Prins autogassystemen b.v. Veldhoven

Prins autogassystemen b.v.VeldhovenMOUNTING INSTRUCTIONENGINE CONVERSION SETMAKE OF AUTOMOBILE:MITSUBISHITYPE:LANCERPISTON DISPLACEMENT:1600 cc MTNUMBER OF VALVES:16VENGINE NUMBER:4G18INJECTION SYSTEM:MULTI-POINT INJECTIONMODEL YEAR: 2003=>NUMBER : 076/1506600DATE : 2003-10-14VERSION NR : 1

PAGE 1 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1GENERAL INSTRUCTIONS• Do not place the 15 A into the fuse holder before having completed the installation of the VSIsystem. The VSI computer has to be activated by means of the diagnosis software (refer to the lastpage).• 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 15 A fuse.• When installing the cable harness, ensure that it does not run near any of the ignition components.• The power supply cable and the ground cable of the VSI system are always to be connected at thebattery.• Solder all electrical connections.• Remove any internal burrs, after having shortened the LPG hose. (This guarantees the maximumflow through the hose.)• If holes have to be drilled in order to facilitate mounting the device frame, the reservoir frame, theLPG cut-off valve, etc., the drilled holes must always be treated with an anti-corrosive, after theburrs have been removed.• After having completed the installation, check the whole system for gas leakage; use a gas leakdetection device.• Mount the VSI-system according to the LPG regulations.Fill the warranty card in completely and return it within 8 days.

PAGE 2 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1BASE VSI LAYOUTELECTRICALCONNECTIONSLPG TANKFILLERLOCK OFFVALVEFUELLEVELINDICATORPETROLINJECTORINJECTOR RAIL VSIPRESSURE RELIEF HOSEINJECTIONEVAPORATOR+LOCK OFF VALVEMODULEECT SENSORPsys+FILTER UNITTlpgSENSOR11 20SWITCH PERSONAL COMPUTERMAIN FUSE15 AmpENGINE ECUIGNITION +RPM- +BEEPERADAPTERBATTERYLAMBDA SENSORVSI COMPUTER5 AmpFUSE LPG INJECTORSPRINS

PAGE 3 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1MOUNTING AND CONNECTION POINTSAD EAHCLJKFIGA : Reducer G : “+” ignition ( 13 )B : Filter unit H : Engine speed signal ( 40 )C : Injector rail I : Lambda signal ( 45 + 46 )D : Vsi Computer J : “+” interruption petrol inj. ( 26+27 )E : Injector moduleK : “--“ interruption petrol. inj.F : Water connectionsL : Overpressure coupling

PAGE 4 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1MOUNTING THE EVAPORATORMount the evaporator by means of a bracket on the right chassis frame behind the headlight unit.Use the original M8 threaded hole.Overpressure hose coupling: with a T-piece in the crankcase breather hose.Water connections: parallel with the heater hoses on the scuttle board.Use thread locking agent when mounting the gas and water line couplings. Do not rotate thecouplings after installation. However, you may rotate the gas and water lines, if required.Ensure that the 2 bolts of the gas valve have been fastened.water connectionsoverpressure

PAGE 5 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1MOUNTING THE INLET MANIFOLD COUPLINGSRemove the petrol rail. Remove the two plastic spacers (not used).Drill the two attachment eyes (8mm) up to 11mm.Remove the o-ring of the injectors. Place a ring and a sealing ring on the injector.Place the vsi injector over the petrol injector with the lpg hoses.Don´t forget the o-ring under the vsi injector before installing the injectorrail back.Mount the petrol rail back and use two spacers (15mm) under the rail attachment.Mount the rail with two M6 bolts.IMPORTANTAlways check the inlet manifold coupling for leakage after installation.Spray brake cleaner onto the couplings and check whether the engine speedand the lambda signal change with the engine running on LPG.spacer

PAGE 6 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1MOUNTING THE INJECTOR RAILMount the bracket on the inlet manifold.Use the 8mm threaded end and nut in the middle of the inlet manifoldMake the electrical connections for petrol injector interruption (powerfeed and measure) beforeinstalling the vsi rail.

PAGE 7 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1MOUNTING THE FILTER UNITMount the filter with the bracket on the original threaded hole.

PAGE 8 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1TUBESLength of hose A, ø 16 mm = 27 cmLength of hose B, ø 6 mm = 100 cmLength of hose C, ø 11 mm = 50 cmLength of hose D, ø 6 mm = 14 cmLength of hose E, ø 6 mm = 13 cmLength of hose F, ø 6 mm = 13 cmLength of hose G, ø 6 mm = 13 cmUse a hose clip on all the connections.CAD E F GB

PAGE 9 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1BASE ELECTRICAL DIAGRAMcylinder 1cylinder 2cylinder 3cylinder 4LAMBDA SONDE461 2 3 4FILTER UNITINJECTOR RAIL VSIPRINSCONNECTIONS LPG TANK10INJECTORSIMULATOR3938543736-42 Not used16 Not used18 Not used1 250BATTERY PERSONAL COMPUTER40ENGINE ECUEVAPORATORRPMLPG VALVENot used4435BEEPER25-51- +ECT SENSORSWITCH+PETROL INJECTOR27 26VSI COMPUTERIGNITION +1315 Amp535 Amp (1-4)FUSE LPG INJECTORS

PAGE 10 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1MOUNTING THE COMPUTERMount the computer and injector module by means of a bracket on the threaded end from the ABSpump bracket.Mount the bracket behind the abs bracket.turn the purple clip 180°

PAGE 11 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1Mount the switch.MOUNTING THE FUEL SELECTION SWITCHAttention:When mounting the switch, only push on its sides. Pushing the switch in the centre may resultin damage to the switch.ELECTRICAL CONNECTION OF THE SWITCHVSI SWITCHPOWER SUPPLY SWITCH EN BEEPER(51) ARE EXCHANGABLE.VSI COMPUTER8-POLECONNECTORSBLUEPOSITION 1 ON CONNECTORTANK INDICATORBEEPERBROWNPOSITION 2 ON CONNECTORYELLOW-GREENPOSITION 3 ON CONNECTORREDPOSITION 4 ON CONNECTORYELLOWPOSITION 5 ON CONNECTORORANGEPOSITION 6 ON CONNECTORBLACKPOSITION 7 ON CONNECTORREDPOSITION 8 ON CONNECTOR50535112494851GROUNDPOWER FEED TANKINDICATIONPOWER FEED SWITCHPULSE FUEL SWITCHDIAGNOSTIC LEDGROUND BEEPERPOWER FEED BEEPER

PAGE 12 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1ELECTRICAL CONNECTIONS ON THE LPG RESERVOIRThe cable harness contains the wires for connecting the LPG reservoir.Refer to the following diagram when connecting the LPG reservoir.TRIPLE WIRE CABLEVSI COMPUTERFITTING BOXCOILTANK VALVEBLACKPRINSBLACK BLUEGROUND SIGNALTANKINDICATORREDREDBLACKBLUEBLACKBLUESOLDER THE CONNECTIONS IN THE FITTING BOXAND PROTECT THEM WITH A SHRINK SLEEVE.

PAGE 13 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1ELECTRICAL CONNECTIONCable number / Cable colour Connectioncode50 MAIN GND brown Connect to the '–' of the battery; use a ring terminal for thispurpose.25-51 +12V BAT red Connect to the '+' of the battery; use a ring terminal for thispurpose.Do not place the 15 A into the fuse holder before havingcompleted the installation of the LPG system.50 LPGVLV GND brown Ground LPG shut-off valve. 2-pole connector shut-off valve.53 + LPG VLV yellow / green Power supply LPG shut-offvalve.42 ECT GND brown Ground ECT sensor. 2-pole black connectortemperature sensor in the43 ECT greyECT measurement. evaporator.22 RS232 TxD grey4-pole black connector diagnosis cable connection.23 RS232 RxD grey50 DIAGNOSE GND brown51 +12V DIAG red15 T LPG grey4-pole black connector filter unit connection.17 Psys pale green18 + 5V Psys red42 Psys GND brown33 33G INJ OUT1 green / white Connector VSI-injector to cylinder 1.34 34 G INJ A PLUS redSee under 'Mounting the injector rail' for the cylinder numbers.32 32G INJ OUT2 green / white Connector VSI-injector to cylinder 2.34 34 G INJ A PLUS redSee under 'Mounting the injector rail' for the cylinder numbers.31 31G INJ OUT3 green / white Connector VSI-injector to cylinder 3.34 34 G INJ A PLUS redSee under 'Mounting the injector rail' for the cylinder numbers.30 30G INJ OUT4 green / white Connector VSI-injector to cylinder 4.34 34 G INJ A PLUS redSee under 'Mounting the injector rail' for the cylinder numbers.44 TPS green For measuring the throttle valve position.Cable not used in this car: insulate.16 MAP18 + 5V MAP42 MAP GNDblueredbrownFor measuring the inlet manifold pressure (MAP).Cables not used in this car: insulate.

PAGE 14 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1ELECTRICAL CONNECTIONS13 IGNITION + grey / white Make a connection to ignition + / contact +.Cable colour : WHITECable location : 12-pole white connector, left side battery,position 1.46 LAMBDA 1-L orange For the measurement of the lambda signal of cylinder bank 1.Connect the cable in parallel to the lambda sensor.Cable colour : WHITECable location : 4-pole connector on the thermostat housing.40 RPM purple / white For measuring the engine speed.Connect the cable in parallel to crankshaft sensor.Cable colour : BROWN-GREENCable location : 3-pole connector, right side engine, frontsidedistribution cover, near steering pump.26 +B INJ IN27 +B INJ OUTredred / whiteFor interrupting injector power supply.Connect cable 26 to the main relay - injector power supplyside and cable 27 to the injector side (refer to the injectordiagram).Cable colour : 4 X RED-YELLOW (there are more cables!)Cable location : in thick wiring harness near petrol injectors.54 INJ SIMULATOR red / black Power supply for the simulation of the injector(s).Connect the red / black cable (54) to the loose red cable of theinjector simulator(s).For the connection of the injector simulator the control cablesof the petrol injectors must be interrupted.Connect the red cables of the module to the injector side andthe black cables of the module to the computer side.Do not interchange the red and the black cables, but connectthose as a pair to each of the injectors (refer to the injectordiagram).Module location: on the computer bracket.

PAGE 15 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1ELECTRICAL CONNECTIONSFor measuring the petrol injectors.Connect each yellow / white measuring cable to the position atwhich the control cables of the petrol injectors have beeninterrupted (refer to the injector diagram).Injector cable locations: in thick wiring harness near petrolinjectors.39 B INJ IN 138 B INJ IN 237 B INJ IN 336 B INJ IN 4yellow / whiteyellow / whiteyellow / whiteyellow / whiteCylinder cable colour 1 : ORANGECylinder cable colour 2 : WHITE-REDCylinder cable colour 3 : GREENCylinder cable colour 4 : REDAttention:Each yellow / white measuring cable corresponds to aspecific LPG injector and cylinder number. Do notinterchange the cables. Refer to the page 'mounting theinjector rail' for the correct cylinder numbers.RED-BLACKYELLOW-WHITE54VSI COMPUTER26 27REDREDINJECTORSIMULATORBLACKREDRED-WHITEGREEN-WHITERED-+VSI INJECTORPETROLINJECTORinterrupt the power supply of each injector

PAGE 16 076/1506600MITSUBISHILANCER 1.6i 16v 2003=>VERSION NR : 1CHECKLIST AFTER THE INSTALLATION1. Connect the serial interface cable and run the VSI diagnosis program.2. When commissioning the LPG system, you must activate the VSI computer with thediagnosis software. When the VSI computer has not been activated, it will keep ongenerating error codes. To activate the VSI computer, select function F11 (activate ECM).3. Check whether the program in the VSI computer matches with the car:Refer with F2 to the box number and car description in the diagnosis software and comparethese with the packer's 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.5. Check all components and connections for any gas or water leakage.6. Let the engine run warm on petrol.Adjust the evaporator pressure:Let the engine run idle on LPG.Refer to the parameter list for the idle level value set.Adjust the evaporator pressure in such a way that the pressure measured ( P-sys ) equalsthe 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 thepressure.7. Use the diagnosis software to check all input and output signals.8. Check the system for error codes and solve these, if required.Check the MMS for EOBD error codes.9. Make a test drive.