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LPG / CNG
18/05/2009
Rev. 03
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INDEX:
SYSTEM DESCRIPTION…………..……………………………………………………………4
LAMBDA SENSORS…..………………………………………………………………………..12
PRESSURE SENSORS………….……………………………………………………………..13
TROUBLESHOOTING………..……………………………………….………………………...24
SERVICING……………………………………………………………….….…………………..25
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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.
5) Cut-off injectors wiring comes with marked letter A cable. During installation this end must
6) Gas rubber hoses from injector rail to manifold 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 60°C
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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
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PRESSURE REGULATORS & SOLENOID VALVES
Pressure regulator must deliver 1 bar pressure to the rail injectors and must transform LPG from
liquid to gaseous.
7
4
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“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.
2 4
1 3
6
2 4
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“RP/M 04S” CNG PRESSURE REGULATOR
2)
3) Gas outlet
Security fitting
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
6
1
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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
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“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
1
3
5
4
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.
3.0
pic. 5 pic. 6
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“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
1
3
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.
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).
6 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.
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“TARTARINI EVO 08” RAIL
1) Gas inlet
2) Solenoids electric plug connectors
3) Pressure meter nozzle
4) Fittings for calibrated gas outlet nozzles
5) Gas temperature sensor Plug-in connector
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.
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 n°6 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.
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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).
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.
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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.
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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.
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 customer’s 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.
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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 n°1 and the
negative (-) on pin n°2. 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 n°2 and the
negative (-) on pin n°1. If there is no pin number indication, please refer to this drawing.
In case the plugs of the petrol injectors aren’t 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 (-).
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PLUGS OF PETROL INJECTORS
- 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.
- Don’t secure the pressure regulator to the insulating panel between the engine
compartment and the driver’s 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.
- Don’t ever secure the gas injector rail to the vehicle’s 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.
- Don’t install the pressure sensor close to the exhaust, since the high temperature can
damage it.
- Don’t ever secure the gas electronic unit to the engine. Engine vibrations could create
malfunctions.
- Don’t 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.
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It is necessary
this to compensate
pressure regulator when
installing it on TURBO vehicles:
1) Thread this hole with a
M6 x 1
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TORQUES & HIGH PRESSURE HOSE FIXING METHOD
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LPG PRESSURE REGULATOR TYPE “RP-G 05S”
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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, hoses…etc.) 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:
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SERVICING
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