Prins Direct LiquiMax Installation Manual

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MANUFACTURER

Ford

TYPE

Tourneo Connect II

ENGINE DISPLACEMENT

1600

NUMBER OF VALVES

ENGINE CODE / NUMBER

JQGA

VEHICLE CATEGORIES

TRANSMISSION

AFC-2.1

VERSION

PETROL ECU MANUFACTURER / CODE

HIGH PRESSURE PETROL POMP

Bosch HDP-5-PE BM5G 0261.520.(076)(077)(139)(140)

HIGH PRESSURE PETROL INJECTOR

Bosch HDEV-5-1LE 0261.500.(155)(156)

MODEL YEAR:

9-2013

SYSTEM APPROVAL NUMBER ( R115 )

E4-115R-000009 / DLM-LPG 02

LOCATION R115 SYSTEM STICKER

right side, centre door post

ENGINE SET NUMBER

347/070047/A

MANUAL NUMBER

076/0705500

DATE

2014-11-12

Version 2013-09-28 D

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Summary of Contents for Prins Direct LiquiMax

Page 1 MANUFACTURER Ford TYPE Tourneo Connect II ENGINE DISPLACEMENT 1600 NUMBER OF VALVES ENGINE CODE / NUMBER JQGA VEHICLE CATEGORIES TRANSMISSION AFC-2.1 VERSION PETROL ECU MANUFACTURER / CODE HIGH PRESSURE PETROL POMP Bosch HDP-5-PE BM5G 0261.520.(076)(077)(139)(140) HIGH PRESSURE PETROL INJECTOR Bosch HDEV-5-1LE 0261.500.(155)(156) MODEL YEAR: 9-2013 SYSTEM APPROVAL NUMBER ( R115 )
Page 2 Tightening moments ........................4 Direct LiquiMax-2.0, AFC-2.1 ......................5 Direct LiquiMax-2.0 diagram, AFC-2.1 ..................... 6 Direct LiquiMax parts / approval numbers ..................7 DLM component location overview ....................8 Removal of the Bosch High Pressure Petrol Pump ................9 Fuel Supply Unit / Fuel Return Unit ....................10 Boost pump / FRU / FSU bracket ....................
Page 3 For maintenance instructions see owner manual.  Prins Autogassystemen is not responsible for any damages to people or objects as a result of changes to Prins products.  Check our website regularly for diagrams, certificates, updates, info-bulletins and product information.
Page 4 Required equipment / tools / materials for installing a complete system Complete workshop toolbox ( wrenches, screwdrivers, cutters, pliers, ratchet, sockets ) Car lift Portable computer Vehicle fuel system scan tool or OBD scan tool Prins ( part nr. 099/99928 ) Exhaust gas analyser Multimeter Oscilloscope...
Page 5 ( filtered ) Banjo bolt Supply line connection Fuel module Allen bolts Filler hose connection Boost pump clamp High pressure petrol fuel line 24-35 EXPLANATION OF SYMBOLS : = WEAR SAFETY GOGGLES = IMPORTANT, CAUTION Copyright © Prins Autogassystemen B.V. 2014...
Page 8 PAGE 7 076/0705500 Direct LiquiMax parts / approval numbers generation generation generation generation Fuel Supply Unit : E4-67R-010269 Fuel Return Unit : E4-67R-010270 Pressure Sensor : E4-67R-010051 Boost pump High Pressure Pump : E4-67R-010266 High Pressure Rail : E4-67R-010267 High Pressure Injectors : E4-67R-010309...
Page 13 PAGE 12 076/0705500 Boost pump / FRU / FSU bracket Remove battery, engine cover, air-filter, ignition coils, cover, wiper box, left wiper motor ( driver side ) Remove fabric. One side M8 washer plate Copyright © Prins Autogassystemen B.V. 2014...
Page 15 If not tightening the bolts or nuts in a straight line with the mating bolt holes or fittings, it may cause a fuel leak due to broken threads. High pressure petrol pipe installation nut: 26.5 ~ 32.4 N.m Installation is reverse of removal. Copyright © Prins Autogassystemen B.V. 2014...
Page 16 Replace the original high pressure petrol pump for the adapted high pressure petrol pump. ( Follow the workshop manual of the car ) Remove low pressure petrol line ( not used ) Install a new ( shorter ) bolt. Copyright © Prins Autogassystemen B.V. 2014...
Page 20 High pressure petrol pump Install the fuel line using two bonded seal washers and banjo bolt : Filtered banjo: ( FSU supply inlets / boost pump inlet / HPP pump inlet : black filtered banjo ) : Copyright © Prins Autogassystemen B.V. 2014...
Page 21 Supply hose – Return hose – Tank wiring Protect the supply- and return hose together with tank-wiring using the Ø16 split tube. Mount the “hose assembly “ with clamps, with a maximum distance of 40cm. Demo photo Copyright © Prins Autogassystemen B.V. 2014...
Page 25 PAGE 24 076/0705500 Switch wiring Remove left wiper motor. Drill a hole and pull wiring through using a grommet. ALSO wire 56, DI2, yellow-green, PWM signal wiring inside, behind isolation Copyright © Prins Autogassystemen B.V. 2014...
Page 29 Remove glove compartment. Extend the yellow-green wire to connect to the WHITE wire: Digital Input 2, OEM petrol pump driver, PWM IN DI 2 Yellow-green Wire colour : white Wire location : behind glove compartment Copyright © Prins Autogassystemen B.V. 2014...
Page 31 Driver room Wire number / code Wire colour Connection 3-pole micro connector Ground fuel switch Brown-black Connect the 3-pole connector to the Prins fuel selection switch. +12V fuel switch Red-white LIN fuel switch Yellow CAN-High Yellow EOBD connector pin 6, white-blue...
Page 32 +12V BATT sense use a ring terminal. Do not place the fuses before having completed the installation of the +12V BATT fused +12V BATT boost pump lpg system. +12V BATT pump driver Wire location : battery+ Copyright © Prins Autogassystemen B.V. 2014...
Page 33 Insulate AD 4 Blue AD 3 Blue-pink AD 9 Blue-purple LSS 1 Purple-white LSS2 Purple-green Digital out pull up 2 Red-purple +12V switched Red-white Digital input 3 Yellow-pink DI 4 Yellow-blue DAC 3 Green-pink Copyright © Prins Autogassystemen B.V. 2014...
Page 34 Grey-red Wire colour : grey-brown Wire location : right side petrol rail, pin 3 MAP sensor signal AD 1 Blue-white Wire colour :yellow Wire location : right side, intake manifold, MAP sensor, pin 3 Copyright © Prins Autogassystemen B.V. 2014...
Page 35 Pin 85 of the driver relay B2 +12V BATT fused Red 2.5mm2 Pin 30 of the driver relay C2-A4 +12V driver Red 2.5mm2 Pin 87 of the driver relay B1 Boost pump connection options: Copyright © Prins Autogassystemen B.V. 2014...
Page 36 From tank pump driver 2-pole connector power driver Red 2.5mm From tank pump relay 87 Brown 2.5mm From main ground 2-pole connector driver Green From AFC pin 71 pwm Grey From AFC pin 64 diagnose Copyright © Prins Autogassystemen B.V. 2014...
Page 38 Install the system fuses. Turn on ignition. Connect the Prins interface wire and run the Prins diagnosis program. When working on the car, beware of moving and rotating parts in the engine compartment ( even when the engine is not running !! ).