBOX BASIC

Page 1: ...any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc Controller User Manual 67R 01 4903 110R 00 4904 10R 03 6616 infor...

Page 2: ...ial control 19 1 9 Full group control 19 1 10 Mounting the controller STAG 4 QBOX QNEXT and STAG 300 QMAX 19 1 11 Selection of pressure regulator 20 1 12 Selection of injector nozzles 20 2 The AC STAG...

Page 3: ...25 1 Diagnostics test actuators 56 2 25 2 Service 57 3 STAG 4 QBOX QNEXT STAG 300 QMAX controller programming 57 3 1 Auto calibration 57 3 2 Collection of the petrol injection map with petrol petrol...

Page 4: ...4 1 Controller installation To ensure proper and long lasting operations of STAG Autogas systems in vehicles equipped with START STOP engine mode high durability gas valves are recommended to mount T...

Page 5: ...and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 5 1 2 Layout diagram STAG 4 QBOX PLUS Fig 2 STAG 4...

Page 6: ...n to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 6 1 3 La...

Page 7: ...to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 7 1 4 Lay...

Page 8: ...to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 8 1 5 Lay...

Page 9: ...any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 9 1 6 Wiring diagram for fuel level emulator FLE Fig 7 Wiring diag...

Page 10: ...ay all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 10 Fig 9 Wiring diagram for fuel level emulator FLE connection to STAG...

Page 11: ...of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 2 5T 2004 2009 B 47 yellow Fuel pump control signal ECM location A 2 green grey Fuel pressure sensor signal...

Page 12: ...sure sensor signal VOLVO XC60 Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 3 0T 3 2T 2009 2010 B 21 yellow orange Fuel pump control signal EC...

Page 13: ...ignal 2 5T 2004 2011 B 47 yellow Fuel pump control signal ECM location A 2 green grey Fuel pressure sensor signal 3 2 2007 2011 B 21 yellow Fuel pump control signal ECM location A 71 green grey Fuel p...

Page 14: ...Petrol ECM harness Installation notes Conne ctor Pin No Wire colour Signal 2 5 3 0 4 0 4 2 2001 FH1 58 white violet Fuel pump control signal ECM location PI1 49 white green Fuel pressure sensor signal...

Page 15: ...ct ure Petrol ECM harness Installation notes Conn ector Pin No Wire colour Signal 2 5 3 0 4 0 4 2 2006 FH300 020 bia o czerwony Fuel pump control signal ECM location PI300 071 niebieski Fuel pressure...

Page 16: ...ontained within this document in particular photographs drawings illustrations trademarks etc 16 FORD KUGA Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No Wire col...

Page 17: ...l ECM harness Installation notes Conne ctor Pin No Wire colour Signal 5 4 2003 2005 B 62 blue orange Fuel pump control signal ECM location E 32 red pink Fuel pressure sensor signal View of the pins in...

Page 18: ...on contained within this document in particular photographs drawings illustrations trademarks etc 18 FORD MUSTANG Engi ne Year of manufac ture Petrol ECM harness Installation notes Conne ctor Pin No W...

Page 19: ...this document in particular photographs drawings illustrations trademarks etc 19 1 8 Semi sequential control Fig 11 Semi sequential control layout diagram 1 9 Full group control Fig 12 Full group cont...

Page 20: ...ucer pressure 1 bar Power per cylinder range KM 1 7 1 8 11 16 1 9 2 2 17 28 2 3 2 5 29 34 2 6 2 8 35 40 2 9 3 0 41 48 3 1 3 2 49 55 The above rough values may in some cases not correspond to actual va...

Page 21: ...en to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 21 Fig...

Page 22: ...orbidden to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks etc 2...

Page 23: ...er OBD digital recorder if they have been closed Language options may be used to select user interface language version Tools option may be used to update hardware devices setup program settings load...

Page 24: ...ation to the nearest inspection An alternative method of inspection set up is an option of inspection by date where the date of scheduled inspection is specified instead of a mileage limit To clear th...

Page 25: ...the engine speed brown wires need not to be connected since the controller can calculate current speed from injection pulses When RPM readings are disrupted RPM changes significantly but the engine o...

Page 26: ...roller switches to LPG at idle run Switch over time time after starting the engine when the controller can switch to LPG Reducer filling time delay between opening solenoid valve and gas injectors The...

Page 27: ...ectors permanently as well However corrections e g resulting from changes in the LPG pressure will be no longer possible The moment when petrol injectors are fully open corresponds to the load value o...

Page 28: ...gas air mixture injected by gas injectors to each engine cylinder Test automatic testing of the flow on individual gas injectors Injector opening correction the window allows configuration of very pr...

Page 29: ...nters should be reset after injector replacement They are used for information purposes only Reducer temperature sensor pressure regulator temperature sensor type selection Gas temp sensor gas tempera...

Page 30: ...close to the engine temperature at which jerking stops NOTE Engine temperature threshold influences the time of function operation Always note if the ratio represents a rich fuel mixture for the warme...

Page 31: ...edure press the Start button and start the engine that has been warmed up earlier The calibration is an automatic process and takes about 3 minutes Correct calibration will end with the Completed succ...

Page 32: ...pressure bar pressure inside the suction collector absolute pressure value 3 Injection time ms petrol injection time P1 P8 Petrol injection time for Injector 1 8 4 Gas injection dose ms Gas injection...

Page 33: ...ine of 5 diodes while LED 300 401B and LED 401 indicate it with 4 diodes arranged around the button The minimum level low fuel alarm is indicated by a red LED diode in LED 300 switches In LED 300 401B...

Page 34: ...nsor starts operating start the auto calibration During the auto calibration the engine should work at idle run Switch off air conditioning and lights and do not turn the steering wheel During the cal...

Page 35: ...er of stored samples application version controller version controller serial number Continuous green line is displayed at top of the oscilloscope screen while the controller operates in the LPG mode...

Page 36: ...d circuit of the gas temperature sensor Reducer temperature sensor missing Disconnected or disrupted circuit of the reducer temperature sensor Gas temperature sensor circuit shorted Gas temperature se...

Page 37: ...iguration Unlike the errors message prompts are displayed in blue The controller can generate the following messages Description in AC STAG application Meaning Gas injectors fully open Check the Lambd...

Page 38: ...d emulator circuits No rotation The controller can see the impulses of petrol injection but does not see RPM signal No petrol injection pulses channel n Despite running engine controller has not regis...

Page 39: ...layed in the right panel of the automatic clearing configuration window Fig 31 The view of the OBD error clearing configuration window If there are other errors recorded for the vehicle besides those...

Page 40: ...hen no point is selected the arrows move the entire map Apart from the multiplier map there are two other maps in the window The blue map represents the petrol injection times with petrol The right ax...

Page 41: ...g 34 Multiplier map Suggested area of gas map acquisition 2 9 1 Multiplier matching When 2 3 of the suggested area on gas and petrol map is acquired button for multiplier matching function is activate...

Page 42: ...is forbidden to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks...

Page 43: ...possible to enrich weaken the mixture for a defined petrol injection time and revolutions In order to calibrate the multiplier the area which is to be calibrated must be selected by moving the mouse w...

Page 44: ...tor control Configuration of petrol post injection is made on a two dimensional map with an RPM and petrol injection time axes Like on the RPM correction map the cursor shows the engine operation curv...

Page 45: ...ion map allows the user to enter manually an additional percentage correction based on gas temperature Entering modifications is just like on the multiplier Fig 39 Gas temperature correction map view...

Page 46: ...The Gas pressure correction map allows the user to enter manually an additional percentage correction based on gas pressure Entering modifications is just like on the multiplier Fig 41 Gas pressure co...

Page 47: ...uired during driving on LPG The two perpendicular yellow lines form a cursor that indicates the current operational point rpm and suction negative pressure of the engine You can rotate the 3D map drag...

Page 48: ...is forbidden to copy publish distribute make available and or use in any way all or any part of information contained within this document in particular photographs drawings illustrations trademarks e...

Page 49: ...re shorter on the gas map than on the reference petrol map Conversely negative values indicate leaning It should be noted that particularly within the low load and short petrol pulse range it is not r...

Page 50: ...ated reader of parameters and faults based on the OBDII EOBD interface It is not necessary to connect an external adapter all required circuits are integrated with the controller board The tool suppor...

Page 51: ...add or remove a parameter from the reader select it or deselect it in the field on the left side next to its description Fig 49 OBD2 EOBD reader configuration If it is necessary to diagnose the vehicl...

Page 52: ...ion records the real pulsing of petrol injectors gas injectors or rpm signals vs time like in advanced measuring tools e g an oscilloscope Fig 50 Digital recorder window 2 22 Assignment of gas injecto...

Page 53: ...ssign the respective injector to the bank 4 Set the injector correction value to 0 After this STFT and LTFT trims should restore the initial values observed before stage 1 Repeat the described procedu...

Page 54: ...stop checking the option will result in automatic blocking of engine operating curve points on MAP correction map when the specified deviation limit is reached see Adaptation enable threshold Active...

Page 55: ...read through OBD2 EOBD or emulated by the controller above which it is allowed to correct the gas dose Fig 54 OBD target correction map Pr g w czenia Warto poszerzaj ca zakres akceptowanej docelowej...

Page 56: ...ontroller update To update the controller connect it to the diagnostic software and turn the engine off Select Tools Devices update from the main menu All available devices are automatically found The...

Page 57: ...56 Gas firing progress window 3 STAG 4 QBOX QNEXT STAG 300 QMAX controller programming The controller may be programmed using the acquired petrol map and the gas map The procedure Auto calibrate the...

Page 58: ...xis of co ordinates for injection times If the LPG map is collected with the PC connected and the diagnostic software running it is possible to immediately correct the multiplier characteristics when...

Page 59: ...be compared If the petrol injection time value is bigger after switching to LPG the positive correction must be made for this LPG temperature value the LPG temperature calibration map must be brought...

Page 60: ...PGH version is required Learning process stage 1 after the WPGH indicator autocalibration the function waits until the driver uses all gas in the tank and fills up to full Learning process stage 2 the...

Page 61: ...ED 300 switchboard The LED switchboard consists of Przycisk LED line indicating LPG level the LED indicating type of fuel button LED line shows current LPG level in the tank 4 green LEDs indicate a fu...

Page 62: ...oller settings Fast blinking 4 times per second with acoustic signals EMERGENCY mode system error prevents gas fueling e g empty gas tank LPG installation fault the engine runs on petrol Continuous li...

Page 63: ...itch has just been turned on is a warning that the system needs to be inspected Three long beeps repeated every minute is a reminder that the engine is operating in emergency mode 4 5 Emergency start...

Page 64: ...five times Programming mode is automatically deactivated after 30 seconds After changing the pairing code it is required to re pair the BT interface in the system Every successful change in the inter...

Page 65: ...nded layout diagram in particular from hooking signal cables up to other terminals than those specified in installation guidelines 2 Damage resulting from installing the controller in places incompati...

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