CNG / LPG /Petrol Kit Installation Guide
These fitting instructions are supplementary to those supplied with the components, and are intended as a guide for a typical installation. They may vary for different vehicles. Your vehicle will run on LPG as well as it runs on petrol once the engine is warm, therefore, if you have a problem with petrol, you will have the same problem using LPG. You are advised to correct any current problems with your engine prior to carrying out the conversion. To enable the conversion to run smoothly, it is recommended that you familiarise yourself with the fitting procedure before commencing. Although fitting a conversion kit is a relatively straightforward procedure, it must be carried out by a trained person. If in doubt, you are advised to contact a suitable mechanic. At almost every stage of the conversion, you will still be able to drive your car, without having to wait to complete the conversion, allowing you the freedom of fitting it at your leisure.
Disclaimer: Dinamik Endüstri Ltd. cannot be held liable for any damage caused due to the improper installation of the products.
Before starting the conversion, ensure you have the correct tools: Various spanners or sockets Flat & Phillips Screwdrivers Allen Keys Electric or Cordless Drill & Drill bits Ø60mm Tank Cutter - see section (3.2) Ø30mm Tank Cutter - see sections (3.4) & (7.2) Wire Stripper/Crimper Various cable connectors - see section (13) & (14) Soldering equipment (13.5) Hacksaw Waterproof Silicone Sealant Rust preventer Bosswhite Sealant
It is recommended that through the conversion you: •
Remove any rough edges from around the holes drilled. • Use rust preventer around any bare edges. • Use Bosswhite on all gas joints
(4)
Fitting Sequence (1) Fit Gas Tank into position (2) Fit Multivalve into the Gas Tank (3) Fit Filler Entry Connect fuel line from Filler Entry to Multivalve •
Position Gas Solenoid
(5a) Fit Petrol Solenoid (Carburettor vehicles only) (6) Position Vaporiser (7) Connect fuel line from Multivalve to Gas Solenoid (8) Connect wiring Loom from Multivalve & run parallel to fuel line (9) Connect fuel line from Solenoid to Vaporiser (10) Connect Vaporiser water hoses (11) Fit Mixer into air Manifold (12) Connect Vaporiser to Mixer (13) Fit Emulator & wire into vehicle injectors (Injection vehicles only) (14) Fit Switch & wire into vehicle electrics (15) Test for Gas Leaks (16) Adjust Gas input
FITTING PROCESS
(1a) FIT THE GAS TANK INTO POSITION (CYLINDRICAL TANKS) When positioning the tank, locate it so that access to the spare wheel is still possible. Although the tank straps provided ensure that it is held tight, these should be used in conjunction with further fixings to prevent the tank from rolling. For example, use a length of angle either side of the tank. (1a.1) Position the tank, bearing in mind where you intend to fit the filler entry. Meanwhile you must ensure that the tank is oriented at the correct angle. You can do this by using an angle gauge. The angle must suit to the particular multivalve/tank combination (eg. Ø360/30º or Ø315/30º etc…) (1a.2) Fix the tank mounting frame onto the boot floor by using the supplied bolts and washers.
(1a.3)
Position one of the metal straps provided towards one end of the cylinder. (1a.4) Bend the strap around the contour of the tank, passing it through the holes on the mounting frame. (1a.5) Connect the two ends of the strap by using the 70mm long bolts and the connection apparatus supplied with the kit. As much as you tighten the 70mm bolts, the straps will
(1a.7)
secure the tank into position better. (1a.6) Repeat the procedure with the other strap. Note that the round boss into which the Multivalve fits should be at 30º to the horizontal, see the FEMA Multivalve instructions for exact details.
Figure 1a (1b) FIT THE GAS TANK INTO POSITION (TOROIDAL TANKS) Installation of a toroidal tank is a relatively easier process than installing a cylindrical tank, because you don’t use any tank mounting frame or tank straps for this process. The most common way to install a toroidal tank is to use the spare wheel well in the boot. However if
the tank is 0º (external), you will have to choose a different place than the spare wheel well for the installation. (1b.1) Take out the spare wheel and the other devices like car lifter of its well. (1b.2) Drill the necessary holes onto the bottom of the well. While doing this, take care not to damage any existing components like the petrol tank etc… (1b.3) Insert the gas tank into this well. (1b.4) Secure the tank by using the supplied bolts and washers. (It is a common method using polyurethane foam to secure the tank better.) (2) FIT MULTIVALVE INTO THE GAS TANK It is important that the float arm of the Multivalve hangs freely before installing into the tank. Ensure also that the filter is proud of the pipe end, so that fuel flow is not restricted. Note also (2.6) before installing, to ensure the fuel gauge reading on the Multivalve matches that on the Switch. (2.1) To ensure the arms are correct, hold the Multivalve so the label reads correctly (2.2) The arm with the large black plastic float, needs to be free of the fixed arm, swinging freely to the left. The gauge on the front of the valve moves as you swing the arm. (2.3) Place the large round black plastic Air-Box onto the round tank boss, ensuring the Ø78mm O-ring sits between the Air-box and the tank boss. The direction of the two hose inlets should be rotated towards the filler entry position. (Please note that the Air-box is used only with the cylindrical tanks.) (2.4) Position the Multivalve onto the round boss, with the two arms inside the tank. (2.5) Secure the Multivalve with the six Allen screws supplied, to a maximum 3N/m torque. (2.6) It is strongly recommended that you complete the conversion, before carrying out (2.5). Hold the Multivalve in position, as it would be in the tank and move the float arm. If the gauge on the switch does not show the same reading as that on the Multivalve, gently bend the float arm as required. Once satisfied, complete (2.5) (3) FIT FILLER ENTRY The filler entry must be on the outside of the car, the choice is yours, but in a position that will be convenient for filling. Most people fit them through the wing or bumper. (3.1) Select a suitable position to fit the filler entry, without obstruction. (3.2) Mark the centre position & using a suitable tank cutter, drill a Ø60mm hole. It may be necessary to hold a wooden block behind the hole ensuring that the panel is not
distorted. Figure 3a shows the assembly of the filler entry with a single skin panel. (3.3) If the position chosen for the filler entry has a double wall, it will be necessary to use the black plastic pipe protector (with the chamfered end), as shown in figure 3b. (3.4) To fit this, drill a Ø30mm hole on the inside panel, centred as the Ø60mm hole. (3.5) Using the pipe protector as a guide, drill, & secure in position with the self tapping screws. (3.6) If there is not enough clearance between the double wall, simply cut the (flat) end of the pipe protector to suit. (3.7) Assemble the filler entry into the hole, using the two countersunk screws & nuts
(4) CONNECT FUEL LINE FROM FILLER ENTRY TO MULTIVALVE (4.1) The Ø8mm Plastic coated copper pipe runs from the Multivalve, position A in figure 4a, through the entry on the Air-box (no air-box if the tank is toroidal), into the pipe connection of the filler entry. (4.2) Cut the Ø8mm pipe to length. (4.3) Trim the plastic coating back 25mm each end. (4.4) Cut a length of the plastic flexible sheathing, long enough to cover the entire length from the filler entry to the entry on the Multivalve housing. (4.5) Connect the pipe, shrouded inside the flexible sheathing ensuring that it passes completely through the olives, and ‘bottoms out’, in both fittings. (4.6) Secure the flexible sheathing with jubilee clips
(5.1)
(5) POSITION GAS SOLENOID Fit the Gas Solenoid in a convenient & safe place in the engine bay near to where you intend to fit the vaporiser. Mount with the blue Solenoid at the top.
(5a) FIT PETROL SOLENOID (Carburettor Vehicles Only) (5a.1) Select a suitable position adjacent to the vehicle’s petrol supply line, and mount the petrol Solenoid securely. (5a.2) Cut the petrol line, fitting each end into the Solenoid, and secure with Jubilee Clips. (6) POSITION VAPORISER (6.1) Using the bracket provided, fit the Vaporiser in a convenient & safe place within the engine bay. In selecting a suitable position, ensure it will not endure excessive vibration, or be too close to a heat source. It must not however, be too far from the vehicle’s heater matrix hose pipes, as the vaporiser will be connected to these (section 10). (6.2) It is important that the Vaporiser be correctly positioned. See the FEMA (6.3) (6.4)
Vaporiser manual Figure 1 for correct position. If the top elbow connector does not face the way you want, you can simply undo the two Phillips screws, rotate it to suit, and re-tighten the screws. Note that the vent pipe should point down. (Position G, Fig.6 – 7 – 8 FEMA Vaporiser manual).
(7) CONNECT FUEL LINE FROM MULTIVALVE TO GAS SOLENOID When installing the fuel line, do not position within 250mm of Exhaust system, if this is not possible, use a suitable heat-shield. Also, avoid suspension or Jacking points. Ensure that no part of the pipe is permanently hidden from view, preventing
inspection. Select the position required to pass the fuel pipe through the boot floor. Noting any obstructions, drill a Ø30mm hole through the boot floor. Depending on the strength of the boot floor, it may be easier to mark a Ø30mm hole, chain drill & file to suit. (7.1) (7.2)
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Locate the pipe protector into the hole with the flat end inside the boot, and the open end of the chamfer protruding beneath the vehicle, angled in the direction o of the fuel pipe to
Gas Solenoid. (7.4) Drill the three fixing holes, and secure into position with the self tapping screws. (7.5) Cut a length of the plastic flexible sheathing, long enough to cover the entire length from the pipe protector to the entry on the Multivalve housing. (7.6) From beneath the vehicle, pass one end of the Ø6mm plastic coated copper pipe, up through the pipe protector, inside the flexible sheathing, and through the inlet of the Multivalve housing. Carry out section (8.2) at the same time. (7.7) Trim the plastic coating back 25mm. (7.8) Connect the Ø6mm pipe into the Multivalve, position B in figure 4a, ensuring that it completely passes through the olive, bottoming out within the valve. (7.9) Secure the flexible sheathing, with jubilee clips (7.10) Working under the vehicle, run the Ø6mm pipe along the underside of the floor and up through into the engine bay to the Gas Solenoid. (7.11) When positioning the pipe, choose the most suitable position that will be best protected from road debris, and where it will not be damaged if the car was to bottom out, over a speed ramp for instance. (7.12) Using the fixing brackets, (checking that holes drilled for them does not cause damage within the vehicle), secure the pipe to the underside of the vehicle. It is suggested that you carry out section (8.3) at the same time. Bracket must be less than 600mm apart. (7.13) Cut the pipe to length. (7.14) Trim the plastic coating back 25mm. (7.15) Connect the pipe into the bottom valve of the Gas Solenoid, ensuring that it completely passes through the olive, bottoming out within the valve.
(8)
CONNECT WIRING LOOM FROM MULTIVALVE & RUN PARALLEL TO FUEL LINE Connect the Wiring loom onto the Multivalve, position D, shown in figure 4a. Run the cable through the inlet of the Multivalve housing, through the flexible
(8.1) (8.2)
sheathing, and through the pipe protector, out to beneath the car. This can be done at the same time as section (7.6). (8.3) Run the wiring underneath the vehicle along the fuel line, securing within the fixing brackets. Care must be taken not to clamp onto the wires, instead position them in the fold of the brackets. This can be done at the same time as section (7.12) (8.4) The wiring is to be connected to the Switch, see section 14.
(9) CONNECT FUEL LINE FROM SOLENOID TO VAPORISER Using Ø6mm fuel pipe, connect from the upper connection on the Solenoid, to the pipe connection on the Vaporiser. (Position B, figure 7, FEMA Vaporiser Manual.) (9.2) Cut the pipe to length. (9.3) Trim the plastic coating back 25mm. (9.4) Connect the pipe ensuring that it completely passes through the olive, bottoming out within the valve.
(9.1)
(10) CONNECT VAPORISER WATER HOSES The vaporiser needs to have a circulation of water to heat the Liquid LPG to Gas. This is done by connecting it into the vehicles water system. The quicker the vaporiser reaches temperature, the quicker the vehicle will run on gas, therefore, you may connect the water hoses in-line, to the water hose that goes to the vehicle’s heater. (10.1)
Cut the vehicle’s water hose in two places, insert the plastic Tee pieces, and
secure with Jubilee Clips. (10. 2) To the first Tee piece, the one furthest from the heater, fit the rubber hose supplied, connecting it to the Vaporiser (Upper Position D, figure 7, FEMA Vaporiser Manual) securing with a Jubilee clip. (10.3) Repeat (10.2) with the other hose, to the lower hose connection on the Vaporiser.
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FIT MIXER INTO AIR MANIFOLD
Mixers vary according to brand, model and type of the vehicle, for this reason there are hundreds of types of mixers. The one you will choose for installation must be a suitable one according to the specifications of your vehicle. Choosing the correct mixer and positioning it correctly is one of the most important points in an installation, because mixers provide a homogenous mixing of air and gas. If you make a mistake, the vehicle may not be driveable or may function inefficiently. In case you are not sure about the type of your mixer, you should apply to an experienced mechanic. •
CONNECT VAPORISER TO MIXER
The mixer, that fits into the air manifold, either has one or two gas inlet connectors. If there is one inlet, a T- Piece connector is used. With two inlets, a Y-Piece connector is used. The following instructions are for use with mixers with two inlets, but the same procedure applies for mixers with a single inlet. (12.1) Cut the Ø13mm wire braided hose in half. (12.1) Fit each of the two resulting hoses onto the two smaller connections of the Mixer, and using jubilee clips, secure in place. (12.2) Fit the other two ends into the Y-Piece, securing with jubilee clips. (12.3) Fit the Ø19mm wire braided hose onto the Vaporiser, secure with a jubilee clip. (Position C, figure 7, FEMA Vaporiser Manual). Note section (6.3) (12.4) Cut to length, if necessary, and connect to the larger connection on the YPiece, securing with a jubilee clip. (13)
FIT EMULATOR & WIRE INTO VEHICLE INJECTORS (Injection Vehicles Only) (13.1) Select & mount the Emulator in a suitable place within the engine bay, away from any sources of excessive heat. (13.2) Connect the wiring loom to the plug on the emulator (13.3) Check the FEMA Emulator Wiring Diagram to see how the wires are connected to the injectors. (13.4) From each injector, there are two wires. Select & cut the same colour wire from each injector. (13.5) Solder each pair of Emulator wires into the cut injector wires as shown in Figure 13a and 13b. (13.6) Connect the separate blue and black wires as shown. (13.7) With extra emulators, simply repeat above procedure. For example, if the
vehicle has six cylinders, only two pairs of wires on the second Emulator are used, the remaining wires are taped up, out the way. The blue & black wires are wired as before.
(14.1) (14.4)
(14) FIT SWITCH & WIRE INTO VEHICLE ELECTRICS Select a suitable position near the driving position and mount the switch. (14.2) Use the wiring diagram supplied with the Switch. (14.3) The Black goes to a suitable earth. The Red to an ignition live, (only live when ignition is on), through an in-line 5A fuse. The Blue wire links to the +ve on the Gas Solenoid AND to the +ve on the Vaporiser.
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(14.6)
The Yellow wire is only used for Carburettor vehicles, and is connected to the +ve on the petrol solenoid. It can be either cut or taped up, on injection vehicles. (14.7) The Green & White wires are connected to the Green & White Multivalve wires, soldering is recommended. (14.8) The Black wire from the Multivalve goes to earth. (14.9) Both the -ve connectors on the Gas Solenoid & Vaporiser Solenoid go to earth. o
The Brown wire is wrapped, bobbin style, several times around the coil lead, secured
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with insulation tape. If there is not a coil wire, wrap the Brown wire around the first sparkplug o HT lead, and loop to the last sparkplug HT lead. For example, with six cylinders, o wrap the wire around the first and sixth leads.
(15) TEST FOR GAS LEAKS (15.1) Turn the Switch to Petrol. (position ll) (15.2) On the Multivalve, close the valve, see figure 4a, position C. (15.3) Put around 10 litres of LPG into your tank. (15.4) Ignition must be off. (15.5) Using soapy water, check for any gas leaks at both the filler entry & Multivalve connections. (15.6) If a leak is detected, gently tighten the joint until the bubbling stops (15.7) Providing there are no leaks, open the valve C. (15.8) Fit the clear plastic cover and large O-ring onto the Multivalve Housing. (15.9) Switch on the vehicles ignition. (15.10) Using soapy water, check for any gas leaks from the upper Gas Solenoid and Vaporiser connections. (15.11) If a leak is detected, gently tighten the joint until the bubbling stops. (15.12) Once satisfied that the system has no leaks, ensure C valve on the Multivalve is fully open. (16) ADJUST GAS INPUT Ensure the engine is warm before commencing adjustments (16.1) Set the Switch to the Gas (Position l) (16.2) Fully open the Y-piece adjustment screw. (16.3) Start the Vehicle. (16.4) Unwind the idle screw (Position J, figure 8, FEMA Vaporiser Manual), slowly, until the correct idle is reached. This should be around 900rpm. It is now set. (16.5) Gently depress the accelerator, but do not rev. The engine will ‘die’ & cut out. (16.6) Unwind the large black plastic screw on the vaporiser, (Position H, figure 6, FEMA Vaporiser Manual), ½ turn at a time, until the engine doesn’t die or cut out. It is now set. (16.7) Rev the engine, to around 3000rpm o
Slowly wind in the Y-Piece adjustment screw, until the engine starts to mis-fire. Then
wind out ½ turn. It is now set. Once satisfied with the settings, take the vehicle for a test drive, accelerate smoothly, accelerate fast, accelerate around bends, etc. ensuring there are no flat spots, loss of (16.9)
(16.10)
power, or the engine cuts out. Repeat the adjustments as necessary.
THE INSTALLATION IS NOW COMPLETE. YOU CAN ENJOY CLEANER AND CHEAPER MOTORING!!
As detailed on page 5 of the FEMA Vaporiser manual, you are advised to keep the system maintained, for both safety and efficiency. We recommend you to make the above adjustments every 3000 km. If for any reason, you have to empty LPG from the tank, for example to adjust the Multivalve float, arm, it is strongly advised that you remove the tank from the vehicle, emptying the tank in an open and safe place, avoiding naked flames, do not smoke. Obviously, if removing the tank, you should use up as much of the LPG as possible beforehand, by driving the vehicle.
To remove the tank, close the shut-off valve (Positions C on Figure 4a). Disconnect the two fuel lines, (Position A & B on figure 4a), and tank fixing straps. When the tank is in a safe place, gently undo the allen screws, releasing the gas. Always take adequate precautions when handling LPG, as it has an immediate freezing effect on contact – wear suitable gloves.
Fault Finding
The Tank Gauge does not register the gas level. Ensure that there is gas in the tank • Remove the plastic cover from the Multivalve, checking that the plastic pointer is not stuck. • It is imperative that the Multivalve float arm swings freely to the LEFT inside the tank. • There is a slight chance, that the float arm can be temporarily jammed on the welding inside the • tank. • This can be rectified by bending the float arm slightly. •
Switch does not operate correctly Check all electrical connections Ensure Brown wire is securely wound round, the HT lead from the coil, or one & four on the sparkplug HT • leads, (or one & five with five cylinders, etc.) •
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The fuel reading on the switch does not match the level on the Multivalve The switch level reading is for indication only, and will not be 100% accurate. •
If the readings are not acceptable, it is possible to gently bend the float arm accordingly.
The engine does not start, or starts with difficulty Ensure that there is gas in the tank. • Check the in-line fuse, from the switch. Check electrical connections, and earth connections. • Idle setting is incorrect •
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Does the Gas Solenoid operate, ie/ click, when gas is selected, if not ensure electrical connections • are correct. • LPG fuel line kinked, thus preventing gas flow. • Clogged Air-Filter, clean & replace if necessary
The Engine does not idle properly Is the Vaporiser idle screw set correctly. • Mixer in wrong position. • Incorrect mixer. Clogged Air-Filter, clean & replace if necessary •
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The engine responds with hesitation when accelerating •
Ensure there is enough LPG in the Tank, if in doubt, fill up the tank. • Ensure you have adjusted the gas properly, as per instructions. • Ensure the fuel lines are not kinked. • Ensure Vaporiser is positioned correctly, as FEMA Manual.
It is impossible to fill the LPG tank Is the tank already 80% full? • Ensure that the shut-off valve (Positions C, figure 4a), is fully open. Ensure that the Gas supply line from the filler entry to the tank, is not kinked. •
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LPG Consumption too high Clogged Air-Filter, clean & replace if necessary Vaporiser Diaphragm damaged, due to dirty LPG being used, see FEMA Vaporiser Manual for details. •
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