Install LPG/CNG sequential fuel injection system

SEQUENTIAL FUEL INJECTION SYSTEM LPG / CNG
SYSTEM INSTALLATION MANUAL

18/05/2009
Rev. 03
Tartarini Auto S.p.a Via Bonazzi 43 40013 Castel Maggiore (Bo) Italy Tel.:+39 051 632 24 11 Fax: 051 632 24 00 E-mail: info@tartariniauto.it www.tartariniauto.it
INDEX:
THE 10 RULES OF THE SEQUENTIAL SYSTEM...3 SYSTEM DESCRIPTION..4 PRESSURE REGULATORS & SOLENOID VALVES ....5 INJECTOR RAIL WITH CALIBRATED NOZZLES & FILTER LPG/CNG.....8 LAMBDA SENSORS....12 PRESSURE SENSORS...13 ELECTRONIC UNIT & HARNESS.....14 FOR A CORRECT INSTALLATION...17 TORQUES & HIGH PRESSURE HOSE FIXING METHOD. 21 SAFETY NORMS DURING INSTALLATION....23 TROUBLESHOOTING......24 SERVICING....25
ENG - SGI System Installation Manual LPG & CNG (May 2009).doc
THE 10 RULES OF THE SEQUENTIAL SYSTEM

1) TARTARINI injector rails gas injection time on idle must be within 4ms and 4,5ms. TARTARINI EVO07 injector rails gas injection time on idle must be within 3ms and 3,5ms. TARTARINI EVO08 injector rails gas injection time on idle must be within 3,5ms and 4ms. MATRIX injector rails gas injection time on idle must be within 3ms and 3,5ms. 2) SEQUENTIAL gas injection time in full load driving condition at 6000 rpm must be lower than 20 ms, even better if lower than18 ms. FULL GROUP gas injection time in full load driving condition at 6000 rpm must be lower than 10 ms. 3) LPG injection pressure must be 1 bar when using pressure regulator G/SEQ. or else 1/1,2 bar when using pressure regulator RPG 05S. 4) CNG injection pressure must be 1,8 bar 5) Cut-off injectors wiring comes with marked letter A cable. During installation this end must be connected to the corresponding letter A of the injectors. 6) Gas rubber hoses from injector rail to manifold must be as short as possible 7) Pressure regulator rubber compensation hose must be as short as possible 8) Gas rubber hose from pressure regulator to the rail injector must be as short as possible. 9) It is mandatory to install MAP pressure sensor with nozzles facing down and with hoses as short as possible. 10) Temperature of pressure regulator during regular driving condition must be at least 60C
SYSTEM DESCRIPTION:
This is a Multipoint Sequential fuel injection system. An electronic unit that controls the sequence and the injection time of gas, operates it by injecting the gas through the injector rails directly into the intake manifold. The system grants the right dosing for a perfect combustion. Gas injection time is obtained by reading the gasoline injection time of the original electronic unit of the vehicle. The sequential fuel injection system has different advantages: 1) It is compatible with vehicles equipped with OBD (On Board Diagnostic) 2) Optimised fuel consumption 3) Optimised vehicle driveability 4) User-friendly installation 5) Autocalibration in idle. 6) Self-diagnosis 7) Self-Adaptive
PRESSURE REGULATORS & SOLENOID VALVES
G/SEQ LPG PRESSURE REGULATOR

Major components of the pressure regulator: 1) Solenoid valve complete with filter 2) Low pressure (compensation) fitting 3) Security valve 4) Gas outlet fitting 5) Water inlet and outlet fittings for heating 6) Solenoid valve plug-in connector 7) At the back of the regulator you will find the fitting for connecting the regulator temperature sensor Pressure regulator must deliver 1 bar pressure to the rail injectors and must transform LPG from liquid to gaseous.
1 2 3
6 5 7 4
RP/ G 05S LPG PRESSURE REGULATOR

Major components of the pressure regulator: 1) Vacuum fitting 2) Gas outlet fitting 0 3) First stage vacuum compensation hole only for overcharged engines (need code 8960354) 4) Temperature sensor fitting 5) Water inlet and outlet fittings for heating 6) Security pressure relief valve Pressure regulator must deliver 1 bar or 1,2 bar pressure to the rail injectors and must transform LPG from liquid to gaseous.
5 6 1 3
OVERSIZED SOLENOID VALVE 1

1) 2) 3) 4) Electrical control plug-in connector Gas inlet Gas outlet Gas filter
RP/M 04S CNG PRESSURE REGULATOR

Major components of the pressure regulator: 1) Vacuum fitting 2) Gas outlet fitting 3) Security valve 4) Temperature sensor plug-in connector 5) Water inlet and outlet fittings for heating 6) First stage vacuum compensation hole only for overcharged engines (need code 8960354) Pressure regulator must reduce high pressure from 220 down to 1,8 bar and deliver stable pressure to the rail injectors.
3 1
CNG SOLENOID VALVE 1

1) Electric control connector 2) High pressure gas inlet 3) Connection for CNG pressure sensor gauge 4) High-pressure gas outlet.
2 4 3
INJECTOR RAIL WITH CALIBRATED NOZZLES & FILTER LPG/CNG

INJECTOR RAIL
Injector rails must be installed as close as possible to the manifold injector nozzles in order to have gas hoses as short as possible. Concerning the position of the manifold nozzles, it is necessary to drill the intake manifolds between 3 to 15cm from engine head. In engines with multiple valves, it is suggested to drill intake manifolds duly before the petrol injectors in order to grant a homogeneous mixing of the fuel before it reaches the intake conducts. In order to preserve the mechanical parts of the rail injectors from any intrusive agent of gas, a filter may be used between the pressure regulator and the rail (Picture 1). The use of filter is highly suggested in LPG systems, while in CNG system may be optional.
Picture 1
TARTARINI RAIL (Type 03)

This device controlled by the gas electronic unit, must deliver the right amount of fuel to each cylinder. 1) Gas inlet 2) Solenoids electric plug-in connectors 3) Pressure meter nozzle 4) Calibrated gas outlet nozzles 5) Plug-in connector for pressure sensor
2 1 3
Inside the top kit you will find the wiring for connecting the solenoids of the rail. Every end of this wiring is marked with letters. NOTE: letter A of the rail wiring must ALWAYS correspond to letter A of the cut-off injector wiring.
CALIBRATED NOZZLES FOR TARTARINI RAIL

Tartarini Rail nozzles are replaceable. The inside diameter of each nozzle is marked on one side of the nozzle-bolt as shown in picture 6. For example diameter of this nozzle is 3.0 mm According to the power and number of cylinders of the vehicle, our technical service will give you the necessary information for the best-suggested solution. Tartarini Rail is available in 2, 3 or 4 cylinder versions and either Standard or Super (with oversized gas flow).
3.0
pic. 5
pic. 6
TARTARINI EVO07 RAIL

This device controlled by the gas electronic unit, must deliver the right amount of fuel to each cylinder. 1) Gas inlet 2) Solenoids electric plug-in connectors 3) Pressure meter nozzle 4) Fittings for calibrated Gas outlet nozzles 5) Gas temperature sensor plug-in connector
5 2
4 CALIBRATED NOZZLES FOR TARTARINI EVO RAIL
pic 1
pic 2
Calibrated nozzles (pic 1), must be screwed inside the gas-outlet fittings of the rail (pic 2.)
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The different diameters of nozzles are recognizable by certain number of marks on the nozzle itself. You may use this data-sheet to recognize the diameter. These nozzles are strictly for TARTARINI EVO07 rail. Nozzle Diameter (mm.) Number of Marks 1,75 0 2,00 1 2,25 2 2,50 3 2,75 4 3,00 5 The marks are visible both on the side and on the edge of the nozzle. Here below you may see an example of nozzle diameter 2,50mm with three marks visible both on the edge (6) that has to be screwed with a screwdriver and also on the opposite external diameter (7).
For the correct choice of the Tartarini EVO rail nozzles diameter according to the engine power and number of cylinders, please refer to the following data-sheet. NOTE: Since the gas-outlet fittings on the rail are diameter 4mm., in order to obtain this diameter size you will not have to use any nozzle. TARTARINI EVO - MAXIMUM POWER RANGE (Kw) Diameter (mm) 4 cylinders 5 cylinders 6 cylinders 8 cylinders 1,75 70 85 100 120 2,00 85 103 120 145 2,25 100 120 140 170 2,50 111 134 155 188 2,75 120 144 167 202 3,00 130 152 178 215 4,00 140 165 190 230 4,00 @ 1,2 bar 150 180 205 245
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TARTARINI EVO 08 RAIL 1) 2) 3) 4) 5) Gas inlet Solenoids electric plug connectors Pressure meter nozzle Fittings for calibrated gas outlet nozzles Gas temperature sensor Plug-in connector
1 3
CALIBRATED NOZZLES FOR TARTARINI EVO 08 RAIL
PIC. 1
PIC. 2
Calibrated nozzles (PIC. 1), must be screwed inside the gas-outlet fittings of the rail (PIC. 2)
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The different diameters of nozzles are recognizable by certain number of marks on the nozzle itself. You may use this data-sheet to recognize the diameter. These nozzles are strictly for TARTARINI EVO08 rail. Diameter (mm) 1.7 1.9 2.2 Numer of marks 0 1 2
In order to recognize the internal diameter of the nozzles there are specific marks visible on the edge and on the side of the nozzle itself. Here below you may see an example of nozzle diameter 2,2mm with two marks visible both on the edge (6) that has to be screwed with a screwdriver n6 and also on the external diameter (7).
For the correct choice of the Tartarini EVO08 rail nozzles diameter according to the engine power and number of cylinders, please refer to the following data-sheet. Diameter (mm) 1.7 1.9 2.2 Without nozzle Power (KW) 3cylinders 35 42 52 70 Power (KW) 4 cylinders 45 55 70 90
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LAMBDA SENSORS
Vehicles with the following type of lambda sensors: 0-1 volt 0-5 volt 5-0 volt 0,8-1,6 volt. Connecting only the purple wire to the Lambda sensor, will allow us to visualize the functioning of the system when driving the car, and it is particularly helpful in open-loop conditions. In case the vehicle has 2 Lambda sensors after the catalytic converter, connect also purple/black wire to the Lambda sensor of the second engine-bank. Vehicles with the following type of lambda sensors: UEGO type BOSCH, or type NTK. Connecting both purple and grey wires to the Lambda sensor, will allow us to visualize the functioning of the system when driving the car, and it is particularly helpful in open-loop conditions. In case the vehicle has 2 Lambda sensors after the catalytic converter, connect also both purple/black and grey/black wires to the Lambda sensor of the second engine-bank. WARNING: The reading of UEGO lambda sensors signals may however not be accurate, due to the various characteristics of these sensors in the world markets. We always suggest in this case to use our palm diagnostic OBDII tester code 4822016 to read the correct signals.
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PRESSURE SENSORS
The pressure sensor is used to inform the electronic unit about the difference of pressure between rail injectors and the intake manifold. There are two types of P.S.: Absolute & Differential. The Absolute (our new version) also simply called MAP (Manifold Absolute Pressure) allows autocalibration of the system with engine in idle (see software manual).
Differential (Old version)
Absolute (New Version)
At the bottom of the pressure meter there are two nozzles: Pressure & V: - Connect the pressure gas-hose that comes from the gas rail injectors to the Pressure nozzle (compensate before with a T in case you have more than one rail injector). - Connect the vacuum hose that comes from the intake manifold to the V nozzle after compensating also with regulator low-pressure fitting. Pressure sensor must be installed with nozzles facing down, as shown in the picture below.
15
ELECTRONIC UNIT & HARNESS

HARNESS ELECTRONIC UNIT (ECU) Sequential Fuel Injection
The harness for 3-4 cylinder vehicles it is provided with: 1) DIAGNOSIS PLUG This plug is the communication port for connecting to laptop. 2) 4 CABLES CONNECTOR It is the plug for connecting the MAP pressure sensor. 3) 10 CABLES CONNECTOR Connector for the cut-off injectors wiring.
16
4)
ORANGE cable & BLACK cable Connections for the temperature sensor of the pressure regulator. 5) ORANGE/BLACK & BLACK cables Connections for the gas-temperature sensor. 6) WHITE cable & GREEN cable Connections for gas-level sensor. 7) RED/BLACK cable Connection to Battery (+) 8) BLACK cable Connection to Battery (-) 9) BROWN cable Connection to RPM signal 10) PURPLE cable 11) GREY cable 12) PURPLE/BLACK cable Connectors for Lambda sensors 13) GREY/BLACK cable 14) Two pairs of BLUE and two pairs of BLACK cables - respectively to be used for the gas tank solenoid valves (LPG) & for the gas interception solenoid valves (LPG/CNG) 15) GREEN cable 16) GREEN/YELLOW cable Connectors for ECU type D 17) GREEN/GREY cable WARNING: It is necessary to isolate each & every other spare wire of the harness that is left unused.
CUT-OFF INJECTORS WIRING

The cut-off injectors wiring it is used to cut-off power from the original petrol injectors by interrupting the negative (-). There are different types of cut-off injectors wiring that may be supplied accordingly to the gasoline injectors plugs upon the customers choice. The followings are the most commonly used: 4822155 Universal type: The wires come without any plug-in connector and can be easily soldered to any petrol injector cable. 4822154 Bosch type & 4822182 Bosch inverted type: These wirings are provided with Bosch type connectors (either straight or inverted) for a fast connection onto the original petrol injectors. In order to understand whether to use Bosch or Bosch inverted type, you must first verify the polarity of the car petrol injector connectors. Read the following instructions in order to identify which one of the two wires is the positive (+): - Disconnect all the petrol injector connectors. - Connect the Multimeter-negative (-) to a ground (-). - Connect the Multimeter-positive (+) to one of the two contacts of the petrol injector connector. - Turn the dashboard car key on, and read immediately. If multimeter displays +12v. the tested contact is the positive +12V.
17
WARNING: Since the +12volt on the petrol injector is temporised, the signal will be lost after a short while that the dashboard car key has been turned on. Furthermore we strongly suggest to verify the polarity of all the connectors of the petrol injectors in order to make sure that there is not only one of them inverted.
4822154: it is used whenever the positive (+) of the injectors is on pin n1 and the negative (-) on pin n2. If there is no pin number indication, please refer to this drawing.
4822182: it is used whenever the positive (+) of the injectors is on pin n2 and the negative (-) on pin n1. If there is no pin number indication, please refer to this drawing. In case the plugs of the petrol injectors arent the types described or else they are difficult to reach by hand, it is always possible to use the cut-off injector wiring UNIVERSAL type code 4822155 by cutting the wires and soldering it. In order to define positive (+) and negative (-) follow the instructions above. WIRES TO CUT ARE THE NEGATIVES (-).
18
PLUGS OF PETROL INJECTORS

For a proper connection, please follow the above diagram. WARNING : - Double-colour wires must be soldered to the wires that are coming from the petrol electronic unit. - Single-colour wires must be soldered to the wires coming from the petrol injectors. - RED/WHITE wire must be soldered to the positive (+) of one of the injectors (It does not matter which one). - The petrol injector that we defined as A must be the one of the cylinder where we are going to inject with gas injector A. - It does not matter if cylinder A is the first, the third or any other. What is important is to respect the sequence as shown in the above picture.
FOR A CORRECT INSTALLATION

Install the regulator always in a position that is lower than the coolant expansion tank. It will facilitate circulation of water into the pressure regulator for its proper heating. Install the regulator as close as possible to the injector rails for a faster gas-flow. Dont secure the pressure regulator to the insulating panel between the engine compartment and the drivers cabin. Vibrations could turn into a noise for the driver. It is opportune to connect a rubber hose 4X11 (see pic.1&2) to the security valve of the pressure regulator/s in order to convoy any possible leakage of gas outside the engine compartment and duly insulated from heat and electrical components. Dont ever secure the gas injector rail to the vehicles body. The gas injector rail must follow the exact vibrations and movements of the engine. Vacuum signal of the intake manifold cannot be sourced from preset existing spots (egs. Petrol pressure regulators, Canister electric-valve, boosted-brake). It is necessary to create a new spot about 5cm after the throttle body. Dont install the pressure sensor close to the exhaust, since the high temperature can damage it. Dont ever secure the gas electronic unit to the engine. Engine vibrations could create malfunctions. Dont lay any wire close to alternator, high voltage cables, coils, belts, pulleys, high temperature parts like exhaust. etc. All these disturb can interfere with the correct functioning of the system.
19
Connection of pressure regulator RPM04S or RPG05S in overcharged vehicles using extra Kit code 8960457
It is necessary to compensate this pressure regulator when installing it on TURBO vehicles: 1) Thread this hole with a M6 x 1
2) Screw the supplied nozzle inside the threaded hole
20
Connect both nozzles to the T fitting using the rubber hose supplied in the kit 8960457.
Connect the other end of the T fitting to the line of the vacuum signal.
21
TORQUES & HIGH PRESSURE HOSE FIXING METHOD
CNG PRESSURE REGULATOR TYPE RP-M 04S
Clear the hose from any residual material and clean it well before connectting it. Introduce first the threaded fitting then the ogiva (conical shape metal oring). Grease the threading of the fitting and the ogiva before connecting them. Screw at torque of 15 Nm
Clean the aluminum gasket and its housing. Grease the internal aluminum gasket. Screw at torque of 80 Nm
22
LPG PRESSURE REGULATOR TYPE RP-G 05S
Clear the hose from any residual material and clean it well before connecting it. Introduce first the threaded fitting then the ogiva (conical shape metal oring). Grease the threading of the fitting and the ogiva before connecting them. Screw at torque of 12 Nm
LPG PRESSURE REGULATOR TYPE G/Seq.
Clear the hose from any residual material and clean it well before connecting it. Introduce first the threaded fitting then the ogiva (conical shape metal oring). Grease the threading of the fitting and the ogiva before connecting them. Screw at torque of 12 Nm
23
SAFETY NORMS DURING INSTALLATION

Disconnect the car battery cables before any sort of electrical work. All system wires must be duly soldered. It is necessary to insulate every soldering with heated sheath. All cables must be securely fastened in order to resist all vibrations of the engine. Place the system fuse in position that will be easy to reach for the end user. Before starting the engine, check that all wrappers are well fastened and that no component of the gas system (including cables, hosesetc.) will interfere with any moving part of the engine (such as belts, fan, etc.). Check for any gas leakage in engine compartment and in tank compartment, both before and after starting the engine while using gasoline and also while using GAS.
WARNING: Never reprogram or reset from base parameters the ECU while engine is running on GAS. After reprogramming the ECU or resetting from base parameters, it is necessary to set the proper vehicle configuration options before proceeding with autocalibration (please refer to the SOFTWARE MANUAL for these procedures).
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TROUBLESHOOTING:
Switch lights turn-off about 10 seconds after starting the engine: RPM signal is missing. Only 3 cylinders work when running on GAS: Once you found the cylinder not working, verify that: 1) Cut-off injectors wiring is properly installed. Make sure of the correct phasing of the cylinders: letter A of the rail injector must correspond to blue & blue/black cable of the cutoff injectors wiring that are connected to the negative pole of the petrol injector A. 2) Gas rubber hose from rail injector to intake manifold is not choked or obstructed or leaking. 3) Gas-nozzle on the intake manifold is not clogged. 4) Rail-nozzle of that cylinder has same internal diameter as the other ones 5) Gas ECU sends correct signal to that injector. 6) GAS injectors piloting cables are not interrupted or unthreaded from connectors of ECU or injector rail control. By manually switching to GAS, system switches immediately back to petrol: If switch blinks just like it should be switching again to GAS: 1) Injection times of GAS are too high 2) Gas filter is clogged 3) Regulator outlet pressure is too low. This Error occurs:CONNECTED INJECTORS NOT COMPATIBLE: PC-ECU link cable was disconnected while the software was in use. Exit the software, connect properly the link cable and restart the software. RPM displayed on PC does not correspond with RPM of the vehicle: 1) Verify the correct setting of IGNITION TYPE in Vehicle Configuration Menu (One Coil/Two Coils/RPM sensor/RPM sensor 2) 2) Verify the correct setting of TYPE OF REVOLUTION SIGNAL in Vehicle Configuration Menu (Standard/Weak) 3) Verify that you connected the brown wire to the correct RPM signal. When switching to GAS engine dies: 1) Verify GAS tank is not empty. 2) Verify that GAS reaches the rail injectors 3) Verify 12v. is given to the system when switching dashboard-key ON. Check engine light turns on: 1) Verify the type of error recorded by the petrol electronic unit. 2) Using the car OBD diagnosis plug, check the fast and slow trimmer positions. In case they did reach the limits: - Correct the system settings and calibration map (SEE SOFTWARE MANUAL) until OBD trimmers move back close to 0 or to the position they are when running on petrol. It is always suggested to take note of the trimmers position before running on GAS. 3) Check the correct functioning of Lambda sensor. 4) If a Timing Advance Processor is connected, try to disconnect it. Cannot connect to ECU: Turn dashboard-key ON, connect anyway the link-cable, reprogram ECU with a new version of FIRMWARE (SEE SOFTWARE MANUAL). When the new firmware is loaded, disconnect and connect back again.
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SERVICING
SERVICE KM 20.000 40.000 60.000 80.000 100.000 120.000 SERVICE TYPE A A B A A B
LPG/CNG SERVICE TYPE A

DESCRIPTION Controllo pressione riduttore, e raccordi Gas Check the operational efficiency and the parameters of the gas fuelling system (using auto-diagnosis connector) Check the correct and secure fastening of the LPG/CNG tanks. Check the LPG/CNG injectors unit Replace gas filter cartridge SERVICING TIME 15 Minutes 30 Minutes 15 Minutes 15 Minutes 15 Minutes + maintenance kit
LPG/CNG SERVICE TYPE B

DESCRIPTION Check pressure of the regulator and gas fittings Check the operational efficiency and the parameters of the gas fuelling system (using auto-diagnosis connector) Check the conditions of water/gas pipes and gas fittings. Check or overhaul the LPG/CNG pressure regulator Check the LPG/CNG injectors unit Replace gas filter cartridge SERVICING TIME 15 Minuti 30 Minuti 15 Minuti + eventuale materiale 60 Minuti + eventuale materiale 15 Minuti 15 Minuti + materiale
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Install LPG/CNG sequential fuel injection system

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Install LPG/CNG sequential fuel injection system

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SEQUENTIAL FUEL INJECTION SYSTEM LPG / CNG

SYSTEM INSTALLATION MANUAL

THE 10 RULES OF THE SEQUENTIAL SYSTEM

PRESSURE REGULATORS & SOLENOID VALVES

G/SEQ LPG PRESSURE REGULATOR

RP/ G 05S LPG PRESSURE REGULATOR

OVERSIZED SOLENOID VALVE 1

RP/M 04S CNG PRESSURE REGULATOR

CNG SOLENOID VALVE 1

INJECTOR RAIL WITH CALIBRATED NOZZLES & FILTER LPG/CNG

TARTARINI RAIL (Type 03)

CALIBRATED NOZZLES FOR TARTARINI RAIL

TARTARINI EVO07 RAIL

4 CALIBRATED NOZZLES FOR TARTARINI EVO RAIL

CALIBRATED NOZZLES FOR TARTARINI EVO 08 RAIL

Differential (Old version)

Absolute (New Version)

ELECTRONIC UNIT & HARNESS

CUT-OFF INJECTORS WIRING

PLUGS OF PETROL INJECTORS

FOR A CORRECT INSTALLATION

2) Screw the supplied nozzle inside the threaded hole

TORQUES & HIGH PRESSURE HOSE FIXING METHOD

CNG PRESSURE REGULATOR TYPE RP-M 04S

LPG PRESSURE REGULATOR TYPE RP-G 05S

LPG PRESSURE REGULATOR TYPE G/Seq.

SAFETY NORMS DURING INSTALLATION

LPG/CNG SERVICE TYPE A

LPG/CNG SERVICE TYPE B

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