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076/0705500 

 

 

 

Copyright © Prins Autogassystemen B.V. 2014 

Required equipment / tools / materials for installing a complete system 

 

-

 

Complete workshop toolbox ( wrenches, screwdrivers, cutters, pliers, ratchet, sockets ) 

-

 

Car lift 

-

 

Portable computer    

-

 

Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 ) 

-

 

Exhaust gas analyser  

-

 

Multimeter  

-

 

Oscilloscope 

-

 

Prins diagnostic software 

-

 

Prins serial interface 

-

 

Torque wrench ( 5-50Nm ) 

-

 

Torque wrench ( 200-250Nm ) 

-

 

Portable light 

-

 

Assortment drill bits 4 to 12 mm 

-

 

Assortment cutters ( ø 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 gun 

-

 

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 

 

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 ) 

 
 
 
 
 
 
 
 
 
 

 

Содержание Direct LiquiMax

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

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

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

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

Страница 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...

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

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

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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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