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Chevrolet IMPALA 3.9L 2009, Cng System Installer Manual, Page: 2 / 32

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Chevrolet IMPALA 3.9L 2009 Cng System Installer Manual Download Page 2

TABLE OF CONTENTS 

 

SAFETY (READ FIRST) ................................................................................................................................ 1 
INTRODUCTION ........................................................................................................................................... 3 

A.  Important Vehicle Owner Advisories ................................................................................................ 3 
B.  SEQUENT P&D Installation Kit Contents ........................................................................................ 3 
C.  Required Tools & Equipment ........................................................................................................... 5 
D. Torque 

Specifications 

...................................................................................................................... 5 

E.  Installation Note (corrosion protection) ............................................................................................ 5 

INSPECT FOR CORRECT VEHICLE INFORMATION & THE OPERATIONAL INTEGRITY OF THE 
ENGINE ......................................................................................................................................................... 6 

A. Preliminary 

Inspection 

..................................................................................................................... 6 

B.  Scan Tool Inspection ....................................................................................................................... 6 
C.  High Mileage Vehicle Inspection (75k+) .......................................................................................... 7 

SEQUENT P&D INSTALLATION .................................................................................................................. 8 

A.  Pre-Installation Bench Assembly ..................................................................................................... 8 
B.  Intake Manifold, Ignition Coil Pack and Air Filter Housing Removal .............................................. 11 
C.  Intake Manifold Modifications ........................................................................................................ 11 
D.  Zenith Regulator and Coolant Hose Installation ............................................................................ 13 
E.  Lockoff and High Pressure Tubing Installation .............................................................................. 14 
F.  Fuel Rail Installation ...................................................................................................................... 15 
G.  CNG Low Pressure Hose Connections ......................................................................................... 16 
H.  Sequent / OEM ECM Electrical Connections ................................................................................. 17 

•

 

Proper Wire Splicing ............................................................................................................... 17 

I. 

Sequent ECM, Relay & Fuse Locations ........................................................................................ 20 

J. Battery 

Connections 

...................................................................................................................... 20 

K.  Re-install the Ignition Coil Pack and Upper Intake Manifold .......................................................... 21 
L.  Sequent MAP Sensor Installation .................................................................................................. 21 
M.  OBD-II Connections and Changeover Switch / Buzzer Installation ............................................... 22 
N.  Sequent Component Electrical Connections ................................................................................. 23 
O. Final 

Connections 

.......................................................................................................................... 23 

P.  Fuel Level Calibration .................................................................................................................... 23 
Q.  Initial Engine Start .......................................................................................................................... 24 
R.  Sequent “Delta-P” Pressure Adjustment ........................................................................................ 24 
S.  Warranty Card, Labels and Owner’s Guide ................................................................................... 25 
T. Maintenance 

.................................................................................................................................. 27 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

Summary of Contents for IMPALA 3.9L 2009

Page 1: ...Rev B...

Page 2: ...al 11 C Intake Manifold Modifications 11 D Zenith Regulator and Coolant Hose Installation 13 E Lockoff and High Pressure Tubing Installation 14 F Fuel Rail Installation 15 G CNG Low Pressure Hose Conn...

Page 3: ...ICULAR FUEL SYSTEMS TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION WITH FEDERAL STATE OR LOCAL LAW IN CANADA REFER TO CAN CGA CNG INSTALLATION CODES LPG AND OR NATURAL GAS INSTALLATIONS ON STATION...

Page 4: ...Before working on any fuel system read and understand all manufacturers recommended procedures 9 Before working on any fuel system make sure you have local code approved safety goggles face shields g...

Page 5: ...Remove all kit package contents and verify all parts are included and undamaged Do not attempt to repair any damaged parts Contact IMPCO Technologies for replacement of damaged or missing parts Part...

Page 6: ...PI A 005 SEQUENT WARRANTY REGISTRATION 1 H5 15342 1 TUBING HEATSHRINK 3 16 BULK 4 ft T4 50880 001 TERM EYE 1 4 STUD 12 10 GA 2 T4 50879 001 TERMINAL WIRE SPLICE 22 16 GA 35 92920000 Washer Flat M6 DIN...

Page 7: ...er mounting banjo bolt 15 22 ft lbs 20 30 Nm CNG high pressure filter blocking screw 37 52 ft lbs 50 70 Nm CNG manometer 15 30 ft lbs 20 40 Nm CNG pressure temperature sensor 20 5 23 5 ft lbs 28 32 Nm...

Page 8: ...ons Family NOTE If the Emissions label identification information does not match exactly you CANNOT install the system in the vehicle Installation in a non certified vehicle may be punishable by a fin...

Page 9: ...physical inspection Start the engine and inspect the exhaust for signs of excessive smoke Remove the engine dip stick and inspect the oil condition Change oil and filter if necessary Remove and inspe...

Page 10: ...stall three Sequent injectors into each of the fuel rails and torque the injector nuts to 71 in lb 8 Nm Install the Fuel Temperature Pressure Sensor into the longer of the two rails and torque the sen...

Page 11: ...er Tighten the manometer so it is in the approximate position keeping the torque between 15 30 ft lbs 20 40 Nm 5 Install the High Pressure Filter onto the regulator Rotate the filter to the position s...

Page 12: ...es and torque them to 62 in lbs 7 Nm NOTE Hose illustrated not actual length Sample Illustration 9 After all fuel hoses have been cut to length and assembled wrap one of the maximum fuel working press...

Page 13: ...m the engine for clarification DO NOT remove the lower intake manifold from the engine 2 Before drilling tapping the runners cover all of the intake ports and OEM injector holes except for those on th...

Page 14: ...perpendicular to the runner face Repeat steps 3 5 for the remaining five intake runners When finished clean all traces of metal chips from the intake runners 5 Apply a light coat of Loxeal to each of...

Page 15: ...r intake manifold for the brass vacuum port adapter using the 5mm drill and the 6mm tap Clean all traces of metal chips from the manifold Apply a light coat of Loxeal to the adapter threads before ins...

Page 16: ...Tees and the Regulator coolant hose nipples 5 Slide hose clamps onto the two hoses and install them onto the Tees 6 Tighten the six clamps on the Tees and remove the hose pliers 7 Slide two more hose...

Page 17: ...ck tower IMPORTANT If the vehicle has ABS be sure to allow for clearance between the Lockoff and the ABS Unit lines 4 Using code approved fuel line and fittings fabricate a fuel line to connect betwee...

Page 18: ...formed hose onto the Regulator fuel nipple slide two fuel hose clamps onto the hose and install the other end onto the single Y inlet nipple 5 Slide two fuel hose clamps onto the other preformed hose...

Page 19: ...ent tools to achieve the best crimps possible before working on the vehicle s wiring harness The first is the U style splice crimp used to splice the Sequent P D harness circuits to the OEM harness ci...

Page 20: ...to the battery cables will help minimize this risk U Style Splice Crimps Heat the terminal and apply the solder in the center of the crimp fold allowing it to wick into the joint Do not worry if some...

Page 21: ...to 1 strips Install one of the strips over the first wire to be reworked 6 Steps 6 through 9 should be done on the wires one at a time Referring to the 2009 3 5L Impala P D Installer s Wiring Diagram...

Page 22: ...tions Crimp and solder the terminals onto the red and black battery wires NOTES The B connection can be made directly to the battery or fuse box DO NOT connect to any circuit directly connected to the...

Page 23: ...engine for clarification purposes only L Sequent MAP Sensor Installation 2 Fabricate the MAP Sensor bracket as illustrated Mount the MAP sensor in the bracket torqueing the nut to 20 5 23 5 ft lbs 28...

Page 24: ...ver Switch can be installed in either a 9 16 diameter hole or a 7 8 diameter hole The 7 8 hole is preferable if the location surface is textured and less than 3 32 thick If the 9 16 hole is to be used...

Page 25: ...e fuel temperature pressure sensor 3 Connect the regulator temperature sensor 4 Connect lockoff 5 Connect the Sequent ECM O Final Connections 1 Connect the high pressure CNG line to the lockoff Leak t...

Page 26: ...aseous operation position When the system begins changing over to CNG operation the engine should continue running without hesitation or stumbling If the engine begins running rough during the changeo...

Page 27: ...y registration is available on IMPCO Technologies Website http www impco ws sequent tools asp requires login If Internet registration is not possible fill out the warranty card completely and drop it...

Page 28: ...E85 Notice label on the inside of the fuel door 4 Put the Sequent P D Owner s Guide in the a prominent location on the dash or center console where the customer can easily locate it It is strongly rec...

Page 29: ...ressure check all other maintenance items are in the IMPCO Owner s Guide Supplement Consult the guide for maintenance schedules 1 The Lockoff fuel filter replacement requires the following parts Part...

Page 30: ......

Page 31: ...Blk Tan Wht L 4444 L 55555 L 666666 L 22 Org L 4444 Org L 1 Org L 333 Org L 666666 Org Underhood Fuse Box Connector X1 L 55555 Org L 666666 Vio L 4444 Vio L 22 Vio L 1 Vio L 333 Vio L 55555 Vio Diagno...

Page 32: ...56 1 Gas Inj Ctrl 15 Wht Grn Pnk Blk Not Used Pnk Blk B2 L 1 Vio L 22 Vio L 333 Vio L 4444 Vio L 55555 Vio L 666666 Vio OEM OBD II J1962 Connector Sequent P D Wiring Schematic 2009 3 5 3 9L Chevy Impa...

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