CANADIAN UPS 6.0L MONO FUEL ENGINE SYSTEM …...90009100 icom ntc sensor 1 19299100 adaptor - ntc sensor 1 100004 evap cap 1 ... p14x4-1405-aa backing plate - fuel tank mounting bracket

CANADIAN UPS

6.0L MONO FUEL ENGINE SYSTEM

INSTALLATION MANUAL

P13C4-9232-AA

Revision: A - Dated 2/12/14

Replaces: None

6) VEHICLE LIFT WITH, PREFERABLY, A MODIFIED TRANSMISSION JACK TO SUPPORT THE FUEL TANK DURING

FITMENT AND INSTALLATION

7) A 'FLUKE 77' MULTIMETER WITH TIME-BASED READOUT (REQUIRED FOR CALIBRATION & DIAGNOSTICS ONLY,

NOT NEEDED FOR GENERAL INSTALLATION).

3) SAFETY GLASSES, GLOVES AND HEARING PROTECTION

4) FUEL PRESSURE GAUGE (ICOM # 88500001) AND CALIBRATOR REMOVAL TOOL (ICOM # 90005400)

5) SOURCE OF COMPRESSED AIR

TO YOU OR SOMEONE ELSE IF YOU DON'T FULLY UNDERSTAND LPG AND ITS PROPERTIES.

BEGIN THE INSTALLATION BY PREPARING YOUR WORK SITE. THE AREA SHOULD BE CLEAN WITH SUFFICIENT LIGHTING. YOU WILL NEED:

1) A WORKBENCH

2) TOOLS, INCLUDING SOCKETS, SCREWDRIVERS, TORQUE WRENCH, METAL CUTTING TOOLS (SMALL RECIPROCATING

SAW, NIBBLERS, DRILLS, ECTC.)

THESE INSTRUCTIONS ARE INTENDED FOR TECHNICIANS WHO ARE CERTIFIED BY ALL AGENCIES THAT GOVERN PROPANE INSTALLATIONS

AND THE TRANSPORTATION OF PROPANE. THE CANADIAN STANDARDS ASSOCIATION PUBLISHES A CODE BOOK OF RULES

(CSA B149.5-05) THAT APPLY TO THE INSTALLATION OF PROPANE FUEL SYSTEMS AND TANKS ON HIGHWAY VEHICLES. LOCAL

PROPANE SUPPLIERS SUCH AS FERRELGAS AND AMERIGAS, AS WELL AS SOME AGENGIES SUCH AS THE TEXAS RAILROAD COMMISION

AND PERC (PROPANE EDUCATION & RESEARCH COUNCIL) OFFER INFORMATIVE COURSES TO HELP PREVENT SEVERE INJURY OR DEATH

LIQUID PROPANE IS EXTREMELY COLD (-40° F) AND CAUSES SERIOUS BURNS WHEN CONTACTING YOUR SKIN OR EYES. PREVENT

CONTACT WHEN HANDLING LPG BY WEARING APPROVED PROTECTIVE GLOVES AND EYE PROTECTION.

PROPANE IS STORED UNDER PRESSURE. THE FUEL SYSTEM OPERATES AT PRESSURES OF UP TO 312 PSI. A SUDDEN RELEASE

OF PROPANE CAN CAUSE SERIOUS INJURIES.

ENSURE THAT ALL PERSONNEL IN THE IMMEDIATE AREA ARE AWARE OF THESE REMINDERS.

PROPANE IS A NONTOXIC, NONPOISONOUS GAS THAT IS EXTREMELY FLAMMABLE. IF SOMETHING IGNITES IT, YOU COULD BE

BADLY BURNED. KEEP SPARKS, OPEN FLAMES AND SMOKING MATERIAL AWAY FROM PROPANE.

INTRODUCTION

SAFETY WARNING

READ BEFORE STARTING THE INSTALLATION OF THE ICOM JTG SYSTEM.

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PACKAGING

CAREFULLY INSPECT THE CONTENTS OF THE KIT ONCE YOU RECEIVE IT TO ENSURE THAT ALL OF THE COMPONENTS ARE

AVAILABLE BEFORE STARTING THE INSTALLATION. A PARTS LIST IS ENCLOSED WITH THIS MANUAL. THE LIST OF PARTS MAY

VARY BASED ON THE APPLICATION.

CONTAMINATED WITH TEFLON TAPE WILL BE RETURNED.

BARE METAL SURFACES

ANYTIME THE OEM PAINTED SURFACE IS BROKEN BY DRILLING OR REMOVAL OF A PARTICULAR COMPONENT, THE EXPOSED

METAL SURFACE MUST BE DEBURRED AND COATED WITH A PRIMER OR SEALER TO PREVENT RAPID CORROSION. THIS IS

EXTREMELY IMPORTANT IN AREAS THAT USE ROAD SALT DURING THE WINTER MONTHS. FOLLOW THE LABEL INSTRUCTIONS

ON THE PRODUCT USED TO ENSURE POSITIVE RESULTS.

SEQUENCE.

THREADED FUEL LINE CONNECTORS / FITTINGS

THE ICOM FUEL HOSES ARE EQUIPPED WITH THREADED END CONNECTORS THAT SEAL WHEN THE PROPER TORQUE IS APPLIED.

DO NOT USE TEFLON TAPE OR THREAD SEALER ON ANY FITTING (UNLESS OTHERWISE INSTRUCTED) AS THIS MAY GET INTO THE

REGULATOR OR FUEL INJECTORS AND CAUSE FUEL PRESSURE PROBLEMS. ANY WARRANTY RETURNED COMPONENT FOUND

INTRODUCTION

IMPORTANTIT IS IMPORTANT THAT YOU REVIEW THIS ENTIRE INSTALLATION MANUAL BEFORE BEGINNING TO FAMILIARIZE YOURSELF WITH THE

INSTALLATION PROCESS. THIS WILL HELP MINIMIZE ANY POTENTIAL ERRORS THAT MAY OCCUR IF A PROCESS IS CONDUCTED OUT OF

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PART NUMBER COMPONENT QTY

P13X4-4232-AB WIRE HARNESS ASSY - ENGINE 1

110000 GROMMET - ENGINE WIRE HARNESS 1

70306602 MONO FUEL ICU MODULE 1

8808000 AUXILIARY FUEL PUMP 1

90004208 FITTING - AUXILIARY FUEL PUMP (PIA) 2

320001 HEAT SHIELD 1

200006 BRACKET - AUXILIARY FUEL PUMP 1

950000 SELF TAP SCREW 1

700002 M6 FLAT WASHER 1

90009100 ICOM NTC SENSOR 1

19299100 ADAPTOR - NTC SENSOR 1

100004 EVAP CAP 1

2003708 1/2" HOSE CLAMP 1

440000 3/16" SHRINK TUBE 1

71301100 BUZZER 1

495000 LED LIGHT 1

464002 CONNECTOR - FEMALE SPADE 2

19318100 EVAP SENSOR ORIFICE 1

P11X4-4219-AA WIRE HARNESS ASSY - EV6 TO EV1 7

P11X4-4220-AA WIRE HARNESS ASSY - EV6 TO EV1 W/KEY ON & RPM 1

480000 RING TERMINAL - 1/4" 1

480001 RING TERMINAL # 10 1

150000 8" TIE STRAP 8

P13X4-9426-AA LABEL - STARTING INSTRUCTIONS

27036000 BRACKET - MONO FUEL ICU MODULE 1

800002 M4 NYLOCK NUT 4

900008 M4 x 30 SCREW 4

P13C4-2027L-AA FUEL RAIL ASSY - 6.0L MONO FUEL ENGINE LH 1

P13C4-2027R-AA FUEL RAIL ASSY - 6.0L MONO FUEL ENGINE RH 1

P13C4-2305-AA REGULATOR W/TEE ASSY 1

P11X4-9302-AA BRACKET ASSY - REGULATOR 1

P13C4-2306-AA NON-RETURN VALVE W/TEE ASSY 1

P14X4-9319-AA BRACKET ASSY - NON RETURN VALVE 1

17091000 FUEL FILL FILTER 1

90004201 MALE / MALE ADAPTOR 2

330003 1-7/8" CABLE CLAMP 2

330005 1-3/8" CABLE CLAMP 10

330009 2-1/2" CABLE CLAMP 5


PACKAGE C

PACKAGE D

PACKAGE E

PACKAGE F (FUEL RAILS)

PACKAGE G

PACKAGE H

INSTALLATION KIT CONTENTS

THE CONTENTS IN THE INSTALLATION KIT LISTED BELOW IS BASED ON A 6.0L MONOFUEL APPLICATION. PART NUMBERS FOR SOME

PARTICULAR COMPONENTS WILL CHANGE BASED ON THE APPLICATION.

PACKAGE A

PACKAGE B

PART NUMBER COMPONENT QTY200018 BRACKET - REMOTE FUEL FILL VALVE 1

650000 FILL VALVE 1

650001 REMOTE BLEEDER VALVE 1

600012 ADAPTOR - 3/8" x 1/4" NPT 1

20010112 WASHER - FLAT 16 x 30 1


700002 M6 FLAT WASHER 4

120000 PINCH WELT 1

90009000 ICOM EMBLEM 1

P11X-9420-AA DIAMOND PROPANE DECAL 1

P13X4-9225-AA ICOM MONO FUEL OWNERS MANUAL 1

200021 BRACKET - FUEL RAIL SUPPORT 4

900006 M4 X 10mm SCREW 8

800002 M4 X 0.7 NYLOCK NUT 8

P13C4-2714-AA ENGINE HOSE - SUPPLY 2

P13C4-2814-AA ENGINE HOSE - RETURN 2

P13C4-3316-AA HOSE ASSY - AUXILIARY FUEL PUMP 1

P13C4-3615-AA HOSE ASSY - REMOTE FUEL FILL 2

P13C4-3004-AA HOSE ASSY - REMOTE BLEEDER VALVE 1

P13C4-3317-AA HOSE ASSY - CHASSIS SUPPLY 1

P13C4-3514-AA HOSE ASSY - CHASSIS RETURN 1

350042 1/4" SPLIT CORRUGATE (L=36") 1

350026 CORRUGATE HOSE - 1-1/2" SOLID (20 FT.) (CHASSIS & FILL HOSES) 2

320000 HEAT SHIELD TUBE 1

900007 BOLT - 1/2" - 13 x 2" 11

810003 NUT - 1/2" - 13 NYLOCK 11

700003 WASHER - 1/2" FLAT 11

P14X4-1405-AA BACKING PLATE - FUEL TANK MOUNTING BRACKET 3

CORRUGATE

ENGINE HOSES

AUXILIARY FUEL PUMP HOSE

FUEL FILL HOSE KIT

REMOTE BLEEDER HOSE KIT

CHASSIS HOSE KIT

FUEL TANK HARDWARE

INSTALLATION KIT CONTENTS

PACKAGE I

PACKAGE J

FUEL RAIL HARDWARE

PROCESS # PROCESS NAME REV

P13C4-9232-0010 INSTALL CHASSIS SUPPLY & RETURN HOSES ONTO FUEL TANK A

P13C4-9232-0020 REMOVE EVAP CANNISTER A

P13C4-9232-0030 INSTALL FUEL TANK MOUNTING BRACKETS A

P13C4-9232-0040 INSTALL FUEL TANK A

P13C4-9232-0050 CONNECT FUEL LEVEL WIRE LEADS A

P13C4-9232-0060 INSTALL FUEL FILL ACCESS HOLE A

P13C4-9232-0070 INSTALL FUEL FILL VALVE & BRACKET A

P13C4-9232-0080 INSTALL FUEL FILL & BLEEDER VALVE HOSES A

P13C4-9232-0090 INSTALL LPG FUEL RAILS A

P13C4-9232-0100 MODIFY EVAP SENSOR A

P13C4-9232-0110 INSTALL LPG FUEL INJECTOR WIRE HARNESS LEADS A

P13C4-9232-0120 INSTALL LPG REGULATOR & NON-RETURN VALVE A

P13C4-9232-0130 INSTALL LPG ENGINE SUPPLY / RETURN HOSES A

P13C4-9232-0140 INSTALL AUXILIARY FUEL PUMP & HOSE ASSY A

P13C4-9232-0150 ATTACH CHASSIS SUPPLY / RETURN HOSES A

P13C4-9232-0160 INSTALL MONO FUEL ICU MODULE A

P13C4-9232-0170 INSTALL LED LIGHT A

P13C4-9232-0180 INSTALL ENGINE START INSTRUCTION LABEL A

P13C4-9232-0190 INSTALL LPG ENGINE WIRE HARNESS ASSY A

P13C4-9232-0200 INSTALL ICOM NTC SENSOR A

P13C4-9232-0210 INSTALL AUDIBLE INDICATOR A

P13C4-9232-0220 ATTACH NEGATIVE BATTERY LEAD A

P13C4-9232-0230 INSTALL PROPANE DIAMOND DECAL A

P13C4-9232-0240 FINAL INSPECTION AND SYSTEM CHECK A

P13C4-9232-0250 TROUBLESHOOTING A

INSTALLATION MANUAL

TABLE OF CONTENTS

10)

20)

30)

40)

ITEM QTY

A 1

B 1

REV

PAGE1 OF 7

INSPECTION ITEM NUMBER

TORQUE OPERATION

CRITICAL PROCESS

OBTAIN THE SUPPLY HOSE ASSY - FUEL TANK TO ENGINE (A)

LOCATE THE (SHORT) SUPPLY NOZZLE COMING OUT OF THE

MULTIVALVE COLLAR BUSHING (FITTING MARKED IN 'GREEN')

HANDSTART THE CRIMPED FITTING ON THE SUPPLY HOSE ONTO

THE SUPPLY NOZZLE

USING A 17mm OPEN END WRENCH ON THE SUPPLY NOZZLE FROM

THE MULTIVALVE, TORQUE THE FITTING ON THE HOSE WITH A 3/4"

OPEN END CROWFOOT & TORQUE WRENCH TO 18 Nm +/- 1.8

PART NUMBER DESCRIPTION TORQUE TOOLS

P13C4-3317-AA SUPPLY HOSE ASSY - FUEL TANK TO ENG. (168")18 Nm +/- 1.8

17mm OPEN END WRENCH

P13C4-3514-AA RETURN HOSE ASSY - FUEL TANK TO ENG. (150") 3/4" CROWFOOT

TORQUE WRENCH

PROCESS NAME

INSTALL CHASSIS SUPPLY & RETURN HOSES

ONTO FUEL TANKA

PROCESS NUMBER

P13C4-9232-0010

?

1

10

A

20

30 40 1

50)

60)

70)

80)

ITEM QTY

A 1

B 1

REV

PAGE2 OF 7


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN THE RETURN HOSE ASSY - FUEL TANK TO ENGINE (B)

LOCATE THE (LONG) RETURN NOZZLE COMING OUT OF THE

MULTIVALVE COLLAR BUSHING (FITTING MARKED IN 'BLACK')

HANDSTART THE CRIMPED FITTING ON THE RETURN HOSE ONTO

THE RETURN NOZZLE

USING A 17mm OPEN END WRENCH ON THE RETURN NOZZLE FROM

THE MULTIVALVE, TORQUE THE FITTING ON THE HOSE WITH A 3/4"

OPEN END CROWFOOT & TORQUE WRENCH TO 18 Nm +/- 1.8


P13C4-3317-AA SUPPLY HOSE ASSY - FUEL TANK TO ENG. (168")18 Nm +/- 1.8

17mm OPEN END WRENCH

P13C4-3514-AA RETURN HOSE ASSY - FUEL TANK TO ENG. (150") 3/4" CROWFOOT

TORQUE WRENCH

PROCESS NAME


ONTO FUEL TANKA

PROCESS NUMBER

P13C4-9232-0010

?

1

50

B

60

70 80 1

90)

100)

110)

120)

ITEM QTY

C 1

REV

PAGE3 OF 7

PROCESS NUMBER

P13C4-9232-0010


ONTO FUEL TANKA

PROCESS NAME

350026 CORRUGATE HOSE (20')


GRASP THE OPPOSITE END OF THE RETURN HOSE ASSY ATTACHED TO

FITTING MARKED IN 'BLACK' ON THE FUEL TANK

INSERT (1) HOSE CLAMP ONTO ONE END OF THE CORRUGATE HOSE (C )

AS SHOWN

REMOVE THE (2) HOSE CLAMPS ATTACHED TO ONE OF THE

SUPPLY / RETURN TUBES ON THE FUEL TANK

OBTAIN (1) CORRUGATE HOSE (20') (C )


TORQUE OPERATION

CRITICAL PROCESS

?

90

C

120

100

110

130)

140)

150)

160)

ITEM QTY

C 1

REV

PAGE4 OF 7


TORQUE OPERATION

CRITICAL PROCESS

COMPLETELY INSERT THE RETURN HOSE INTO THE CORRUGATE

HOSE

ALIGN AND SEAT THE CORRUGATE HOSE ONTO THE FUEL TANK

COLLAR BUSHING; POSITION THE HOSE CLAMP ON THE CORRUGATE

HOSE OVER THE BUSHING; FULLY TIGHTEN THE HOSE CLAMP TO SECURE

THE CORRUGATE ONTO THE BUSHING

OBTAIN (1) CORRUGATE HOSE (20') (C )

INSERT (1) HOSE CLAMP ONTO ONE END OF THE CORRUGATE HOSE (C )

AS SHOWN


350026 CORRUGATE HOSE (20')

PROCESS NAME


ONTO FUEL TANKA

PROCESS NUMBER

P13C4-9232-0010

?

130

140

C

150

160

170)

180)

190)

ITEM QTY

REV

PAGE5 OF 7


TORQUE OPERATION

CRITICAL PROCESS

GRASP THE OPPOSITE END OF THE SUPPLY HOSE ASSY ATTACHED TO

FITTING MARKED IN 'GREEN' ON THE FUEL TANK; GRASP THE FUEL TANK

WIRE HARNESS

COMPLETELY INSERT THE SUPPLY HOSE AND FUEL TANK WIRE

HARNESS INTO THE CORRUGATE HOSE

ALIGN AND SEAT THE CORRUGATE HOSE ONTO THE FUEL TANK

COLLAR BUSHING; POSITION THE HOSE CLAMP ON THE CORRUGATE

HOSE OVER THE BUSHING; FULLY TIGHTEN THE HOSE CLAMP TO SECURE

THE CORRUGATE ONTO THE BUSHING


PROCESS NAME


ONTO FUEL TANKA

PROCESS NUMBER

P13C4-9232-0010

?

170

180

190

200)

210)

ITEM QTY

REV

PAGE6 OF 7

PROCESS NUMBER

P13C4-9232-0010


ONTO FUEL TANKA

PROCESS NAME


USING A RAZOR BLADE, CAREFULLY SLICE OPEN THE CORRUGATE HOSE

AND LOCATE THE FUEL LEVEL SENDING UNIT LEAD; REMOVE LEAD

THROUGH OPENING

MEASURE 30" FROM THE FUEL TANK BUSHING ON THE CORRUGATE

HOSE THAT CONTAINS THE CHASSIS SUPPLY HOSE AND FUEL TANK

WIRE HARNESS ASSY


TORQUE OPERATION

CRITICAL PROCESS

?

200

210

220)

230)

ITEM QTY

REV

PAGE7 OF 7

PROCESS NUMBER

P13C4-9232-0010


ONTO FUEL TANKA

PROCESS NAME

ELECTRICAL TAPE


SEAL CUT OPENING ON 1-1/2" CORRUGATE HOSE WITH ELECTRICAL TAPE

AS SHOWN

OBTAIN 1/4" SPILT CORRUGATE (D) FROM THE ENGINE KIT; INSTALL

CORRUGATE ONTO EXPOSED WIRE LEADS AND CUT TO REQUIRED LENGTH


TORQUE OPERATION

CRITICAL PROCESS

?

220

D

230

10)

20)

30)

ITEM QTY

REV

PAGE1 OF 2

PROCESS NUMBER

P13C4-9232-0020

REMOVE EVAP CANNISTER A

PROCESS NAME


REMOVE THE (2) FASTENERS THAT SECURE THE EVAP CANNISTER

BRACKET TO THE UNDERSIDE OF THE PASSENGER FRAME RAIL

REMOVE THE (2) EVAP HOSES FROM THE STEEL TUBES LOCATED ON THE

INBOARD SIDE OF THE PASSENGER FRAME RAIL

FROM THE UNDERSIDE OF THE VEHICLE, LOCATE THE EVAP CANNISTER

ASSEMBLY ATTACHED TO THE INBOARD SIDE OF THE PASSENGER

FRAME RAIL


TORQUE OPERATION

CRITICAL PROCESS

?

10

20

30

40)

50)

60)

70)

ITEM QTY

A 1

B 1

REV

PAGE2 OF 2

PROCESS NUMBER

P13C4-9232-0020

REMOVE EVAP CANNISTER A

PROCESS NAME

100004 EVAP CAP

20003708 1/2" CLAMP


TIGHTEN SECURELY

INSTALL EVAP CAP (A) ONTO THE STEEL LINE CIRCLED IN THE ADJACENT

PHOTO; INSTALL THE 1/2" HOSE CLAMP (B) ONTO THE EVAP CAP AND

OBTAIN THE EVAP CAP (A) AND 1/2" CLAMP (B) FROM PACKAGE D

CAREFULLY REMOVE THE EVAP CANNISTER ASSEMBLY FROM THE VEHICLE

REMOVE THE (1) FASTENER THAT SECURES THE EVAP CANNISTER

BRACKET TO THE CROSSMEMBER


TORQUE OPERATION

CRITICAL PROCESS

?

40

50

60

70

10)

20)

30)

40)

50)

ITEM QTY

REV

PAGE1 of 4

PROCESS NUMBER

P13C4-9232-0030

INSTALL FUEL TANK MOUNTING BRACKETS A

PROCESS NAME

DRILL

1/2" DRILL BIT


FRAME RAIL (11 PLACES)

USING A DRILL WITH A 1/2" DRILL BIT, CAREFULLY DRILL THE (11)

MARKED HOLES INTO THE PASSENGER SIDE FRAME RAIL

EDGE OF THE TEMPLATE NESTED AGAINST THE VEHICLE ENTRY STEP AND

THE TOP EDGE OF TEMPLATE NESTED AGAINST THE FLOOR PAN

REINFORCEMENTS

MARK THE BRACKET ATTACHMENT HOLES ONTO THE PASSENGER SIDE

PASSENGER SIDE OF THE VEHICLE, POSITION THE TEMPLATE WITH THE

SIDE MARKED 'FRONT' TOWARDS THE FRONT OF THE VEHICLE AND 'TOP'

POINTING UP

FROM UNDERNEATH THE VEHICLE, SEAT THE TEMPLATE ONTO THE

OUTBOARD PASSENGER SIDE OF THE FRAME RAIL; PLACE THE FRONT

OBTAIN THE FUEL TANK MOUNTING BRACKET TEMPLATE; FROM THE

REMOVE & SEPARATE THE FUEL TANK ATTACHMENT BRACKETS FROM THE

FUEL TANK AS SHOWN; SET FASTENERS ASIDE FOR LATER

RE-INSTALLATION


TORQUE OPERATION

CRITICAL PROCESS

?

10

60)

70)

80)

90)

100)

ITEM QTY

A 11

B 11

C 11

D 3

REV

PAGE2 of 4

PROCESS NUMBER

P13C4-9232-0030


PROCESS NAME

810003 NUT - 1/2" - 13 NYLOCK TORQUE WRENCH

P11X4-1405-AA BACKING PLATE - FUEL TANK MTG. BRKT.

900007 BOLT - 1/2" - 13 X 2 19mm WRENCH

700003 WASHER -1/2" FLAT 19mm SOCKET100 Nm +/- 10


TORQUE ALL (4) BOLTS/NUTS TO 100 Nm +/- 10

ALIGN MOUNTING HOLES AND INSERT (4) 1/2" x 2" BOLTS FROM

INBOARD SIDE OF THE FRAME THROUGH THE BACKING PLATE AND INTO

THE MOUNTING BRACKET; INSTALL A 1/2" WASHER ONTO EACH BOLT;

HANDSTART 1/2" NYLOCK NUT ONTO EACH BOLT

ALIGN AND SEAT (1) BACKING PLATE (D) TO THE INBOARD SIDE OF THE

FRAME (OPPOSITE OF MOUNTING BRACKET); ALIGN MOUNTING HOLES

IN BACKING PLATE TO THE REAR DRILLED HOLES

OBTAIN (1) FUEL TANK MOUNTING BRACKET; ORIENTATE BRACKET

WITH THE J-PORTION OF THE BRACKET AT THE BOTTOM; ALIGN AND

SEAT THE ATTACHMENT HOLES IN THE BRACKET TO THE REAR DRILLED

HOLES ON THE OUTBOARD SIDE OF THE FRAME

OBTAIN THE (11) 1/2" x 2" BOLTS (A), (11) 1/2" FLAT WASHERS (B), (11)

1/2" NYLOCK NUTS (C ) AND (3) BACKING PLATES (D) FROM THE

ENGINE KIT


TORQUE OPERATION

CRITICAL PROCESS

?

A B C

60

J-PORTION OF BRACKET 70

80 90 100 1

1

110)

120)

130)

140)

ITEM QTY

REV

PAGE3 of 4

PROCESS NUMBER

P13C4-9232-0030


PROCESS NAME

TORQUE WRENCH

19mm WRENCH

19mm SOCKET100 Nm +/- 10









IN BACKING PLATE TO THE MIDDLE DRILLED HOLES



SEAT THE ATTACHMENT HOLES IN THE BRACKET TO THE MIDDLE DRILLED



TORQUE OPERATION

CRITICAL PROCESS

?

110

120 130 140 1

1

150)

160)

170)

180)

ITEM QTY

REV

PAGE4 of 4


TORQUE OPERATION

CRITICAL PROCESS



SEAT THE ATTACHMENT HOLES IN THE BRACKET TO THE FRONT DRILLED




IN BACKING PLATE TO THE FRONT DRILLED HOLES







19mm WRENCH


TORQUE WRENCH

PROCESS NAME


PROCESS NUMBER

P13C4-9232-0030

?

150

160 170 180 1

1

10)

20)

30)

40)

ITEM QTY

REV

PAGE1 OF 5


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN THE (3) FUEL TANK 'HOOP' BRACKETS & FASTENERS REMOVED

IN OPERATION 0020 STEP #10

POSITION THE FUEL TANK TO THE PASSENGER SIDE OF THE VEHICLE WITH

THE MULTIVALVE ON THE END OF THE FUEL TANK FACING TOWARD

THE REAR OF THE VEHICLE

USING AN APPROPRIATE LIFTING DEVICE, ALIGN AND CENTER FUEL TANK

TO THE FUEL TANK BRACKETS MOUNTED TO PASSENGER SIDE FRAME;

CAREFULLY LIFT TANK AND SEAT FUEL TANK INTO BRACKETS

ALIGN AND SEAT THE (3) 'HOOP' BRACKETS ONTO THE FUEL TANK

BRACKETS MOUNTED TO THE FRAME RAIL; LOOSELY SECURE THE

BRACKETS TOGETHER WITH THE REMOVED FASTENERS


PROCESS NAME

INSTALL FUEL TANK A

PROCESS NUMBER

P13C4-9232-0040

?

10

20

30

40

50)

60)

70)

80)

ITEM QTY

REV

PAGE2 OF 5


TORQUE OPERATION

CRITICAL PROCESS

MOVE THE TANK AS NEEDED TO CENTER THE TANK FRONT TO REAR

INSIDE THE BRACKETS AND ROTATE THE TANK TO POSITION THE 'TOP'

DECAL AT TOP CENTER

ONCE TANK IS POSITIONED CORRECTLY, TORQUE THE (6) FASTENERS

TO 100 Nm +/- 10 TO SECURE THE FUEL TANK IN PLACE

GRASP THE (2) CORRUGATE HOSES ATTACHED TO THE MULTIVALVE

COLLAR ON THE FUEL TANK

ROUTE THE (2) CORRUGATE HOSES TOWARD THE INBOARD SIDE OF THE

VEHICLE ABOVE THE PASSENGER SIDE FRAME RAIL


19mm WRENCH


TORQUE WRENCH

PROCESS NAME

INSTALL FUEL TANK A

PROCESS NUMBER

P13C4-9232-0040

?

50

60

1

1

70

80

90)

100)

110)

ITEM QTY

A 5

B 5

REV

PAGE3 OF 5


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN (5) 2-1/2" CABLE CLAMPS (A) FROM THE ENGINE KIT AND (5)

SELF TAP SCREWS (B) FROM PACKAGE H

INSTALL (1) CABLE CLAMP (A) ONTO CORRUGATE HOSE AND SECURE

CLAMP TO FLOOR PAN REINFORCEMENT WITH SELF TAP SCREW (B)

CONTINUE ROUTING BOTH CORRUGATE HOSES TOWARD THE FRONT

OF THE VEHICLE ABOVE THE FRAME CROSSMEMBER AND ALONG THE

INBOARD SIDE OF THE THE FRAME RAIL


330009 2-1/2" CABLE CLAMP CORDLESS DRILL

950000 SELF TAP SCREW (PKG H) 8mm SOCKET

PROCESS NAME

INSTALL FUEL TANK A

PROCESS NUMBER

P13C4-9232-0040

?

90

A

B

100

110

120)

130)

140)

150)

160)

ITEM QTY

REV

PAGE4 OF 5


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN (1) 2-1/2" CABLE CLAMP (A) AND (1) SELF TAP SCREW (B)

INSTALL CABLE CLAMP (A) ONTO CORRUGATE HOSE AND SECURE CLAMP

TO FLOOR PAN REINFORCEMENT WITH SELF TAP SCREW (C ) BETWEEN

THE (2) FRAME CROSSMEMBERS AS SHOWN

CONTINUE ROUTING BOTH CORRUGATE HOSES ABOVE THE DRIVESHAFT

HOOP CROSSMEMBER AND TOWARD THE FRONT OF THE VEHICLE

ALONG THE INBOARD SIDE OF THE FRAME RAIL AS SHOWN

OBTAIN (1) 2-1/2" CABLE CLAMP (A) AND (1) SELF TAP SCREW (B)

INSTALL CABLE CLAMP (A) ONTO CORRUGATE HOSE AND SECURE CLAMP

TO FLOOR PAN REINFORCEMENT WITH SELF TAP SCREW (C ) JUST

FORWARD OF THE ABS MODULE AS SHOWN

CONTINUE ROUTING BOTH CORRUGATE HOSES TOWARD THE ENGINE

COMPARTMENT ALONG THE INBOARD SIDE OF THE PASSENGER FRAME

RAIL

INSTALL THE REMAINING (2) 2-1/2" CABLE CLAMPS (A) AND (2) SELF

TAP SCREWS (B) ONTO BOTH CORRUGATE HOSES EVERY TWO FEET FROM

THE ABS MODULE FORWARD; SECURE CLAMPS TO A FLOOR PAN

REINFORCEMENT WITH SELF TAP SCREW


CORDLESS DRILL

8mm SOCKET

PROCESS NAME

INSTALL FUEL TANK A

PROCESS NUMBER

P13C4-9232-0040

?

120

FRAME CROSSMEMBERS

130

ABS MODULE

140

150 160

170)

180)

190)

ITEM QTY

C 1

REV

PAGE5 OF 5


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN THE HEAT SHEILD TUBE (C ) FROM THE ENGINE KIT

INSTALL HEAT SHIELD TUBE (C ) ONTO THE END OF BOTH CORRUGATE

HOSES; POSITION HEAT SHIELD ONTO CORRUGATE HOSES AS SHOWN

BY THE TRANSMISSION BELL HOUSING

ROUTE BOTH CORRUGATE HOSES INTO THE PASSENGER SIDE OF THE

ENGINE COMPARTMENT AS SHOWN


320000 HEAT SHIELD TUBE

PROCESS NAME

INSTALL FUEL TANK A

PROCESS NUMBER

P13C4-9232-0040

?

170

C

180

190

10)

20)

ITEM QTY

REV

PAGE1 OF 3

PROCESS NUMBER

P13C4-9232-0050

CONNECT FUEL LEVEL WIRE LEADS A

PROCESS NAME

RAZOR BLADE


CAREFULLY USING A RAZOR BLADE, OPEN THE CORRUGATE IN CLOSE

PROXIMITY TO THE FUEL LEVEL SENDING UNIT LEAD

ALONG THE INBOARD SIDE OF THE PASSENGER SIDE FRAME RAIL, LOCATE

THE OEM WIRE HARNESS LOOM FOR THE GASOLINE FUEL TANK

FROM THE UNDERSIDE OF THE VEHICLE PASSENGER SIDE, LOCATE THE

FUEL LEVEL SENDING UNIT LEAD ATTACHED TO THE CORRUGATE HOSE

COMING FROM THE LPG FUEL TANK (YELLOW / GREEN WIRES)


TORQUE OPERATION

CRITICAL PROCESS

?

10

20

30)

40)

50)

60)

70)

80)

ITEM QTY

A 1

REV

PAGE2 OF 3

PROCESS NUMBER

P13C4-9232-0050


PROCESS NAME

440000 3/16" SHRINK TUBE (PKG D) WIRE CUTTERS

WIRE STRIPPERS


CAREFULLY REMOVE APPROXIMATELY 1/2" OF INSULATION FROM THE

END OF THE GREEN WIRE COMING FROM THE LPG FUEL TANK WIRE

HARNESS; INSTALL A 1-1/2" PIECE OF SHRINK TUBE (A) ONTO WIRE


END OF THE YELLOW WIRE COMING FROM THE LPG FUEL TANK WIRE

HARNESS; INSTALL A 1-1/2" PIECE OF SHRINK TUBE (A) ONTO WIRE

INSULATION FROM THE END OF THE BLACK SENDING UNIT

WIRE (FRONT HALF)

USING WIRE STRIPPERS, CAREFULLY REMOVE APPROXIMATELY 1/2" OF

INSULATION FROM THE END OF THE PURPLE/WHITE SENDING UNIT

WIRE (FRONT HALF)

CUT THE PURPLE/WHITE WIRE IN HALF AND SEPARATE THE FRONT HALF

FROM THE REAR

USING WIRE STRIPPERS, CAREFULLY REMOVE APPROXIMATELY 1/2" OF

FROM THE REAR

LOCATE THE PURPLE/WHITE SENDING UNIT WIRE INSIDE THE OEM WIRE

HARNESS LOOM

LOCATE THE BLACK SENDING UNIT WIRE INSIDE THE OEM WIRE

HARNESS LOOM

CUT THE BLACK WIRE IN HALF AND SEPARATE THE FRONT HALF


TORQUE OPERATION

CRITICAL PROCESS

?

30

40

50

60

70

80

90)

100)

110)

ITEM QTY

REV

PAGE3 OF 3

PROCESS NUMBER

P13C4-9232-0050


PROCESS NAME

SOLDER IRON

ROSIN CORE SOLDER


AS SHOWN

SOLDER CONNECTIONS TOGETHER AND SEAL WITH SHRINK TUBE

ATTACH THE PURPLE/WHITE SENDING UNIT LEAD AND YELLOW WIRE

LEAD FROM THE LPG FUEL TANK HARNESS TOGETHER A SHOWN

ATTACH THE BLACK SENDING UNIT LEAD AND GREEN WIRE LEAD

FROM THE LPG FUEL TANK HARNESS TOGETHER A SHOWN


TORQUE OPERATION

CRITICAL PROCESS

?

90

100

110

10)

20)

30)

ITEM QTY

REV

PAGE1 OF 1

INSPECTION

TORQUE

CRITICAL PROCESS

MEASURE 66-1/4" FROM THE REAR EDGE OF THE PASSENGER DOOR

USING A FILE, REMOVE ANY SHARP BURRS FROM THE DRILLED HOLE

THE CENTER OF THE HOLE FOR THE FUEL FILL OPENING

FRAME AND 15-1/2" FROM THE BOTTOM EDGE OF THE BODY TO LOCATE

4-3/8" HOLE SAW

DRILL

PART NUMBER DESCRIPTION

AS SHOWN

TOOLS

A

PROCESS NUMBER

P13C4-9232-0060

PROCESS NAME

INSTALL FUEL FILL ACCESS HOLE

ITEM NUMBER

OPERATION

TORQUE

USING A DRILL WITH A 4-3/8" HOLE SAW, DRILL A HOLE IN THE BODY

?

66-1/4" 10

15-1/2"

20 30

10)

20)

30)

40)

ITEM QTY

A 1

B 1

C 1

D 1

E 1

F 4 REV

G 4

H 1

PAGE1 OF 4

PROCESS NUMBER

P13C4-9232-0070

700002 M6 FLAT WASHERINSTALL FUEL FILL VALVE & BRACKET A120000 PINCH WELT (L=15")

20010112 REMOTE FILL VALVE

950000 SELF TAP SCREW PROCESS NAME

650001 FLAT WASHER

600012 ADAPTOR - REMOTE BLEEDER VALVE

200018 BRACKET - FUEL FILL VALVE 1-1/4" WRENCH

650000 REMOTE BLEEDER VALVE


OBTAIN THE FUEL FILL BRACKET (A); INSERT THE REMOTE FILL VALVE

INTO THE LARGE 'D' RING HOLE INTO THE BRACKET AS SHOWN

RE-INSTALL LOCK WASHER ONTO FILL VALVE; HANDSTART AND FULLY

SECURE NUT ONTO FILL VALVE USING A 1-1/4" WRENCH

OBTAIN THE REMOTE FILL VALVE (E ); REMOVE THE NUT AND LOCK

WASHER FROM THE FILL VALVE AND SET ASIDE

D - ADAPTOR - REMOTE BLEEDER VALVE (QTY. 1)

E - REMOTE FILL VALVE (QTY. 1)

F - SELF TAP SCREW (QTY. 4)

G - M6 WASHER (QTY. 4)

H - PINCH WELT (QTY. 1)

OBTAIN THE FOLLOWING FROM PACKAGE 'I';

A - BRACKET - FUEL FILL VALVE (QTY. 1)

B - REMOTE BLEEDER VALVE (QTY. 1)

C - FLAT WASHER (QTY. 1)

ITEM NUMBER

OPERATION

INSPECTION

TORQUE

CRITICAL PROCESS

?

20

30

40

A

B

C

D E

F

G

H

10

50)

60)

70)

80)

ITEM QTY

B 1

C 1

D 1

F 4

G 4REV

PAGE2 OF 4

PROCESS NUMBER

P13C4-9232-0070

INSTALL FUEL FILL VALVE & BRACKET A

700002 M6 FLAT WASHER

PROCESS NAME

600012 ADAPTOR - REMOTE BLEEDER VALVE

950000 SELF TAP SCREW

650000 REMOTE BLEEDER VALVE 9/16" WRENCH

650001 FLAT WASHER 16mm WRENCH


16mm WRENCH

OBTAIN THE (4) SELF TAP SCREWS (F) AND (4) M6 FLAT WASHERS (G)

KNOB CLOCKWISE UNTIL IT STOPS)

APPLY THREAD SEALER ONTO THE REMOTE BLEEDER VALVE THREADS;

INSTALL THE FLAT WASHER ONTO THE BLEEDER VALVE; HANDSTART

THE ADAPTOR ONTO THE BLEEDER VALVE; HOLDING THE BLEEDER VALVE

IN PLACE WITH A 9/16" WRENCH, FULLY TIGHTEN THE ADAPTOR WITH A

INSERT THE REMOTE BLEEDER VALVE INTO THE SMALL HOLE ON THE

FUEL FILL BRACKET AS SHOWN; POSITION THE SMALL HOLE ON THE SIDE

OF THE BLEEDER VALVE 'DOWN' TOWARD THE EDGE OF THE BRACKET

AS SHOWN (VERIFY BLEEDER VALVE IS CLOSED BY FULLY ROTATING THE

OBTAIN THE REMOTE BLEEDER VALVE (B), FLAT WASHER (C ) AND

BLEEDER VALVE ADAPTOR (D) FROM PACKAGE 'I'

ITEM NUMBER

OPERATION

INSPECTION

TORQUE

CRITICAL PROCESS

?

60

70

50

80

90)

100)

110)

120)

ITEM QTY

REV

PAGE3 OF 4

PROCESS NUMBER

P13C4-9232-0070


PROCESS NAME

SILICONE ADHESIVE

CORDLESS DRILL

8mm SOCKET


LENGTH OF THE PINCH WELT CHANNEL

THE FLOOR PAN)

OBTAIN THE PINCH WELT (H)

APPLY A SMALL BEAD OF SILICONE ADHESIVE DOWN THE ENTIRE

POSITION & CENTER (2) MOUNTING HOLES ON EACH END OF THE

BRACKET TO THE FLOOR PAN REINFORCEMENTS; INSTALL (1) M6 FLAT

WASHER (G) ONTO EACH SELF TAP SCREW (F); USING A CORDLESS

DRILL W/8mm SOCKET, SECURE THE FILL VALVE BRACKET TO THE FLOOR

PAN REINFORCEMENTS (EXERCISE CAUTION NOT TO INSERT SCREWS INTO

FROM THE PASSENGER UNDERSIDE OF THE VEHICLE, CENTER THE

FILL VALVE AND BLEEDER VALVE TO THE ACCESS HOLE CUT INTO THE

VEHICLE BODY; POSITION THE BRACKET APPROXIMATELY 2 INCHES

FROM THE ACCESS HOLE


TORQUE OPERATION

CRITICAL PROCESS

?

ACCESS HOLE

90

100

110

120

2"

130)

ITEM QTY

REV

PAGE4 OF 4


TORQUE OPERATION

CRITICAL PROCESS

CAREFULLY ALIGN AND SEAT THE PINCH WELT CHANNEL ONTO AND

AROUND THE EDGES OF THE FILL VALVE ACCESS HOLE; TRIM AND

DISCARD EXCESS PINCH WELT AS REQUIRED; CAREFULLY WIPE AND

REMOVE ANY EXCESS SILICONE ADHESIVE FROM THE BODY EXTERIOR


RAZOR BLADE

PROCESS NAME


PROCESS NUMBER

P13C4-9232-0070

?

130

10)

20)

30)

40)

ITEM QTY

A 2

B 1

C 1

D 2

E 2REV

PAGE1 OF 6

PROCESS NUMBER

P13C4-9232-0080

INSTALL FUEL FILL & BLEEDER VALVE HOSES A

330003 1-7/8" CABLE CLAMP

PROCESS NAME

17091000 FUEL FILL FILTER


P13C4-3615-AA HOSE ASSY - REMOTE FUEL FILL 7/8" CROWFOOT

P13C4-3004-AA HOSE ASSY - BLEEDER VALVE TORQUE WRENCH30 Nm +/- 3.0


D - SELF TAP SCREW (QTY. 2)

E - 1-7/8" CABLE CLAMP (QTY. 2)

VALVE; USING A 7/8" CROWFOOT AND TORQUE WRENCH, TORQUE THE

HOSE FITTING TO 30 Nm +/- 3.0

OBTAIN THE FOLLOWING ITEMS FROM PACKAGE H

C - FUEL FILL FILTER (QTY. 1)

TORQUE THE HOSE FITTING TO 30 Nm +/- 3.0

FROM THE UNDERSIDE OF THE VEHICLE, LOCATE THE REMOTE FUEL

FILL VALVE; OBTAIN (1) FUEL FILL HOSE (A); HANDSTART THE HOSE

FITTING ON ONE END OF THE HOSE ONTO THE REMOTE FUEL FILL

FROM THE UNDERSIDE OF THE VEHICLE, LOCATE THE FUEL FILL VALVE

ON THE FUEL TANK; OBTAIN (1) FUEL FILL HOSE (A); HANDSTART THE

HOSE FITTING ON ONE END OF THE HOSE ONTO THE FUEL FILL VALVE

ON THE TANK; USING A 7/8" CROWFOOT AND TORQUE WRENCH,

OBTAIN THE (2) FUEL FILL HOSES (A) AND THE (1) BLEEDER VALVE

HOSE (B)


TORQUE OPERATION

CRITICAL PROCESS

?

20

1

1

30 1

A

B

C

D

E

50)

60)

70)

80)

ITEM QTY

REV

PAGE2 OF 6

PROCESS NUMBER

P13C4-9232-0080


PROCESS NAME

CORDLESS DRILL

8mm SOCKET

7/8" CROWFOOT

TORQUE WRENCH30 Nm +/- 3.0


(1) SELF TAP SCREW INTO EACH FILTER CLAMP ATTACHMENT HOLE;

SEAT BOTH CLAMPS TO THE FLOOR PAN REINFORCEMENT ABOVE

FILTER; USING A CORDLESS DRILL W/8mm SOCKET, TIGHTEN BOTH

SELF TAP SCREWS TO SECURE CLAMPS TO FLOOR PAN REINFORCEMENT

(EXERCISE CAUTION NOT TO INSTALL SCREWS INTO FLOOR PAN)

HANDSTART THE HOSE FITTING ONTO THE ARROWHEAD END OF THE

FUEL FILTER FITTING AS SHOWN; USING A 7/8" CROWFOOT AND

TORQUE WRENCH, TORQUE THE HOSE FITTING TO 30 Nm +/- 3.0

INSTALL THE (2) 1-7/8" CABLE CLAMP (E) ONTO THE FUEL FILTER; INSERT

OBTAIN LEFT OVER SECTION OF CORRUGATE HOSE USED FOR THE

CHASSIS SUPPLY / RETURN HOSES; INSERT CORRUGATE ONTO FUEL FILL

HOSE ATTACHED TO THE FILL VALVE ON THE FUEL TANK AS SHOWN

AND TRIM CORRUGATE TO REQUIRED LENGTH

LOCATE THE ARROW LABEL ON THE FUEL FILL FILTER (C); FROM

THE UNDERSIDE OF THE VEHICLE, POSITION THE ARROW ON THE FUEL

FILL FILTER TO POINT TOWARDS THE FILL VALVE ON THE FUEL TANK


TORQUE OPERATION

CRITICAL PROCESS

?

1

50

60

70 1

80

90)

100)

110)

120)

ITEM QTY

D 4

F 4

REV

PAGE3 OF 6

PROCESS NUMBER

P13C4-9232-0080


PROCESS NAME

950000 SELF TAP SCREW30 Nm +/- 3.0

7/8" CROWFOOT

330005 1-3/8" CABLE CLAMP TORQUE WRENCH


FUEL FILTER FITTING AS SHOWN; USING A 7/8" CROWFOOT AND

TORQUE WRENCH, TORQUE THE HOSE FITTING TO 30 Nm +/- 3.0

OBTAIN (4) SELF TAP SCREWS (D) AND (4) 1-3/8" CABLE CLAMPS (F)

FROM PACKAGE H

CHASSIS SUPPLY / RETURN HOSES; INSERT CORRUGATE ONTO FUEL FILL

HOSE ATTACHED TO THE REMOTE FUEL FILL VALVE AS SHOWN AND

TRIM CORRUGATE TO REQUIRED LENGTH

HANDSTART THE HOSE FITTING ONTO THE OPPOSITE END OF THE

LOCATE THE FUEL FILL HOSE ATTACHED TO THE REMOTE FUEL FILL

VALVE



TORQUE OPERATION

CRITICAL PROCESS

?

1

90

110 1

F

D

120

100

130)

140)

150)

160)

170)

ITEM QTY

REV

PAGE4 OF 6

PROCESS NUMBER

P13C4-9232-0080


PROCESS NAME

CORDLESS DRILL

8mm SOCKET


LOCATE THE REMOTE BLEEDER VALVE ATTACHED TO THE FUEL FILL

BRACKET

INSERT (1) SELF TAP SCREW INTO THE ATTACHMENT HOLE IN THE

CLAMP; SEAT THE CLAMP ONTO THE FLOOR PAN REINFORCEMENT AS

SHOWN; USING A CORDLESS DRILL W/8mm SOCKET, TIGHTEN THE

SELF TAP SCREW TO SECURE THE CLAMP TO THE FLOOR PAN

REINFORCEMENT (EXERCISE CAUTION NOT TO INSTALL SCREW INTO

FLOOR PAN)

INSTALL (1) 1-3/8" CABLE CLAMP ONTO THE FUEL FILL HOSE CORRUGATE

ATTACHED TO THE REMOTE FUEL FILL VALVE; POSITION CLAMP

APPROXIMATELY 12" INBOARD OF THE REMOTE FUEL FILL VALVE

AS SHOWN

INSERT (1) SELF TAP SCREW INTO EACH CLAMP ATTACHMENT HOLE;

SEAT CLAMPS ONTO THE FLOOR PAN REINFORCEMENTS SHOWN; USING

A CORDLESS DRILL W/8mm SOCKET, TIGHTEN THE SELF TAP SCREWS

TO SECURE THE CLAMPS TO THE FLOOR PAN REINFORCEMENTS

(EXERCISE CAUTION NOT TO INSTALL SCREWS INTO FLOOR PAN)

INSTALL (3) 1-3/8" CABLE CLAMPS ONTO THE BOTH FUEL FILL HOSE

CORRUGATE IN THE LOCATIONS AS SHOWN


TORQUE OPERATION

CRITICAL PROCESS

?

130 140

150 160

170

180)

190)

200)

210)

ITEM QTY

REV

PAGE5 OF 6

PROCESS NUMBER

P13C4-9232-0080


PROCESS NAME

3/4" CROWFOOT



TO 18 Nm +/- 1.8

ON THE FUEL TANK

HANDSTART HOSE FITTING ONTO FUEL TANK BLEEDER VALVE; USING

A 3/4" CROWFOOT AND TORQUE WRENCH, TORQUE THE HOSE FITTING

LOCATE THE BLEEDER VALVE ON THE FUEL TANK; GRASP THE OPPOSITE

END OF THE BLEEDER HOSE AND ROUTE TOWARD THE BLEEDER VALVE


CHASSIS SUPPLY / RETURN HOSES; INSERT CORRUGATE ONTO THE

BLEEDER VALVE HOSE AND TRIM CORRUGATE TO REQUIRED LENGTH

HANDSTART HOSE FITTING ON ONE END OF THE BLEEDER VALVE HOSE

ONTO THE BLEEDER VALVE; USING A 3/4" CROWFOOT AND TORQUE

WRENCH, TORQUE THE HOSE FITTING TO 18 Nm +/- 1.8


TORQUE OPERATION

CRITICAL PROCESS

?

180 2

2

190

200 210 2

220)

230)

240)

250)

260)

ITEM QTY

D 2

F 2

REV

PAGE6 OF 6

PROCESS NUMBER

P13C4-9232-0080


PROCESS NAME

950000 SELF TAP SCREW CORDLESS DRILL

330005 1-3/8" CABLE CLAMP 8mm SOCKET




FLOOR PAN)

VALVES IN THE FUEL TANK AS SHOWN




FLOOR PAN)

INSTALL (1) 1-3/8" CABLE CLAMP ONTO THE BLEEDER HOSE CORRUGATE;

POSITION THE CLAMP IS CLOSE PROXIMITY TO THE FILL / BLEEDER






INSTALL (1) 1-3/8" CABLE CLAMP ONTO THE BLEEDER HOSE CORRUGATE;

POSITION THE CLAMP APPROXIMATELY 12" INBOARD OF THE REMOTE

BLEEDER VALVE AS SHOWN

OBTAIN (2) SELF TAP SCREWS (D) AND (2) 1-3/8" CABLE CLAMPS (F)

FROM PACKAGE H


TORQUE OPERATION

CRITICAL PROCESS

?

220 F

D

230 240

250 260

10)

20)

30)

40)

50)

ITEM QTY

REV

PAGE1 of 3

PROCESS NUMBER

P13C4-9232-0090

INSTALL LPG FUEL RAILS A

PROCESS NAME


PASSENGER SIDE GASOLINE FUEL RAILS TO THE INTAKE MANIFOLD

CAREFULLY REMOVE THE DRIVER & PASSENGER SIDE GASOLINE FUEL

RAILS FROM THE ENGINE

DISCONNECT THE OEM GASOLINE SUPPLY LINE ATTACHED TO THE DRIVER

SIDE GASOLINE FUEL RAIL

LOOSEN AND REMOVE THE (4) SCREWS THAT SECURE THE DRIVER AND

FROM INSIDE THE VEHICLE, REMOVE THE ENGINE COVER AND SET ASIDE

DISCONNECT THE NEGATIVE CABLE FROM THE BATTERY


TORQUE OPERATION

CRITICAL PROCESS

?

10

30

40 50

60)

70)

80)

90)

ITEM QTY

A 1

1

B 4

8

8REV

PAGE2 OF 3

PROCESS NUMBER

P13C4-9232-0090


800002 NUT - M4 x 0.7 NYLOCK

PROCESS NAME

200021 BRACKET - FUEL RAIL SUPPORT 5W30 MOTOR OIL

900006 SCREW - M4 x 10

P13C4-2027L-AA FUEL RAIL ASSY - 6.0L MONO FUEL ENGINE LH PHILLIP SCREWDRIVER

P13C4-2027R-AA FUEL RAIL ASSY - 6.0L MONO FUEL ENGINE RH 7mm SOCKET WRENCH


ON THE PASSENGER SIDE OF THE ENGINE, POSITION THE LPG FUEL RAIL

WITH THE BRACKET ON THE RAIL FACING TOWARD THE CENTER OF THE

ENGINE; LUBRICATE THE (4) INJECTOR NOZZLE O-RINGS WITH 5W30

MOTOR OIL; ALIGN AND SEAT EACH INJECTOR INTO EACH OF THE

GASOLINE INJECTOR PORT

LOOSLY INSTALL THE (2) FUEL RAIL MOUNTING BRACKETS TO THE

FUEL RAIL MAIN BRACKET IN THE LOCATIONS SHOWN

OBTAIN THE PASSENGER SIDE LPG FUEL RAIL ASSY (SHOWN WITH THE

NON-RETURN VALVE ON THE LEFT SIDE OF THE RAIL), (2) FUEL RAIL

MOUNTING BRACKETS, (4) M4 SCREWS, (4) M4 NYLOCK NUTS

OBTAIN THE DRIVER/PASSENGER LPG FUEL RAILS (A) AND FUEL RAIL

MOUNTING HARDWARE (B)


TORQUE OPERATION

CRITICAL PROCESS

?

A

B

60

70

80

90

100)

110)

120)

130)

140)

ITEM QTY

REV

PAGE3 OF 3

PROCESS NUMBER

P13C4-9232-0090


PROCESS NAME

5W30 MOTOR OIL

PHILLIP SCREWDRIVER

7mm SOCKET WRENCH


FUEL RAIL MAIN BRACKET IN THE LOCATIONS SHOWN

REPEAT STEPS 90 THROUGH 110 FOR THE DRIVER SIDE LPG FUEL RAIL

OBTAIN THE DRIVER SIDE LPG FUEL RAIL ASSY (SHOWN WITH THE

NON-RETURN VALVE ON THE LEFT SIDE OF THE RAIL), (2) FUEL RAIL

MOUNTING BRACKETS, (4) M4 SCREWS, (4) M4 NYLOCK NUTS

LOOSLY INSTALL THE (2) FUEL RAIL MOUNTING BRACKETS TO THE

MOUNTING SCREWS)

SECURELY TIGHTEN THE (4) SCREWS / NUTS THAT SECURE MOUNTING

BRACKET SCREWS TO THE FUEL RAIL BRACKET

ALIGN AND SEAT THE (2) FUEL RAIL MOUNTING BRACKETS TO THE

MOUNTING BOSSES ON THE INTAKE MANIFOLD USED TO MOUNT THE

GASOLINE FUEL RAIL; SECURE MOUNTING BRACKETS TO MANIFOLD

WITH (2) SCREWS REMOVED IN STEP #40 (GASOLINE FUEL RAIL


TORQUE OPERATION

CRITICAL PROCESS

?

100

110

120

130

10)

20)

30)

ITEM QTY

A 1

REV

PAGE1 OF 2

PROCESS NUMBER

P13C4-9232-0100

MODIFY EVAP SENSOR A

PROCESS NAME

19318100 EVAP SENSOR ORIFICE


CAREFULLY DISCONNECT AND REMOVE THE EVAP HOSES AND WIRE

HARNESS CONNECTION FROM THE EVAP SENSOR; REMOVE THE

EVAP SENSOR FROM THE ENGINE

LOCATE THE EVAP SENSOR AT THE DRIVER SIDE FRONT OF THE ENGINE

OBTAIN THE EVAP SENSOR ORIFICE (A) FROM PACKAGE D


TORQUE OPERATION

CRITICAL PROCESS

?

10

A

20

30

40)

50)

ITEM QTY

REV

PAGE2 OF 2

PROCESS NUMBER

P13C4-9232-0100

MODIFY EVAP SENSOR A

PROCESS NAME


REINSTALL THE EVAP SENSOR ONTO THE ENGINE; RECONNECT THE

EVAP HOSES AND ELECTRICAL CONNECTION

CAREFULLY ALIGN AND SEAT THE EVAP ORIFICE (A) INTO THE NOZZLE

NEXT TO THE ELECTRICAL CONNECTOR ON THE EVAP SENSOR AS SHOWN

(BLACK COLORED NOZZLE ON EVAP SENSOR)


TORQUE OPERATION

CRITICAL PROCESS

?

40

50

10)

20)

30)

40)

ITEM QTY

A 7

B 1

REV

PAGE1 OF 2

PROCESS NUMBER

P13C4-9232-0110

INSTALL LPG FUEL INJECTOR WIRE HARNESS

LEADSA

PROCESS NAME

P11X4-4219-AA WIRE HARNESS ASSY - EV6 TO EV1

P11X4-4220-AA WIRE HARNESS ASSY - EV6 TO EV1 W/KEY ON & RPM


REPEAT STEPS 20 AND 30 FOR THE REMAINING (3) LPG FUEL INJECTORS

ON THE DRIVER SIDE FUEL RAIL

(PUSH/PULL CONNECTORS TO VERIFY FULLY SEATED)

ALIGN AND SEAT THE EV6 CONNECTOR ON THE WIRE HARNESS ASSY (A)

INTO THE ADJACENT OEM EV6 GASOLINE INJECTOR LEAD CONNECTOR

AS SHOWN


STARTING WITH THE REAR DRIVER SIDE LPG FUEL INJECTOR, ALIGN

AND SEAT THE EV1 CONNECTOR ON THE WIRE HARNESS ASSY (A) ONTO

THE LPG FUEL INJECTOR AS SHOWN

(PUSH/PULL CONNECTOR TO VERIFY FULLY SEATED)

FROM PACKAGE D, OBTAIN THE (7) EV6 TO EV1 WIRE HARNESS

LEADS (A) AND (1) EV6 TO EV1 WIRE HARNESS LEAD WITH KEY-ON & RPM


TORQUE OPERATION

CRITICAL PROCESS

?

20

30

40

A

B

50)

60)

70)

80)

90)

ITEM QTY

REV

PAGE2 OF 2


TORQUE OPERATION

CRITICAL PROCESS

STARTING WITH THE FRONT PASSENGER SIDE LPG FUEL INJECTOR,


ONTO THE LPG FUEL INJECTOR AS SHOWN




AS SHOWN


REPEAT STEPS 50 AND 60 FOR THE NEXT (2) LPG FUEL INJECTORS ON

THE PASSENGER SIDE FUEL RAIL


ALIGN AND SEAT THE EV1 CONNECTOR ON THE WIRE HARNESS ASSY (B)

(WIRE HARNESS LEAD W/KEY ON & RPM) ONTO THE REAR PASSENGER

SIDE LPG FUEL INJECTOR AS SHOWN


ALIGN AND SEAT THE EV6 CONNECTOR ON THE WIRE HARNESS ASSY (B)


AS SHOWN



PROCESS NAME

INSTALL LPG FUEL INJECTOR WIRE HARNESS

LEADSA

PROCESS NUMBER

P13C4-9232-0110

?

50

60

70

80

90

10)

20)

30)

40)

ITEM QTY

A 1

B 1

C 1

D 1

REV

PAGE1 OF 2

PROCESS NUMBER

P13C4-9232-0120

INSTALL LPG REGULATOR AND NON-RETURN

VALVEA

PROCESS NAME

P14X4-9319-AA NON-RETURN VALVE BRKT ASSY

P13C4-2306-AA NON-RETURN VALVE ASSY

P13C4-2305-AA REGULATOR ASSY M4 TEE HANDLE

P11X4-9302-AA REGULATOR BRACKET ASSY M6 TEE HANDLE


ATTACH THE REGULATOR BRACKET TO THE INTAKE MANIFOLD AS

SHOWN (ATTACHMENT SCREW NOT INCLUDED WITH KIT)

POSITION THE REGULATOR WITH THE BRANCH TEE POINTING

TOWARD THE REAR OF THE VEHICLE

FROM INSIDE THE VEHICLE, LOCATE THE THREADED HOLE IN THE

TOP OF THE INTAKE MANIFOLD TOWARD THE REAR OF THE ENGINE

ATTACH THE REGULATOR BRACKET (D) TO THE REGULATOR (C )

USING THE SCREWS PROVIDED WITH THE REGULATOR AS SHOWN

(1) NON-RETURN VALVE ASSY

OBTAIN THE FOLLOWING ITEMS FROM PACKAGE 'G'

(1) REGULATOR ASSY (A)

(1) REGULATOR BRACKET (B)

(1) NON-RETURN VALVE BRACKET ASSY


TORQUE OPERATION

CRITICAL PROCESS

?

20

30 40

A B C D

10

50)

60)

70)

ITEM QTY

REV

PAGE2 OF 2

PROCESS NUMBER

P13C4-9232-0120

INSTALL LPG REGULATOR AND NON-RETURN

VALVEA

PROCESS NAME


INSTALL THE NON-RETURN VALVE ASSY ONTO THE MANIFOLD BOSS

AS SHOWN (ATTACHMENT SCREW NOT INCLUDED WITH KIT)

POSITION THE NON-RETURN VALVE WITH THE INLET PORT ON THE

VALVE POINTING TOWARD THE PASSENGER SIDE OF THE VEHICLE

LOCATE THE THREADED BOSS ON THE PASSENGER FRONT SIDE OF

THE INTAKE MANIFOLD

ATTACH THE NON-RETURN VALVE BRACKET (B) TO THE NON-RETURN

VALVE (A) USING THE SCREWS PROVIDED WITH THE NON-RETURN VALVE


TORQUE OPERATION

CRITICAL PROCESS

?

50

60 70

10)

20)

30)

40)

50)

60)

ITEM QTY

A 2

B 2

REV

PAGE1 OF 4

PROCESS NUMBER

P13C4-9232-0130

INSTALL LPG ENGINE SUPPLY/RETURN HOSES A

PROCESS NAME

P13C4-2814-AA RETURN HOSE ASSY - FUEL RAIL TO TEE18 Nm +/- 1.8

3/4" CROWFOOT

P13C4-2714-AA SUPPLY HOSE ASSY - FUEL RAIL TO TEE TORQUE WRENCH

WRENCH TO 18 Nm +/- 1.8


INSTALL AND HANDTIGHTEN THE HOSE FITTING ONTO THE PASSENGER

SIDE OF THE TEE AS SHOWN

TORQUE THE HOSE FITTING WITH A 3/4" CROWFOOT AND TORQUE

ROUTE THE OPPOSITE END OF THE HOSE TOWARDS THE TEE MOUNTED

ON THE NON-RETURN VALVE

THE FITTINGS ON THE HOSE ONTO THE SUPPLY FITTING LOCATED ON

THE FRONT OF THE PASSENGER SIDE FUEL RAIL



OBTAIN (1) SUPPLY HOSE ASSY - FUEL RAIL TO TEE (B)

FROM THE FRONT OF THE VEHICLE, INSTALL AND HANDTIGHTEN ONE OF

OBTAIN THE FOLLOWING ITEMS:

(2) - RETURN HOSE ASSY - FUEL RAIL TO TEE (A)

(2) - SUPPLY HOSE ASSY - FUEL RAIL TO TEE (B)


TORQUE OPERATION

CRITICAL PROCESS

?

1

20 30 1

40

50 60 1

10 A

B

70)

80)

90)

100)

110)

120)

ITEM QTY

REV

PAGE2 OF 4

PROCESS NUMBER

P13C4-9232-0130


PROCESS NAME

18 Nm +/- 1.83/4" CROWFOOT

TORQUE WRENCH




INSTALL AND HANDTIGHTEN THE HOSE FITTING ONTO THE DRIVER

SIDE OF THE TEE AS SHOWN


ROUTE THE OPPOSITE END OF THE HOSE TOWARDS THE TEE MOUNTED

ON THE NON-RETURN VALVE

FROM THE FRONT OF THE VEHICLE, INSTALL AND HANDTIGHTEN THE

FITTING ON THE HOSE ONTO THE SUPPLY FITTING LOCATED ON THE

FRONT OF THE DRIVER SIDE FUEL RAIL


OBTAIN THE SECOND SUPPLY HOSE ASSY - FUEL RAIL TO TEE (B)


TORQUE OPERATION

CRITICAL PROCESS

?

1

80 90 1

100

110 120 1

70

B

130)

140)

150)

160)

170)

180)

ITEM QTY

REV

PAGE3 OF 4

PROCESS NUMBER

P13C4-9232-0130


PROCESS NAME

18 Nm +/- 1.83/4" CROWFOOT

TORQUE WRENCH




INSTALL AND HANDTIGHTEN THE OPPOSITE END OF THE PASSENGER

SIDE RETURN HOSE ONTO THE PASSENGER SIDE OF THE REGULATOR TEE

AS SHOWN


ROUTE THE HOSE TOWARD THE REGULATOR AS SHOWN

FROM INSIDE THE VEHICLE, INSTALL AND HANDTIGHTEN THE

FITTING ON THE HOSE ONTO THE RETURN FITTING LOCATED ON THE

REAR OF THE PASSENGER SIDE FUEL RAIL


OBTAIN (1) HOSE ASSY - ENGINE RETURN (A)


TORQUE OPERATION

CRITICAL PROCESS

?

1

140 150 1

160

170 180 1

130 A

190)

200)

210)

220)

230)

240)

ITEM QTY

REV

PAGE4 OF 4

PROCESS NUMBER

P13C4-9232-0130


PROCESS NAME

18 Nm +/- 1.83/4" CROWFOOT

TORQUE WRENCH




INSTALL AND HANDTIGHTEN THE OPPOSITE END OF THE DRIVER

SIDE RETURN HOSE ONTO THE DRIVER SIDE OF THE REGULATOR TEE

AS SHOWN


ROUTE THE HOSE TOWARD THE REGULATOR AS SHOWN

FROM INSIDE THE VEHICLE, INSTALL AND HANDTIGHTEN THE

FITTING ON THE HOSE ONTO THE RETURN FITTING LOCATED ON THE

REAR OF THE DRIVER SIDE FUEL RAIL


OBTAIN THE SECOND HOSE ASSY - ENGINE RETURN (A)


TORQUE OPERATION

CRITICAL PROCESS

?

1

200 210 1

220

230 240 1

190 A

10)

20)

30)

40)

ITEM QTY

A 1

B 1

C 1

D 1

E 1REV

PAGE1 OF 4

PROCESS NUMBER

P13C4-9232-0140

INSTALL AUXILIARY FUEL PUMP AND HOSE

ASSYA

320001 HEAT SHIELD PADDING

PROCESS NAME


700002 M6 FLAT WASHER

88080000 AUXILIARY FUEL PUMP

200006 BRACKET - AUXILIARY FUEL PUMP


WITH THE ATTACHMENT POINT AT THE TOP AS SHOWN

AND THE PUMP FITTINGS POINTING TO THE LEFT AS SHOWN

INSTALL THE FUEL PUMP BRACKET (B) ONTO THE FUEL PUMP HOUSING

POSITION THE FUEL PUMP WITH THE 'OUT' PORT FACING YOU

REMOVE AND DISCARD THE ADHESIVE BACKING FROM THE HEAT SHIELD

PADDING (C ); INSTALL PADDING AROUND THE PUMP HOUSING; TRIM

AND DISCARD ANY EXCESS PADDING

D - M6 FLAT WASHER (QTY. 1)

E - HEAT SHIELD PADDING (QTY. 1)

FROM PACKAGE 'C', OBTAIN THE FOLLOWING ITEMS:

A - AUXILIARY FUEL PUMP ASSY (QTY. 1)

B - AUXILIARY FUEL PUMP BRACKET (QTY. 1)

C - SELF TAP SCREW (QTY. 1)


TORQUE OPERATION

CRITICAL PROCESS

?

OUT

30

40

10 A

B

C D

E

50)

60)

70)

80)

90)

ITEM QTY

REV

PAGE2 OF 4

PROCESS NUMBER

P13C4-9232-0140


ASSYA

PROCESS NAME

CORDLESS DRILL

8mm SOCKET


COOLANT BRACKET; INSERT SCREW INTO THE HOLE IN THE ENGINE

COOLANT RESERVOIR BRACKET AND SECURE

INSTALL (1) M6 FLAT WASHER ONTO (1) SELF TAP SCREW

SEAT THE AUXILIARY FUEL PUMP AND BRACKET ONTO THE ENGINE

FITTINGS POINTING INBOARD TO THE CENTERLINE OF THE VEHICLE

ALIGN THE HOLE IN THE MOUNTING TAB ON THE FUEL PUMP BRACKET

TO THE THIRD HOLE FROM THE BOTTOM OF THE ENGINE COOLANT

RESERVOIR BRACKET

POSITION THE AUXILIARY FUEL PUMP ONTO THE BACKSIDE OF THE

ENGINE COOLANT RESERVOIR BRACKET WITH THE MOUNTING TAB

ON THE FUEL PUMP BRACKET AT THE TOP AND THE FUEL PUMP

WITH THE HOOD OPEN FROM THE FRONT OF THE VEHICLE, LOCATE

THE ENGINE COOLANT RESERVOIR ATTACHED TO THE PASSENGER

SIDE COWL PANEL


TORQUE OPERATION

CRITICAL PROCESS

?

50

ENGINE COOLANT RESERVOIR

60 70

80 90

100)

110)

120)

130)

ITEM QTY

F 1

REV

PAGE3 OF 4

PROCESS NUMBER

P13C4-9232-0140


ASSYA

PROCESS NAME

P13C4-3316-AA HOSE ASSY - AUXILIARY FUEL PUMP18 Nm +/- 1.8

3/4" CROWFOOT

TORQUE WRENCH


ROUTE THE HOSE TOWARD THE SUPPLY ELECTROVALVE MOUNTED

ON THE TOP FRONT OF THE INTAKE MANIFOLD

USING A 15mm WRENCH TO HOLD THE FITTING ON THE AUXILIARY

FUEL PUMP, TORQUE THE HOSE FITTING WITH A 3/4" CROWFOOT

AND TORQUE WRENCH TO 18 Nm +/- 1.8

INSTALL AND HANDTIGHTEN ONE OF THE HOSE FITTINGS

ONTO THE REAR 'OUT' PORT FITTING ON THE AUXILIARY FUEL PUMP

AS SHOWN

OBTAIN THE HOSE ASSY - AUXILIARY FUEL PUMP (F)


TORQUE OPERATION

CRITICAL PROCESS

?

1

110 120 1

100

130

F

140)

150)

ITEM QTY

REV

PAGE4 OF 4

PROCESS NUMBER

P13C4-9232-0140


ASSYA

PROCESS NAME

18 Nm +/- 1.83/4" CROWFOOT

TORQUE WRENCH




LOCATE AND GRASP THE OPPOSITE END OF THE AUXILIARY FUEL PUMP

HOSE; INSTALL AND HANDTIGHTEN THE HOSE FITTING ONTO THE

THE NON-RETURN VALVE FITTING AS SHOWN


TORQUE OPERATION

CRITICAL PROCESS

?

1

140 150 1

10)

20)

30)

40)

50)

ITEM QTY

REV

PAGE1 OF 2


TORQUE OPERATION

CRITICAL PROCESS

FROM THE FRONT OF THE VEHICLE, INSIDE THE ENGINE COMPARTMENT,

LOCATE THE CHASSIS SUPPLY / RETURN HOSES AND FUEL TANK

WIRE HARNESS ON THE PASSENGER SIDE OF THE ENGINE BAY

LOCATE AND GRASP THE CHASSIS SUPPLY HOSE (FITTING MARKED

WITH 'GREEN')

ROUTE THE CHASSIS SUPPLY HOSE TOWARD THE AUXILIARY FUEL

PUMP MOUNTED BEHIND THE COOLANT RESERVOIR

INSTALL AND HANDTIGHTEN THE HOSE FITTING ONTO THE 'IN' PORT

FITTING ON THE AUXILIARY FUEL PUMP




3/4" CROWFOOT


PROCESS NAME

ATTACH CHASSIS SUPPLY / RETURN HOSES A

PROCESS NUMBER

P13C4-9232-0150

?

10

20

40

1

30

50 1

60)

70)

80)

90)

ITEM QTY

REV

PAGE2 OF 2

PROCESS NUMBER

P13C4-9232-0150

ATTACH CHASSIS SUPPLY / RETURN HOSES A

PROCESS NAME

3/4" CROWFOOT





INSTALL AND HANDTIGHTEN THE HOSE FITTING ONTO THE FITTING

INSTALLED ON THE SIDE OF THE REGULATOR AS SHOWN

ROUTE THE HOSE TOWARD THE REGULATOR MOUNTED ON THE TOP

FRONT OF THE INTAKE MANIFOLD

LOCATE AND GRASP THE CHASSIS RETURN HOSE (FITTING MARKED

WITH 'BLACK')


TORQUE OPERATION

CRITICAL PROCESS

?

60

70

80 90 1

1

10)

20)

ITEM QTY

A 1

B 1

C 4

D 4

REV

PAGE1 OF 2


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN THE FOLLOWING ITEMS:

(1) MONO FUEL ICU MODULE (A)

(1) BRACKET - ICU MODULE (B)

(4) M4 x 30 SCREW (C )

(4) M4 NYLOCK NUT (D)

(2) SELF TAP SCREW (E)

POSITION THE ICU BRACKET (B) WITH THE MOUNTING TAB AT THE TOP

POINTING UP; ALIGN AND SEAT THE ICU MODULE (A) ONTO THE

BRACKET WITH THE CONNECTOR OPENING ON THE MODULE

POSITIONED TO THE RIGHT; SECURE THE MODULE TO THE BRACKET

WITH THE (4) M4 x 30 SCREWS (C ) AND (4) M4 NYLOCK NUTS (D)


70306602 MONO FUEL ICU MODULE 3mm ALLEN WRENCH

27036000 BRACKET - ICU MODULE (PKG E) 7mm SOCKET WRENCH

900008 SCREW - M4 x 30 (PKG E)

800002 NUT - M4 x 0.7 NYLOCK (PKG E)

PROCESS NAME

INSTALL MONO FUEL ICU MODULE A

PROCESS NUMBER

P13C4-9232-0160

?

10

MOUNTING TAB

20

A

B

C

D

E

30)

40)

50)

ITEM QTY

REV

PAGE2 OF 2


TORQUE OPERATION

CRITICAL PROCESS

FROM INSIDE THE DRIVERS SIDE OF THE VEHICLE, POSITION THE

ICU MODULE WITH THE MOUNTING TAB ON THE BRACKET POINTING

TOWARD THE PASSENGER SIDE OF THE VEHICLE

ALIGN AND SEAT THE MOUNTING TAB ON THE BRACKET TO THE DRIVER

SIDE UPPER PANEL INSIDE THE ENGINE COMPARTMENT AS SHOWN

INSERT THE (2) SELF TAP SCREWS (E) INTO THE BRACKET MOUNTING

TAB; USING A CORDLESS DRILL W/8mm SOCKET, FULLY TIGHTEN SCREWS

TO SECURE BRACKET IN PLACE


CORDLESS DRILL

8mm SOCKET

PROCESS NAME

INSTALL MONO FUEL ICU MODULE A

PROCESS NUMBER

P13C4-9232-0160

?

30 40

50

10)

20)

30)

40)

50)

ITEM QTY

A 1

B 2

REV

PAGE1 OF 1


TORQUE OPERATION

CRITICAL PROCESS

FROM PACKAGE 'D', OBTAIN THE FOLLOWING ITEMS:

A - LED LAMP - QTY (1)

B - SPADE CONNECTOR - QTY (2)

FROM INSIDE THE DRIVER SIDE OF THE VEHICLE, LOCATE THE

'ENGINE START' TOGGLE SWITCH ON THE INSTRUMENT PANEL

USING A CORDLESS DRILL WITH A 5/16" DRILL BIT, CAREFULLY DRILL

A HOLE INTO THE INSTRUMENT PANEL JUST TO THE RIGHT OF THE

TOGGLE SWITCH AS SHOWN

REMOVE LED ATTACHMENT NUT ON BACK OF LED LIGHT

INSERT THE LED LIGHT INTO THE DRILLED HOLE; FROM THE BACKSIDE OF

THE INSTRUMENT PANEL, INSTALL NUT ONTO THE LED HOUSING AND

HANDTIGHTEN ONTO THE BACKSIDE OF THE LED LIGHT BEZEL


495000 LED LIGHT (PKG D) CORDLESS DRILL

464002 SPADE CONNECTOR (PKG D) 5/16" DRILL BIT

PROCESS NAME

INSTALL LED LIGHT A

PROCESS NUMBER

P13C4-9232-0170

?

A B

10

20

30

40

50

10)

20)

30)

ITEM QTY

A 1

REV

PAGE1 OF 1

PROCESS NUMBER

P13C4-9232-0180

INSTALL ENGINE START INSTRUCTION LABEL A

PROCESS NAME

P13X4-9426-AA LABEL - STARTING INSTRUCTIONS


INSTRUMENT PANEL A SHOWN

POSITION THE LABEL BELOW THE 'ENGINE START' TOGGLE SWITCH

AND THE LED LIGHT; ALIGN AND SEAT THE LABEL ONTO THE

REMOVE AND DISCARD THE ADHESIVE BACKING FROM THE

STARTING INSTRUCTION LABEL

OBTAIN THE STARTING INSTRUCTION LABEL (A) FROM PACKAGE 'D'


TORQUE OPERATION

CRITICAL PROCESS

?

10

30

10)

20)

30)

40)

ITEM QTY

A 1

REV

PAGE1 OF 11

PROCESS NUMBER

P13C4-9232-0190

INSTALL LPG ENGINE WIRE HARNESS ASSY A

PROCESS NAME

P13X4-4232-AB WIRE HARNESS ASSY - 6.0L ENGINE CORDLESS DRILL

1/2" DRILL BIT


ON THE LPG ENGINE WIRE HARNESS; INSERT BOTH LEADS INTO

THE DRILLED HOLE AS SHOWN

USING A CORDLESS DRILL WITH 1/2" DRILL BIT, CAREFULLY DRILL A

HOLE THROUGH THE DRIVER SIDE ENGINE COMPARTMENT PANEL

BY THE ICU MODULE A SHOWN

LOCATE AND GRASP THE 'LED LIGHT' AND 'AUDIBLE INDICATOR' LEADS

FROM INSIDE THE VEHICLE, ALIGN AND SEAT INSERT THE MAIN

CONNECTOR ON THE WIRE HARNESS INTO THE ICU MODULE AS SHOWN


OBTAIN THE ICOM LPG ENGINE WIRE HARNESS ASSY (A)


TORQUE OPERATION

CRITICAL PROCESS

?

10

20

30

40

A

50)

60)

70)

80)

ITEM QTY

REV

PAGE2 OF 11


TORQUE OPERATION

CRITICAL PROCESS

ROUTE THE REMAINDER OF THE LPG ENGINE WIRE HARNESS TOWARD

THE PASSENGER SIDE OF THE ENGINE COMPARTMENT

FROM THE FRONT OF THE VEHICLE, LOCATE AND GRASP THE LPG WIRE

HARNESS LEAD LABELED ''AUXILIARY FUEL PUMP'

CAREFULLY ROUTE THE WIRE HARNESS LEAD TO THE AUXILIARY FUEL

PUMP MOUNTED TO THE BACKSIDE OF THE ENGINE COOLANT RESERVOIR

BOTTLE ON THE PASSENGER SIDE OF THE ENGINE COMPARTMENT

ALIGN AND SEAT THE WIRE HARNESS CONNECTOR TO THE AUXILIARY

FUEL PUMP CONNECTOR



PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

50

60 70

80

90)

100)

110)

120)

130)

140)

ITEM QTY

A 2

B 2

REV

PAGE3 OF 11


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN (2) 1-3/8" CABLE CLAMPS (A) AND (2) SELF TAP SCREWS (B)

FROM PACKAGE H

INSTALL (1) 1-3/8" CABLE CLAMP ONTO THE LPG ENGINE WIRE

HARNESS ASSY; SEAT THE CABLE CLAMP ONTO THE COWL PANEL IN

CLOSE PROXIMITY TO THE AUXILIARY FUEL PUMP AS SHOWN

INSTALL (1) SELF TAP SCREW (B) INTO THE CABLE CLAMP ATTACHMENT

HOLE; USING A CORDLESS DRILL W/8mm SOCKET, TIGHTEN THE SCREW

TO SECURE THE CABLE CLAMP TO THE COWL PANEL AS SHOWN

CONTINUE ROUTING THE MAIN LPG ENGINE WIRE HARNESS LEAD

ALONG THE FRON EDGE OF THE COWL PANEL TOWARD THE DRIVER

SIDE OF THE VEHICLE AS SHOWN

INSTALL (1) 1-3/8" CABLE CLAMP ONTO THE LPG ENGINE WIRE

HARNESS ASSY; SEAT THE CABLE CLAMP ONTO THE COWL PANEL JUST

ABOVE THE BRAKE FLUID RESERVOIR AS SHOWN

INSTALL (1) SELF TAP SCREW (B) INTO THE CABLE CLAMP ATTACHMENT

HOLE; USING A CORDLESS DRILL W/8mm SOCKET, TIGHTEN THE SCREW

TO SECURE THE CABLE CLAMP TO THE COWL PANEL AS SHOWN


330005 1-3/8" CABLE CLAMP CORDLESS DRILL

950000 SELF TAP SCREW 8mm SOCKET

PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

90

100 110

120

130 140

150)

160)

170)

180)

ITEM QTY

C 1

D 1

REV

PAGE4 OF 11


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN THE SMALL DIAMETER RING TERMINAL (C ) AND LARGE

DIAMETER RING TERMINAL (D) FROM PACKAGE D

LOCATE AND GRASP THE NEGATIVE AND POSITIVE WIRE LEADS ON THE

LPG ENGINE WIRE HARNESS

USING WIRE STRIPPERS, CAREFULLY REMOVE APPROXIMATELY 1/2"

OF WIRE INSULATION FROM THE ENDS OF BOTH THE NEGATIVE AND

POSITIVE WIRE LEADS

USING WIRE CRIMPERS, ATTACH THE SMALL DIAMETER RING TERMINAL

ONTO THE END OF THE NEGATIVE WIRE LEAD


480000 RING TERMINAL - 1/4" WIRE STRIPPERS

480001 RING TERMINAL # 10 WIRE CRIMPERS

PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

150

160

170

190)

200)

210)

220)

ITEM QTY

REV

PAGE5 OF 11


TORQUE OPERATION

CRITICAL PROCESS

LOCATE THE GROUND STUD ATTACHED TO THE DRIVER SIDE DASH

PANEL; REMOVE THE NUT ATTACHED TO THE GROUND STUD

INSTALL THE RING TERMINAL ATTACHED TO THE NEGATIVE WIRE LEAD

ONTO THE GROUND; REINSTALL THE GROUND STUD NUT AND TIGHTEN

SECURELY

USING WIRE CRIMPERS, ATTACH THE LARGE DIAMETER RING TERMINAL

ONTO THE END OF THE POSITIVE WIRE LEAD

ROUTE THE POSITIVE WIRE LEAD TOWARD THE FUSE - RELAY CENTER


WIRE CRIMPERS

PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

190

200

220

230)

240)

250)

ITEM QTY

REV

PAGE6 OF 11


TORQUE OPERATION

CRITICAL PROCESS

REMOVE THE FUSE-RELAY COVER; ATTACH THE POSITIVE WIRE LEAD

TO THE POSITIVE TERMINAL INSIDE THE FUSE BOX; REINSTALL COVER

LOCATE AND GRASP THE LPG ENGINE WIRE HARNESS LEAD

LABELED 'IRIS'; ROUTE LEAD TOWARD THE FRONT OF THE ENGINE

LOCATE THE SUPPLY SOLENOID MOUNTED ON THE TOP FRONT OF THE

ENGINE; ALIGN AND SEAT THE 'IRIS' LEAD AND SUPPLY SOLENOID

LEAD CONNECTORS TOGETHER



PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

230

250

260)

270)

280)

290)

300)

310)

320)

ITEM QTY

REV

PAGE7 OF 11


TORQUE OPERATION

CRITICAL PROCESS

LOCATE THE OEM TEMPERATURE SENSOR WIRE LEAD LOCATED ON

THE DRIVER SIDE OF THE ENGINE

(TWO WIRE LEAD - YELLOW WIRES)

CAREFULLY REMOVE APPROXIMATELY 1/2" OF INSULATION FROM

BOTH WIRES (DO NOT CUT WIRES)


BOTH WIRES (DO NOT CUT WIRES)

LOCATE AND GRASP THE LPG ENGINE WIRE HARNESS LEAD LABELED

'TEMP SENSOR OEM'


END OF BOTH WIRES ON THE 'TEMP SENSOR OEM' LEAD

ATTACH THE WHITE/GREEN WIRE FROM THE 'TEMP SENSOR OEM'

LEAD ON THE LPG ENGINE HARNESS TO ONE OF THE STRIPPED YELLOW

WIRES ON THE OEM TEMP SENSOR WIRE; SOLDER CONNECTION

TOGETHER AND SEAL WITH ELECTRICAL TAPE

ATTACH THE GREEN WIRE FROM THE 'TEMP SENSOR OEM' LEAD ON

THE LPG ENGINE HARNESS TO THE OTHER STRIPPED YELLOW WIRE

ON THE OEM TEMP SENSOR WIRE; SOLDER CONNECTION TOGETHER

AND SEAL WITH ELECTRICAL TAPE


WIRE STRIPPERS

SOLDER IRON

ROSIN CORE SOLDER

ELECTRICAL TAPE

PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

260

310

320

330)

340)

350)

360)

370)

ITEM QTY

REV

PAGE8 OF 11


TORQUE OPERATION

CRITICAL PROCESS

LOCATE AND GRASP THE BROWN WIRE ATTACHED TO THE FUEL TANK

HARNESS COMING OUT OF THE SUPPLY HOSE CORRUGATE (PASSENGER

SIDE OF THE ENGINE COMPARTMENT)

OBTAIN THE 1-PIN CONNECTOR, TERMINAL AND SEAL THAT COMES

ATTACHED TO THE FUEL TANK WIRE HARNESS

ATTACH THE SEAL, TERMINAL AND 1-PIN CONNECTOR ONTO THE

END OF THE BROWN WIRE AS SHOWN

LOCATE AND GRASP THE BLACK 1-PIN CONNECTOR AND LEAD ATTACHED

TO THE LPG ENGINE WIRE HARNESS

ALIGN AND SEAT THE BROWN WIRE LEAD CONNECTOR ON THE FUEL

TANK WIRE HARNESS TO THE BROWN WIRE LEAD CONNECTOR ON THE

LPG ENGINE WIRE HARNESS



WIRE STRIPPERS

WIRE CRIMPERS

PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

330

340

340

370

380)

390)

400)

410)

420

430)

ITEM QTY

REV

PAGE9 OF 11


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN THE 2-PIN CONNECTOR, TERMINALS AND SEALS THAT COME

ATTACHED TO THE FUEL TANK WIRE HARNESS

LOCATE AND GRASP THE RED & BLACK WIRES ATTACHED TO THE FUEL

TANK WIRE HARNESS

ATTACH THE SEALS AND TERMINALS ONTO THE ENDS OF THE RED AND

BLACK WIRES

INSERT THE RED WIRE W/TERMINAL INTO POSITION 'A' OF THE

CONNECTOR

(PUSH/PULL WIRE TO VERIFY TERMINAL IS FULLY SEATED INTO CONNECTOR)

INSERT THE BLACK WIRE W/TERMINAL INTO POSITION 'B' OF THE

CONNECTOR

(PUSH/PULL WIRE TO VERIFY TERMINAL IS FULLY SEATED INTO CONNECTOR)

ALIGN AND SEAT THE RED/BLACK WIRE LEAD CONNECTOR ON THE FUEL

TANK WIRE HARNESS TO THE LEAD CONNECTOR ON THE LPG ENGINE

WIRE HARNESS LABELED 'FUEL PUMP'



WIRE STRIPPERS

WIRE CRIMPERS

PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

380

390

410

420

430

440)

450)

460)

ITEM QTY

REV

PAGE10 OF 11


TORQUE OPERATION

CRITICAL PROCESS

LOCATE AND GRASP THE WIRE LEADS LABELED 'NTC SENSOR' AND

'FUEL INJ. / KEY ON SIGNAL' ATTACHED TO THE LPG ENGINE WIRE

HARNESS ASSY

ROUTE BOTH LEADS TOWARD THE PASSENGER SIDE REAR LPG

FUEL INJECTOR

LOCATE AND GRASP THE LEAD AND CONNECTOR ATTACHED TO THE EV1

TO EV6 WIRE HARNESS ON THE PASSENGER SIDE REAR LPG FUEL

INJECTOR; ALIGN AND SEAT THE 'FUEL INJECTOR SIGNAL / KEY ON'

CONNECTOR TO THE CONNECTOR ON THE EV1 TO EV6 LEAD



PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

440

450

460

470)

480)

490)

ITEM QTY

REV

PAGE11 OF 11


TORQUE OPERATION

CRITICAL PROCESS

LOCATE AND GRASP THE LPG WIRE HARNESS LEAD LABELED 'RPM'

DISCONNECT THE OEM WIRE HARNESS LEAD TO THE REAR PASSENGER

SIDE IGNITION COIL (EACH IGNITION COIL HAS (4) WIRES - TWO OF THE

WIRES ARE GROUNDS (BLACK/BROWN) - ONE OF THE WIRES IS THE SAME

COLOR FROM COIL TO COIL (POWER) - THE OTHER WIRE IS A DIFFERENT

COLOR FROM COIL TO COIL - THIS IS THE RPM SIGNAL)


THE DIFFERENT COLOR WIRE (DO NOT CUT WIRE)


END OF THE 'RPM' WIRE LEAD

ATTACH THE 'RPM' WIRE LEAD TO THE STRIPPED IGNITION COIL WIRE;

SOLDER CONNECTION TOGETHER AND SEAL WITH ELECTRICAL TAPE


WIRE STRIPPERS

SOLDER IRON

ROSIN CORE SOLDER

ELECTRICAL TAPE

PROCESS NAME


PROCESS NUMBER

P13C4-9232-0190

?

470

480

490

10)

20)

30)

40)

ITEM QTY

A 1

REV

PAGE1 OF 1


TORQUE OPERATION

CRITICAL PROCESS

OBTAIN (1) ICOM NTC SENSOR FROM PACKAGE D

FROM INSIDE THE VEHICLE, LOCATE THE THREADED HOLE ON THE TOP

REAR PASSENGER SIDE OF THE ENGINE BLOCK

INSTALL & HANDSTART THE ICOM NTC SENSOR INTO THE THREADED

HOLE AND SECURELY TIGHTEN WITH A 8mm WRENCH

LOCATE AND GRASP THE LPG ENGINE WIRE HARNESS LEAD LABELED

'SENSOR NTC'; ALIGN AND SEAT THE WIRE LEAD CONNECTOR INTO

THE ICOM NTC SENSOR LEAD CONNECTOR



90009100 NTC SENSOR (PKG D) 8mm WRENCH

PROCESS NAME

INSTALL ICOM NTC SENSOR A

PROCESS NUMBER

P13C4-9232-0200

?

10

20

30

40

10)

20)

30)

40)

ITEM QTY

A 1

B 1

REV

PAGE1 OF 1

PROCESS NUMBER

P13C4-9232-0210

INSTALL AUDIBLE INDICATOR (BUZZER) A

PROCESS NAME

71301100 AUDIBLE INDICATOR (BUZZER) (PKG D)

150000 8" TIE STRAP


BUNDLE THE 'AUDIBLE INDICATOR' LEADS TOGETHER; TIE STRAP THE

AUDIBLE INDICATOR TO THE AUDIBLE INDICATOR LEADS; TRIM AND

DISCARD EXCESS TIE STRAP

ALIGN AND SEAT THE AUDIBLE INDICATOR CONNECTOR AND THE

WIRE HARNESS LEAD CONNECTOR TOGETHER


LOCATE THE WIRE HARNESS LEADS LABELED 'AUDIBLE INDICATOR' ON THE

DRIVERS SIDE PASSENGER COMPARTMENT BY THE LED LIGHT

OBTAIN THE FOLLOWING ITEMS FROM PACKAGE 'D';

A - AUDIBLE INDICATOR

B - 8" TIE STRAP (QTY. 1)


TORQUE OPERATION

CRITICAL PROCESS

?

10

30

40

10)

20)

ITEM QTY

REV

PAGE1 OF 1

PROCESS NUMBER

P13C4-9232-0220

ATTACH NEGATIVE BATTERY LEAD A

PROCESS NAME


ATTACH THE NEGATIVE LEAD TO THE BATTERY

LOCATE AND GRASP THE BLACK NEGATIVE BATTERY LEAD


TORQUE OPERATION

CRITICAL PROCESS

?

20

10)

20)

30)

ITEM QTY

REV

PAGE1 OF 1

PROCESS NUMBER

P13C4-9232-0230

INSTALL PROPANE DIAMOND DECAL A

PROCESS NAME


CLEAN THE AREA ABOVE THE REAR BUMPER ON THE PASSENGER

SIDE OF THE VEHICLE; ALIGN AND CENTER THE DIAMOND PROPANE

DECAL ABOVE THE REAR BUMPER; SEAT DECAL ONTO THE VEHICLE

AS SHOWN

REMOVE AND DISCARD THE ADHESIVE BACKING FROM THE DIAMOND

PROPANE DECAL

OBTAIN THE DIAMOND PROPANE DECAL FROM PACKAGE J


TORQUE OPERATION

CRITICAL PROCESS

?

10

30

10)

20)

30)

40)

50)

60)

70)

80)

ITEM QTY

REV

PAGE1 OF 4

PROCESS NUMBER

P13C4-9232-0240

FINAL INSPECTION AND SYSTEM CHECK A

PROCESS NAME


RECORD TANK SERIAL # ON INSPECTION FORM

VERIFY MANUAL SHUT-OFF KNOB IS FULLY OPEN (ROTATE KNOB

COUNTERCLOCKWISE TO OPEN)

VERIFY TANK LABEL IS INSTALLED

VERIFY BLEEDER VALVE IS FULLY CLOSED (ROTATE KNOB CLOCKWISE

TO CLOSE) (ONLY FOR SYSTEMS THAT ARE NOT EQUIPPED WITH

REMOTE BLEEDER VALVE HOSE KIT)

VERIFY PROPER RETENTION OF HOSES (FRONT AND REAR)

VERIFY PROPER TORQUE OF TANK FASTENERS

POSITION AND RAISE VEHICLE UP ON SUITABLE LIFT

INSPECT HOSE ROUTING AND VERIFY PROPER CLEARANCE AND

SHIELDING BY HEAT SOURCES

PLEASE READ THE INTRODUCTION SECTION OF THIS MANUAL BEFORE

BEGINNING THIS PROCEDURE

UNDER VEHICLE INSTALLATION INSPECTION


TORQUE OPERATION

CRITICAL PROCESS

?

50 BLEEDER VALVE

60

MANUAL SHUT-OFF KNOB

30

90)

100)

110)

120)

130)

ITEM QTY

REV

PAGE2 OF 4

PROCESS NUMBER

P13C4-9232-0240


PROCESS NAME


CHASSIS HOSE CORRUGATE ROUTED TO PREVENT WATER INGRESS

BATTERY CABLES PROPERLY TIGHTENED

INSPECT LPG WIRE HARNESSES FOR PROPER ROUTING

HEAT SHIELDING INSTALLED WHERE APPLICABLE

ENGINE COMPARTMENT INSTALLATION INSPECTION

INSPECT HOSES FOR PROPER ROUTING


TORQUE OPERATION

CRITICAL PROCESS

?

130

140)

150)

160)

180)

190)

200)

210)

220)

230)

ITEM QTY

REV

PAGE3 OF 4

PROCESS NUMBER

P13C4-9232-0240


PROCESS NAME

REINSTALL CORRUGATE ONTO TANK BUSHING; POSITION HOSE CLAMP

OVER BUSHING AND TIGHTEN CLAMP TO SECURE CORRUGATE


FITTINGS AND CHECK FOR LEAKS AND REPAIR IF NEEDED

REMOVE CORRUGATE FROM TANK; SPRAY THE CHASSIS RETURN AND

SUPPLY HOSE FITTINGS AT THE TANK AND CHECK FOR LEAKS; REPAIR

IF NEEDED

POSITION AND RAISE VEHICLE UP ON SUITABLE LIFT

USING AN APPROVED LEAK DETECTION SOLUTION, SPRAY FILL HOSE

CYCLE THE KEY TO START THE VEHICLE; VERIFY VEHICLE STARTS AND

RUNS

ALLOW VEHICLE TO RUN FOR A FEW MINUTES THEN SHUT VEHICLE OFF

INSERT IGNITION KEY AND CYCLE TO THE 'ON' POSITION; WAIT TO

VERIFY GREEN LED LIGHT ON DASH PANEL ILLUMINATES AFTER A

SHORT PERIOD OF TIME

VERIFY FUEL LEVEL INDICATION ON OEM FUEL GAUGE AND RECORD

RESULTS ON INSPECTION FORM

SYSTEM FUNCTION / ROAD TEST

FILL FUEL TANK WITH PROPANE - RECORD GALLONS INSTALLED ON

INSPECTION FORM


TORQUE OPERATION

CRITICAL PROCESS

?

160

210

220 230

240)

250)

260)

270)

280)

290)

ITEM QTY

REV

PAGE4 OF 4

PROCESS NUMBER

P13C4-9232-0240


PROCESS NAME


DRIVE THE VEHICLE AND VERIFY NO HESITATION, STUMBLE OR

SURGING IS EXHIBITED

VERIFY NO ENGINE LIGHT COMES ON DURING THIS TIME

DRIVEABILITY INSPECTION

VERIFY VEHICLE DOES NOT EXHIBIT AN EXTENDED CRANK TIME

WHEN STARTING

VERIFY THE PROPANE DIAMOND LABEL IS INSTALLED ON THE LOWER

PASSENGER SIDE OF THE VEHICLE ABOVE THE REAR BUMPER

LOWER VEHICLE ON HOIST

FROM INSIDE THE ENGINE COMPARTMENT, SPRAY THE ENGINE AND

CHASSIS HOSE CONNECTIONS AND CHECK FOR LEAKS; REPAIR AS NEEDED


TORQUE OPERATION

CRITICAL PROCESS

?

260

250

REV

PAGE1 OF 1

PROCESS NUMBER

P13C4-9232-0250

JTG TROUBLESHOOTING A

PROCESS NAME

C) NON-RETURN VALVE BLOCKED

B) LPG FUEL PUMP DEFECTIVE

THE DIFFERENTIAL PRESSURE (LPG FUEL PUMP PRESSURE) IS HIGHER THAN THE MAXIMUM VALUE

POSSIBLE CAUSES:

A) REGULATOR NEEDS TO BE ADJUSTED

B) LPG RETURN HOSE (BLACK HOSE FROM THE REGULATOR TO THE TANK) IS BENT/KINKED

POSSIBLE CAUSE:

A) DIFFERENTIAL PRESSURE IS LESS THAN THE MINIMUM VALUE

THE DIFFERENTIAL PRESSURE (LPG FUEL PUMP PRESSURE) IS LESS THAN THE MINIMUM VALUE

POSSIBLE CAUSES:

A) REGULATOR NEEDS TO BE ADJUSTED

ENGINE IS HARD TO START IN COLD OUTSIDE TEMPERATURES

POSSIBLE CAUSE:

A) ONE OR MORE LPG FUEL INJECTORS ARE LEAKING

WHILE DRIVING AT A CONSTANT SPEED (IN LPG MODE), THE ENGINE HESITATES (JERKS)

A) REMOTE FILL HOSE BENT / KINKED

B) LACK OF SUFFICIENT PUMP PRESSURE AT FILL STATION

A) REMOTE FILL HOSE BENT / KINKED

- PROCEED TO CHECK IF ANY OF THE FILL HOSES ARE BENT/KINKED PREVENTING LPG TO PASS THROUGH THE HOSE - IF A HOSE IS FOUND TO

BE BENT/KINKED, REPLACE IT.

JTG II TROUBLESHOOTING

FAILURE TO FILL THE SYSTEM

- THE SYSTEM DOES NOT ALLOW THE REFUELING OF LPG

POSSIBLE CAUSES:

VIN # Vehicle:

Date:

ingress

Yes ______ No _____

Yes ______ No _____

F 3/4 1/2 1/4 E Yes ______ No _____

COMMENTS

Installed By: Approved By:

Leak check engine hoses

Leak check chassis hoses (at tank)

Leak check chassis hoses (at engine)

Propane diamond label installed

LED lamp functions

Auxiliary pump functions

Leak check fill hoses

OVERALL DRIVEABILITY

Gallons installed Starting Crank Time - Stalls - Stumbles

Fuel Gauge Level Operation (circle one:) Hesitations - Surging - Stability

Check Engine Light

COMMENTS

SYSTEM FUNCTION / ROAD TEST INSPECTION

Propane fill complete

Inspect hoses for proper routing Chassis hose corrugate routed to prevent water

Inspect LPG wire harnesses for proper routing

Heat shielding installed where applicable Battery cables properly tightened

Manual Supply Shut-Off Operates (leave fully open)

Tank Serial #

COMMENTS

ENGINE COMPARTMENT INSTALLATION INSPECTION

and shielding by heat sources for systems that are not equipped with remote

Verify proper retention of hoses (front to rear) bleeder valve hose kit

Verify proper torque of tank fasteners Tank Label Installed

LPG MONOFUEL CONVERSION

INSTALLATION INSPECTION FORM

UNDER VEHICLE INSTALLATION INSPECTION

Inspect hose routing and verify proper clearance Verify bleeder valve closed on fuel tank (only

QF-82-04-1

Revision: (A) - Dated 10/16/12

Replaces: None

Title:

Rev A

A 2/12/2014 M. STEPPEY

Author: Approval: Date: 2/12/2014

Title: Title:

Initials

CANADIAN UPS - 6.0L MONO FUEL

ENGINE SYSTEM INSTALLATION

MANUAL

Document I.D.: P13C4-9232 Page

REVISIONS

OPERATION

NUMBER

REVISION

LEVELDESCRIPTION OF CHANGE DATE

APPROVED

BY

INITIAL RELEASE

Marc Steppey

Technical Manager

Documents

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