Prins Direct LiquiMax Page 2 Installation Manual Download

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076/0705500

TABLE OF CONTENTS

General instructions......................................................................................................................... 2

Required equipment / tools / materials for installing a complete system ........................................... 3

Vehicle check .................................................................................................................................. 3

Tightening moments ........................................................................................................................ 4

Direct LiquiMax-2.0, AFC-2.1 ........................................................................................................... 5

Direct LiquiMax-2.0 diagram, AFC-2.1 ............................................................................................. 6

Direct LiquiMax parts / approval numbers ........................................................................................ 7

DLM component location overview .................................................................................................. 8

Removal of the Bosch High Pressure Petrol Pump .......................................................................... 9

Fuel Supply Unit / Fuel Return Unit ................................................................................................ 10

Boost pump / FRU / FSU bracket ................................................................................................... 11

Boost pump / FRU / FSU bracket ................................................................................................... 12

Boost pump / FRU / FSU bracket ................................................................................................... 13

Installation of the Bosch High Pressure Petrol Pump ..................................................................... 14

High pressure petrol pump installation ........................................................................................... 15

High pressure petrol pump LPG return........................................................................................... 16

Boost pump inlet............................................................................................................................ 17

Cover adaption .............................................................................................................................. 18

LPG / petrol fuel lines .................................................................................................................... 19

Supply hose

– Return hose – Tank wiring ...................................................................................... 20

Hose routing .................................................................................................................................. 21

Mounting the AFC-2.1 without Start-Stop battery ( small ) .............................................................. 22

Mounting the AFC with Start-Stop battery ( large ) ......................................................................... 23

Switch wiring ................................................................................................................................. 24

Wiring............................................................................................................................................ 25

Wiring............................................................................................................................................ 26

Mounting the fuse / relay box ......................................................................................................... 27

PWM Signal .................................................................................................................................. 28

Mounting the fuel selection switch ................................................................................................. 29

Electrical connections .................................................................................................................... 30

Electrical connections .................................................................................................................... 31

Insulate not used wires: ................................................................................................................. 32

Electrical connections .................................................................................................................... 33

Electrical connections .................................................................................................................... 34

Electrical connections .................................................................................................................... 35

Prins safety stickers....................................................................................................................... 36

Checklist after installation .............................................................................................................. 37

FOR EXPLANATION AND CIRCUIT DIAGRAMS SEE : INSTALLATION MANUAL GENERAL PART 1 / 2

Summary of Contents for Direct LiquiMax

Page 1: ...MANUFACTURER CODE HIGH PRESSURE PETROL POMP Bosch HDP 5 PE BM5G 0261 520 076 077 139 140 HIGH PRESSURE PETROL INJECTOR Bosch HDEV 5 1LE 0261 500 155 156 MODEL YEAR 9 2013 SYSTEM APPROVAL NUMBER R115 E...

Page 2: ...ch High Pressure Petrol Pump 14 High pressure petrol pump installation 15 High pressure petrol pump LPG return 16 Boost pump inlet 17 Cover adaption 18 LPG petrol fuel lines 19 Supply hose Return hose...

Page 3: ...he 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 len...

Page 4: ...e light Assortment drill bits 4 to 12 mm Assortment cutters 20 30 50 70 mm Portable drill or pneumatic drill Thread cutting device male M6x1 M8x1 M10x1 Air gun Vacuum cleaner Safety goggles Hot air gu...

Page 5: ...3 10 M 7 x 1 0 14 5 11 M 8 x 1 24 5 13 M 8 x 1 25 27 3 13 M 10 x 1 52 15 16 17 M 10 x 1 5 54 15 16 17 filtered Banjo bolt 10 14 Supply line connection 15 13 Fuel module Allen bolts 20 7 Filler hose co...

Page 6: ...PAGE 5 076 0705500 Copyright Prins Autogassystemen B V 2014 Direct LiquiMax 2 0 AFC 2 1...

Page 7: ...PAGE 6 076 0705500 Copyright Prins Autogassystemen B V 2014 Direct LiquiMax 2 0 diagram AFC 2 1...

Page 8: ...st generation 2nd generation Fuel Supply Unit E4 67R 010269 Fuel Return Unit E4 67R 010270 Pressure Sensor E4 67R 010051 Boost pump High Pressure Pump E4 67R 010266 High Pressure Rail E4 67R 010267 Hi...

Page 9: ...PAGE 8 076 0705500 Copyright Prins Autogassystemen B V 2014 DLM component location overview HPP pump FSU AFC FRU Fuse relay box Boost pump R115 approval sticker Right side centre door post R115...

Page 10: ...ve cable Ware safety goggles Disconnect the fuel pressure regulator valve connector Disconnect the High Pressure fuel feed pipe B Remove the Low Pressure fuel pipe hose A Remove the installation bolts...

Page 11: ...PAGE 10 076 0705500 Copyright Prins Autogassystemen B V 2014 Fuel Supply Unit Fuel Return Unit Black filtered banjo will only be used on inlet connections Filter inside sensor banjo...

Page 12: ...PAGE 11 076 0705500 Copyright Prins Autogassystemen B V 2014 Boost pump FRU FSU bracket...

Page 13: ...705500 Copyright Prins Autogassystemen B V 2014 Boost pump FRU FSU bracket Remove battery engine cover air filter ignition coils cover wiper box left wiper motor driver side Remove fabric One side M8...

Page 14: ...PAGE 13 076 0705500 Copyright Prins Autogassystemen B V 2014 Boost pump FRU FSU bracket Connect tank supply and return...

Page 15: ...on the location where the protrusion C is installed Installation bolts When tightening the installation bolts of the high pressure fuel pump tighten and turn the bolts in small step 0 5 turns after ti...

Page 16: ...installation Remove air filter ignition coils cover wiper box left wiper motor driver side Replace the original high pressure petrol pump for the adapted high pressure petrol pump Follow the workshop...

Page 17: ...PAGE 16 076 0705500 Copyright Prins Autogassystemen B V 2014 High pressure petrol pump LPG return Replace original M6 bolt for normal M6x25...

Page 18: ...PAGE 17 076 0705500 Copyright Prins Autogassystemen B V 2014 Boost pump inlet...

Page 19: ...PAGE 18 076 0705500 Copyright Prins Autogassystemen B V 2014 Cover adaption Remove bolt cut away...

Page 20: ...washers and banjo bolt Filtered banjo FSU supply inlets boost pump inlet HPP pump inlet black filtered banjo Hose from to Length cm 1 XD Adapter original petrol hose Petrol boost pump 45 2 XD Fuel su...

Page 21: ...Prins Autogassystemen B V 2014 Supply hose Return hose Tank wiring Protect the supply and return hose together with tank wiring using the 16 split tube Mount the hose assembly with clamps with a maxim...

Page 22: ...PAGE 21 076 0705500 Copyright Prins Autogassystemen B V 2014 Hose routing...

Page 23: ...PAGE 22 076 0705500 Copyright Prins Autogassystemen B V 2014 Mounting the AFC 2 1 without Start Stop battery small...

Page 24: ...PAGE 23 076 0705500 Copyright Prins Autogassystemen B V 2014 Mounting the AFC with Start Stop battery large...

Page 25: ...0705500 Copyright Prins Autogassystemen B V 2014 Switch wiring Remove left wiper motor Drill a hole and pull wiring through using a grommet ALSO wire 56 DI2 yellow green PWM signal wiring inside behin...

Page 26: ...PAGE 25 076 0705500 Copyright Prins Autogassystemen B V 2014 Wiring...

Page 27: ...PAGE 26 076 0705500 Copyright Prins Autogassystemen B V 2014 Wiring...

Page 28: ...PAGE 27 076 0705500 Copyright Prins Autogassystemen B V 2014 Mounting the fuse relay box Bend bracket Drill 6mm...

Page 29: ...ogassystemen B V 2014 PWM Signal Remove glove compartment Extend the yellow green wire to connect to the WHITE wire 56 DI 2 Yellow green Digital Input 2 OEM petrol pump driver PWM IN Wire colour white...

Page 30: ...PAGE 29 076 0705500 Copyright Prins Autogassystemen B V 2014 Mounting the fuel selection switch Mount the switch drill 8 2mm...

Page 31: ...lours Insulate not used wires Driver room Wire number code Wire colour Connection 3 pole micro connector 66 Ground fuel switch 3 12V fuel switch 49 LIN fuel switch Brown black Red white Yellow Connect...

Page 32: ...1 32 MAIN GND ecu MAIN GROUND SENSE Brown Connect to the of the battery 31 use a ring terminal Wire location battery ground left suspension strut 4 13 12V BATT sense 12V BATT fused 12V BATT boost pump...

Page 33: ...sed wires Wire number code Wire colour Insulate 19 AD 4 Blue 20 AD 3 Blue pink 21 AD 9 Blue purple 22 LSS 1 Purple white 23 LSS2 Purple green 42 Digital out pull up 2 Red purple 58 12V switched Red wh...

Page 34: ...asuring the engine speed signal Wire colour brown blue Wire location cam sensor pin 2 7 12V IGNITION Grey white Make a connection to ignition contact 15 Do not place the fuses in the holder before hav...

Page 35: ...off FRU 34 C Ground Red white Brown black Connect the 2 pole connector to the lock off valve of the Fuel Return Unit 4 pole diagnose connector 46 Service TxD 65 Service RxD 68 C Ground Grey Grey Brow...

Page 36: ...the 3 pole connector to the tank level sensor 2 pole driver connector 71 LSS 3 PWM driver 64 AD 5 driver diagnose Purple pink Blue grey Connect the 2 pole connector to the pump driver 4 1 2 pole conn...

Page 37: ...PAGE 36 076 0705500 Copyright Prins Autogassystemen B V 2014 Prins safety stickers Boost pump Drivers door LPG TANK...

Page 38: ...dedicated engine set See Identification in the diagnosis program 4 Check all components and connections for any LPG leakage use a LPG leak detector device or a fluid detection like soap Also check for...

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