Vialle LPi LPE-7 User manual

HZ 221838.0 -1-
Set-instruction: 220714.0 Assembly manual 221838.0
First release: 29-01-09 DC/name D09 008 RD
Release 29-01-09 RD
Assembly manual for a
Multipoint Liquid Propane Injection (LPi) System
Make of vehicle : Citroën
Type : Berlingo 1.6i 16V
Cubic capacity : 1587 cc
Engine type : NFR
Transmission : Manual
Model year : 2008
Tank situation : Under floor 67 ltr. ring tank

HZ 221838.0 -2-
Page: Code: Date: Content
1 221838.0 29-01-09 Cover sheet
2 221838.0 29-01-09 Contents table, general guidelines
3 221838.0 29-01-09 Summary of components engine room, interior
4 221838.0 29-01-09 Manifold assembly/disassembly
(Injector assembly by Vialle)
5 221838.0 29-01-09 Pressure regulator assembly
6 221838.0 29-01-09 LPE-7 assembly (LPi control unit)
7 221838.0 29-01-09 LPE-7 assembly (LPi control unit)
8 221838.0 29-01-09 Wiring harness, Fuel Switch, Stickers
9 221838.0 29-01-09 Wiring harness connections
10 221838.0 29-01-09 Wiring harness connections
11 221838.0 29-01-09 Tank assembly
12 221838.0 29-01-09 Tank assembly
13 221838.0 29-01-09 Tank assembly
14 221838.0 29-01-09 Tank assembly
15 221838.0 29-01-09 Electrical diagram LPE-7
* Consult the workshop manual before
components are disassembled
* All instructions provided in this
manual are from the perspective of
the driver’s position behind the stee-
ring wheel
* Cylinder 1, as described in the con-
nection of wiring harnesses is loca-
ted on the distribution side of the
engine!
* Undo the earth cable from the batte-
ry before starting to build in the LPG
installation (unless otherwise speci-
fied in the workshop instructions).
Note: the memories of any radios
and/or telephone may be wiped, the
central door locking may engage and
the alarm may go off. If necessary
the battery may be connected tem-
porarily
* Deburr the drilled holes, remove any
chippings from the vehicle and treat
the edges with an anti-rust agent
* Lay the wiring harness such that no
water can get into the interior
Seal any open splits after the
assembly of the wiring harness with
silicon rubber to prevent noise and
water leakage
* The LPG installation should be built
in in accordance with the National
Instructions for the fitting of a LPG
Installation
Failure to comply with the instructions in
this manual may result in a poor or
inoperative gas installation or may
cause a hazardous situation
The illustrations, technical information,
data and text were correct at the time of
printing. In spite of the care taken in the
composition of this publication, no liabili-
ty can be accepted on the grounds of
any fault or error which might occur in
this publication
published by Vialle Alternative Fuel
Systems BV
General guidelines
Contents table
English
- Contents table
- General guidelines

- Summary of components
- Wiring harness route
- Line bundle route
HZ 221838.0 -3-
9
L
B
3a
5
6 6 6 6
ZH
7
M
1
+
–
3b 2
K
Fig 1
LLPE-7 (LPi control unit)
ZFuse holder
K Pressure regulator
B Fuel Switch
H Main relay
RResistor box
M Engine running module
1 Battery+
2Ground engine
3 Engine running safety conn.
4 Won’t be used
5 Petrol injector interrupt
6 LPG injector conn.
7λ-probe connection
8Won’t be used
9 Petrol gauge reset
Wiring harness route
Line bundle route
Engine running harness route

- Manifold assembly/disassembly
(Injector assembly by Vialle)
HZ 221838.0 -4-
Manifold assembly/disassembly
- Disassemble the inlet manifold in accordance with
the workshop manual.
- NOTE: the disassembled manifold must be sent to
Vialle with the consignment note and will be retur-
ned with the fitted LPi-injectors.
- Assemble the inlet manifold in accordance with the
workshop manual
Fig 2

- Pressure regulator assembly
HZ 221838.0 -5-
Pressure regulator assembly
- Assemble the pressure regulator with the bracket
at the bolt of the engine bracket
- Lay the LPG-lines in a curl
Fig 5a Fig 5b
Fig 3
Pressure regulator assembly
- Adjust the bracket in accordance with the fig.
Fig 4
Pressure regulator assembly
- Assemble the bracket to the pressure regulator,
see insert.
- Assemble the LPG lines from the manifold to the
pressure regulator.
1
3
4
2
1
2
3
4
Spacer
Bracket
Rubber
Washer
1
90º
30

HZ 221838.0 -6-
Fig 6
Fig 7
Fig 8
- LPE-7 assembly (LPi control unit)
LPE-7 assembly
- Adjust the LPE-bracket in accordance with the fig.
LPE-7 assembly
- Assemble the LPE to the bracket
- Assemble the 70-pole connector to the LPE
LPE-7 assembly
-Stick a 12cm piece of rubber next to the
fuse/relaybox in accordance with the fig.

- LPE-7 assembly (LPi control unit)
HZ 221838.0 -7-
Fig 9
LPE-7 assembly
- Position the LPE next to the fuse/relaybox in
accordance with the fig.
- Drill a hole Ø3mm and assemble the bracket with
asheet metal screw (6,3x19)
Fig 10
LPE-7 assembly
- Assemble main relay Hand fuse holder Z
in accordance with the fig.
Ø3mm
Fig 11
LPE-7 assembly
- Assemble engine running module M
in accordance with the fig.
H
Z
M

- Fitting the wiring harness
- Fuel Switch assembly
-Positioning the stickes
HZ 221838.0 -8-
Fig 14
Positioning of the fuses sticker
-Stick the yellow sticker “Fuses of the Autogas sys-
tem” on the cover of the LPi-fuse holder
- On the other sticker enter the amperages of the
fuses (see the electrical diagram) and stick it in the
cover of the fuse holder.
Fitting the combi-switch
- Drill a hole of Ø8 mm at the position indicated and
press the switch into the hole (glue if necessary).
Fig 12
Fitting the wiring harness
-Lay the wiring harness in the vehicle in accordance
with fig.1 on page 3..
NOTE: For 5 or 6 cyl, solder the provided wiring har-
ness connectors for the LPG injectors, (5-6 cyl) to
the main wiring harness. See diagram, note the
colour of the label. Ø10mm
25
30
Fig 13
!
40
S
u
p
r
T
y
r
e
s
1
6
5
/
4
5
/
1
5
X
X
X
P
S
I
Fitting the wiring harness
- Drill a hole Ø10mm at the position indicated, see fig.
(double layered sheet)
!NOTE!!! Drill max. 40mm deep!
- Feed the wiring harness through.
- Assemble isolation-tube.
- Make sure there is a good seal to prevent leakage
and engine noise.

HZ 221838.0 -9-
LPi wiring harnesses connection
Stick the connectors in the associated female plugs.
Connections to the original electrical system
1Red wire with eye
Connection : Battery+
Position : At the plus clamp of the fuse/relaybox
Joint : Clip off the red wire as short as possible
NOTE : Solder the provided eye Ø8.5
2Eye with black wire
Connection : Ground engine
Position : Left front of the engine, at the lifting ring
Joint : M6 nut
3 Green/red wire + engine safety module
Connection : Engine running safety, see drawing:
Position : Connect to the green/red wire from the
engine running module provided
Joint : Solder and insulate
3a Pink/yellow wire from Engine running module
Connection : Alternator (see fig.)
Position : The two-pole connector at the alternator,
pos.1,see fig.
Joint : Solder and insulate
3b Red wire from the Engine running module
Connection : Constant+ (see fig.)
Position :The not-spliced red wire in the LPI wiring har-
ness, just underneath the fuse box,see fig.
Joint : Solder and insulate
- LPi wiring harnesses connection
Overview of connection points, see fig.1 on page 3
Electrical diagram, see last page
The wires without connector can be clipped off at
the right length. DO NOT ROLL UP any excess
length of the wires with connector because of
faults but tidy them away using a ‘detour’
Alternator pos.1 (warning light)
black (ground)
pink/yellow(signal)
red (positive)
blue wire
DONʼt cut
green/red
green/red
LPE 1x red
2x red
!
3b
3a
Engine running
module
LPi Fuse box
!Don’t use the spliced wires!
Use this wire to give the
Engine running
module a constant+
Pos.1
Route engine running module-alternator
3a
3b

Grey/black en grey/white wire
Connection : λ-Probe-2 signal and ground
Position : Not used
Connection : Clip off and insulate
8 Brown/black and brown/white wire
Connection : λ-Probe-1 signal and ground
Position : Not used
Connection : Clip off and insulate
Orange/black and orange/white wire
Connection : λ-Probe-2 signal and ground
Position : Not used
Connection : Clip off and insulate
9 Relay with resistor A
Connection : Reset of the petrol gauge
Position : 6-pole connector at the petrol pump
pos.3: 12Volt
pos.4: ground
pos.6: signal wire petrol gauge
measure! (resistance to ground = 10-300Ω)
Connection : Solder and Insulate
Main relay 7-pole black connector
Connection : Fit the relay in the black 7-pole connector
Fuses Black fusebox
Connection : Insert the 4 fuses into the fusebox
see electrical diagragram on the last page
Fuel switch 3-pole black connectors
Connection: 3 wires of switch and wiring harness
Connection: Fit the contacts in the 3-pin connector as follows:
Tank 3 Connectors
Connection : Fit the connectors to the tap, the fueltronic
and the pump control
Eye with black wire
Connection : Earth multivalve
Connection : M5 bolt
HZ 221838.0 -10-
LPi wiring harnesses connection
Stick the connectors in the associated female plugs.
Connections to the original electrical system
4 Pink and grey/red wire
Connection : Optional
Position : Won’t be used
Connection : Clip off and insulate
5 Interrupt relay (internal LPe-7)
Connection : Petrol Injector interrupt
Position : Injectors will be interrupted at the middelmost
48-pole grey/black ECU-connector B
Connection : Solder and insulate
6 Connectors with coloured labels
Connection :LPi injectors
Postion : Stick the connector
at the right injector
7 Purple/white and yellow/white wire
Connection : λ-Probe-1 signal and ground
Position : 4-pole green connector, at the left bof the engine
Connection : Solder and insulate
- LPi wiring harnesses connection
Overview of connection points, see fig.1 on page 3
Electrical diagram, see last page
The wires without connector can be clipped off at
the right length. DO NOT ROLL UP any excess
length of the wires with connector because of
faults but tidy them away using a ‘detour’
WHITE
WHITE
GREY
BLACK
heating
heating
ground
signal
PURPLE/WHITE
YELLOW/WHITE
If not extant, attach
yellow/white to
ground engine
4-pin
connector
position to ECU to injector
Cyl 1 M3 white white/green
Cyl 2 J4 brown brown/green
Cyl 3 K4 blue blue/green
Cyl 4 L4 grey grey/green
interrrupt relay
654321
B
9A
Cyl.1 RED
Cyl.2 BLUE
Cyl.3 YELLOW
Cyl.4 WHITE
LABELS
Connector switch Connector wiring harness
pos. wire colour wire colour
1 blue/red blue/red
2 yellow yellow
3 white white