TYPE: TRANSIT PISTON DISPLACEMENT: 2400 …...Memory HD space : 5MB Screen : 256 colours, advise...

MAKE OF VEHICLE: FORD TYPE: TRANSIT PISTON DISPLACEMENT: 2400 NUMBER OF VALVES: 16 ENGINE NUMBER: DURATORQ ZSD-424 VEHICLE CATEGORIES ( M or N ) N TRANSMISSION MT VERSION ( LPG ) VSI-2.0 INJECTION SYSTEM: FoMoCo MODEL YEAR: 2009- SYSTEM APPROVAL NUMBER ( R115 ) R115-0000** LOCATION SYSTEM STICKER right side, centre door post ENGINE SET NUMBER 347/100001/A

NUMBER : 076/0703500

DATUM : 2013-06-14 Copyright © Prins Autogassystemen B.V. 2011 VERSION NR : 2011-02-17 DB

http://www.care.nl/

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TABLE OF CONTENTS

Required equipment / tools / materials for installing a complete system ................................................ 2 Vehicle check .......................................................................................................................................... 2 Base diagram 4 cylinder ......................................................................................................................... 3 Approval numbers ................................................................................................................................... 4 Mounting and connection points ............................................................................................................. 5 Mounting the Prins AFC .......................................................................................................................... 6 System fuse + diagnosis connector ........................................................................................................ 7 Switch ...................................................................................................................................................... 7 Wiring loom route. ................................................................................................................................... 8 Electrical diagram ................................................................................................................................... 9 Electrical connections ........................................................................................................................... 10 Electrical connections ........................................................................................................................... 11 RPM module ......................................................................................................................................... 12 MAF sensor ........................................................................................................................................... 13 Electrical connections ........................................................................................................................... 14 Mounting the inlet couplings ................................................................................................................. 15 PTFE hose ............................................................................................................................................ 16 Injector rail ............................................................................................................................................ 17 Hose lengths ......................................................................................................................................... 18 Reducer................................................................................................................................................. 19 Water connection .................................................................................................................................. 20 MAP sensor .......................................................................................................................................... 21 Filter unit ............................................................................................................................................... 22

= Important, Attention

PAGINA 2 076/0703500 Ford Transit Duratorq 2.4 Copyright © Prins Autogassystemen B.V. 2011 VERSIE NR : DB

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Required equipment / tools / materials for installing a complete system

- Complete workshop toolbox ( wrenches, screwdrivers, cutters, pliers, ratchet, sockets ) - Car lift - Portable AFC : operating on Windows 98,W2000 or XP.

Internal memory : 16 Mb or more Memory HD space : 5MB Screen : 256 colours, advise colours 16 bits or more Com port : 1 free COM port 1 or COM port 2 with a 9 or 25 pins connector

- Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 ) - Exhaust gas analyser - Multimeter - Oscilloscope - Prins VSI diagnostic software - Prins VSI serial interface - Prins VSI break out box - Torque wrench ( 10Nm ) - Portable light - Assortment drill bits 4 to 12 mm - Assortment cutters ( ø 20, 30, 50, 70 mm ) - Punching tool ø 70 mm - Round file - Portable drill or pneumatic drill - Threading device ( male M6x1, M8x1, M10x1 ) - Pipe-flaring tool ( for 6 and 8 mm copper pipe ) - Air gun - Vacuum cleaner - Hot air gun - Allan spanner for inlet couplings 3,5mm ( part nr. 099//9970 ) - Reducer adjustment tool ( part nr. 099/9960 ) - 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 - Engine coolant

Vehicle check

- Check the vehicle drivability on diesel - Check the fuel system for error codes ( scan tool )


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Base diagram 4 cylinder


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Approval numbers

Reducer VSI LPG Prins : E4-67R-010054 Lock-off valve OMB : E8-67R-014327 Lock-off valve Valtek : E4-67R-010041

Injector rail Prins : LPG E4-67R-010093 CNG E4-110R-000021

Filter unit T1 / T2 Prins : LPG E4-67R-010096 CNG E4-110R-000028

Injector Keihin :LPG E4-67R-010092 CNG E4-110R-000020

AFC VSI-4 / 6 Prins: LPG E4-67R-010098 CNG E4-110R-000083

LPG hoses Tubithor : LPG E13-67R-010145 CNG E13-110R-000017 Rubia : LPG E4-67R-010068

CNG E4-110R-000003


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Mounting and connection points

A : Reducer H : Cam shaft signal

B : Filter unit I : CAN high / low ( inside, eobd conn)

C : Injector rail J : Diagnose connector + fuse

D : RPM module K : Prins AFC

E : MAP sensor L : Power

F : Water connection M : Grommet

G : Ground N : Crank sensor signal & MAF signal


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Mounting the Prins AFC Connections inside :

- CAN wiring - Switch - Grommet location : left side fire wall behind engine ecu.

grommet


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System fuse + diagnosis connector

Switch Drill a Ø8.2mm hole.


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Wiring loom route.


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Electrical diagram


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Electrical connections

Wire number / code Wire colour Connection

1 ground battery -31

brown with a ring terminal.

32 ground battery sense -31

brown with a ring terminal.

44 +12V ecu +30

red Connect to the battery Do not place the fuse in the holder before having completed the installation of the LPG system.

13 +12V battery sense +30

red Connect to the battery, together with VSI wire 44 +12V ecu.

112 +ignition Switched battery+ +15

Red-grey Connect to a contact switched ( +15 ) power Wire location : fuse box, use an AMP terminal


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CAN

70 CAN LOW twisted

blue Wire colour : white Wire location : eobd connector, pin 14

51 CAN HIGH twisted

blue-yellow Wire colour : blue-white Wire location : eobd connector, pin 6


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RPM module

RPM module For measuring the engine speed.

36 ground brown RPM module connector, pin 1

58 +12V switched red RPM module connector, pin 2

8 RPM engine speed purple-white RPM module connector, pin 4

RPM wiring and MAF wire can be find in this loom

RPM Twisted pair :

Black wire 1 Black wire 2

Green-brown Yellow-purple Wire location : wiring loom in front of fuse box

MAF


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MAF sensor

Air flow / MAF sensor Interruption

Vsi wire:

119 & 29

22 & 30

Wire color : Yellow-purple ( not twisted ) Wire location : wiring loom in front of fuse box ( previous page ) Interrupt the MAF sensor signal wire ( pin 5 on sensor ) Connect to MAF sensor side Connect to ECU side


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Injector rail connectors:

98 –GAS INJ 1 106 +GAS INJ 1

white-yellow red

Connector VSI-injector cylinder 1. ( front side )


green-yellow red

Connector VSI-injector cylinder 2.


pink-yellow red

Connector VSI-injector cylinder 3.


blue-yellow red

Connector VSI-injector cylinder 4. Gear box side

Filter Unit

35 ground brown connector, pin 1

14 T-gas grey connector, pin 2

9 +5V sensor red connector, pin 3

16 Psys green connector, pin 4

121 CAM sensor ( phase sensor connector not used : Cut of terminal)

white-yellow Wire colour : Brown-light Blue Wire location :3-pole grey cam sensor connector

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Mounting the inlet couplings Remove the valve cover and inlet manifold. Drill 4 holes of Ø9mm and cut M10x1 thread into the holes. Install couplings with a locking compound and install the PTFE hose, sticking out for 60 mm and cut of the hose above coupling. Insert the hose pillar and lock the nut. See next page. Do this for each coupling/cylinder. Before re-installing the manifold : see page 17, photo 1 & 2.


16

PTFE hose


17

Injector rail

1. 2.

Install a clamp for the Ø11mm hose


18

Hose lengths

Hose (Ø..mm)

From component To component Hose length (cm)

16 Reducer Prins filter unit 5

11 Prins filter unit VSI injector rail 86

5 Reducer MAP connection Y-piece 50

5 Reducer overpressure Y-piece 25

5 Y-piece Y-piece 30

5 Y-piece MAP sensor 25

5 Y-piece Inlet manifold coupling 60

5 VSI injector 1 Inlet manifold hose pillar cyl.1 22




6 Hose pillar PTFE hose cyl.1 19




16 engine coolant outlet coolant connection 65

16 engine coolant inlet coolant connection 65

Attention ! Cut the hoses on length


19

Reducer


20

Water connection


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MAP sensor

MAP sensor connector For measuring the inlet manifold pressure ( MAP ).

18 AD1 ( MAP ) blue MAP sensor connector, pin 3

27 +5V sensor red MAP sensor connector, pin 1

37 sensor ground brown MAP sensor connector, pin 2


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Filter unit


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TYPE: TRANSIT PISTON DISPLACEMENT: 2400 …...Memory HD space : 5MB Screen : 256 colours, advise...

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