MAKE OF AUTOMOBILE: BMW TYPE: 650 Ci PISTON

Transcription

MAKE OF AUTOMOBILE:
TYPE:
PISTON DISPLACEMENT:
NUMBER OF VALVES:
ENGINE NUMBER:
TRANSMISSION TYPE ( MT / AT )
VEHICLE CATEGORIES M or N
TYPE VSI INJECTOR ( NUMBER + COLOR )
VERSION ( LPG / CNG )
INJECTION SYSTEM:
MODEL YEAR:
SYSTEM APPROVAL NUMBER ( R115 )
LOCATION SYSTEM STICKER
ENGINE SET NUMBER
Copyright © Prins Autogassystemen B.V. 2008
BMW
650 Ci
4800 CC
32 V
N62B48
AT
M
2 X 180/30440 YELLOW
LPG
BOSCH MOTRONIC ME
2005
R115-000059
right side, centre door post
343/1780000
NUMBER :
DATE :
VERSION NR :
076/0301100
06-06-2007
09-05-2007 B
TABLE OF CONTENTS
Required equipment / tools / materials for installing a complete system ...........................................2
Vehicle check......................................................................................................................................2
Base diagram......................................................................................................................................3
VSI approval numbers ........................................................................................................................4
Mounting and connection points .........................................................................................................5
Mounting the reducer ..........................................................................................................................6
Mounting the inlet manifold couplings bank 1.....................................................................................7
Mounting the inlet manifold couplings bank 2.....................................................................................8
Mounting the VSI injector rail..............................................................................................................9
Mounting the filter unit...................................................................................................................... 10
LPG hoses ....................................................................................................................................... 10
Mounting the VSI computer ............................................................................................................. 11
Mounting the fuel selection switch ................................................................................................... 12
Electrical connections ...................................................................................................................... 13
Check and measure the wiring in case of changes in the cars wiring colors.................................. 13
Checklist after installation ................................................................................................................ 16
Trouble code chart ........................................................................................................................... 17
FOR EXPLANATION AND CIRCUIT DIAGRAMS SEE : INSTALLATION MANUAL GENERAL PART 1 / 2
www.Prins.eu
EXPLANATION OF SYMBOLS :
= IMPORTANT, CAUTION
PAGE 2
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
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
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 )
2
+
-
+
-
+
-
+
+
petrol ECU
Designed :
T.S. 22-01-2007
Version / Date : 4 / 20-12-2007
-
petrol injectors
-
-
-
+
-
+
engine RPM
+
petrol injectors
Part :
Injector simulator
Part nr. :
091/71004
Part :
Injector simulator
Part nr. :
091/71004
ignition+
Part :
Part nr. :
-
Part :
Part nr. :
Part nr. :
LPG approval :
T-lpg + Psys sensor
080/70032
battery
+
reducer
180/10003 ( 8mm )
180/10013 ( 8mm MAP )
E4-67R-010054
reducer lock-off valve
081/13014 (8mm)
E4-67R-010041 Valtec
E8-67R-014327 OMB
T-ect sensor
077/70001
Part :
Part nr. :
LPG approval :
LPG approval :
Part :
Part nr. :
E13-110R-000017
overpressure hose
E13-110R-000017
CNG approval : E4-110R-000003
Part :
11 mm LPG hose
Part nr. :
081/24003
LPG approval : E4-67R-010068
E13-67R-010145
Part :
16 mm LPG hose
Part nr. :
081/25001
E13-67R-010145
Part :
Filter unit
Part nr. :
080/80210
VSI base diagram 8 cylinder LPG (080/72060)
BLUE
GROUND SIGNAL
BLACK
PRINS
Tank gauge
080/70065 Hall
080/70064 0-90 Ohm
085/20020 0-95 Ohm
E13-110R-000017
tank lock-off valve
Part :
Part nr. :
Part nr. :
Part nr. :
Part :
5 mm LPG hose
Part nr. :
081/23001
E13-67R-010145
Part :
Part nr. :
Part nr. :
Part nr. :
0
1
2
Fuel switch
080/70058 Hall / Ohm
080/70059 93-9,3 Ohm
080/70063 0-5 Volt
1
inlet manifold
petrol injector
diagnose
connector
Part :
Part nr. :
connector cover
080/70130
Lambda sensor
exhaust manifold
Part :
Injector rail
Part nr. :
180/304**
wiring loom
080/72060
Part :
VSI computer
Part nr. :
080/70003
Part :
Part nr. :
Lambda sensor
PAGE 3
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Base diagram
3
PAGE 4
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
VSI approval numbers
Reducer VSI LPG Prins : E4-67R-010054
Lock-off valve OMB
: E8-67R-014327
Lock-off valve Valtek
: E4-67R-010041
Injector rail Prins : LPG E4-67R-010093
CNG E4-110R-000021
Filter unit T1 / T2 Prins : LPG E4-67R-010096
CNG E4-110R-000028
Injector Keihin :LPG E4-67R-010092
CNG E4-110R-000020
Computer VSI- 4 / 8 / 10 Prins: LPG E4-67R-010098
CNG E4-110R-000083
LPG hoses Tubithor : LPG E13-67R-010145
CNG E13-110R-000017
Rubia : LPG E4-67R-010068
CNG E4-110R-000003
4
PAGE 5
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Mounting and connection points
A
B
C
D
E
F
G
:
:
:
:
:
:
:
Reducer
Filter unit
Injector rail
VSI Computer
Injection module
Water connections
“+” ignition ( 13 )
H
I
J
K
L
M
: Engine speed signal RPM ( 40 )
: Lambda signal ( 45 + 46 ): na
: “-“ interruption petrol injector
: Overpressure coupling
: Approval sticker: na
: grummet
R115 approval sticker :
Right side centre door post
5
PAGE 6
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Mounting the reducer
Drill a ø 9 mm hole into the left of the bumper bar. Mount the bracket with a M8 bolt/nut.
Overpressure hose coupling: left side, behind throttle body, drill ø 5 mm and tap M6x1 thread into
this hole. Mount a coupling with a locking compound.
Water connections: parallel, see pictures.
left water connection
overpressure coupling
right water connection
hole for pressure adjustment
6
PAGE 7
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Mounting the inlet manifold couplings bank 1
Remove the inlet manifold.
Drill 4 holes of 5 mm in the inlet manifold.
Tap M6x1 thread in these holes.
Place the VSI couplings with a lock compound in the inlet manifold.
Watch out that the lock compound doesn’t come inside the VSI couplings.
BANK 1 : right side engine
Cylinder 1 = the cylinder closest to the timing belt / chain
7
PAGE 8
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Mounting the inlet manifold couplings bank 2
Remove the inlet manifold.
Drill 4 holes of 5 mm in the inlet manifold.
Tap M6x1 thread in these holes.
Place the VSI couplings with a lock compound in the inlet manifold.
Watch out that the lock compound doesn’t come inside the VSI couplings.
BANK 2 : left side engine
8
PAGE 9
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Mounting the VSI injector rail
Mount the 5 mm hoses onto the couplings. Attach a M6 bolt onto the frame and secure with two nuts (
see picture ). Before installing the rail and frame, install the VSI injector wiring. Mount the combination
onto the existing hole in the petrol rail and secure with a M6 nut. Remove the lip from the grey BMW
valve cover. Remove the foam on the inside of the engine cover there were the rails are mounted.
right engine bank 1
left engine bank 2 ( rotate the vsi-injectors )
9
PAGE 10
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Mounting the filter unit
Mount the filter with the hoses on the left side of the throttle body with a screw, use the special filter
bracket.
Filter replacement must be recorded in the service book supplied
LPG hoses
Length of hose,
Length of hose,
Length of hose,
Length of hose,
Length of hose,
Length of hose,
Length of hose,
Length of hose,
Length of hose,
Length of hose,
Length of hose,
Length of hose,
ø 16 mm
reducer
ø 5 mm
reducer
ø 11 mm
filter unit
ø 11 mm
filter unit
ø 5 mm VSI injector 1
-> filter unit
-> inlet manifold
-> rail
-> rail
-> manifold coupling
= ± 120
= ± 120
= ± 55
= ± 67
= ± 21
= ± 20
= ± 21
= ± 23
= ± 26
= ± 23
= ± 30
= ± 30
cm
cm
cm
cm
cm
cm
cm
cm
cm
cm
cm
cm
Cut the hoses on length.
Please observe that there is no damage or fouling to the hoses.
10
PAGE 11
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Mounting the VSI computer
Remove the white ECU frame out of the ECU box and make the adaption, see picture.
Replace the white frame and ECU’s.
Place the VSI computer with wiring loom ( without connector cover ) into the ECU box ( right side
under the interior filter.
Injection module connectors
VSI loom without cover
Grummet
Fuse holders and diagnosis connector
11
PAGE 12
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Mounting the fuel selection switch
Mount the switch.
Use the original grummet for switch and ignition+ wiring.
When mounting the switch, only push on its sides.
Pushing the switch in the centre may result in damage to the switch.
See general manual for programming the selection switch
original grummet
12
PAGE 13
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Electrical connections
1
+
8
+
7
power feed
+
6
5
BMW 650 4.8V8 2005Bosch Motronic ME
9-pole
brown
5
1
power feed
+
2
+
3
-
+
Petrol injectors
Ground
+
-
white-purple
-
white-green
-
52-pole
16
8
25
-
white
24
6
-
white-brown
white-brown
7
11
-
white-green
white
4
white-purple
green-red
13
26
Engine speed
RPM
+
yellow-blue
ignition positive
voltage (15+)
EOBD diagnose
connector
9-pole
7
black
-
+
battery positive
voltage (30+)
Check and measure the wiring in case of changes in the cars wiring colors.
13
PAGE 14
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Check and me–asure the wiring in case of changes in the cars wiring colors.
Wire number / code
50
MAIN GND
25-51
+12V BAT
Wire color
brown
red
33
34
32
34
31
34
30
34
5
6
4
6
3
6
2
6
13
33G INJ OUT 1
34 G INJ A PLUS
32G INJ OUT 2
34 G INJ A PLUS
31G INJ OUT 3
34 G INJ A PLUS
30G INJ OUT 4
34 G INJ A PLUS
5G INJ OUT 5
34 G INJ A PLUS
4G INJ OUT 6
34 G INJ A PLUS
3G INJ OUT 7
34 G INJ A PLUS
2G INJ OUT8
34 G INJ A PLUS
IGNITION +
46
LAMBDA 1-L
orange
Not used
45
LAMBDA 2-R
orange / white
Not used
40
RPM
White / yellow
red
Green / yellow
red
Pink / yellow
red
Blue / yellow
red
Grey / yellow
red
Brown / yellow
red
Lightblue / yellow
red
Red / yellow
red
grey / white
Connection
Wire color : BROWN
Wire location :petrol ECU, right 9-pole connector, pin 5
Wire color : BLACK
Wire location : petrol ECU, left 9-pole connector, pin 7
Do not place the fuse in the holder before having
completed the installation of the LPG system.
Connector VSI-injector to cylinder 1.
Purple-white
ground
Make a connection to ignition + / contact +.
Wire color : GREEN-RED
Wire location : left side under dashboard, EOBD
diagnosis connector, pin 1.
For measuring the engine speed.
Wire color :YELLOW-light BLUE
Wire location : petrol ECU, 52-pole connector, pin 16.
injector- / RPM
battery+
14
PAGE 15
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Check and measure the wiring in case of changes in the cars wiring colors.
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 bicolored VSI measuring wire to the ecu side, ( wire code: ECU SIDE ).
Connect the corresponding full colored VSI wire to the petrol injector side ( wire code: MIN INJ SIDE ).
See diagrams: Installation manual general part 1 / 2.
Attention:
Each bicolored measuring wire corresponds to a specific LPG injector and petrol injector / cylinder
number. Do not interchange the wires.
VSI measure wire nr.
:
Full colored / Bicolored
To interrupt petrol injector wire color / location
VSI wire nr. 39
Petrol injector / cyl.
1
VSI wire nr. 38
2
VSI wire nr. 37
3
VSI wire nr. 36
4
VSI wire nr. 11
5
VSI wire nr. 10
6
VSI wire nr. 9
7
VSI wire nr. 8
8
White / White-yellow
Color :white
Location : petrol ECU, 52-pole connector, pin 13
Green / Green-yellow
Color :white-brown
Pink / pink-yellow
Color :white-green
Blue / blue-yellow
Color :white-purple
Grey / grey-yellow
Color :white-purple
Brown / brown-yellow
Color :white-green
Light Blue / light Blue-yellow Color :white-brown
Red / red-yellow
Color :white
15
PAGE 16
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Checklist after installation
1.
Connect the serial interface wire and run the VSI diagnosis program.
Install the VSI mini fuse, and program the 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 system, you must activate the VSI computer with the diagnosis
software. When the VSI computer has not been activated, it will keep generating error code
160. To activate the VSI computer, select function F11 (activate ECM).
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 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 leak detector device or
a fluid detection like soap. Caution for moving and rotating parts in the engine compartment !
6.
Let the engine run warm on petrol >80°C.
Check if the evaporator heats up.
Check the engine signals, petrol injection time, RPM, ECT, lambda
Let the engine run idle on LPG.
Adjust the evaporator pressure. Refer to the parameter list ( or F2 : ID box) for the idle level
value set.
Adjust the 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 drivability on LPG and petrol.
16
PAGE 17
076/0301100
BMW
650 4.8V8 2005VERSION NR : B
Trouble code chart
Trouble code
100
Definition
Lambda to long to rich.
Check / solution
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 Check when operating on petrol and LPG that there is good lambda
loop.
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- VSI injector
Injector current to high, check for short circuiting
280
overload
211-221-231-241-251-261-271- VSI injector
Injector current to low, check for bad connections.
281
noload
310
Adjusted pressure on idle out of
Adjust the idle pressure to the value shown by parameter “ Idle Level “
range
311
Programm error during flahing the
Check parameter settings, contact Prins Autogassystemen.
memory
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.
Check the system for gasleakage.
341
Gas leakage, system pressure is less
then 1.25 bar after 4 hours when the
engine is not running
System switches to LPG but engine LPG tank empty ?
stalls immediately.
Lock-off valves open ?
No injection timing on LPG ( 0
Check the injection module.
Msec.)
The LPG system switches
- Check coolant system for air.
constantly between LPG and Petrol - T-ect sensor in the evaporator malfunction.
Engine hesitates on high revs, and Check for kinked or jammed LPG hoses (between VSI injector and
not running on all cylinders. Engine couplings).
runs good on idle.
Check for blocked inlet couplings.
Switch LED’s don’t lit up
Check the main fuse of the VSI system
Check ignition+ (VSI wire 13)
Fault codes when turning the
Caused by different switch off times between ignition+ and injector power.
ignition off ( key out the ignition )
Connect VSI wire 13 to the petrol injector feed instead of ignition+.
The orange LED on the switch
Activate the LPG computer with the diagnostic program, using the F11
flashes
function key.
The LPG system switches to LPG
LPG tank empty?
but engine stalls immediately
Not running on all cylinders on lpg
Check parameter 10, number of cylinders.
No injection times on lpg
Check the connections of the injection module.
Injection time “falls” to 0 mSec on
Check the injection module.
LPG
Check engine while running on
Replace injection module
LPG, injector circuit malfunction, no
lambda control (limb home)
Not starting / running on petrol
Check the connections of the injection module.
17

MAKE OF AUTOMOBILE: BMW TYPE: 650 Ci PISTON

Transcription

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