Prins Direct LiquiMax Manual de usuario

MANUFACTURER

Ford

TYPE

Tourneo Connect II

ENGINE DISPLACEMENT

1600

NUMBER OF VALVES

ENGINE CODE / NUMBER

JQGA

VEHICLE CATEGORIES

TRANSMISSION

VERSION

AFC-2.1

PETROL ECU 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 )

E4-115R-000009 / DLM-LPG 02

LOCATION R115 SYSTEM STICKER

right side, centre door post

ENGINE SET NUMBER

347/070047/A

MANUAL NUMBER

076/0705500

DATE

2014-11-12

Version 2013-09-28 D

PAGE 1

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

PAGE 2

076/0705500

General instructions

The installation of the system shall be done in accordance with the installation manual provided by Prins Autogassystemen.

This manual is based on Dutch regulations, always install the system in accordance to the local regulations.

For an optimal functioning of the Direct LiquiMax-2.0 system, maintain a clean and organized work environment during

installation and maintenance to prevent pollution of the LPG components.

Always download the “general manual 1/2 “ from our website for basic instructions and diagrams.

Always disconnect the battery when installing / servicing the LPG system. Make sure the ignition key is outside the car.

Be aware of central door locking, radio / telephone memory code, alarm system.

Wear safety goggles when working on the petrol filled system / connections ( pressurized petrol )

Do not place the main fuse into the fuse holder before having completed the installation of the system.

The AFC has to be activated by means of the Prins diagnosis software.

Never disconnect the AFC connector, unless you have removed the main fuse.

When installing the wiring harness, ensure that it does not run near any of the ignition components.

Solder and insulate all electrical connections.

The 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 length of the wires.

Ensure maximum care is taken when connecting wiring.

Make professional joints using solder and shrink sleeve. Do not stretch the wiring harness.

No component of the LPG-system shall be located within 100 mm of the exhaust or similar heat

source, unless such components are adequately shielded against heat.

If holes have to be drilled (wear safety glasses) for installing brackets, etc., the drilled holes must always be treated

with an anti-corrosion agent, after the chips have been removed ( especially when mounting a exterior filler into body work).

After having completed the installation, check the whole system for LPG leakage; use a LPG leak detection device.

Also check for leak of engine coolant, petrol and air.

Fitting and maintenance is only allowed by Prins Autogassystemen selected LPG engineers.

Failure to follow the instructions in this manual can result in a poor or non-working LPG installation or a dangerous situation.

For maintenance instructions see owner manual.

Prins Autogassystemen is not responsible for any damages to people or objects as a result of changes to Prins products.

Check our website regularly for diagrams, certificates, updates, info-bulletins and product information.

PAGE 3

076/0705500

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 )

PAGE 4

076/0705500

Tightening moments

Spanner mm

M 4 x 0,7

3.3

M 5 x 0,8

6.5

M 6 x 1,0

11.3

M 7 x 1,0

14.5

M 8 x 1

24.5

M 8 x 1,25

27.3

M 10 x 1

15-16-17

M 10 x 1,5

15-16-17

( filtered ) Banjo bolt

Supply line connection

Fuel module Allen bolts

Filler hose connection

Boost pump clamp

High pressure petrol fuel line

24-35

EXPLANATION OF SYMBOLS :

= IMPORTANT, CAUTION

= WEAR SAFETY GOGGLES

PAGE 5

076/0705500

Direct LiquiMax-2.0, AFC-2.1

PAGE 6

076/0705500

Direct LiquiMax-2.0 diagram, AFC-2.1

PAGE 7

076/0705500

Direct LiquiMax parts / approval numbers

1st generation

2nd generation

1st 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

High Pressure Injectors : E4-67R-010309

Prins AFC: E4-67R-010098

E4-10R-030507

Fuel lines series XD : E4-67R-010247 XD3

E4-67R-010247 XD4

PAGE 8

076/0705500

DLM component location overview

HPP pump

FSU

AFC

FRU

Fuse / relay box

Boost pump

R115 approval sticker :

Right side centre door post

R115

PAGE 9

076/0705500

Removal of the Bosch High Pressure Petrol Pump

-REMOVAL-

-WARNING-

In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, there may be injury caused by

leakage of the high pressure fuel.

Don’t do any repair work right after engine stops ( HOT engine ).

Turn the ignition switch OFF and disconnect the battery negative (-) 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 (E), and then remove the high pressure fuel pump from the cylinder head

assembly.

CAUTION:

Unscrew in turn the two bolts in small steps (0.5 turns). In case of fully unscrewing one of the two bolts with the

other bolt installed, the housing surface of the cylinder head may break because of tension of the pump spring.

CAREFULLY store the removed petrol pump. Make sure no pollution can come into the pump.

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