Prins Direct LiquiMax User manual
MANUFACTURER
Ford
TYPE
Tourneo Connect II
ENGINE DISPLACEMENT
1600
NUMBER OF VALVES
16
ENGINE CODE / NUMBER
JQGA
VEHICLE CATEGORIES
M
TRANSMISSION
AT
VERSION
AFC-2.1
PETROL ECU MANUFACTURER / CODE
-
HIGH PRESSURE PETROL POMP
Bosch HDP-5-PE BM5G 0261.520.(076)(077)(139)(140)
HIGH PRESSURE PETROL INJECTOR
Bosch HDEV-5-1LE 0261.500.(155)(156)
MODEL YEAR:
9-2013
SYSTEM APPROVAL NUMBER ( R115 )
E4-115R-000009 / DLM-LPG 02
LOCATION R115 SYSTEM STICKER
right side, centre door post
ENGINE SET NUMBER
347/070047/A
MANUAL NUMBER
076/0705500
DATE
2014-11-12
Version 2013-09-28 D
PAGE 1
076/0705500
Copyright © Prins Autogassystemen B.V. 2014
TABLE OF CONTENTS
General instructions.........................................................................................................................2
Required equipment / tools / materials for installing a complete system ...........................................3
Vehicle check..................................................................................................................................3
Tightening moments........................................................................................................................4
Direct LiquiMax-2.0, AFC-2.1...........................................................................................................5
Direct LiquiMax-2.0 diagram, AFC-2.1.............................................................................................6
Direct LiquiMax parts / approval numbers........................................................................................7
DLM component location overview..................................................................................................8
Removal of the Bosch High Pressure Petrol Pump ..........................................................................9
Fuel Supply Unit / Fuel Return Unit................................................................................................10
Boost pump / FRU / FSU bracket...................................................................................................11
Boost pump / FRU / FSU bracket...................................................................................................12
Boost pump / FRU / FSU bracket...................................................................................................13
Installation of the Bosch High Pressure Petrol Pump .....................................................................14
High pressure petrol pump installation...........................................................................................15
High pressure petrol pump LPG return...........................................................................................16
Boost pump inlet............................................................................................................................17
Cover adaption..............................................................................................................................18
LPG / petrol fuel lines....................................................................................................................19
Supply hose –Return hose –Tank wiring......................................................................................20
Hose routing..................................................................................................................................21
Mounting the AFC-2.1 without Start-Stop battery ( small )..............................................................22
Mounting the AFC with Start-Stop battery ( large ).........................................................................23
Switch wiring.................................................................................................................................24
Wiring............................................................................................................................................25
Wiring............................................................................................................................................26
Mounting the fuse / relay box.........................................................................................................27
PWM Signal ..................................................................................................................................28
Mounting the fuel selection switch .................................................................................................29
Electrical connections....................................................................................................................30
Electrical connections....................................................................................................................31
Insulate not used wires:.................................................................................................................32
Electrical connections....................................................................................................................33
Electrical connections....................................................................................................................34
Electrical connections....................................................................................................................35
Prins safety stickers.......................................................................................................................36
Checklist after installation..............................................................................................................37
FOR EXPLANATION AND CIRCUIT DIAGRAMS SEE : INSTALLATION MANUAL GENERAL PART 1 / 2
PAGE 2
076/0705500
Copyright © Prins Autogassystemen B.V. 2014
General instructions
The installation of the system shall be done in accordance with the installation manual provided by Prins Autogassystemen.
This manual is based on Dutch regulations, always install the system in accordance to the local regulations.
For an optimal functioning of the Direct LiquiMax-2.0 system, maintain a clean and organized work environment during
installation and maintenance to prevent pollution of the LPG components.
Always download the “general manual 1/2 “ from our website for basic instructions and diagrams.
Always disconnect the battery when installing / servicing the LPG system. Make sure the ignition key is outside the car.
Be aware of central door locking, radio / telephone memory code, alarm system.
Wear safety goggles when working on the petrol filled system / connections ( pressurized petrol )
Do not place the main fuse into the fuse holder before having completed the installation of the system.
The AFC has to be activated by means of the Prins diagnosis software.
Never disconnect the AFC connector, unless you have removed the main fuse.
When installing the 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 harness 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-system shall be located within 100 mm of the exhaust or similar heat
source, unless such components are adequately shielded against heat.
If holes have to be drilled (wear safety glasses) for installing brackets, etc., the drilled holes must always be treated
with an anti-corrosion agent, after the chips have been removed ( especially when mounting a exterior filler into body work).
After having completed the installation, check the whole system for LPG leakage; use a LPG leak detection device.
Also check for leak of engine coolant, petrol and air.
Fitting and maintenance is only allowed by Prins Autogassystemen selected LPG engineers.
Failure to follow the instructions in this manual can result in a poor or non-working LPG installation or a dangerous situation.
For maintenance instructions see owner manual.
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 diagrams, certificates, updates, info-bulletins and product information.
Register ( warranty card ) the system on the Prins warranty portal .
PAGE 3
076/0705500
Copyright © Prins Autogassystemen B.V. 2014
Required equipment / tools / materials for installing a complete system
-Complete workshop toolbox ( wrenches, screwdrivers, cutters, pliers, ratchet, sockets )
-Car lift
-Portable computer
-Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 )
-Exhaust gas analyser
-Multimeter
-Oscilloscope
-Prins diagnostic software
-Prins serial interface
-Torque wrench ( 5-50Nm )
-Torque wrench ( 200-250Nm )
-Portable light
-Assortment drill bits 4 to 12 mm
-Assortment cutters ( ø 20, 30, 50, 70 mm )
-Portable drill or pneumatic drill
-Thread cutting device ( male M6x1, M8x1, M10x1 )
-Air gun
-Vacuum cleaner
-Safety goggles
-Hot air gun
-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
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 )
PAGE 4
076/0705500
Copyright © Prins Autogassystemen B.V. 2014
Tightening moments
Nm
Spanner mm
M 4 x 0,7
3.3
7
M 5 x 0,8
6.5
8
M 6 x 1,0
11.3
10
M 7 x 1,0
14.5
11
M 8 x 1
24.5
13
M 8 x 1,25
27.3
13
M 10 x 1
52
15-16-17
M 10 x 1,5
54
15-16-17
( filtered ) Banjo bolt
10
14
Supply line connection
15
13
Fuel module Allen bolts
20
7
Filler hose connection
50
22
Boost pump clamp
7
10
High pressure petrol fuel line
24-35
17
EXPLANATION OF SYMBOLS :
= IMPORTANT, CAUTION
= WEAR SAFETY GOGGLES
PAGE 7
076/0705500
Copyright © Prins Autogassystemen B.V. 2014
Direct LiquiMax parts / approval numbers
1st generation
2nd generation
1st generation
2nd generation
Fuel Supply Unit : E4-67R-010269
Fuel Return Unit : E4-67R-010270
Pressure Sensor : E4-67R-010051
Boost pump
High Pressure Pump : E4-67R-010266
High Pressure Rail : E4-67R-010267
High Pressure Injectors : E4-67R-010309
Prins AFC: E4-67R-010098
E4-10R-030507
Fuel lines series XD : E4-67R-010247 XD3
E4-67R-010247 XD4
PAGE 9
076/0705500
Copyright © Prins Autogassystemen B.V. 2014
Removal of the Bosch High Pressure Petrol Pump
-REMOVAL-
-WARNING-
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, there may be injury caused by
leakage of the high pressure fuel.
Don’t do any repair work right after engine stops ( HOT engine ).
Turn the ignition switch OFF and disconnect the battery negative (-) cable.
Ware safety goggles.
Disconnect the fuel pressure regulator valve connector
Disconnect the High Pressure fuel feed pipe (B)
Remove the Low Pressure fuel pipe / hose (A).
Remove the installation bolts (E), and then remove the high pressure fuel pump from the cylinder head
assembly.
CAUTION:
Unscrew in turn the two bolts in small steps (0.5 turns). In case of fully unscrewing one of the two bolts with the
other bolt installed, the housing surface of the cylinder head may break because of tension of the pump spring.
CAREFULLY store the removed petrol pump. Make sure no pollution can come into the pump.
PAGE 14
076/0705500
Copyright © Prins Autogassystemen B.V. 2014
Installation of the Bosch High Pressure Petrol Pump
-INSTALLATION-
Before installing the high pressure fuel pump, position the roller tappet ( B&C) in the lowest position by rotating the
crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.
Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). ( roller
tappet, only if removed from cylinder head )
Also apply engine oil to the groove on the location where the protrusion (C) is installed.
Installation bolts:
When tightening the installation bolts of the high pressure fuel pump, tighten and turn the bolts in small step
( 0.5 turns ) after tightening them with hand-screwed torque.
High pressure petrol pump installation bolt: 12.8 ~ 14.7 N.m
Petrol pipe:
First hand-tighten the nut(s) fully until they are not fastened any more in order to have them inserted in place and then
completely tighten to the specified torque using a torque wrench.
If not tightening the bolts or nuts in a straight line with the mating bolt holes or fittings, it may cause a fuel leak due to
broken threads.
High pressure petrol pipe installation nut: 26.5 ~ 32.4 N.m
Installation is reverse of removal.
PAGE 15
076/0705500
Copyright © Prins Autogassystemen B.V. 2014
High pressure petrol pump installation
Remove air-filter, ignition coils, cover, wiper box, left wiper motor ( driver side )
Replace the original high pressure petrol pump for the adapted high pressure petrol pump.
( Follow the workshop manual of the car )
Remove low pressure petrol line ( not used )
Install a new ( shorter ) bolt.
PAGE 19
076/0705500
Copyright © Prins Autogassystemen B.V. 2014
LPG / petrol fuel lines
1
2
3
4
Install the fuel line using two bonded seal washers and banjo bolt :
Filtered banjo: ( FSU supply inlets / boost pump inlet / HPP pump inlet : black filtered banjo ) :
Hose
from
to
Length ( cm )
1 XD
Adapter original petrol hose
Petrol boost pump
45
2 XD
Fuel supply unit
High pressure petrol pump
60
3 XD
Petrol boost pump
Fuel supply unit
25
4 XD
Fuel return unit
High pressure petrol pump
110
Table of contents
Popular Engine manuals by other brands
Briggs & Stratton
Briggs & Stratton 400000 Intek Operator's manual
Kohler
Kohler Command PRO EFI PCV850 owner's manual
HOLDEN
HOLDEN GEN III V8 Service training
O.S. engine
O.S. engine MAX-21TM instruction manual
Briggs & Stratton
Briggs & Stratton PROFESSIONAL SERIES 110000 Operator's manual
Hydro-Gear
Hydro-Gear ZT-5400 Powertrain Service and repair manual
