Prins VSI LPG, VSI CNG Installation Manual

DATE :

2013-09-04

C

Table of contents

Required equipment / tools / materials for installing a complete system _______________________ 3 Vehicle check ________________________________________________________________________ 3 General instructions __________________________________________________________________ 4 Introduction _________________________________________________________________________ 5 Approval numbers VSI LPG / CNG components ___________________________________________ 6 The Prins LPG reducer ________________________________________________________________ 7 The Keihin CNG regulator ______________________________________________________________ 8 The injector rail ______________________________________________________________________ 9 The Prins filter unit __________________________________________________________________ 10 The Keihin filter unit _________________________________________________________________ 10 The VSI computer ____________________________________________________________________ 11 VSI-I _______________________________________________________________________________ 11 VSI-2.0 computer ____________________________________________________________________ 12 Instructions rotating the Prins VSI injector rail ___________________________________________ 13 The wiring loom. _____________________________________________________________________ 14 VSI-I _______________________________________________________________________________ 14 VSI-2.0 _____________________________________________________________________________ 14 Hose connections ___________________________________________________________________ 15

Diagram 1 VSI inlet manifold coupling _________________________________________________ 16 Diagram 2 VSI inlet manifold coupling with nylon hose __________________________________ 17 Diagram 3 Parallel water connection __________________________________________________ 18 Diagram 4 Serial water connection____________________________________________________ 19

Diagram 5 Serial water connection CNG regulator _______________________________________ 20 The VSI-I fuel switch _________________________________________________________________ 21 The VSI-2.0 fuel switch _______________________________________________________________ 22 Electrical connections on the LPG reservoir _____________________________________________ 23 Electrical connections VSI-I wiring harness ______________________________________________ 24 Electrical connections VSI-I wiring harness ______________________________________________ 25 Electrical connections VSI-2.0 wiring harness ____________________________________________ 26 Electrical connections VSI-2.0 wiring harness ____________________________________________ 27 Insulate all not used wires. ____________________________________________________________ 27 Electrical connections VSI-2.0 wiring harness ____________________________________________ 28 Electrical connections VSI-2.0 wiring harness ____________________________________________ 29 Electrical connections RPM module 091/0236 ____________________________________________ 30 Electrical connections Petrol Pressure Simulator 091/0252 _________________________________ 31 Electrical connections Dual Sensor Interface (DSI) ________________________________________ 32 Electrical connections CNG Prins Timing Optimizer (PTO) _________________________________ 33 Diagram CNG PTO wiring Prins Turbo / MAP sensor ______________________________________ 33 Prins Turbo / MAP sensor _____________________________________________________________ 34

Diagram 5 LPG Base layout VSI 4 cylinder connector ____________________________________ 35

Diagram 6 LPG Base layout VSI 4 cylinder solder _______________________________________ 36

Diagram 7 LPG Base layout VSI 5 cylinder _____________________________________________ 37

Diagram 8 LPG Base layout VSI 6 cylinder connector ____________________________________ 38

Diagram 9 LPG Base layout VSI 6 cylinder solder _______________________________________ 39

Diagram 10 LPG Base layout VSI 8 cylinder connector ___________________________________ 40

Diagram 11 LPG Base layout VSI 8 cylinder solder ______________________________________ 41

Diagram 12 CNG Base layout ________________________________________________________ 42

Diagram 13 VSI-2.0 LPG Base layout __________________________________________________ 43

Diagram 14 VSI-2.0 MAP LPG Base layout _____________________________________________ 44

Diagram 13 Injection module 4-cylinder ( 180/70024 connector ) ___________________________ 46

Diagram 14 Injection module 4-cylinder ( 180/ 70024 solder ) ______________________________ 47

Diagram 15 Injection module 6-cylinder ( 180/70026 connector ) ___________________________ 48

Diagram 16 Injection module 6-cylinder ( 180/70026 solder ) ______________________________ 49

Diagram 17 Injection module 8-cylinder ( 180/ 70024 connector) ___________________________ 50

Diagram 18 Injection module 8-cylinder ( 180/70024 solder) _______________________________ 51

Diagram 19 Repair module 180/30024 (4-8 cylinder) _____________________________________ 52

Diagram 20 connector injection module 091/71004 ______________________________________ 53

Diagram 21 injection module 091/71006 _______________________________________________ 54

Diagram 22 Replacing the injection module 180/70024 → 091/0145 _________________________ 55

Diagram 23 Replacing the injection module 180/70024 → 091/71004 (4 cylinder) _____________ 56

Diagram 24 Replacing the injection module 180/70026 → 091/71006 (6 cylinder) _____________ 57

Diagram 25 Replacing the injection module 180/70024 → 091/71004 (8 cylinder) _____________ 58

Diagram 26 LPG wiring 180/70014 ____________________________________________________ 59

Diagram 27 LPG wiring 180/70004 ____________________________________________________ 60

Diagram 28 LPG wiring 180/70016 ____________________________________________________ 61

Diagram 29 LPG wiring 180/70006 ____________________________________________________ 62

Diagram 30 LPG wiring 180/70018 ____________________________________________________ 63

Diagram 31 LPG wiring 180/70008 ____________________________________________________ 64

Diagram 32 LPG wiring 080/72040 ____________________________________________________ 65

Diagram 33 LPG wiring 080/72045 ____________________________________________________ 66

Diagram 34 LPG wiring 080/72050 ____________________________________________________ 67

Diagram 35 LPG wiring 080/72055 ____________________________________________________ 68

Diagram 36 LPG wiring 080/72060 ____________________________________________________ 69

Diagram 37 LPG wiring 080/72065 ____________________________________________________ 70

Diagram 38 CNG wiring 095/72045 ____________________________________________________ 71

Diagram 39 VSI-2.0 wiring 191/040002 _________________________________________________ 72 Trouble code chart LPG ______________________________________________________________ 73 Maintenance instructions _____________________________________________________________ 74 Checklist after installation ____________________________________________________________ 76

Required equipment / tools / materials for installing a complete system

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

- Car lift

- Portable computer : 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 or USB

- 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 ( part nr. 080/70090 )

- 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 )

- Molex extraction tool for VSI switch connector ( part nr. 090/9929 )

- 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 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 )

General instructions

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

Autogassystemen.

 Always disconnect the battery when installing the LPG/CNG system.  Do not place the main fuse into the fuse holder before having completed the installation of the VSI system.  The VSI computer has to be activated by means of the diagnosis software.  In the unlikely event the VSI computer fails, it will automatically switch over to petrol.

Never disconnect the VSI computer connector, unless you have removed the main fuse.

 When installing the VSI 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 loom 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/CNG-system shall be located within 100 mm of the exhaust or similar heat source, unless such components are adequately shielded against heat.

 Remove any internal burrs, after having shortened the LPG/CNG hose. (This guarantees the maximum flow

through the hose without pollution.)

 If holes have to be drilled (wear safety glasses) in order to facilitate mounting the device frame, the reservoir

frame, the LPG/CNG cut-off valve, etc., the drilled holes must always be treated with an anti-corrosive, after the burrs have been removed ( especially when mounting a exterior filler ).

 After having completed the installation, check the whole system for gas leakage; use a gas leak detection device.  Fitting and maintenance is only allowed by Prins Autogassystemen selected LPG/CNG engineers.  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 updates, info-bulletins and product information. ( www.prinsautogassytemen.com )

 For installing a dedicated VSI-system download DEDICATED MANUAL ( part 2/2 )

Please fill in the warranty card completely and return it within 8 days after installation.

Introduction

VSI stands for “vapour sequential injection”, it points directly to the most important properties of the system. This second-generation gas injection system is based on a vapour LPG/CNG injection that is injected sequentially in the engine. Sequential means that the gas injectors will inject the LPG/CNG in the sequence equal to the injection sequence of the petrol injectors, This sequence in most applications is equal to the firing order of the ignition sequence of the engine, for example with a 4-cylinder engine this is normally 1-3-4-2. Sequential injection means that the amount of injected fuel per cylinder the can be metered and timed individually.

This achieves a much higher level of performance emission and drivability. The VSI system was designed and developed in-house by Prins Autogassystemen B.V.

VSI characterizes itself with a high level of integration into to the petrol management system. The two systems integrate as “master-slave” system. This means that the original petrol management ECM controls the amount of LPG/CNG injected via the gas injectors into the engine. The VSI ECM only translates the relevant signals coming from the engine management system necessary for MASTER /SLAVE strategy.

Following this strategy the petrol management system is the “MASTER” and the VSI ECM the “SLAVE”.

The advantage of this strategy: while driving on LPG/CNG the lambda control and OBD functions keep within the OE parameters, functioning correctly and controlled by the petrol management system. So when operating on LPG/CNG it is not necessary to generate simulated signals.

There is one exception made for the petrol injector signals, while driving on LPG/CNG the petrol injector’s

are switched off to discontinue the petrol supply. To maintain the injection control signals it is necessary to simulate the petrol injectors to ensure the original ECM does not detect a fault code. Secondly when operating on LPG/CNG it is necessary to maintain a petrol injector control signal to measure the required fuel demand.

The second generation injection system VSI has the ability to inject sequentially making it quicker and more accurate, large benefits can be gained in engine and emission performance.

Approval numbers VSI LPG / CNG components

Mark

Component

LPG

CNG

Prins

VSI Reducer

E4-67R-010054

Valtec

6 / 8mm lock-off valve

E4-67R-010041

Keihin

Regulator

E4-110R-000092

OMB

lock-off valve

E4-110R-000095

Wika

CNG Pressure indicator

E4-110R-000190

Prins

VSI Injector rail

E4-67R-010093

E4-110R-000021

Keihin

VSI Injector

E4-67R-010092

E4-110R-000020

Prins

Filter unit

E4-67R-010096

E4-110R-000028

Keihin

Filter unit

E4-67R-010177

E4-110R-000091

Prins

ECU

E4-67R-010098

E4-110R-000083

Electrical VSI components

EMC : E4-10R-020507

VSI-I LPG VSI-2.0 LPG / VSI-2.0 DI LPG

VSI-1 CNG VSI-2-0 CNG / VSI-2-0 DI CNG

The Prins LPG reducer

 Mount the reducer to the body of the vehicle in the engine compartment, never on the engine!  Mount the reducer so that it is easy to adjust the pressure.  Install the supplied 8 mm threaded end in the back cover of the reducer.  Mount the reducer as shown in the drawing.  Mount the reducer on a bracket and bolt on with a M8x1 nut.  The LPG lock-off valve can be installed in different positions. Do not damage the O-rings when

rotating the lock-off valve. See picture for torque moment.

 The reducer is connected to the heating system circuit by couplings between the coolant fluid

hoses: dependant on the converted vehicle the reducer is placed in series or in parallel with the heating system.

 Overpressure 5mm relief hose : connect to the intake manifold.  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.

 The pressure can be adjusted with the adjusting screw (Allan screw) in the front cover.  Seal the adjusting screw, with the sticker, in the front cover of the reducer after adjusting the

pressure.

mounting positions

Standard reducer, 6 mm LPG pipe, used for engines with a HP up to 135 kW ( 180 HP ).

High Output reducer, 8 mm LPG pipe, used for engines with a HP over 135 kW ( 180 HP ). Use a High Output MAP reducer on blown engines ( turbo / compressor )

NO threat locking compound allowed !!

The Keihin CNG regulator

 Mount the Keihin regulator to the body of the vehicle in the engine compartment, never on the

engine!

 Mount the regulator so that it is easy to replace the inlet filter.  Mount the regulator as shown in the drawing with the water connections downwards.  Mount the regulator on a bracket and bolt on with 3 M6x1 nuts.  The regulator is connected to the heating system circuit by couplings between the coolant fluid

hoses.

 Optional MAP connection: connect to the intake manifold if needed.  No component of the CNG-system shall be located within 100 mm of the exhaust or similar heat

source, unless such components are adequately shielded against heat.

 The pressure may not be adjusted and is fixed on 3.3 bar

The injector rail

VSI 4-cylinder injector rail [KN8/KN9]

The Prins injector rail is available in 2 - 3 - 4 - 5 rail versions. Guideline VSI injector choice : divide total engine power in kW up into the amount of cylinders.

LPG:

CNG:

Color ID

(KN-8)

Injector size

Minimum power per

cylinder [LPG]

Maximum power per

cylinder [LPG]

kW

HP

kW

HP

Green

32cc /stroke

13,0

17,4

white

42cc/stroke

9,0

12,1

15,0

20,1

Blue

52cc/stroke

13,0

17,4

20,0

26,8

Orange

63cc/stroke

18,0

24,1

27,0

36,2

Yellow

73cc/stroke

25,0

33,5

35,0

46,9

82cc/stroke

28.0

37,6

39,0

52,3

Brown

100cc/stroke

31,0

41,6

45,0

60,3

Color ID

(KN-8)

Injector size

Minimum power per

cylinder [CNG]

Maximum power per

cylinder [CNG]

kW

HP

kW

HP

Green

9,0

12,1

White

42cc/stroke

7,0

9,4

12,0

16,1

Blue

52cc/stroke

10,0

13,4

16,0

21,5

Orange

63cc/stroke

14,0

18,8

22,0

29,5

Yellow

73cc/stroke

20,0

26,8

28,0

37,5

82cc/stroke

23,0

30,8

33,0

44,2

Brown

100cc/stroke

25

33,5

36,0

48,3

The Prins filter unit

The filter unit filters the LPG/CNG and is also used to measure the gas temperature (T_gas) and gas pressure (Psys) in the VSI system, by means of a combination sensor. The filter unit has a single or a double outlet of 11mm. Single outlet : on converted vehicle with 3-4 or 5 cylinder engines with one VSI injector rail. Double outlet : on converted vehicle with 6 or 8 cylinder engines with two VSI injector rails.

Single outlet Double outlet 3-4-5 cylinder engine 6-8 cylinder engine

The Keihin filter unit

The VSI computer

The VSI computer can be mounted into the engine room as well as inside the car, depending on the converted vehicle. Never mount the computer near a heat source. Never mount the computer upside down. Never clean engine room with a high pressure cleaner.

VSI-I

VSI-2.0 computer

The Prins VSI-2.0 computer is the second generation master-slave management system. This new design has distinctive features and will be used as a new platform for current and future Prins injection systems.

Instructions rotating the Prins VSI injector rail

This is an instruction how to convert a “right” rail into a “left” injector rail Tools : Ring spanner size 13 mm

Torque spanner ( 0-3 Nm )

Disassembly / assembly:

1. Unscrew both M8 (4) nuts.

2. Remove the strip (2).

3. Remove the injectors (10) with a rotating movement out of the fuel rail (1).

4. Rotate the rail (1) 180 degrees.

5. Mount the injectors (10) with a rotating movement into the fuel rail (1).

6. Mount the strip (2) on the injectors (10).

7. Tighten the strip (2) with two M8 nuts (4). Tightening moment 2.5 Nm.

The wiring loom.

The cables in the loom are provided with numbers and text. The text on the cable explains the function of the wire. The wire loom is not model specific, therefore is it may be necessary to adjust the length of the wires.

The watertight ECM housing is made from aluminium; this material is chosen for its excellent heat dissipation qualities, necessary for cool the injector drivers. Always fix the computer in the coolest place in the engine compartment.

Ensure maximum care is taken when connecting wiring. Make professional solder joints and insulate the joints. Do not stretch the wiring harness.

VSI-I

The wiring harness is equipped with a 56 position interlocking connector which slots into the VSI computer. Pull the purple interlocking clip and push the connector into the VSI computer, push the clip back into its original position, the connector is now locked into the VSI computer.

VSI-2.0

The wiring harness connects to the computer via two Bosch a 81+40 pins connector which is locked to the VSI-2.0 computer by means of connector clamping mechanism.

All cable numbers correspond with a position numbered on the connector.

Example wire number 4 is mounted on connector position 4.

Hose connections

Try to keep the inlet manifold hoses as short as possible. Use a hose clamp on all the LPG/CNG hose connections. Please observe that there is no damage or fouling to the hoses.

16

Diagram 1 VSI inlet manifold coupling

Lambda sensor

exhaust manifold

VSI inlet manifold coupling

inlet manifold

petrol injector

VSI injector

Hose clamp

LPG hose

Hose clamp

Coupling

Diagram 2 VSI inlet manifold coupling with nylon hose

petrol injector

Coupling

Barrel

Hose clamp

Nylon hose

LPG hose

Nut

VSI injector

Hose clamp

inlet manifold

VSI inlet manifold coupling with nylon hose

exhaust manifold

oxygen sensor

Diagram 3 Parallel water connection

injector rail

filter unit

+

lock-off valve

reducer

oxygen sensor

heater valve

petrol injector cylinder 1

VSI injector 1

2 3

4

exhaust

T-piece

interior heater with valve

LPG fuel line Tank

overpressure hose

Psys + Tlpg sensor

engine coolant

in

out

inlet manifold

vsi coupling

throttle body

Diagram 4 Serial water connection

injector rail

filter unit

+

lock-off valve

reducer

overpressure hose

oxygen sensor

interior heater without valve

engine coolant

LPG fuel line Tank

petrol injector cylinder 1

VSI injector 1

2 3 4

inlet manifold

exhaust

vsi coupling

in

out

throttle body

Psys + Tlpg sensor

in

Diagram 5 Serial water connection CNG regulator

21

The VSI-I fuel switch

Mount the switch on a visible and approachable place for the driver. When mounting the switch, only push on its sides.

Pushing the switch in the centre may result in damage to the switch.

ELECTRICAL CONNECTION OF THE LPG SWITCH with loose beeper

ELECTRICAL CONNECTION OF THE LPG SWITCH with internal beeper

ELECTRICAL CONNECTION OF THE CNG SWITCH with internal beeper

The LPG VSI switch with internal beepers is programmable for different types of tank indicators. Standard setting of the switch is 0-95 Ohm. For reprogramming the switch:

1. Make sure that the ignition switch is turned off.

2. Place the VSI main fuse.

3. Push the switch for 5 seconds until a signal sounds (beep).

4. Make a choice immediately: push 1 x for 0-95 Ohm tank indicator push 2 x for Hall tank indicator ( push 3 x preparation VSI2, not used )

5. The VSI switch will confirm the choice with a beep signal ( 1 or 2 signals ) To change the choice of indicator: remove the VSI main fuse and start with step 1.

The CNG switch is not programmable. The CNG switch is not exchangeable with a LPG switch!

BEEPER

50 53 51 12 49 48 51

TANK INDICATOR

GROUND

POWER FEED TANKINDICATION

POWER FEED SWITCH

PULSE FUEL SWITCH

DIAGNOSTIC LED

GROUND BEEPER

POWER FEED BEEPER

BLUE

BROWN

YELLOW-GREEN

RED

YELLOW

ORANGE

BLACK

RED

8-POLE

CONNECTORS

POWER FEEDS (51) ARE EXCHANGABLE.

VSI SWITCH partnr. 080/70060 Hall partnr. 080/70062 0-95 Ohm partnr. 080/70063 0-5 Volt

POSITION 1 ON CONNECTOR

POSITION 2 ON CONNECTOR

POSITION 3 ON CONNECTOR

POSITION 4 ON CONNECTOR

POSITION 5 ON CONNECTOR

POSITION 6 ON CONNECTOR

POSITION 7 ON CONNECTOR

POSITION 8 ON CONNECTOR

5 6 7 8 1 2 3 4

50 53 51

12

49 48

TANK INDICATOR

GROUND

POWER FEED TANKINDICATION

POWER FEED SWITCH

PULSE FUEL SWITCH

DIAGNOSTIC LED

GROUND BEEPER

BLUE

BROWN

YELLOW-GREEN

RED

YELLOW

ORANGE

BLACK

8-POLE

CONNECTORS

VSI SWITCH WITH INTERNAL BEEPER partnr. 080/70058

POSITION 1 ON CONNECTOR

POSITION 2 ON CONNECTOR

POSITION 3 ON CONNECTOR

POSITION 4 ON CONNECTOR

POSITION 5 ON CONNECTOR

POSITION 6 ON CONNECTOR

POSITION 7 ON CONNECTOR

5 6 7 8 1 2 3 4

50 53

51 12 49 48

Pressure gauge signal

GROUND

POWER FEED TANKINDICATION

POWER FEED SWITCH

PULSE FUEL SWITCH

DIAGNOSTIC LED

GROUND BEEPER

BLUE

BROWN

YELLOW-GREEN

RED

YELLOW

ORANGE

BLACK

8-POLE

CONNECTORS

VSI SWITCH WITH INTERNAL BEEPER partnr. 095/70058

POSITION 1 ON CONNECTOR

POSITION 2 ON CONNECTOR

POSITION 3 ON CONNECTOR

POSITION 4 ON CONNECTOR

POSITION 5 ON CONNECTOR

POSITION 6 ON CONNECTOR

POSITION 7 ON CONNECTOR

5 6 7 8 1 2 3 4

The VSI-2.0 fuel switch

The VSI-2.0 switch is designed for the new VSI-2.0 platform. The switch is controlled by the VSI-2.0 computer through LIN communication.

Operation mode

Fuel selection

Active fuel

Status LED

Tank LEDS

Beeper

Diagnose LED

Engine off

GAS/Petrol

No

Off

Contact+ on /engine of

Petrol

No

Off

On

Off

on 3 sec (system check)

Contact+ on /engine of

Gas

No

flashing1, 0Hz

Off

on 3sec (system check)

Engine on

Petrol

Off

On

Off

Gas standby

Gas

Petrol

flashing 1,0Hz

On

Off

Gas mode

Gas

On

Off

Tank empty, switched back to petrol mode

Gas

Petrol

flashing1, 0Hz

LED 1 1,0Hz

3x0,5Hz

Off

Tank empty, petrol mode

Petrol

Off

Led1 on

Off

Critical fault

Gas

Petrol

flashing 1,0 Hz

On

On, 2Hz

On

Non critical fault, petrol mode

Petrol

Off

On

Off

Non critical fault, gas mode

Gas

on

On

Off

Flashing 1,0 Hz

Electrical connections on the LPG reservoir

The wire harness contains the wires for connecting the LPG reservoir. Refer to the following diagram when connecting the LPG reservoir.

BLACK BLUE

GROUND SIGNAL

PRINS

SOLDER THE CONNECTIONS IN THE FITTING BOX AND PROTECT THEM WITH A SHRINK SLEEVE.

BLUE

BLACK

Tank gauge Hall

COIL TANK VALVE

BLACK

RED

RED BLACK BLUE

FITTING BOX

VSI COMPUTER

TRIPLE WIRE CABLE

SOLDER THE CONNECTIONS IN THE FITTING BOX AND PROTECT THEM WITH A SHRINK SLEEVE.

GREEN

BLACK

Tank gauge 0-95 Ohm

COIL TANK VALVE

BLACK

RED

RED BLACK BLUE

FITTING BOX

VSI COMPUTER

TRIPLE WIRE CABLE

Electrical connections VSI-I wiring harness

Check and measure the wiring in case of changes in the cars wiring colours.

Wire number / code

Wire colour

Connection

50 MAIN GND

brown

Connect to the '–' of the battery; use a ring terminal for this purpose.

25-51 +12V BAT

red

Connect to the '+' of the battery; use a ring terminal for this purpose or solder. Do not place the main fuse into the fuse holder before having completed the installation of the system.

50 LPG/CNG VLV GND 53 + LPG/CNG VLV

brown

yellow - green

Ground shut-off valve. Power supply shut-off

valve.

2-pole connector shut-off valve. 42 ECT GND

43 ECT

brown

grey

Ground ECT sensor. ECT measurement.

2-pole black connector temperature sensor in the evaporator.

22 RS232 TxD 23 RS232 RxD 50 DIAGNOSE GND 51 +12V DIAG

grey grey

brown

red

4-pole black connector diagnosis wire connection.

15 T LPG 17 Psys 18 + 5V Psys 42 Psys GND

grey

pale green

red

brown

4-pole black connector filter unit connection. 33 33G INJ OUT 1

34 34 G INJ A PLUS

white - yellow

red

Connector VSI-injector to cylinder 1.

32 32G INJ OUT 2 34 34 G INJ A PLUS

green - yellow

red

Connector VSI-injector to cylinder 2.

31 31G INJ OUT 3 34 34 G INJ A PLUS

pink - yellow

red

Connector VSI-injector to cylinder 3.

30 30G INJ OUT 4 34 34 G INJ A PLUS

blue - yellow

red

Connector VSI-injector to cylinder 4.

5 5G INJ OUT 5 6 34 G INJ A PLUS

grey - yellow

red

Connector VSI-injector to cylinder 5.

4 4G INJ OUT 6 6 34 G INJ A PLUS

brown - yellow

red

Connector VSI-injector to cylinder 6.

3 3G INJ OUT 7 6 34 G INJ A PLUS

light blue -

yellow

red

Connector VSI-injector to cylinder 7. 2 2G INJ OUT 8

6 34 G INJ A PLUS

red - yellow

red

Connector VSI-injector to cylinder 8.

44 AD1

green

Option, programmable input

16 MAP 18 + 5V MAP 42 MAP GND

blue

red

brown

For measuring the inlet manifold pressure (MAP). In combination with Prins Turbo/MAP sensor.

PTO CRANK-D

purple / purple-

yellow

For interrupting the crank signal on CNG.

50 Ground 53 + CNG Signal

blue

green-yellow

blue

For measuring the high pressure signal of the CNG system In combination with Prins High Pressure gauge

Electrical connections VSI-I wiring harness

Check and measure the wiring in case of changes in the cars wiring colors.

13 IGNITION +

grey-white

Make a connection to ignition + / contact +. Make sure that the voltage will not fail during starting the engine.

46 LAMBDA 1-L

orange

For the measurement of the lambda signal of cylinder bank 1. Connect the wire parallel to the lambda sensor signal wire.

45 LAMBDA 2-R

orange-white

For the measurement of the lambda signal of cylinder bank 2. Connect the wire parallel to the lambda sensor signal wire.

40 RPM

purple-white

For measuring the engine speed. Connect to a Hall-sensor or camshaft sensor, Make sure that the squared signal is not higher then 30 Volt ! Never connect to the ignition coil (only with a RPM module) !

Injector measure wire ( injection module )

39 38 37 36 11 10 9 8

Bicolour /

Full colour

For measuring / interrupting the petrol injectors :

Interrupt each petrol injector control wire ( injector min ) Each VSI wire has a cylinder number printed on the wire, connect this wire to the corresponding petrol injector.

Connect the bicoloured VSI measuring wire to the ecu side, ( wire code: ECU SIDE ).

Connect the accompanying full coloured VSI wire to the petrol injector side ( wire code: MIN INJ SIDE ).

See diagrams in Installation Manual General part 1 / 2.

Attention: Each bicoloured measuring wire corresponds to a specific LPG injector and cylinder number. Do not interchange the wires.

Injection module => VSI-ecm => VSI injector rail

White-yellow vsi nr. 39 ( petrol injector cyl.1 ) =>VSI-ecm=> White-yellow vsi nr.33 ( vsi injector cyl.1 ) Green-yellow vsi nr. 38 ( petrol injector cyl.2 ) =>VSI-ecm=> Green-yellow vsi nr.32 ( vsi injector cyl.2 ) Pink-yellow vsi nr. 37 ( petrol injector cyl.3 ) =>VSI-ecm=> Pink-yellow vsi nr.31 ( vsi injector cyl.3 ) Blue-yellow vsi nr. 36 ( petrol injector cyl.4 ) =>VSI-ecm=> Blue-yellow vsi nr.30 ( vsi injector cyl.4 ) Grey-yellow vsi nr. 11 ( petrol injector cyl.5 ) =>VSI-ecm=> Grey-yellow vsi nr.05 ( vsi injector cyl.5 ) Bruin-yellow vsi nr. 10 ( petrol injector cyl.6 ) =>VSI-ecm=> Brown-yellow vsi nr.04 ( vsi injector cyl.6 )

Light blue-yellow vsi nr. 09 ( petrol injector cyl.7 ) =>VSI-ecm=> Light blue-yellow vsi nr.03 ( vsi injector cyl.7 )

Red-yellow vsi nr. 08 ( petrol injector cyl.8 ) =>VSI-ecm=> Red-yellow vsi nr.02 ( vsi injector cyl.8 )

Electrical connections VSI-2.0 wiring harness

Check and measure the wiring in case of changes in the cars wiring colours.

Insulate all not used wires.

Wire number / code

Wire colour

Connection

1 ground battery

brown

Connect to the ‘–‘ of the battery; use a ring terminal for this

purpose. Wire colour : Wire location :

32 ground battery sense

brown

Connect to the ‘–‘ of the battery together with VSI wire 1

ground battery.

44 +12V battery

red

Connect to the '+' of the battery; use a ring terminal for this purpose or solder. Wire colour : Wire location : Do not place the fuse in the holder before having completed the installation of the LPG system.

13 +12V battery sense

red

Connect to the ‘+‘ of the battery together with VSI wire 44

+12V battery.

112 + petrol injectors or ignition+ ( +15 )

red-grey

Make a connection to + petrol injector or ignition+ ( +15 ) Wire colour : Wire location :

20 AD3 ( lambda 1 )

orange

For the measurement of the lambda signal of cylinder bank 1 Connect the wire in parallel to the lambda sensor. Wire colour : Wire location :

19 AD4 ( lambda 2 )

orange-white

For the measurement of the lambda signal of cylinder bank 2 Connect the wire in parallel to the lambda sensor. Wire colour : Wire location :

18 AD1 ( MAP )

blue

For measuring the inlet manifold pressure ( MAP ). Wire colour : Wire location :

17 AD2 ( Valve Care )

green

Optional connection. Wire colour : Wire location :

8 RPM

purple-white

For measuring the engine speed. Wire colour : Wire location :

Electrical connections VSI-2.0 wiring harness

Check and measure the wiring in case of changes in the cars wiring colours.

Insulate all not used wires.

3-pole connector 18 AD1 ( MAP ) 27 +5 volt sensor 37 C ground

blue

brown

red

For measuring the inlet manifold pressure ( Prins MAP sensor). Connect the 3-pole connector to the Prins MAP sensor.

2-pole blue connector 15 Tect 34 C ground

grey

brown

For measuring the engine coolant temperature ( Tect ). Connect the connector to the reducer temperature sensor.

4-pole connector 35 C ground 14 T-Gas 9 +5 Volt sensor 16 Psys

brown

grey

red

green

For measuring gas pressure and temperature. Connect the connector to the filter unit sensor.

2-pole connector 24 +12V reducer lock off 31 Ground reducer lock off

yellow-green

brown

Connect the connector to the reducer lock-off valve.

4-pole connector 46 Service TxD 65 Service RxD 68 C ground

grey grey

brown

Diagnose connector.

3-pole connector 3 +12V fuel switch 66 ground fuel switch 49 LIN fuel switch

red brown yellow

Connect to the VSI switch.

Tank wiring loom 2 Power tank valve 1 12 Tank level in 26 ground tank lock off

red

blue

black

Connect to the tank lock-off. Connect the tank level gauge. Connect to the tank lock-off.

Electrical connections VSI-2.0 wiring harness

Check and measure the wiring in case of changes in the cars wiring colours.

Some wires/connectors are only available in the Full Spec VSI loom.

Insulate all not used wires.

51 CAN 1 High 70 CAN 1 Low

blue-yellow

blue

Optional / insulate / Connect to EOBD diagnose connector Pin : 6 Pin : 14

53 CAN 2 High 72 CAN 2 Low

pink-yellow

pink

Optional / insulate / Connect to EOBD diagnose connector 23 ground switched 2

yellow

Optional / insulate

28 +5V ( EXT )

red

Optional / insulate

29 +5V PU1 ( optional )

red

Optional / insulate

30 +5V PU2 ( optional )

red

Optional / insulate

43 +GAS injectors

red

Optional / insulate

45 K-line

pink

Optional / insulate

57 +12V (external)

red

Optional / insulate

76 power tank valve 2 22 ground switched 1

red

brown

Connect to the second tank lock-off valve. Optional / insulate

3-pole connector 11 + manometer 12 tank level in 33 ground manometer

red

blue

brown

Connect to the CNG high pressure gauge Optional / insulate

Electrical connections VSI-2.0 wiring harness

Check and measure the wiring in case of changes in the cars wiring colours.

For measuring the petrol injectors : Interrupt each petrol injector control wire (injector min)

Each VSI wire has a petrol injector / cylinder number printed on the wire, connect this wire to the corresponding petrol injector / cylinder.

Connect the bicoloured VSI measuring wire to the ecu side, ( wire code: ecu side inj ). Connect the corresponding full coloured VSI wire to the petrol injector side ( wire code: min inj side ).

Attention: Each bicoloured measuring wire corresponds to a specific VSI injector and petrol injector / cylinder number. Do not interchange the wires.

VSI measure wire nr. :

Full coloured / Bicoloured

To interrupt petrol injector wire colour / location

121 ecu side injector 1 120 injector side inj 1

white-yellow

white

Colour : Location :

119 ecu side injector 2 118 injector side inj 2

green-yellow

green

Colour : Location :

117 ecu side injector 3 116 injector side inj 3

pink-yellow

pink

Colour : Location :

115 ecu side injector 4 114 injector side inj 4

blue-yellow

blue

Colour : Location :

VSI injector connectors:

98 –GAS INJ 1 106 +GAS INJ 1

white-yellow

red

Connector VSI-injector cylinder 1. ( timing belt side )

99 –GAS INJ 2 107 +GAS INJ 2

green-yellow

red

Connector VSI-injector cylinder 2.

100 –GAS INJ 3 108 +GAS INJ 3

pink-yellow

red

Connector VSI-injector cylinder 3.

82 –GAS INJ 4 90 +GAS INJ 4

blue-yellow

red

Connector VSI-injector cylinder 4.

Electrical connections RPM module 091/0236

 Connect the brown wire of the RPM module to the brown wire nr.50 of the VSI wiring loom.  Connect the purple-white wire of the RPM module to the purple-white wire nr.40 of the VSI wiring

loom.

 Connect the grey-white wire of the RPM module to the grey-white wire nr.13 of the VSI wiring loom.  Connect the purple wire of the RPM module to the ignition coil driver wire.

RPM module

ignition coil -

rpm 40

ground 50

ignition + 13

VSI computer

+

-

batteryignition +

solder

Electrical connections Petrol Pressure Simulator 091/0252

Engines equipped with a return less fuel system. These engines can generate trouble codes and/or have difficulties with the fuel trims(mixture) on both petrol and lpg.

Brands: Mainly brands who are connected with Ford technologies like: * Ford models from 2003/2004 * Jaguar models from 2003/2004 * Some Volvo models from 2003

Connections and Set-up

Connect the PPS module according the shown schematic. Measure the voltage, on petrol, for the blue wire (pressure sensor signal wire) when the engine is idling. Or read the actual petrol pressure when you have the disposal of a scan tool which can read the actual petrol system pressure. Next we have to setup the same Voltage (pressure) when running on LPG via de pot meter. The pot meter is accessible when you remove the small protection cover of the module.

RED-WHITE

BLUE

BLUE-WHITE

BROWN

VSI

PETROL ECU

Petrol Pressure signal sensor side

Petrol Pressure signal ECU side

12 Volt Contact + VSI wire 13 Sim Low=On VSI wire 26 Ground Battery VSI wire 50

PETROL PRESSURE SENSOR

Petrol Pressure Simulator 091/0252

1 2 3 4 4

Interrupt the petrol pressure signal wire

GREY-BLACK

0-5 Volt

Electrical connections Dual Sensor Interface (DSI)

DSI connection: Connect the interface wiring according to drawing, all blue and black wires are exchangeable since they

are internally connected. The DSI makes it possible to connect two level sensors to one lpg switch.

The DSI will always show the highest lpg level on the switch.

PRINS

GROUND SIGNAL

BLACK BLUE

GROUND SIGNAL

BLACK BLUE

PRINS

Dual Sensor Interface 080/70066

Hall level indicator

080/70065

Tank lock off valve

Electrical connections CNG Prins Timing Optimizer (PTO)

Connect the PTO module according the shown diagram. Check if the latest software is downloaded in the PTO!

Diagram CNG PTO wiring

Prins Turbo / MAP sensor

35

Diagram 5 LPG Base layout VSI 4 cylinder connector

36

Diagram 6 LPG Base layout VSI 4 cylinder solder

37

Diagram 7 LPG Base layout VSI 5 cylinder

38

Diagram 8 LPG Base layout VSI 6 cylinder connector

39

Diagram 9 LPG Base layout VSI 6 cylinder solder

40

Diagram 10 LPG Base layout VSI 8 cylinder connector

41

Diagram 11 LPG Base layout VSI 8 cylinder solder

42

Diagram 12 CNG Base layout

43

Diagram 13 VSI-2.0 LPG Base layout

44

Diagram 14 VSI-2.0 MAP LPG Base layout

45

46

Diagram 13 Injection module 4-cylinder ( 180/70024 connector )

-

injection module 4 cylinder 180/70024

white min inj side 1

white-yellow 39 ecu side 1

+

36 ecu side 4

39 ecu side 1

38 ecu side 2

26 SIMU LOW=ON

50 MAIN GROUND

petrol ecu

4-CYLINDER CONNECTOR INJECTION MODULE VSI 1 REV.B 06-06-2005

green min inj side 2

green-yellow 38 ecu side 2

pink min inj side 3

pink-yellow 37 ecu side 3

blue min inj side 4

blue-yellow 36 ecu side 4

37 ecu side 3

VSI-4 computer

4

+

-

+

-

+

-

+

-

321

---

petrol ecu petrol ecu petrol ecu

PETROL INJECTORS

Make sure that the polarity of the petrol injectors and the VSI

connectors are simular !

47

Diagram 14 Injection module 4-cylinder ( 180/ 70024 solder )

---

+

1 2

3

-

4

white min inj side 1

white-yellow 39 ecu side 1

petrol ecu

+

36 ecu side 4

39 ecu side 1

38 ecu side 2

26 SIMU LOW=ON

50 MAIN GROUND

petrol ecu

PETROL INJECTORS

4-CYLINDER SOLDER INJECTION MODULE VSI 1 REV.B 06-06-2005

green min inj side 2

green-yellow 38 ecu side 2

pink min inj side 3

pink-yellow 37 ecu side 3

blue min inj side 4

blue-yellow 36 ecu side 4

37 ecu side 3

VSI-4 computer

injection module

4 cylinder

180/70024

48

Diagram 15 Injection module 6-cylinder ( 180/70026 connector )

-

injection module

6 cylinder

180/70026

white min inj side 1

white-yellow 39 ecu side 1

36 ecu side 4

39 ecu side 1

38 ecu side 2

26 SIMU LOW=ON

50 MAIN GROUND

petrol ecu

6-CYLINDER CONNECTOR INJECTION MODULE VSI 1 REV.B 06-06-2005

green min inj side 2

green-yellow 38 ecu side 2

pink min inj side 3

pink-yellow 37 ecu side 3

blue min inj side 4

blue-yellow 36 ecu side 4

37 ecu side 3

VSI-8 computer

4

+

-

+

-

+

-

+

-

321

---

petrol ecu petrol ecu petrol ecu

PETROL INJECTORS

petrol ecu

-

+

-

petrol ecu

6

-

+

5

brown min inj side 6

brown-yellow 10 ecu side 6

grey min inj side 5

grey-yellow 11 ecu side 5

11 ecu side 5

10 ecu side 6

Make sure that the polarity of the petrol injectors and the VSI connectors are simular !

49

Diagram 16 Injection module 6-cylinder ( 180/70026 solder )

---

+

1 2

3

-

4

injection module 6 cylinder 180/70026

white min inj side 1

white-yellow 39 ecu side 1

petrol ecu

+

36 ecu side 4

37 ecu side 3

39 ecu side 1

38 ecu side 2

26 SIMU LOW=ON

50 MAIN GROUND

petrol ecu

PETROL INJECTORS

6-CYLINDER SOLDER INJECTION MODULE VSI 1 REV.B 06-06-2005

green min inj side 2

green-yellow 38 ecu side 2

pink min inj side 3

pink-yellow 37 ecu side 3

blue min inj side 4

blue-yellow 36 ecu side 4

5

+

6

--

petrol ecu

11 ecu side 5

10 ecu side 6

grey min inj side 5

grey-yellow 11 ecu side 5

brown min inj side 6

brown-yellow 10 ecu side 6

VSI-8 computer

50

Diagram 17 Injection module 8-cylinder ( 180/ 70024 connector)

-

+

petrol ecu

8-CYLINDER CONNECTOR INJECTION MODULE VSI 1 REV.B 06-06-2005

green min inj side 2

green-yellow 38 ecu side 2

brown min inj side 6

brown-yellow 10 ecu side 6

blue min inj side 4

blue-yellow 36 ecu side 4

7

+

-

+

-

+

-

+

-

5

31

---

petrol ecu petrol ecu petrol ecu

PETROL INJECTORS

petrol ecu

pink min inj side 3

4

petrol ecu

PETROL INJECTORS

-

2

-

+

white-yellow 39 ecu side 1

white min inj side 1

- -

petrol ecu

6

-

+

-

+

8 cylinder injection module 180/70024

grey-yellow 11 ecu side 5

grey min inj side 5

pink-yellow 37 ecu side 3

light blue min inj side 7

light blue-yellow 9 ecu side 7

-

petrol ecu

8

-

+

50 MAIN GROUND

26 SIMU LOW=ON

VSI-8 computer

11 ecu side 5

37 ecu side 3

39 ecu side 1

9 ecu side 7

50 MAIN GROUND

26 SIMU LOW=ON

36 ecu side 4

38 ecu side 2

8 ecu side 8

10 ecu side 6

red min inj side 8

red-yellow 8 ecu side 8

8 cylinder injection module 180/70024

Make sure that the polarity of the petrol injectors and the VSI connectors are simular !

51

Diagram 18 Injection module 8-cylinder ( 180/70024 solder)

---

+

2 4

6

-

8

green min inj side 2

green-yellow 38 ecu side 2

petrol ecu

+

9 ecu side 7

petrol ecu

PETROL INJECTORS

8-CYLINDER SOLDER INJECTION MODULE VSI 1 REV.B 06-06-2005

blue min inj side 4

blue-yellow 36 ecu side 4

brown min inj side 6

brown-yellow 10 ecu side 6

red min inj side 8

red-yellow 8 ecu side 8

pink min inj side 3

white min inj side 1

white-yellow 39 ecu side 1

PETROL INJECTORS

+

1 3

-

petrol ecu

--

5

+

7

-

petrol ecu

grey-yellow 11 ecu side 5

grey min inj side 5

pink-yellow 37 ecu side 3

light blue min inj side 7

petrol ecu

light blue-yellow 9 ecu side 7

petrol ecu

11 ecu side 5

37 ecu side 3

39 ecu side 1

50 main ground

26 simu low=on

VSI-8 computer

26 simu low=on

50 main ground

38 ecu side 2

36 ecu side 4

10 ecu side 6

8 ecu side 8

8 cylinder injection module

180/70024

8 cylinder injection module

180/70024

PETROL ECU

52

Diagram 19 Repair module 180/30024 (4-8 cylinder)

injection module

4 & 8 CYLINDER REPAIR INJECTION MODULE VSI 1 REV.B 180/30024 06-06-2005

INJ SIDE A ECU SIDE A

INJ SIDE B ECU SIDE B

INJ SIDE C ECU SIDE C

INJ SIDE D ECU SIDE D

ECU SIDE A

ECU SIDE D

ECU SIDE C

ECU SIDE B

50 MAIN GROUND

26 SIMU LOW=ON

4 cylinder 8 cylinder module A 8 cylinder module B

1 2 3 4 1 3

5 7

2 4 6 8

A BCD

REPAIR MODULE wire

53

Diagram 20 connector injection module 091/71004

54

Diagram 21 injection module 091/71006

55

Diagram 22 Replacing the injection module 180/70024 → 091/0145

petrol ecu

white min inj side 1

PETROL INJECTORS

13 ignition +

50 main ground

white-yellow 39 ecu side 1

white min inj side 1

37 ecu side 3

50 MAIN GROUND

26 SIMU LOW=ON

38 ecu side 2

39 ecu side 1

36 ecu side 4

27

13 50

5026

54

VSI computer

+

NEW TYPE

injection module

180/70024

petrol ecu

-

1

--

PETROL INJECTORS

2

3

-

+

pink-yellow 37 ecu side 3

petrol ecu

green min inj side 2

petrol ecu

pink min inj side 3

green-yellow 38 ecu side 2

INTERRUPT THE POWER FEED OF EACH INJECTOR

4

+

1 2

- -

petrol ecu

blue-yellow 36 ecu side 4

blue min inj side 4

petrol ecu

36 ecu side 4

39 ecu side 1

38 ecu side 2

37 ecu side 3

50 main ground

50

13 ignition +

13

27

26 50

54

VSI computer

26 SIMU LOW=ON

3

4

+

-

insulate

green-yellow 38 ecu side 2

blue min inj side 4

petrol ecu

pink min inj side 3

green min inj side 2

blue-yellow 36 ecu side 4

pink-yellow 37 ecu side 3

Red

Black

Red

Black

Red

Black

54

OLD TYPE

Injection module 091/0145

white-yellow 39 ecu side 1

Black

Red

Change wiring when replacing module 180/30024 into module 091/0145. Change VSI wires 26, 27 and 54 and connect the measuring wires to module 091/0145

Extend VSI wires 26, 27 and 54.

REPLACING THE INJECTION MODULE VSI 1 REV.B BY OLD TYPE 06-06-2005

56

Diagram 23 Replacing the injection module 180/70024 → 091/71004 (4 cylinder)

26 27 135436373839

+ - + - + - +

-

Petrol injectors

1 2 3 4

injection module

180/70024

+ - + - + - +

-

Petrol injectors

1 2 3 4

B4 C4 B3 C3 B2 C2

A2 A3 A4 A5 A6 A7C8B8 B1

26 275436373839

C5

B5

C6

B6

C7

B7

injection module

with connector

091/71004

module wiring loom

080/71996

13

insulate

= solder

VSI LPG / CNG ECU

manufacturer : Prins

version :

software :

VSI LPG / CNG ECU

manufacturer : Prins version : software :

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector petrol injector petrol injector vsi ecm

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

white green pink blue grey brown

grey-white

red-white

13 ingnition plus 39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4 11 ecu side 5 10 ecu side 6 26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu petrol ecu petrol ecu

39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4 11 ecu side 5 10 ecu side 6

min inj side 2 min inj side 3 min inj side 4 min inj side 5 min inj side 6

injection module / wiring loom

print on wirewire colorconnected topin

module wiring loom

080/71996

injection module

with connector

091/71004

57

Diagram 24 Replacing the injection module 180/70026 → 091/71006 (6 cylinder)

+ - + - + - + - + - +

-

Petrol injectors

1 2 3 4 5 6

B4 C4 B3 C3 B2 C2

A2 A3 A4 A5 A6 A7C8B8 B1

26 27 1354101136373839

C5

B5

C6

B6

C7

B7

injection module

with connector

091/71006

module wiring loom

080/71996

= solder

+ - + - + - +

-

+ - +

-

Petrol injectors

1 2 3 4 5 6

26 27 1354101136373839

injection module

180/70026

VSI LPG / CNG ECU

manufacturer : Prins

version : software :

VSI LPG / CNG ECU

manufacturer : Prins version : software :

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector petrol injector petrol injector vsi ecm

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

white green pink blue grey brown

grey-white

red-white

13 ingnition plus 39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4 11 ecu side 5 10 ecu side 6 26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu petrol ecu petrol ecu

39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4 11 ecu side 5 10 ecu side 6

min inj side 2 min inj side 3 min inj side 4 min inj side 5 min inj side 6

injection module / wiring loom

print on wirewire colorconnected topin

module wiring loom

080/71996

injection module

with connector

091/71006

58

Diagram 25 Replacing the injection module 180/70024 → 091/71004 (8 cylinder)

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector petrol injector petrol injector vsi ecm

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

white green pink blue grey brown

grey-white

red-white

13 ingnition plus 39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4 11 ecu side 5 10 ecu side 6 26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu petrol ecu petrol ecu

39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4 11 ecu side 5 10 ecu side 6

min inj side 2 min inj side 3 min inj side 4 min inj side 5 min inj side 6

injection module / wiring loom

print on wirewire colorconnected topin

module wiring loom

080/71996

injection module

with connector

091/71004

1 2 3 4

Petrol injectors

+ - + - + - +

-

5 6 7 8

Petrol injectors

+ - + - + - +

-

26 27 13543938 37 36 89

1011

VSI LPG / CNG ECU

manufacturer : Prins version : software :

injection module

180/70024

injection module

180/70024

+ - + - + - +

-

Petrol injectors

1 2 3 4

B4 C4 B3 C3 B2 C2 A2 A3 A4 A5 A6 A7C8B8B1

26 275436373839

C5

B5

C6

B6

C7

B7

injection module

with connector

091/71004

module wiring loom

080/71996

13

insulate

= solder

VSI LPG / CNG ECU

manufacturer : Prins version : software :

+ - + - + - +

-

Petrol injectors

5 6 7 8

B4 C4 B3 C3 B2 C2 A2 A3 A4 A5 A6 A7C8B8B1

C5

B5

C6

B6

C7

B7

injection module

with connector

091/71004

module wiring loom

080/71996

insulate

= solder

89

1011

59

Diagram 26 LPG wiring 180/70014

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer : version : software :

tank gauge

reducer

lock-off

valve

Filter unit Psys / T-lpg sensor

Hall sensor engine RPM

injection module cylinder 1-2-3-4

+

-

1 2 3 4

Petrol injectors

26 27 1354

1

2

3

4

1 2 1 2 1 2 1 2

39 38 37 36

Oxygen

sensor 1

Bank 1

t°

34 33 32 31 30

4046

35

53

25 51

2

1

tank lock-off valve

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

180/70014 VSI Wiring diagram 4 cylinder LPG (with connectors)

15 18 17 22 23

fuel switch

50

main ground

VSI LPG ECU

manufacturer : Prins

version :

software :

Engine control relay

VSI injectors

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white

black

grey

blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow

green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

black ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching

diagnose LED

color

brown

green

black orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1 white-yellow

RPM engine speed

purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

Prins Alternative Fuel Systems

Version nr. / date

Checked by :

Designed : T.S. 23-04-2007

Approved by :

Description :

1 / 29-05-2007

sealed

+12 volt diagnose

red

sealed

ground

sealed sealed sealed sealed sealed sealed sealed sealed sealed

18

+5 Volt MAP

red

50

switch ground

brown

43 42

t°

2 1

T-ect sensor

main fuse

injector fuse

T.S. 23-04-2007 T.S. 23-04-2007

4 cyl.

+ LPG injectors

Sheet : 1/1

Project name :

60

Diagram 27 LPG wiring 180/70004

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer : version : software :

tank gauge

reducer lock-off valve

Hall sensor engine RPM

26 27 1354

1

2

3

4

Oxygen sensor 1 Bank 1

t°

34 33 32 31

4046

35

53

25 51

main fuse

2

1

tank lock-off valve

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

180/70004 VSI wiring diagram 4 cylinder LPG (without connectors)

43 42 15 18 17 22 23

50

main ground

VSI LPG ECU

manufacturer : Prins version : software :

Engine control relay

VSI injectors

36373839

Filter unit Psys / T-lpg sensor

+ - + - + - +

-

Petrol injectors

1 2 3 4

30

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white black grey blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD

sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

black ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching

diagnose LED

color

brown

green

black orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1

white-yellow

RPM engine speed purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

Prins Alternative Fuel Systems

Version nr. / date

Checked by :

Designed :

T.S. 23-04-2007

Approved by :

Description :

1 / 29-05-2007

sealed

+12 volt diagnose

red

sealed

ground

sealed sealed sealed sealed sealed sealed sealed sealed sealed

18

+5 Volt MAP

red

50

switch ground

brown

t°

2 1

fuel switch

T-ect sensor

injection module

cylinder 1-2-3-4

injector fuse

R.K. 23-04-2007 R.K. 23-04-2007

4 cyl.without conn.

+ LPG injectors

Sheet :

1/1

Project name :

61

Diagram 28 LPG wiring 180/70016

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer : version : software :

tank gauge

reducer lock-off valve

Hall sensor engine RPM

Oxygen sensor 1 Bank 2

t°

1 2 3

Petrol injectors

26 27 1354

1

2

3

4

5

6

1 2 1 2 1 2

Oxygen sensor 1 Bank 1

t°

346 33 32 31 30 5 4

404546

35 7

53

25 51

2

1

tank lock-off

valve

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

180/70016 VSI wiring diagram 6 cylinder LPG (with connectors)

15 18 17 22 23

fuel switch

50

main ground

VSI LPG ECU

manufacturer : Prins version : software :

Engine control relay

VSI injectors

1 2 1 2 1 2

101136373839

4 5 6

Filter unit

Psys / T-lpg sensor

G INJ B plus

G INJ OUT 6 G INJ OUT 5

+ LPG injectors

ecu side inj 6 ecu side inj 5

brown-yellow grey-yellow red black

brown-yellow grey-yellow

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white black grey blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow

white-yellow

red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

black ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching

diagnose LED

color

brown

green

black

orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1

white-yellow

RPM engine speed purple-white

grey

lambda bank 1 orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

Prins Alternative Fuel Systems

Version nr. / date

Checked by :

Designed :

T.S. 23-04-2007

Approved by :

Description :

1 / 29-05-2007

sealed

+12 volt diagnose

red

ground

sealed

sealed sealed

18

+5 Volt MAP red

50

switch ground

brown

lambda bank 2 orange-white

43 42

t°

2 1

T-ect sensor

injection module

1-2-3-4-5-6

main fuse

injector fuse

R.K. 23-04-2007 R.K. 23-04-2007

6 cyl.with conn.

+ LPG injectors

Sheet : 1/1

Project name :

injector fuse

62

Diagram 29 LPG wiring 180/70006

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer :

version :

software :

tank gauge

reducer lock-off valve

Hall sensor engine RPM

Oxygen sensor 1

Bank 2

t°

1

2

3

4

5

6

Oxygen sensor 1

Bank 1

t°

346 33 32 31 30 5 4

404546

35 7 53

25 51

2

1

tank lock-off valve

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

180/70006 VSI wiring diagram 6 cylinder LPG (without connectors)

15 18 17 2223

fuel switch

50

main ground

VSI LPG ECU

manufacturer : Prins version : software :

Engine control relay

VSI injectors

G INJ B plus

G INJ OUT 6 G INJ OUT 5

ecu side inj 6 ecu side inj 5

brown-yellow grey-yellow red

brown-yellow grey-yellow

Filter unit Psys / T-lpg sensor

+ - + - + - + - + - +

-

Petrol injectors

1 2 3 4

5 6

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys

+5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white black grey blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

black ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching

diagnose LED

color

brown

green

black

orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1 white-yellow

RPM engine speed

purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground

tank valve ground

diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

Prins Alternative Fuel Systems

Version nr. / date

Checked by :

Designed :

T.S. 23-04-2007

Approved by :

Description :

1 / 29-05-2007

sealed

+12 volt diagnose

red

ground

sealed

sealed sealed

18

+5 Volt MAP red

50

switch ground

brown

lambda bank 2

orange-white

43 42

t°

2 1

T-ect sensor

injection module

1-2-3-4-5-6

26 27 1354101136373839

main fuse

R.K. 23-04-2007 R.K. 23-04-2007

6 cyl. without conn.

+ LPG injectors

black

Sheet : 1/1

Project name :

injector fuse

+ LPG injectors

injector fuse

63

Diagram 30 LPG wiring 180/70018

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer : version : software :

tank gauge

reducer lock-off valve

Filter unit

Psys / T-lpg sensor

Hall sensor

engine RPM

Oxygen sensor 1 Bank 2

injection module cylinder 1-2-3-4

+

-

t°

1 2 3 4 5 6 7 8

Petrol injectors

26 27 1354

1

2

3

4

5

6

7

8

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

39 38 37 36

Oxygen sensor 1 Bank 1

t°

346

89

1011

33 32 31 3054 3 2

404546

35

7 53

25 51

2

1

tank lock-off valve

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

180/70018 VSI wiring diagram 8 cylinder LPG (with connectors)

43 15 18 17 2223

fuel switch

50

main ground

VSI LPG ECU

manufacturer : Prins version : software :

Engine control relay

VSI injectors

ecu side inj 8 ecu side inj 7

red-yellow

light blue-yellow

G INJ B plus

G INJ OUT 6 G INJ OUT 5

+ LPG injectors

ecu side inj 6 ecu side inj 5

brown-yellow grey-yellow red black

brown-yellow grey-yellow

1

2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white black grey blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

black ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed

ECT sensor ground

ECT coolant temp.

sealed beeper low switching

diagnose LED

color

brown

green

black orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1 whi te-yellow

RPM engine speed purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground

tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

Prins Alternative Fuel Systems

Version nr. / date

Checked by :

Designed :

T.S. 23-04-2007

Approved by :

Description :

1 / 29-05-2007

+12 volt diagnose

red

ground

18

+5 Volt MAP red

50

switch ground

brown

G INJ OUT 8 G INJ OUT 7

red-yellow

light blue-yellow

lambda bank 2

orange-white

42

t°

2 1

T-ect sensor

injection module cylinder 5-6-7-8

T.S. 23-04-2007 T.S. 23-04-2007

8 cyl. with conn.

1/1Sheet :

Project name :

injector fuse

+ LPG injectors

injector fuse

main fuse

64

Diagram 31 LPG wiring 180/70008

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer :

version : software :

tank gauge

reducer lock-off valve

Filter unit Psys / T-lpg sensor

Hall sensor engine RPM

Oxygen sensor 1 Bank 2

t°

1 2 3 4

Petrol injectors

1

2

3

4

5

6

7

8

Oxygen sensor 1 Bank 1

t°

346 33 32 31 3054 3 2

404546

35

7 53

25 51

2

1

tank lock-off valve

2

1

31 Battery ground

ecu side inj 8 ecu side inj 7

red-yellow

light blue-yellow

+ LPG

48 4912

30 battery +12V

15 ignition switch

180/70008 VSI wiring diagram 8 cylinder LPG (without connectors)

15 18 17 22 23

fuel switch

50

main ground

VSI LPG ECU

manufacturer : Prins version : software :

Engine control relay

VSI injectors

+ - + - + - +

-

1212 12 12

5

6

7

8

Petrol injectors

+ - + - + - +

-

1212 12 12

G INJ B plus

G INJ OUT 6 G INJ OUT 5

+ LPG injectors

ecu side inj 6 ecu side inj 5

brown-yellow grey-yellow red black

brown-yellow grey-yellow

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white black grey blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

black ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching

diagnose LED

color

brown

green

black orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1

white-yellow

RPM engine speed

purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

Prins Alternative Fuel Systems

Version nr. / date

Checked by :

Designed :

T.S. 23-04-2007

Approved by :

Project name :

1 / 29-05-2007

+12 volt diagnose

red

ground

18

+5 Volt MAP

red

50

switch ground

brown

G INJ OUT 8 G INJ OUT 7

red-yellow

light blue-yellow

lambda bank 2

orange-white

43 42

t°

2 1

T-ect sensor

injection module cylinder 1-2-3-4

26 27 13543938 37 36 89

1011

injection module cylinder 5-6-7-8

main fuse

R.K. 23-04-2007 R.K. 23-04-2007

8 cyl. without conn. 1/1Sheet :

Project name :

injector fuse

+ LPG injectors

injector fuse

65

Diagram 32 LPG wiring 080/72040

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer : n.a. version : n.a. software : n.a.

tank

gauge

reducer lock-off valve

Hall sensor

engine RPM

26 27 1354

1

2

3

4

Oxygen sensor 1 Bank 1

t°

34 33 32 31

4046

35

53

25 51

main fuse 2 A

2

1

tank

lock-off

valve

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

080/72040 VSI wiring diagram 4 cylinder LPG (without connectors)

43 42 15 18 17 2223

50

main ground

Engine control relay

VSI injectors

36373839

Filter unit

Psys / T-lpg sensor

+ - + - + - +

-

Petrol injectors

1 2 3 4

30

1

2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white

black

grey

blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

green-yellow ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed

ECT sensor ground

ECT coolant temp.

sealed

beeper low switching diagnose LED

color

brown

green

black orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1

white-yellow

RPM engine speed purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

sealed

+12 volt diagnose

red

sealed

ground

sealed sealed sealed sealed sealed sealed sealed sealed sealed

18

+5 Volt MAP red

50

switch ground

brown

t°

2 1

fuel switch

T-ect sensor

injection module cylinder 1-2-3-4

A2

C2

B2

C3

B3

C4

B4

C5

B5

A3 A4 A5C8B8 B1

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector

vsi ecm

white-yellow

green-yellow pink-yellow blue-yellow

white

green pink blue

grey-white

red-white

13 ingnition plus

39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4

26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

white-yellow

green-yellow pink-yellow blue-yellow

vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu

39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4

min inj side 2 min inj side 3 min inj side 4

injection module

injector

fuse

10 A

+ LPG injectors

Injection module

manufacturer : Prins part number : 091/71004 version : A

VSI ECU

manufacturer : Prins part number : 080/70001

software : S209 / S211

version : C / D

Prins Alternative Fuel Systems

Approved by / date

Designed by / date

Description :

Checked by / date

Project name :

R.K. 23-04-2007

1/1Sheet :

Revision by / date

T.S. 23-04-2007

Part nr :

4 cyl. without conn.

R.K. 03-07-2007

080/72040

66

Diagram 33 LPG wiring 080/72045

Petrol ECU

manufacturer : n.a. version : n.a. software : n.a.

tank gauge

reducer lock-off valve

Hall sensor engine RPM

+

-

1 2 3 4

Petrol injectors

26 27 1354

1 2 1 2 1 2 1 2

39 38 37 36

34 33 32 31 30

40

35 53

25 51

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

080/72045 VSI Wiring diagram 4 cylinder LPG (with connectors)

fuel switch

50

Engine control relay

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white

black

grey

blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

green-yellow ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching diagnose LED

color

brown

green

black

orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1

white-yellow

RPM engine speed

purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

Prins Alternative Fuel Systems

Revision / by / date

Checked by / date

Designed by/ date TS / 23-04-07

Approved by / date

sealed

+12 volt diagnose

red

ground

sealed sealed sealed sealed sealed sealed sealed sealed sealed

18

+5 Volt MAP red

50

switch ground

brown

A2

B2

C2

B3

C3

B4

C4

B5

C5

A3 A4 A5C8B8 B1

main fuse 2 A

injector

fuse

10 A

+ LPG injectors

Sheet : 1/1

Description :

Injection module

manufacturer : Prins part number : 091/71004 version : A

Part nr :

4 cyl. with conn.

080/72045

A1 A2 A3 A4 A5 A6

B6

A7

A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector

vsi ecm

white-yellow green-yellow pink-yellow blue-yellow

white green pink blue

grey-white

red-white

13 ingnition plus

39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4

26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

white-yellow green-yellow pink-yellow blue-yellow

vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu

39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4

min inj side 2 min inj side 3 min inj side 4

injection module

VSI ECU

manufacturer : Prins part number : 080/70001

software : S209 / S211

version : C / D

Project name :

Oxygen sensor 1 Bank 2 (optional)

t°

Oxygen sensor 1

Bank 1

t°

4546

lambda bank 2

orange-white

VSI injectors

1

2

3

4

1 14 29

RK / 26-10-07

main ground

-1 JT / 26-10-07

tank lock-off valve

2

1

diagnosis connector

1 2 3 4

t°P

U

contra connector

43 42 15 18 17 22 23

Filter unit Psys / T-lpg sensor

t°

2 1

T-ect sensor

44 16

+ 5V

sensor

(optional)

MAP

(optional)

TPS

(optional)

MAP ground

sensor

(optional)

67

Diagram 34 LPG wiring 080/72050

Injection module

manufacturer : Prins part number : 091/71006 version : A

VSI ECU

manufacturer : Prins part number : 080/70003

software : S209 / S211

version : C / D

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer : n.a. version : n.a. software : n.a.

tank gauge

reducer lock-off valve

Hall sensor engine RPM

Oxygen sensor 1

Bank 2

t°

Oxygen sensor 1 Bank 1

t°

346 33 32 31 30 5 4

404546

7 53

25 51

2

1

tank lock-off valve

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

080/72050 VSI wiring diagram 6 cylinder LPG (without connectors)

15 18 17 22 23

fuel switch

50

Engine control relay

G INJ B plus

G INJ OUT 6 G INJ OUT 5

ecu side inj 6 ecu side inj 5

brown-yellow grey-yellow red

brown-yellow grey-yellow

Filter unit Psys / T-lpg sensor

+ - + - + - +

-

+ - +

-

Petrol injectors

1 2 3 4 5 6

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white black grey blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

green-yellow ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching diagnose LED

color

brown

green

black

orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1

white-yellow

RPM engine speed

purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

sealed

+12 volt diagnose

red

ground

sealed

sealed sealed

18

+5 Volt MAP red

50

switch ground

brown

lambda bank 2

orange-white

43 42

t°

2 1

T-ect sensor

injection module

1-2-3-4-5-6

B4 C4 B3 C3 B2 C2 A2 A3 A4 A5 A6 A7C8B8 B1

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector petrol injector petrol injector vsi ecm

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

white green pink blue grey brown

grey-white

red-white

13 ingnition plus

39 ecu side 1 38 ecu side 2 37 ecu side 3

36 ecu side 4 11 ecu side 5 10 ecu side 6

26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu petrol ecu petrol ecu

39 ecu side 1 38 ecu side 2 37 ecu side 3

36 ecu side 4 11 ecu side 5 10 ecu side 6

min inj side 2

min inj side 3

min inj side 4

min inj side 5

min inj side 6

injection module

26 27 1354101136373839

C5

B5

C6

B6

C7

B7

main

fuse 2 A

injector fuse

10 A

+ LPG injectors

green-yellow

Prins Alternative Fuel Systems

Approved by / date

Designed by / date

Description :

Checked by / date

Project name :

1/1Sheet :

Revision by / date

T.S. 23-04-07

Part nr :

6 cyl. without conn.

080/72050

R.K. 26-10-07

-1 / J.T. 26-10-07

1

2

3

4

5

6

VSI injectors

1 14 29

main ground

35

+ LPG injectors

+ 5V

sensor

(optional)

MAP ground

sensor

(optional)

44 16

MAP

(optional)

TPS

(optional)

68

Diagram 35 LPG wiring 080/72055

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer : n.a. version : n.a. software : n.a.

tank gauge

reducer lock-off valve

Hall sensor engine RPM

Oxygen sensor 1 Bank 2

t°

1 2 3

Petrol injectors

26 27 1354

1 2 1 2 1 2

Oxygen sensor 1 Bank 1

t°

346 33 32 31 30 5 4

404546

35 7

53

25 51

2

1

tank lock-off valve

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

080/72055 VSI wiring diagram 6 cylinder LPG (with connectors)

15 18 17 22 23

fuel switch

50

Engine

control

relay

1 2 1 2 1 2

101136373839

4 5 6

Filter unit Psys / T-lpg sensor

G INJ B plus

G INJ OUT 6 G INJ OUT 5

+ LPG injectors

ecu side inj 6 ecu side inj 5

brown-yellow

grey-yellow

red

green-yellow

brown-yellow

grey-yellow

1

2 3 4

5 6 7

8 9

10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white

black

grey

blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD

sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

green-yellow ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching diagnose LED

color

brown

green

black orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1

white-yellow

RPM engine speed purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

sealed

+12 volt diagnose

red

ground

sealed

sealed sealed

18

+5 Volt MAP red

50

switch ground

brown

lambda bank 2

orange-white

43 42

t°

2 1

T-ect sensor

injection module

1-2-3-4-5-6

C4 B4 C3 B3 C2 B2

B5 C5 B6 C6 B7 C7

A2 A3 A4 A5 A6 A7C8B8 B1

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector petrol injector petrol injector vsi ecm

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

white green pink blue grey brown

grey-white

red-white

13 ingnition plus 39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4 11 ecu side 5 10 ecu side 6 26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

white-yellow green-yellow pink-yellow blue-yellow grey-yellow brown-yellow

vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu petrol ecu petrol ecu

39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4 11 ecu side 5 10 ecu side 6

min inj side 2 min inj side 3 min inj side 4 min inj side 5 min inj side 6

injection module

Main fuse 2A

Injector fuse 10 A

+ LPG injectors

Injection module

manufacturer : Prins part number : 091/71006 version : A

VSI ECU

manufacturer : Prins part number : 080/70003

software : S209 / S211

version : C / D

Prins Alternative Fuel Systems

Approved by / date

Designed by / date

Description :

Checked by / date

Project name :

R.K. 26-10-07

1/1Sheet :

Revision by / date

T.S. 23-04-07

Part nr :

6 cyl. with conn.

080/72055

-1 / J.T. 26-10-07

1 14 29

main ground

+ 5V

sensor

(optional)

MAP ground

sensor

(optional)

44 16

MAP

(optional)

TPS

(optional)

1

2

3

4

5

6

VSI injectors

69

Diagram 36 LPG wiring 080/72060

VSI ECU

manufacturer : Prins part number : 080/70003

software : S209 / S211

version : C / D

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer : n.a. version : n.a. software : n.a.

tank gauge

reducer lock-off

valve

Filter unit Psys / T-lpg sensor

Hall sensor engine RPM

Oxygen sensor 1 Bank 2

t°

1 2 3 4

Petrol injectors

1

2

3

4

5

6

7

8

Oxygen sensor 1 Bank 1

t°

346 33 32 31 30 5 4 3 2

404546

35 7 53

25 51

2

1

tank

lock-off

valve

2

1

31 Battery ground

ecu side inj 8 ecu side inj 7

red-yellow

light blue-yellow

+ LPG

48 4912

30 battery +12V

15 ignition switch

080/72060 VSI wiring diagram 8 cylinder LPG (without connectors)

15 18 17 22 23

fuel switch

50

Engine control relay

VSI injectors

+ - + - + - +

-

1212 12 12

5 6 7 8

Petrol injectors

+ - + - + - +

-

1212 12 12

G INJ B plus

G INJ OUT 6 G INJ OUT 5

+ LPG injectors

ecu side inj 6 ecu side inj 5

brown-yellow grey-yellow red green-yellow

brown-yellow grey-yellow

1

2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white black grey blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

green-yellow ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching diagnose LED

color

brown

green

black orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1 white-yellow

RPM engine speed purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground

tank valve ground

diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

+12 volt diagnose

red

ground

18

+5 Volt MAP red

50

switch ground

brown

G INJ OUT 8 G INJ OUT 7

red-yellow

light blue-yellow

lambda bank 2

orange-white

43 42

t°

2 1

T-ect sensor

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector

vsi ecm

white-yellow

pink-yellow blue-yellow

white green pink blue

grey-white

red-white

13 ingnition plus

26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu

39 ecu side 1

37 ecu side 3 36 ecu side 4

min inj side 2 min inj side 3 min inj side 4

green-yellow 38 ecu side 2

white-yellow

pink-yellow blue-yellow

green-yellow

39 ecu side 1

37 ecu side 3 36 ecu side 4

38 ecu side 2

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector

vsi ecm

grey-yellow

lightblue-yellow red-yellow

grey brown light blue red

grey-white

red-white

13 ingnition plus

26 inj. mod. command

min inj side 5

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu

11 ecu side 5

9 ecu side 7 8 ecu side 8

min inj side 6 min inj side 7 min inj side 8

brown-yellow 10 ecu side 6

grey-yellow

lightblue-yellow red-yellow

brown-yellow

11 ecu side 5

9 ecu side 7 8 ecu side 8

10 ecu side 6

injection module A injection module B

injection module cylinder 1-2-3-4

26 27 13543938 37 36 89

1011

C2

C3

C4

C5

B2

B3

B4

B5

A2 A3 A4 A5C8B8 B1

injection module cylinder 5-6-7-8

B8C8A2 A3 A4 A5 B1

C2

C3

C4

C5

B2

B3

B4

B5

Main

fuse 2 A

Injector fuse 15 A

+ LPG injectors

Injection module

manufacturer : Prins part number : 091/71004 version : A

Injection module

manufacturer : Prins part number : 091/71004 version : A

Prins Alternative Fuel Systems

Approved by / date

Designed by / date

Description :

Checked by / date

Project name :

1/1Sheet :

Revision by / date

T.S. 23-04-07

Part nr :

8 cyl. without conn.

080/72060

R.K. 26-10-07

-1 / J.T. 26-10-07

1 14 29

main ground

+ LPG injectors

+ 5V

sensor

(optional)

MAP ground

sensor

(optional)

44 16

MAP

(optional)

TPS

(optional)

70

Diagram 37 LPG wiring 080/72065

diagnosis connector

1 2 3 4

t°P

U

contra connector

Petrol ECU

manufacturer : n.a. version : n.a. software : n.a.

tank gauge

reducer lock-off valve

Filter unit Psys / T-lpg sensor

Hall sensor engine RPM

Oxygen sensor 1

Bank 2

injection module

cylinder 1-2-3-4

+

-

t°

1 2 3 4 5 6 7 8

Petrol injectors

26 27 1354

1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2

39 38 37 36

Oxygen

sensor 1

Bank 1

t°

6

89

1011

404546

35 7 53

25 51

2

1

tank lock-off valve

2

1

31 Battery ground

+ LPG

48 4912

30 battery +12V

15 ignition switch

080/72065 VSI wiring diagram 8 cylinder LPG (with connectors)

43 1518 17 22 23

fuel switch

Engine control relay

ecu side inj 8 ecu side inj 7

red-yellow

light blue-yellow

G INJ B plus

G INJ OUT 6 G INJ OUT 5

+ LPG injectors

ecu side inj 6 ecu side inj 5

brown-yellow grey-yellow red green-yellow

brown-yellow grey-yellow

1

2 3 4

5

6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys +5 Volt Psys

T-LPG lpg temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white black grey blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

G INJ A plus

RS232 TxD RS232 RxD

sealed

inj. mod. command

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ LPG injectors

green-yellow ecu side inj 4 ecu side inj 3

ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching diagnose LED

color

brown

green

black orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1

white-yellow

RPM engine speed purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground Psys sensor ground

brown brown

50 50 50 50

51 51

color

51

52

reducer valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power reducer valve

green-yellow

brown

red green-yellow

54

INJ simulator ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

+12 volt diagnose

red

ground

18

+5 Volt MAP red

50

switch ground

brown

G INJ OUT 8 G INJ OUT 7

red-yellow

light blue-yellow

lambda bank 2

orange-white

42

t°

2 1

T-ect sensor

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector

vsi ecm

white-yellow

pink-yellow blue-yellow

white

green pink blue

grey-white

red-white

13 ingnition plus

26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu

39 ecu side 1

37 ecu side 3 36 ecu side 4

min inj side 2 min inj side 3 min inj side 4

green-yellow 38 ecu side 2

white-yellow

pink-yellow blue-yellow

green-yellow

39 ecu side 1

37 ecu side 3 36 ecu side 4

38 ecu side 2

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector

vsi ecm

grey-yellow

lightblue-yellow red-yellow

grey brown light blue red

grey-white

red-white

13 ingnition plus

26 inj. mod. command

min inj side 5

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu

11 ecu side 5

9 ecu side 7 8 ecu side 8

min inj side 6 min inj side 7 min inj side 8

brown-yellow 10 ecu side 6

grey-yellow

lightblue-yellow red-yellow

brown-yellow

11 ecu side 5

9 ecu side 7 8 ecu side 8

10 ecu side 6

injection module A injection module B

B2

B3

B4

B5

C2

C3

C4

C5

A2 A3 A4 A5C8B8 B1

B2

B3

B4

B5

C2

C3

C4

C5

B8C8A2 A3 A4 A5 B1

injection module

cylinder 5-6-7-8

Main fuse 2 A

Injector

fuse

15 A

+ LPG injectors

VSI ECU

manufacturer : Prins part number : 080/70003

software : S209 / S211

version : C / D

Injection module

manufacturer : Prins part number : 091/71004 version : A

Injection module

manufacturer : Prins part number : 091/71004

version : A

Prins Alternative Fuel Systems

Approved by / date

Designed by / date

Description :

Checked by / date

Project name :

1/1Sheet :

Revision by / date

Part nr :

8 cyl. with conn.

080/72065

T.S. 23-04-07

1

2

3

4

5

6

7

8

34 33 32 31 30 5 4 3 2

VSI injectors

main ground

+ LPG injectors

R.K. 26-10-07

-1 / J.T. 26-10-07

50 1 14 29

+ 5V

sensor

(optional)

MAP ground

sensor

(optional)

44 16

MAP

(optional)

TPS

(optional)

71

Diagram 38 CNG wiring 095/72045

+

-

1 2 3 4

1 2 1 2 1 2 1 2

diagnosis connector

contra connector

pressure gauge WIKA

Main lock-off valve

26 27 1354

1

2

3

4

Oxygen sensor 1 Bank 1

t°

34 33 32 31

46

35

53

25 51

2

1

31 Battery ground

+ CNG

48 4912

30 battery +12V

15 ignition switch

CNG Wiring diagram 4 cylinder connector CNG NOT RELEASED!

22 23

fuel switch IGPS CNG

50

Engine control relay

VSI injectors

36373839

Petrol injectors

30

tank

lock-off

valve

2

1

P

U

1 2 3 4

Spare connector

Spare contra connector

1 2

3

Main fuse 2 A

Injector fuse 10 A

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

19

ground

MAP Psys

T-Gas cng temp.

ignition +

pulse fuel switch

sealed

color

black

yellow grey-white black grey blue

light green

red

31 32 33 34 35 36 37 38

+12 volt battery

ignition +

+ G INJ A OUT

RS232 TxD RS232 RxD sealed

sealed G INJ A ground G INJ OUT 4

color

grey

red red-white

pink-yellow green-yellow white-yellow red

grey-white

black blue-yellow

grey

23 24 25 26 27 28 29 30

20 21 22

sealed sealed

G INJ OUT 3 G INJ OUT 2 G INJ OUT 1

+ G INJ A IN

green-yellow ecu side inj 4 ecu side inj 3 ecu side inj 2

pink-yellow

green-yellow

blue-yellow

TPS throttle position

sealed ECT sensor ground

ECT coolant temp.

sealed beeper low switching

diagnose LED

color

brown

green

black orange

42

43 44 45 46 47 48 49

39

40 41

ecu side inj 1 white-yellow

RPM engine speed

purple-white

grey

lambda bank 1

orange

42 42

MAP sensor ground brown

brown

50 50 50 50

51 51

color

51

52

main valve ground main ground tank valve ground diagnose ground

+12 volt fuel switch

brown brown brown brown

red

+12 volt battery

red

53 53

sealed

53

power fuel indication power tank valve power main valve

green-yellow

brown

red green-yellow

54

INJ module ground

55 56

sealed sealed

vsi wire vsi wire vsi wire vsi wire

sealed

+12 volt diagnose

red

lambda bank 2

ground

sealed sealed sealed sealed sealed sealed sealed sealed sealed

18

+5 Volt MAP red

50

switch ground

brown

1 3 4

+ CNG injectors

Petrol ECU

manufacturer : n.a.

version : n.a. software : n.a.

Injection module

manufacturer : Prins part number : 091/71004 version : A

VSI ECU

manufacturer : Prins part number : 080/70001

software :

version : C / D

Prins Alternative Fuel Systems

Revision / by / date

Checked by / date

Designed by/ date JT / 18-09-07

Approved by / date

Sheet : 1/1

Description :

Part nr :

CNG 4 cyl. conn.

095/72045

Project name :

095/72045

2

40

Optional PTO use

Optional

injection module cylinder 1-2-3-4

A2

B2

C2

B3

C3

B4

C4

B5

C5

A3 A4A5C8 B8 B1

A1 A2 A3 A4 A5 A6

B6

A7 A8 B1 B2 B3 B4 B5

B8

B7

vsi ecu

C6

C1 C2 C3 C4 C5

C8

C7

petrol injector petrol injector petrol injector petrol injector

vsi ecm

white-yellow green-yellow pink-yellow blue-yellow

white green pink blue

grey-white

red-white

13 ingnition plus 39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4

26 inj. mod. command

min inj side 1

brown 54 inj. mod. ground

petrol ecu petrol ecu

vsi ecu

white-yellow green-yellow pink-yellow blue-yellow

vsi ecu vsi ecu vsi ecu vsi ecu

petrol ecu petrol ecu

39 ecu side 1 38 ecu side 2 37 ecu side 3 36 ecu side 4

min inj side 2 min inj side 3 min inj side 4

injection module

1 3 42

Hall sensor engine RPM or Tacho signal

Oxygen sensor 2 Bank 2

t°

45

1 14 29

orange-white

t°

1 2 3 4

t°P

U

T-ect sensor

43 42 15 18 17

Filter unit Psys / T-cng sensor

2 1

1 2

3

16

1 2

3

Map/Turbo connector

Map/Turbo contra connector

Optional

Map/Turbo sensor use

main ground

26 Inj. mod.command

+5 Volt P/T sys

P/Tsys sensor ground

72

Diagram 39 VSI-2.0 wiring 191/040002

73

Trouble code chart LPG

Trouble code

Definition

Check / solution

100

Lambda to long to rich.

Check when operating on petrol and LPG that there is good lambda signal movement.

101

Lambda to long to lean.

Check when operating on petrol and LPG that there is good lambda signal movement.

102

Lambda to long to lean during open loop.

Check when operating on petrol and LPG that there is good lambda signal movement.

110

T-ECT>= 171°C

Check if the ECT sensor (blue) in the reducer is connector is connected to ground.

111

T-ECT>= -40°C

Check if the ECT sensor (blue) in the reducer has a power connection.

120

T-LPG>= 171°C

Check the ground connection of the Pressure/temperature sensor in the filter unit.

121

T-LPG>= -40°C

Check the power connection of the Pressure/temperature sensor in the filter unit.

150

Psys<= Low_Level

Based on a pressure drop in the system, this can be caused by an empty LPG tank, incorrect solenoid valve, polluted filter or incorrectly adjusted pressure.

160

ECM-VSI not activated

Activate the LPG computer with the diagnostic program, using the F11 function key.

180

T-Board >= 90°C

LPG computer circuit board to hot, replace the VSI computer in a cooler area.

181

Battery voltage to high

Check board voltage / alternator output and condition of the battery.

210-220-230-240-250-260-270-280

VSI injector overload

Injector current to high, check for short circuiting

211-221-231-241-251-261-271-281

VSI injector noload

Injector current to low, check for bad connections. 310

Adjusted pressure on idle out of range

Adjust the idle pressure to the value shown by parameter “ Idle Level “

311

Programm error during flahing the memory

Check parameter settings, contact Prins Autogassystemen.

320

Psys voltage to low

Check the ground connection of the Pressure/temperature sensor in the filter unit.

321

Psys voltage to high

Check the power connection of the Pressure/temperature sensor in the filter unit.

322

Psys > 3,5 Bar

Check the coolant temperature (T-ect) and the evaporator for leakage of the first stage.

330

unexpected parameter change

Contact Prins Autogassystemen.

340

reducer warms up to slow

Check the water connections / circuit.

341

Gas leakage, system pressure is less then

1.25 bar after 4 hours when the engine is not running

Check the system for gas leakage. div.

System switches to LPG but engine stalls immediately.

LPG tank empty ? Lock-off valves open ?

div.

No injection timing on LPG ( 0 Msec.)

Check the injection module.

div.

The LPG system switches constantly between LPG and Petrol

- Check coolant system for air.

- T-ect sensor in the evaporator malfunction.

div.

Engine hesitates on high revs, and not running on all cylinders. Engine runs good on idle.

Check for kinked or jammed LPG hoses (between VSI injector and couplings). Check for blocked inlet couplings.

div.

Switch LED’s don’t lit up

Check the main fuse of the VSI system Check ignition+ (VSI wire 13)

div.

Fault codes when turning the ignition off ( key out the ignition )

Caused by different switch off times between ignition+ and injector power. Connect VSI wire 13 to the petrol injector feed instead of ignition+.

div.

The orange LED on the switch flashes

Activate the LPG computer with the diagnostic program, using the F11 function key.

div.

The LPG system switches to LPG but engine stalls immediately

LPG tank empty? div.

Not running on all cylinders on lpg

Check parameter 10, number of cylinders.

div.

No injection times on lpg

Check the connections of the injection module.

div.

Injection time “falls” to 0 mSec on

LPG

Check the injection module.

div.

Check engine while running on LPG, injector circuit malfunction, no lambda control (limb home)

Replace injection module div.

Not starting / running on petrol

Check the connections of the injection module.

74

Dealer stamp

Maintenance instructions

When you drive on LPG/CNG, maintaining your car is even more important than when using petrol. Since the specifications of LPG/CNG differ from those of petrol, minor engine problems which won't disturb the driving comfort while using petrol, may cause major problems while using CNG. Follow the maintenance instructions in order to use LPG/CNG without any problem.

 General maintenance to the car regarding spark plugs, spark plug cables, ignition circuit, valves, etc., has

to be carried out according to the instructions of the car manufacturer.

 Proof of maintenance according to the guidelines of the importer is obligatory (completely filled in

maintenance booklet).

 Maintenance has to be carried out by a dealer authorised by the importer.  Adjustments and repairs on your Prins VSI- system should only be carried out by a dealer authorised by

Prins Autogassystemen B.V.

MAINTENANCE AND SERVICE Registration of maintenance and service of the VSI-LPG system.

25.000 km

or after 2 years

100.000 km

or after 2 years

175.000 km

or after 2 years

250.000 km

or after 2 years

Checklist executed services:

Lock off valve filter replacement* Filter unit filter replacement* Hoses + filling hoses checked Fastening of components checked Electrical connection + wiring checked Checked for fuel leakage Checked for trouble codes (petrol and

LPG) + system pressure Checked for exhaust emissions Tightening torque of the allen screws

of the reducer checked at 8Nm

      



      



      



      



Number of kilometres: Date:

Number of kilometres:

Date:

Number of kilometres:

Date:

Number of kilometres:

Date:

*The service intervals of the filter replacements may be divergent because of the variable LPG quality. Ask your Prins dealer for more information.

75

Dealer stamp

Registration of maintenance and service of the VSI-CNG system.

25.000 km

or after 2 years

100.000 km

or after 2 years

175.000 km

or after 2 years

250.000 km

or after 2 years

Checklist executed services:

Keihin inlet filter replacement* Filter unit filter replacement* Hoses + pipes checked Fastening of components checked Electrical connection + wiring checked Checked for fuel leakage Checked for trouble codes (petrol and

CNG) + system pressure Checked for exhaust emissions

      



      



      



      



Number of kilometres: Date:

Number of kilometres:

Date:

Number of kilometres:

Date:

Number of kilometres:

Date:

*The service intervals of the filter replacements may be divergent because of the variable CNG quality. Ask your Prins dealer for more information.

76

Checklist after installation

1. Connect the serial interface cable and run the VSI diagnosis program. Install the VSI main fuse, and program the fuel switch.

Turn the ignition key in the accessory position. When working on the car, beware of moving and rotating parts in the engine compartment.

2. When commissioning the LPG/CNG system, you must activate the VSI computer with the diagnosis software. When the VSI-I computer has not been activated, it will keep generating error code 160. To activate the VSI-I computer, select function F11 (activate ECM). After activation erase foultcode 160.

3. Check whether the program in the VSI computer matches with the car ( dedicated engine set ): Refer with F2 to the box number and car description in the diagnosis software and compare these with the set number.

4. The system will switch over to LPG/CNG as soon as the temperature of the coolant (T-ect)

becomes higher than the parameter T-min set and when the TSO-cold time is expired.

5. Check all components and connections for any gas leakage ( use a LPG/CNG leak detector device ) or foam leak spray. Caution for moving and rotating parts in the engine compartment !

6. Let the engine run warm on petrol >80°C. Check if the evaporator/coolant water heats up. Check the engine signals: petrol injection time, RPM, ECT, lambda

Let the engine run idle on LPG/CNG.

Adjust the LPG evaporator pressure. Refer to the parameter list ( or F2 : ID box) for the idle level value set. Adjust the LPG evaporator pressure in such a way that the pressure measured ( P-sys ) equals the idle level value. Turn the socket-head screw at the front of the evaporator to adjust the pressure. An error code will be generated whenever the pressure variation is to high. Seal the evaporator with the sticker included in the delivery after having adjusted the pressure.

7. Use the diagnosis software to check again all input and output signals.

8. Check the system for error codes and solve these, if required. Check the petrol MMS for EOBD error codes.

Place the protection connector on the VSI communication connector.

9. Make a test drive and check the driveability on LPG/CNG and petrol.