" We Put The Quality In Conversions"

GM CNG BOSS

Installation Instructions
PN 5922

APPLICATION
The GM CNG Boss PN 5922 is designed to provide full support for the conversion
to dual fuel CNG/gasoline operation of all 1987-1995 General Motors vehicles
equipped with HEI or DIS ignition systems. It has the same vehicle applications
as the GM Integrated Processor PN 5920.

FEATURES
• Fits ALL late model GM vehicles
• Provides automatic switch-over from CNG to gasoline
• All-in-one unit for TOTAL conversion support to CNG
• Allows CNG tank level to be read on OEM dashboard gasoline gauge
• Easy to install
• Incorporates all the functions of PN 5920

OVERVIEW
The GM CNG Boss incorporates all the functions of the GM Integrated Processor
PN 5920. As such, it supports the conversion of 1987 - 1995 GM vehicles
equipped with HEI or DIS ignition systems. It also provides the same functions
of Computer Support, Load-Sensitive Timing Advance, Closed-Loop Fuel
Control, and Fuel Injector shut-off when on CNG. The CNG Boss differs from
the Integrated Processor in that it is designed specifically for dual-fuel CNG/
gasoline conversions. For these conversions, it provides the additional function
of automatic fuel switch-over from CNG to gasoline when the CNG fuel supply is
exhausted (cylinder pressure drops below 300 psi). The CNG Boss gives you
the option of either manual over-ride, allowing the vehicle operator to switch to
gasoline operation at will, or complete automatic functioning, allowing gasoline
Parts in this kit specific to PN 5922
1 - Pressure transducer with wiring harness
3 - Cable ties
1 - Single Pole Double Throw (SPDT) Relay
1 - RED LED light

OPERATING CONDITIONS
SWITCH CNG CYLINDER OPERATING GAUGE READS
POSITION PRESSURE MODE OEM FUEL
Gasoline N/A Gasoline Gasoline
Above 300 psi Gasoline Gasoline
CNG
Below 300 psi CNG CNG
Transducer CNG FULL(CNG)
CNG
Disconnected

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2 INSTALLATION INSTRUCTIONS
operation only when the CNG fuel pressure drops below 300 psi. In addition, when
the vehicle is being operated on CNG, the CNG Boss allows the CNG fuel cylinder
level to be read on the OEM dashboard gasoline fuel gauge. An optional “check”
function allows the operator to check gasoline tank fuel level even when operating
on CNG. When the CNG Boss has switched the vehicle to gasoline operation, the
OEM fuel gauge functions normally, showing the gasoline tank fuel level. The CNG
Boss will work with CNG systems up to 4000 psi.

NOTE: All connections must be soldered and sealed. Use rosin core solder. Keep
ALL wires away from hot or moving parts or spark plug wires.

INSTALLATION:

STEP 1: INITIAL INSTALLATION OF PN 5922

Since the GM CNG Boss PN 5922 is substantially similar to the GM Integrated
Processor PN 5920, you should follow the instructions for installation of PN 5920
which are included in the kit. The only difference between the two units is an extra
6 Pin connector on the PN 5922 to accommodate the wiring Harness for the pressure
transducer and the fuel gauge interface.
See Figure 1

NOTE: The illustration in Figure 1 shows the schematic of the SPDT relay, as it is
printed on the top of the relay box. The position of the spade terminals on the
bottom of the relay box is NOT the same. The number for each spade terminal is
stamped into the white plastic next to the terminal.

STEP 2: YELLOW WIRE, WIRING THE PN 5922 AND THE SPDT

RELAY
Connect the YELLOW wire from the PN 5922 harness to Terminal 85 of the SPDT
relay.
See Figure 1

STEP 3: GROUNDING THE SPDT RELAY

Using a piece of 18 gauge wire (not supplied with the kit), connect Terminal 86 of
the SPDT relay to a CLEAN engine or chassis ground.
See Figure 1

STEP 4: WIRING THE FUEL GAUGE

On the top of the vehicle’s fuel tank, you will find a male three pin weatherpack
connector which is hooked to a female connector. The wiring from the female
connector runs to the front of the vehicle, carrying the signal from the fuel tank float
to the dashboard fuel gauge. Unplug these two connectors and plug the male and
female connectors from the PN 5922 harness which have the LIGHT GREEN and
LIGHT BLUE wires in series with these plugs.
See Figure 1

STEP 5 : WIRING THE FUEL PUMP TO THE SPDT RELAY

On Pin C of the factory female connector into which you have just plugged the PN
5922 is the wire to the fuel pump relay inertia switch. Using a piece of 18 gauge wire
(not supplied with the kit) connect between this wire and Terminal 30 of the SPDT
relay. Next cut the BLACK wire going between the C Pins of the two three pin plugs
from the PN 5922. Using a piece of 18 gauge wire (not supplied with the kit),
connect the wire from Pin C of the FEMALE plug to Terminal 87A of the SPDT relay.
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 INSTALLATION INSTRUCTIONS 3
FIGURE 1

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4 INSTALLATION INSTRUCTIONS

NOTE that making the connections in this manner is an important SAFETY factor.
With the connections done according to these instructions, the inertia switch will kill
EITHER the fuel pump or the CNG solenoid in the event of collision or roll-over.
See Figure 1

STEP 6: WIRING THE CNG LOCK-OFF SOLENOID

Using a piece of 18 gauge wire (not supplied with the kit) connect Terminal 87 of the
SPDT relay to the positive terminal of the CNG lock-off solenoid.
See Figure 1

STEP 7: PINK WIRE, WIRING THE LED GASOLINE OPERATION

INDICATOR
Make a connection between the PINK wire from the PN 5922 to the RED wire from
the LED. Connect the BLACK wire from the LED to a CLEAN ground. With the
wiring done in this manner, the LED will be illuminated whenever you are operating
on gasoline. Mount the LED in any convenient location that is easily visible to the
vehicle operator.
See Figure 1

STEP 8: DARK BLUE WIRE, WIRING THE FUEL SELECTOR

SWITCH
Hook the DARK BLUE wire located at Pin C of the wiring harness to the fuel selector
switch in such a way that +12V will select CNG operation and automatic switching
and -0-V will select gasoline operation. The switch can be left permanently in the
“CNG” position. The CNG Boss will automatically override the switch and change
to gasoline operation when the CNG fuel supply is exhausted. At this time, it will
also illuminate the LED warning light. It will automatically switch back to CNG
operation and turn off the LED as soon as the CNG tank is refilled. You only need
to use the switch when you wish for any reason to go from CNG to gasoline operation
even though there is an adequate supply of CNG in the cylinder. You can test the
automatic switching feature by leaving the fuel selector in the “CNG” position and
shutting off the CNG cylinder valve. You will observe the unit automatically switching
fuels and illuminating the RED LED.
See Figure 1

NOTE: You can eliminate the selector switch by simply wiring the DARK BLUE wire
to any keyed 12V source. This will keep the vehicle in permanent CNG operation
with automatic fuel switching to gasoline.

STEP 9: (OPTIONAL) GASOLINE TANK LEVEL CHECKING

FUNCTION
If you desire to have the ability to check the level in the gasoline tank WITHOUT
switching to gasoline operation, a push-button switch (not supplied with the kit)
may be installed as shown in the boxed area of Figure 1. Installation of the switch
in the manner shown will allow the vehicle operator, by depressing the button, to
read the gasoline tank level on the dashboard gauge WITHOUT switching from
CNG to gasoline operation.

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INSTALLATION INSTRUCTIONS 5

STEP 10: INSTALLING THE PRESSURE TRANSDUCER

Install the 1/8" NPT threaded end of the pressure transducer between the CNG
cylinder manual shut-off and the 3000psi regulator. Most regulators have a 1/8"
NPT port on the high pressure (3000psi) side of the regulator into which the
transducer can be easily installed.

STEP 11: CONNECTING THE PRESSURE TRANSDUCER

Connect the round 3 pin connector on the PN 5922 wiring harness to the female
receptacle on the pressure transducer.

TECH NOTES

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© Copyright 1995 Autotronic Controls Corporation All rights reserved

Limited Warranty
A utotronic Controls Corporation warrants this product to be free from defects in material and
workmanship under normal use and if properly installed for a period of one year from date of purchase.
If found to be defective as mentioned above, it will be replaced or repaired if returned prepaid along with
proof of date of purchase. This shall constitute the sole remedy of the purchaser and the sole liability of
Autotronic Controls Corporation. To the extent permitted by law, the foregoing is exclusive and in lieu of
all other warranties or representations whether expressed or implied, including any implied warranty of
merchantability or fitness. In no event shall Autotronic Controls Corporation be liable for special or
consequential damages.

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FRM14893 Created 02/95 DR., EL PASO, TEXAS 79936 • (915) 857-5200
HENRY BRENNAN Printed In 857-3344
• FAX (915) U.S.A.
INSTALLATION INSTRUCTIONS 7

AUTOTRONIC CONTROLS CORPORATION • 1490 HENRY BRENNAN DR., EL PASO, TEXAS 79936 • (915) 857-5200 • FAX (915) 857-3344