These fitting instructions are supplementary to those supplied with the components, and are
intended as a guide for a typical installation. They may vary for different vehicles.
Your vehicle will run on LPG as well as it runs on petrol once the engine is warm, therefore, if
you have a problem with petrol, you will have the same problem using LPG. You are advised to
correct any current problems with your engine prior to carrying out the conversion.
To enable the conversion to run smoothly, it is recommended that you familiarise yourself with
the fitting procedure before commencing. Although fitting a conversion kit is a relatively
straightforward procedure, it must be carried out by a trained person. If in doubt, you are
advised to contact a suitable mechanic.
At almost every stage of the conversion, you will still be able to drive your car, without having to
wait to complete the conversion, allowing you the freedom of fitting it at your leisure.
Disclaimer: Dinamik Endüstri Ltd. cannot be held liable for any damage caused due to the
improper installation of the products.
Before starting the conversion, ensure you have the correct tools:
Various spanners or sockets
Flat & Phillips Screwdrivers
Allen Keys
Electric or Cordless Drill & Drill bits
Ø60mm Tank Cutter - see section (3.2)
Ø30mm Tank Cutter - see sections (3.4) & (7.2)
Wire Stripper/Crimper
Various cable connectors - see section (13) & (14)
Soldering equipment (13.5)
Hacksaw
Waterproof Silicone Sealant
Rust preventer
Bosswhite Sealant
Fitting Sequence
(1) Fit Gas Tank into position
(2) Fit Multivalve into the Gas Tank
(3) Fit Filler Entry
(4) Connect fuel line from Filler Entry to Multivalve
(5) Position Gas Solenoid
(5a) Fit Petrol Solenoid (Carburettor vehicles only)
(6) Position Vaporiser
(7) Connect fuel line from Multivalve to Gas Solenoid
(8) Connect wiring Loom from Multivalve & run parallel to fuel line
(9) Connect fuel line from Solenoid to Vaporiser
(10) Connect Vaporiser water hoses
(11) Fit Mixer into air Manifold
(12) Connect Vaporiser to Mixer
(13) Fit Emulator & wire into vehicle injectors (Injection vehicles only)
(14) Fit Switch & wire into vehicle electrics
(15) Test for Gas Leaks
(16) Adjust Gas input
FITTING PROCESS
(1a) FIT THE GAS TANK INTO POSITION (CYLINDRICAL TANKS)
When positioning the tank, locate it so that access to the spare wheel is still
possible. Although the tank straps provided ensure that it is held tight, these
should be used in conjunction with further fixings to prevent the tank from rolling.
For example, use a length of angle either side of the tank.
(1a.1) Position the tank, bearing in mind where you intend to fit the filler entry. Meanwhile you
must ensure that the tank is oriented at the correct angle. You can do this by using an
angle gauge. The angle must suit to the particular multivalve/tank combination (eg.
Ø360/30º or Ø315/30º etc…)
(1a.2) Fix the tank mounting frame onto the boot floor by using the supplied bolts and washers.
(1a.3) Position one of the metal straps provided towards one end of the cylinder.
(1a.4) Bend the strap around the contour of the tank, passing it through the holes on the
mounting frame.
(1a.5) Connect the two ends of the strap by using the 70mm long bolts and the connection
apparatus supplied with the kit. As much as you tighten the 70mm bolts, the straps will
secure the tank into position better.
(1a.6) Repeat the procedure with the other strap.
(1a.7) Note that the round boss into which the Multivalve fits should be at 30º to the
horizontal,
see the FEMA Multivalve instructions for exact details.
Figure 1a
(1b) FIT THE GAS TANK INTO POSITION (TOROIDAL TANKS)
Installation of a toroidal tank is a relatively easier process than installing a cylindrical tank,
because you don’t use any tank mounting frame or tank straps for this process. The most
common way to install a toroidal tank is to use the spare wheel well in the boot. However
if
the tank is 0º (external), you will have to choose a different place than the spare wheel
well for the installation.
(1b.1) Take out the spare wheel and the other devices like car lifter of its well.
(1b.2) Drill the necessary holes onto the bottom of the well. While doing this, take care not
to
damage any existing components like the petrol tank etc…
(1b.3) Insert the gas tank into this well.
(1b.4) Secure the tank by using the supplied bolts and washers. (It is a common method using
polyurethane foam to secure the tank better.)
freely to the left. The gauge on the front of the valve moves as you swing the arm.
(2.3) Place the large round black plastic Air-Box onto the round tank boss,
ensuring the Ø78mm O-ring sits between the Air-box and the tank boss. The direction of
the two hose inlets should be rotated towards the filler entry position. (Please note that the
Air-box is used only with the cylindrical tanks.)
(2.4) Position the Multivalve onto the round boss, with the two arms inside the tank.
(2.5) Secure the Multivalve with the six Allen screws supplied, to a maximum 3N/m torque.
(2.6) It is strongly recommended that you complete the conversion, before carrying out (2.5).
Hold the Multivalve in position, as it would be in the tank and move the float arm. If the
gauge on the switch does not show the same reading as that on the Multivalve, gently
bend the float arm as required. Once satisfied, complete (2.5)
will be convenient for filling. Most people fit them through the wing or bumper.
(3.1) Select a suitable position to fit the filler entry, without obstruction.
(3.2) Mark the centre position & using a suitable tank cutter, drill a Ø60mm hole. It may be
necessary to hold a wooden block behind the hole ensuring that the panel is not distorted.
Figure 3a shows the assembly of the filler entry with a single skin panel.
(3.3) If the position chosen for the filler entry has a double wall, it will be necessary to use the
black plastic pipe protector (with the chamfered end), as shown in figure 3b.
(3.4) To fit this, drill a Ø30mm hole on the inside panel, centred as the Ø60mm hole.
(3.5) Using the pipe protector as a guide, drill, & secure in position with the self tapping screws.
(3.6) If there is not enough clearance between the double wall, simply cut the (flat) end of the
pipe protector to suit.
(3.7) Assemble the filler entry into the hole, using the two countersunk screws & nuts.
Figure 3a Figure 3b
through the entry on the Air-box (no air-box if the tank is toroidal), into the pipe
connection
of the filler entry.
(4.2) Cut the Ø8mm pipe to length.
(4.3) Trim the plastic coating back 25mm each end.
(4.4) Cut a length of the plastic flexible sheathing, long enough to cover the entire length from
Figure 4a
intend to fit the vaporiser. Mount with the blue Solenoid at the top.
engine bay. In selecting asuitable position, ensure it will not endure excessive vibration,
or be too close to a heat source. It must not however, be too far from the vehicle’s heater
matrix hose pipes, as the vaporiser will be connected to these (section 10).
(6.2) It is important that the Vaporiser be correctly positioned. See the FEMA
Vaporiser manual Figure 1 for correct position.
(6.3) If the top elbow connector does not face the way you want, you can simply undo the two
not possible, use a suitable heat-shield. Also, avoid suspension or Jacking points.
Ensure that no part of the pipe is permanently hidden from view, preventing
inspection.
(7.1) Select the position required to pass the fuel pipe through the boot floor.
(7.2) Noting any obstructions, drill a Ø30mm hole through the boot floor. Depending on the
strength of the boot floor, it may be easier to mark a Ø30mm hole, chain drill & file to suit.
(7.3) Locate the pipe protector into the hole with the flat end inside the boot, and the open end
of the chamfer protruding beneath the vehicle, angled in the direction of the fuel pipe to
Gas Solenoid.
(7.4) Drill the three fixing holes, and secure into position with the self tapping screws.
(7.5) Cut a length of the plastic flexible sheathing, long enough to cover the entire length from
completely passes through the olive, bottoming out within the valve.
(7.9) Secure the flexible sheathing, with jubilee clips
(7.10) Working under the vehicle, run the Ø6mm pipe along the underside of the floor and up
from road debris, and where it will not be damaged if the car was to bottom out,
over a
speed ramp for instance.
(7.12) Using the fixing brackets, (checking that holes drilled for them does not cause damage
within the vehicle), secure the pipe to the underside of the vehicle. It is suggested
that
you carry out section (8.3) at the same time. Bracket must be less than 600mm
apart.
(7.13) Cut the pipe to length.
(7.14) Trim the plastic coating back 25mm.
(7.15) Connect the pipe into the bottom valve of the Gas Solenoid, ensuring that it completely
(8) CONNECT WIRING LOOM FROM MULTIVALVE & RUN PARALLEL TO FUEL LINE
(8.1) Connect the Wiring loom onto the Multivalve, position D, shown in figure 4a.
(8.2) Run the cable through the inlet of the Multivalve housing, through the flexible
sheathing, and through the pipe protector, out to beneath the car. This can be done at
the same time as section (7.6).
(8.3) Run the wiring underneath the vehicle along the fuel line, securing within the fixing
brackets. Care must be taken not to clamp onto the wires, instead position them in the
fold of the brackets. This can be done at the same time as section (7.12)
(8.4) The wiring is to be connected to the Switch, see section 14.
water hoses in-line, to the water hose that goes to the vehicle’s
heater.
(10.1) Cut the vehicle’s water hose in two places, insert the plastic Tee pieces, and
secure
with Jubilee Clips.
(10. 2) To the first Tee piece, the one furthest from the heater, fit the rubber hose supplied,
connecting it to the Vaporiser (Upper Position D, figure 7, FEMA Vaporiser Manual)
securing with a Jubilee clip.
(10.3) Repeat (10.2) with the other hose, to the lower hose connection on the Vaporiser.
(13) FIT EMULATOR & WIRE INTO VEHICLE INJECTORS (Injection Vehicles Only)
(13.1) Select & mount the Emulator in a suitable place within the engine bay, away from any
Şekil 13a
Şekil 13b
Vaporiser connections.
(15.11) If a leak is detected, gently tighten the joint until the bubbling stops.
(15.12) Once satisfied that the system has no leaks, ensure C valve on the Multivalve
is fully open.
accelerate fast, accelerate around bends, etc. ensuring there are no flat spots, loss of
power, or the engine cuts out.
(16.10) Repeat the adjustments as necessary.
As detailed on page 5 of the FEMA Vaporiser manual, you are advised to keep the system
maintained, for both safety and efficiency. We recommend you to make the above adjustments
every 3000 km.
If for any reason, you have to empty LPG from the tank, for example to adjust the Multivalve
float, arm, it is strongly advised that you remove the tank from the vehicle, emptying the tank in
an open and safe place, avoiding naked flames, do not smoke. Obviously, if removing the tank,
you should use up as much of the LPG as possible beforehand, by driving the vehicle.
To remove the tank, close the shut-off valve (Positions C on Figure 4a). Disconnect the two fuel
lines, (Position A & B on figure 4a), and tank fixing straps. When the tank is in a safe place,
gently undo the allen screws, releasing the gas. Always take adequate precautions when
handling LPG, as it has an immediate freezing effect on contact – wear suitable gloves.
FAULT FINDING
The fuel reading on the switch does not match the level on the Multivalve
The switch level reading is for indication only, and will not be 100% accurate.
• If the readings are not acceptable, it is possible to gently bend the float arm accordingly.