SECTION 8A2 - LPG SYSTEM

IMPORTANT

Before p erforming any Serv ice Operation or other procedu re described in this Section , refer to Section 00

CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property damage.

CONTENTS

1 GENERAL INFORMATION

1.1 SAFETY PRECAUTIONS7

1.2 IDENTIFICATION PLATES & WARNING

LABELS

2. PRINCIPLES OF OPERATION

2.1 LPG SYSTEM (TYPICAL)

2.2 LPG TANK

SEDAN & UTILITY

WAGON

2.3 FILLER VALVE

2.4 AUTOMATIC FILL LIMITER (AFL)

2.5 PRESSURE RELIEF VALVE

2.6 MANUAL SERVICE VALVE ASSEMBLY

MANUAL SHUT-OFF VALVE

SOLENOID VALVE

EXCESS FLOW VALVE

2.7 SMART UNIT

2.8 TANK FUEL GAUGE ASSEMBLY

2.9 LPG LOCK-OFF

2.10 SERVICE LINE

2.11 CONVERTER

PRIMARY REGULATION

SECONDARY REGULATION

2.12 FUEL CONTROL VALVE

2.13 REGULATOR CHECK VALVE

2.14 MIXER

2.15 FUEL MODE SWITCH

2.16 INSTRUMENT CLUSTER DISPLAY

2.17 TRACTION CONTROL OPERATION

2.18 POWERTRAIN CONTROL MODULE

PETROL MODE

LPG MODE

3. SERVICE OPERATIONS

3.1 SERVICE LINE DRAINING

3.2 LPG TANK UNLOADING

3.3 LEAK TESTING

COMBUSTIBLE GAS DETECTORS

FOAM

LEAK TEST PROCEDURE

3.4 FILLER VALVE & CONNECTOR PIPE

SEDAN

WAGON

UTILITY

3.5 FILLER LINE

SEDAN

WAGON

UTILITY

3.6 LPG TANK

SEDAN

WAGON

UTILITY

3.7 VENT TUBE FLANGE

SEDAN

WAGON

UTILITY

3.8 SMART UNIT & SOLENOID VALVE

REMOVE

REINSTALL

3.9 MANUAL SERVICE VALVE ASSEMBLY

EXCESS FLOW VALVE

REMOVE

REINSTALL

3.10 PICK-UP PIPE & STRAINER

REMOVE

REINSTALL

3.11 AUTOMATIC FILL LIMITER (AFL)

TEST

REMOVE

REINSTALL

3.12 PRESSURE RELIEF VALVE

REMOVE

REINSTALL

3.13 TANK FUEL GAUGE ASSEMBLY

REMOVE

REINSTALL

CONTENTS GAUGE

3.14 FRONT SERVICE LINE

REMOVE

REINSTALL

3.15 REAR SERVICE LINE

SEDAN

WAGON

UTILITY

3.16 INTERMEDIATE SERVICE LINE

REMOVE

REINSTALL

3.17 LPG LOCK-OFF

REMOVE

FILTER ELEMENT REPLACEMENT

TEST

REINSTALL

3.18 CONVERTER

CONVERTER ON-VEHICLE TEST

REMOVE

OVERHAUL

CONVERTER OFF-VEHICLE TEST

REINSTALL

3.19 REGULATOR CHECK VALVE

TEST

REMOVE

REINSTALL

3.20 FUEL CONTROL VALVE

REMOVE

TEST

REINSTALL

3.21 MIXER

TEST

REMOVE

OVERHAUL

REINSTALL

3.22 FUEL MODE SWITCH

REMOVE

TEST

REINSTALL

3.23 COOLANT HOSES

Techline

3.24 AIR CLEANER ASSEMBLY

REMOVE

REINSTALL

3.25 SPARE WHEEL CARRIER, WAGON

REMOVE

REINSTALL

4. TECH 2 PROCEDURES

4.1 LPG SETUP PROCEDURE

4.2 LPG FCV TEST

4.3 LPG ENABLE TEST

5. AFTER INSTALLATION CHECK

5.1 GENERAL INFORMATION

5.2 UNDERBODY

5.3 REAR COMPARTMENT

5.4 UNDER HOOD

5.5 LEAK CHECK

6. DIAGNOSIS

6.1 PREREQUISITES TO DIAGNOSIS AND

TROUBLESHOOTING

PRELIMINARY SYSTEM REQUIREMENTS

SAFETY REQUIREMENTS

CHECKING EQUIPMENT

6.2 GENERAL INFORMATION

6.3 LPG VEHICLE PRELIMINARY DIAGNOSIS

6.4 DOES NOT OPERATE ON LPG

6.5 FUEL MODE SWITCH DOES NOT OPERATE

6.6 ENGINE DOES NOT CRANK

6.7 ENGINE CRANKS BUT WILL NOT

START ON LPG

TEST 1

TEST 2

TEST 3

6.8 ENGINE BACKFIRES ON LPG

6.9 POOR PERFORMANCE, FLAT

SPOTTING, SLUGGISH OR POOR

FUEL CONSUMPTION WHEN

OPERATING ON LPG

6.10 FUEL CONTROL VALVE DOES NOT

OPERATE

6.11 TECH 2 SCAN TOOL: ENGINE DATA

7. WIRING & CONNECTORS

8. SPECIFICATIONS

9. TORQUE WRENCH SPECIFICATIONS

10. SPECIAL TOOLS

1. GENERAL INFORMATION

Liquefied Petroleum Gas ( LPG) , pr oduction option KL7, is available f or domestic MY2003 VY Series Sedan, Wagon

and Utility vehicles fitted with a V6 engine and automatic transmission.

The LPG system is identical across all vehicles with the exception of the LPG tank and filler assembly, which are

unique for each body style.

Sedan vehicles are fitted with a conventional cylindrical tank mounted in the rear compartment between the rear

wheelhouses, refer to Figure 8A2-1.

W agon vehic les employ a toroidal tank, als o com monly known as a doughnut tank . The tank is fitted into the spar e

wheel-well necessitating relocation of the spare wheel to an upright position in a carrier mounted on the right-hand

side of the rear compartment. Due to the increase in height of the tank compared to the spare wheel, a modified

rear compartment floor carpet is fitted, refer to Figure 8A2-2.

The tank fitted to Utility vehicles is also cylindrical in shape, but is wider and lower in profile to allow installation at

the front of the load compartment, under the rear window. A metal cover is fitted to protect the tank from damage

from objects placed in the load compartment, refer to Figure 8A2-3.

All filler valves are located within the fuel filler pocket above the petrol filler, however due to the tank differences,

routing and installation is unique to each body style.

The rear service lines ar e also unique for each body s tyle as is the rear connection of the interm ediate service line,

which is routed within the fuel and brak e line harness assembly. From this point, each system is com mon with the

intermediate line connecting to the converter via a front service line within the engine compartment. The converter is

incorporated into the cooling system circuit to aid vaporisation of the gas.

The last major component in the system is the mixer. The mixer is fitted in-line of the air inlet ducting and is

responsible for combining the LPG vapour with the inlet air prior to entering the engine.

The LPG system is controlled by the Powertrain Control Module (PCM), which is set to a unique program for LPG

operation. This allows for ease of set-up and provides optimum control of the system. Diagnostic functions and

trouble codes within the PCM support the LPG system.

The driver is able to switch the vehicle to LPG or petrol operation via a fuel mode switch, located in the front floor

console, even while the vehic le is being dr iven. An icon is dis played on the instrum ent c lus ter when LPG is s elec ted

and the standard fuel gauge changes from displaying the contents of the petrol tank to the LPG tank contents.

Further description of the LPG system operation and components is provided in 2. PRINCIPLES OF OPERATION.

All vehicles fitted with the KL7 LPG option are fitted with upgraded springs. For service information, refer to

Section 4A, REAR SUSPENSION.

SEDAN

Figure 8A2-1

Legend

1. Instrument Cluster Display LPG Icons 6. LPG Lock-off

2. Fuel Mode Switch 7. Converter

3. LPG Filler Valve 8. Mixer

4. Manual Service Valve Assembly 9. Fuel Control Valve

5. Powertrain Control Module (PCM) 10 Rear Springs

WAGON

Figure 8A2-2

Legend

1. Instrument Cluster Display LPG Icons 2. LPG Lock-off

3. Fuel Mode Switch 4. Converter

5. LPG Filler Valve 6. Mixer

7. Manual Service Valve Assembly 8. Fuel Control Valve

9. Powertrain Control Module (PCM) 10. Rear Springs

UTILITY

Figure 8A2-3

Legend

1. Instrument Cluster Display LPG Icons 6. LPG Lock-off

2. Fuel Mode Switch 7. Converter

3. LPG Filler Valve 8. Mixer

4. Manual Service Valve Assembly 9. Fuel Control Valve

5. Powertrain Control Module (PCM)

1.1 SAFETY PRECAUTIONS

• Any servicing or testing of the LPG system high pressure area must be performed by trained and/or licensed

LPG installers or fitters, in a Specialist Gas Workshop and in accordance with Australian Standards

AS 2746-1985 and AS 1425-1989.

• Norm al vehicle m aintenance ser vice and any s ervicing of the LPG system not affecting the high- pressure area

(filler line, LPG tank , servic e line, LPG lock - off and converter ) m ay be perform ed by dealership technicians who

are not accredited installers or fitters.

• DO NOT smoke or allow naked flames, or any ignition source near the vehicle.

• LPG m ust never com e in contact with any part of the body as it can caus e severe frostbite. Due to its very low

boiling point, LPG readily absorbs heat from its surroundings or any surface it comes in contact with when

released into the atmosphere.

• When working on the LPG system, suitable protective clothing including gloves and safety goggles must be

worn to prevent personal injury.

• LPG in the vapour form is highly flammable. In the interests of safety, the LPG system should be leak tested

and isolated by turning off the m anual service valve and draining the s ervice lines of LPG prior to c omm encing

any work on the vehicle, refer to 3.1 SERVICE LINE DRAINING.

• During servic ing, the m anual servic e valve m ust r em ain off at all tim es, except when gas is specif ically required

for servicing or testing of the LPG system.

• Whenever any service operation is performed on the high-pressure area of the system (filler line, LPG tank,

service line, LPG lock -off and converter ), a leak test m ust be perf ormed on the com plete LPG system, r efer to

3.3 LEAK TESTING.

• Prior to the removal of any component from the LPG tank, the LPG tank must be emptied of LPG, refer to

3.2 LPG TANK UNLOADING. The LPG tank must then be safety tested in accordance with Australian Standard

AS 2030-1 and according to the laws of the state in which the vehicle is registered. A leak test must be

performed on the complete LPG system before the LPG tank is returned to service in the vehicle.

1.2 IDENTIFICATION PLATES & WARNING LABELS

Several identification plates and warning labels are fitted to vehicles with LPG, as shown below .

NOTE: If the vehicle is repaired or the components that the labels / plates are attached to are replaced, the

label or plate must also be replaced.

1. The LPG precaution label, fitted to the

windscreen right-hand upper, provides the driver

with information for operating the vehicle on LPG.

Figure 8A2-4

2. An LPG compliance plate, if required by State

regulations, is riveted to the left-hand front

wheelhouse.

3. A warning label is affixed to the LPG tank (1 –

Sedan, 2 – Wagon, 3 – Utility) and provides

important information regarding the tank

assembly, refer to Figure 8A2-6.

Figure 8A2-5

Figure 8A2-6

4. A Holden By Design identification plate is riveted

to the front upper panel.

Figure 8A2-7

2. PRINCIPLES OF OPERATION

2.1 LPG SYSTEM (TYPICAL)

Figure 8A2-8

Legend

1. LPG Filler Valve 11. LPG Lock-off

2. Filler Line 12. Converter A. Liquid

3. AFL 13. Fuel Control Valve B. Vapour

4. LPG Tank Assembly 14. Mixer C. Vacuum

5. Relief Valve 15. Wiring Harness D. Coolant

6. Fuel Contents Gauge / Sender 16. Powertrain Control Module (PCM) E. Breather

7. Manual Service Valve Assembly 17. Fuel Mode Switch F. Balance / Vacuum

8. Rear Service Line 18. Instrument Cluster Display LPG Icons G. Air Intake

9. Intermediate Service Line 19. Instrument Cluster Fuel Gauge H. To Engine Inlet Manifold

10. Front Service Line 20. Coolant Hoses

2.2 LPG TANK

The LPG Tank is made of carbon steel and is

manufactured to stringent safety standards.

LPG m ust be stored at appr oxim ately 750 k Pa at 20°C

to remain a liquid. The vapour pres s ur e inside the LPG

tank will vary with ambient temperature, as the ambient

temperature rises so does the vapour pressure.

The LPG tank is heat treated during manufacture and

MUST NOT be heated or welded in any way.

SEDAN & UTILITY

For sedan vehicles, the LPG tank is fitted in the rear

compartment, under the rear parcel shelf.

Utility vehicles have the tank mounted at the front of

the load compartment, below the rear window.

The LPG tank incorporates a gas-tight compartment

(valve box) which is vented to atmosphere via a vent

hose and contains the following components, refer to

Figure 8A2-10 (Sedan, Utility is similar):

1. Pressure relief valve,

2. Smart unit, solenoid, manual service valve and

excess flow valve,

3. Tank fuel gauge assembly, and

4. Automatic fill limiter (AFL).

Thes e components are either attached into or onto the

LPG tank. As the LPG tank is loc ated in the luggage or

load compartments, if any of these components were

to leak, or there was an excess pressure discharge,

the LPG would be vented to atmosphere via the vent

hose and will not vent into the vehicle.

Figure 8A2-9

Figure 8A2-10

Legend

1. Pressure Relief Valve 3. Tank Fuel Gauge Assembly

2. Smart Unit, Solenoid, Manual Service Valve and Excess Flow Valve 4. Automatic Fill Limiter (AFL)

WAGON

Due to s pace lim itations, a toroidal s haped tank is fitted to Wagon vehic les. It is designed to fit within the spare

wheel compartment, necessitating the relocation of the spare wheel to a bracket assembly on the right-hand side

of the luggage compartment.

The LPG tank fitted to Wagon vehicles also has a gas-tight compartment (valve box), which contains the

following components, refer to Figure 8A2-11:

1. Pressure relief valve,

2. Automatic fill limiter (AFL),

3. Smart unit, solenoid and manual service valve assembly, and

4. Tank fuel gauge assembly.

These components are either attached into or onto the LPG tank. As the LPG tank is located in the luggage

compartment, if any of these components were to leak, or there was an excess pressure discharge, the LPG

would be vented to atmosphere via a vent hose and will not vent into the vehicle.

Figure 8A2-11

Legend

1. Pressure Relief Valve 3. Smart Unit, Solenoid, Manual Service Valve and Excess Flow Valve

2. Automatic Fill Limiter (AFL) 4. Tank Fuel Gauge Assembly

2.3 FILLER VALVE

The filler valve is located in the fuel filler pocket,

adjacent to the petrol filler.

The valve incorporates two spring-loaded non-return

valves (1 & 2) and a sealed cap (3) fitted to the filling

connection (4).

The c onnection is designed to shear off in the event of

the vehicle being driven away with the filler hose

inadvertently attached. In this situation, the lower valve

remains intact, avoiding the LPG discharging.

The filler valve is connected to the LPG tank AFL inlet

elbow by a filler line, which is routed through the LPG

tank vent hose.

Figure 8A2-12

2.4 AUTOMATIC FILL LIMITER (AFL)

The Automatic fill limiter (AFL) is fitted into the LPG

tank. T he inlet elbow (1) connects the to the LPG filler

line.

W hen the tank is being filled with liquid LPG, the AFL

float (2) rises with the liquid within the LPG tank. The

float arm is connected to an actuator (3) that operates

a shut-off piston (4). When the level reaches

approximately 80% full, the piston is in the closed

position, shutting off the flow of LPG into the tank.

The remaining 20% of the tank volume is necessary

vapour space to allow for the expansion of the liquid

that occurs as the temperature of the liquid increases.

The AFL is also fitted with a non-return valve (5) to

prevent the gas escaping.

Figure 8A2-13

2.5 PRESSURE RELIEF VALVE

The pressure relief valve is housed within the valve

box and attached into the LPG tank.

Pressur e within the LPG tank exceeding approxim ately

2,550 kPa c auses the valve (1) to open by overcom ing

spring tension (2). The excess pressure will then be

vented into the valve box through the orifice (3) and

then to atmosphere via the vent hose.

The valve will continue to vent the LPG tank until the

pressur e drops below 2,550 k Pa and the spring closes

the valve.

During normal operating conditions the pressure relief

valve should not operate.

Figure 8A2-14

2.6 MANUAL SERVICE VALVE ASSEMBLY

The manual service valve assembly is attached onto

the LPG tank and is three valves in one:

• manual shut off valve,

• electrically operated solenoid valve, and

• excess flow valve.

The manual service valve assembly also incorporates

the smart unit, refer to 2.7 SMART UNIT.

MANUAL SHUT OFF VALVE

The manual s hut of f valve (1) allows the s upply of LPG

to be manually shut off for servicing, if a leak in the

system develops, or in the event of a vehicle accident

by turning the knob (2).

SOLENOID VALVE

The s olenoid valve (3) is an electric ally oper ated valve,

which allows the flow of LPG from the tank into the

service line when energised by the smart unit (4). The

solenoid valve is energis ed f or thr ee seconds when the

ignition key is first turned on, or constantly while the

engine is being cranked or is running.

The solenoid valve will s hut off the LPG f low when the

ignition is switched off and/or the engine stops running.

EXCESS FLOW VALVE

The ex cess f low valve (5) will close autom atically if the

flow of liquid LPG is excessive, shutting off the supply

of liquid LPG. The valve will automatically reopen when

the excess flow condition has ceased.

The ex ces s f low valve is des igned to shut off if the flow

exceeds a specified amount, as would occur if the

service line was severed or opened.

Figure 8A2-15

2.7 SMART UNIT

The smart unit (1) is attached to the manual

service valve (2) and controls the operation of the

solenoid valve (3) and the LPG lock-off, refer to

2.9 LPG LOCK-OFF.

W hen operating in LPG m ode, the PCM will signal the

smart unit to energise the solenoid valve and LPG

lock-off for three seconds when the ignition switch is

first turned on or when the engine is being cranked

and while the engine is running.

If the engine stops running, the PCM signal to the

smart unit will cease and the smart unit will de-

energise the so lenoid valve and LPG lock -of f . The f low

of LPG will then stop.

Figure 8A2-16

2.8 TANK FUEL GAUGE ASSEMBLY

The tank fuel gauge assembly (1, typical) has a float

(2) similar to a petrol gauge sender unit, and a fuel

contents gauge (3).

As the liquid level in the LPG tank rises, so to does the

float. The float is connected to a magnet within the

assem bly. Any change in the position of the liquid level

is transmitted to the fuel contents gauge via the float

and magnet.

The magnetic field produced by the magnet causes the

fuel contents gauge mounted on the exterior of the

tank to move in relation to the magnet's position.

Referr ing to Figure 8A2- 18, (A) Sedan and Utility or (B)

Wagon, the f uel c ontents gauge (1) will show full when

the liquid level in the tank is at 80% (2). It will show

empty when the tank contents falls to approximately

8.5 litres (3).

The fuel gauge sender unit within the fuel contents

gauge incorporates a variable resistor, which will vary

its resistance from approximately 40 ohms when the

tank is empty to approximately 255 ohms when the

tank is full.

This change in resistance is sensed by the instrument

cluster fuel gauge, which will display the contents of

the LPG tank when the vehicle is operating on LPG. If

the vehicle is switched back to petrol operation, the

contents of the petrol tank will be displayed.

Figure 8A2-17

Figure 8A2-18

2.9 LPG LOCK-OFF

The LPG lock-off is an electrically operated solenoid

valve, which allows or prevents the flow of LPG to the

converter when energised or de-energised by the

smart unit.

The LPG lock-off is energised for three seconds when

the ignition is turned on, or c onstantly while the engine

is being cranked or is running.

The valve (1) opens and allows LPG from the tank to

flow through a fuel filter (2) and then to the converter.

When the engine stops running, or the ignition is

turned off, the smart unit de-energises the LPG lock-

off and the supply of LPG is shut off.

Figure 8A2-19

2.10 SERVICE LINE

The service line carries the liquid LPG from the manual service valve to the LPG lock-off. The service line

consists of thr ee major components: the front (1), intermediate (2) and r ear (3) service lines, ref er to Figure 8A2-

20, (A) Sedan, (B) Wagon, (C) Utility.

Figure 8A2-20

Legend

1. Front Service Line A. Sedan

2. Intermediate Service Line B. Wagon

3. Rear Service Line C. Utility

2.11 CONVERTER

The converter is a combined two-stage regulator and vaporiser.

It receives LPG (1) at tank pressure from the LPG lock-off and reduces that pressure in two stages to slightly

less than atmospheric. When the engine is cranked or running, a partial vacuum is created in the vapour line

from the mixer, which opens the converter permitting LPG to flow to the mixer (2), refer to Figure 8A2-21.

In the process of reducing the pressure from approximately 1260 kPa in the tank to atm ospheric pressure, the

LPG expands to become a vapour, causing refrigeration. To compensate for this and to assist in vaporisation,

coolant from the engine cooling system circulates through a heat exchanger (3). The converter seals off LPG

flow when the engine is stopped.

Figure 8A2-21

PRIMARY REGULATION

The primary regulator spring (1), acting on the upper side of the primary diaphragm (2), pushes the primary

diaphragm down. This opens the primary valve (3) and allows LPG to enter the converter (4), which then flows

through the heat exchanger (5) where the LPG changes state from a liquid to a gas.

The pressure of the LPG acting on the underneath side of the primary diaphragm causes the diaphragm to move

upward, closing off the primary valve.

SECONDARY REGULATION

W hen the engine is cranked or running, a vacuum is created by the mixer in the secondary chamber (6). This

vacuum (slightly below atmospheric) acting on the underneath of the secondary diaphragm (7), overcomes the

secondary spring force (8), allowing LPG as a vapour to enter the secondary chamber. This increases the

pressure acting on the underneath side of the diaphragm, overcoming the secondary spring force, causing the

diaphragm to move upward closing off the secondary valve (9). The gas can then flow to the mixer (10).

Figure 8A2-22

2.12 FUEL CONTROL VALVE

The fuel control valve (FCV) is used to control fuel

delivery.

Because the diaphragm of the converter is very large,

little movement is required to control the amount of

LPG deliver ed. T he f uel contr ol valve is connec ted into

the balance line between the atmospheric vent of the

converter secondary diaphragm (2) and the air valve

venturi of the mixer (1).

This applies a very low vacuum to the atmospheric

side of the converter secondary diaphragm. Any

pressure less than atmospheric results in a reduction

in LPG delivery. This assures extremely accurate LPG

delivery and rapid response time.

With the exhaust gas oxygen sensor at operating

temperature and the powertrain control module (PCM)

operating in closed loop mode, there is a wide range of

control. This permits the PCM to optimise the air/fuel

mixture to varying engine requirements.

The FCV is controlled by the PCM. To open the FCV

and decrease the pressure acting on the secondary

diaphragm of the converter, the PCM pulses the FCV

coil (3) on and off at a frequency of 10 Hz. The ratio

between the on and off time is called the duty cycle.

To open the FCV plunger (4) the PCM increases the

duty cycle, which decreases the pressure applied to

the secondary diaphragm. The amount of time the

FCV is on will determine the pressure acting on the

converter secondary diaphragm. In this way, the PCM

can control the air/fuel ratio.

Figure 8A2-23

Figure 8A2-24

Legend

1. FCV 4. Secondary diaphragm A. Vacuum from mixer

2. Vacuum inlet 5. Converter

3. Balance hose 6. Regulator check valve

2.13 REGULATOR CHECK VALVE

To maintain correct control during normal driving the

pressur e above the s ec ondary diaphragm is inf luenc ed

by the air valve vacuum but is finally controlled by the

FCV.

However, when the accelerator is depressed quickly,

the pressure in the air valve chamber will rise very

quickly, far above its normal working value. This is

because the movement of the mixer diaphragm and

air-gas valve will lag behind the movement of the

throttle valve. This will momentarily subject the air

valve chamber to a high vacuum.

Because the FCV duty cycle has been controlling the

air fuel ratio with a steady vacuum value, this sudden

increase in vacuum will delay the movement of the

converter diaphragm at precisely the time it needs to

move freely. This would cause a lean air/fuel ratio.

Whenever the vacuum above the diaphragm exceeds

16” W C i.e. when the diaphragm needs to m ove down

quickly as the accelerator is suddenly depressed, the

regulator check valve (1) will open and allow

atmospheric pressure to act on the secondary

diaphragm.

Figure 8A2-25

2.14 MIXER

The mixer is installed between the engine intake

manifold and the intake air filter.

When the engine is cranked or running, manifold

vacuum is transm itted through vacuum ports in the air

valve (1) to the upper side of mixer diaphragm (2). As

a result, atmospheric pressure pushing upwards on the

underneath side of the diaphragm, lifts it against the

downward force of the metering valve spring (3).

The pressure applied to the upper side of the

diaphragm varies with engine speed and throttle

position. The pressure difference between

atmos pheric pr essur e acting on the underneath s ide of

the diaphragm and the pressure acting on the upper

side of the diaphragm determines the metering valve

(4) position.

The position and the shape of the metering valve

determines the amount of LPG (5) delivered to the

engine.

Maximum fuel delivery is determined by the power

valve (6), which limits the maximum fuel flow. The

power valve is pre-calibrated in the factory and is not

adjustable in service.

Idle air by-pass adjustment is provided by the

adjustment screw (7).

Figure 8A2-26

2.15 FUEL MODE SWITCH

On all vehicles f itted with a LPG system, the fuel m ode

switch (1) is mounted in the floor console.

When the fuel mode switch is pressed, the switch

supplies B+ volts to PCM terminal X3-F4. The PCM

sees this voltage as a request to change over from

petrol to LPG or from LPG to petrol.

NOTE: The PCM will only toggle between the petrol

and LPG mode if the ignition is on and the engine is

not running, or if the engine speed is greater that 1500

RPM.

The operational mode that the PCM is in is stored in

the PCM mem or y so that the engine starts in the same

mode on the next ignition cycle.

Figure 8A2-27

2.16 INSTRUMENT CLUSTER DISPLAY

Whenever the vehicle is switched from petrol to LPG

mode, the LPG tank icon and letters LPG (1) will be

displayed in the instrument cluster multifunction display

(MFD) for two seconds.

In addition, the icon LPG (2) will also be displayed in

the upper right corner of the MFD while the vehicle

remains in LPG mode.

When the vehicle is in LPG mode the fuel gauge

displays the amount of LPG within the tank.

W hen the level falls to a pr edeterm ined point, the LPG

tank icon is displayed with the words Low LPG in tank .

If the level decreases further to second predetermined

point, the icon is displayed again with the words Very

Low LPG in tank. T hese warnings are accom panied by

a warning chime.

NOTE: As the vehicle may continue to use a small

amount of petrol during LPG operation, the level of

the petrol tank is also monitored, refer to

2.18 POWERTRAIN CONTROL MODULE. If the level

falls below predetermined points, similar warnings will

be issued regarding the petrol status, even though the

fuel gauge is displaying LPG tank status.

For further information refer to Section 12C

INSTRUMENT CLUSTER.

Figure 8A2-28

2.17 TRACTION CONTROL OPERATION

Whenever the vehicle is operating in the LPG mode,

the traction control system (if fitted) is disabled. The

traction control off icon (1) and the words Traction Ctrl

Off will be displayed in the instrument cluster

multifunction display (MFD) for two seconds.

In addition, the icon TRAC OFF will also be displayed

on the right-hand side of the MFD while the traction

control system remains disabled.

The traction control system is disabled by the PCM,

which sends a message to the ABS/ETC control

module via the serial data circuit, requesting the

traction control system be switched off.

Figure 8A2-29

2.18 P O WERTRAIN CONTROL MODULE

When programmed with the correct LPG calibration,

the Powertrain Control Module (PCM) is capable of

operating in either of two operating modes: Petrol or

LPG.

PETROL MODE

When operating in petrol mode, the LPG system is

turned off and the vehicle operates on petrol with full

engine management control in the same manner as a

vehicle not fitted with LPG. In this mode, the

instrument cluster fuel gauge will show the amount of

petrol in the petrol fuel tank.

LPG MODE

When operating in the LPG mode, the engine

management s ystem is switched to LPG mode and the

LPG system is turned on, enabling the vehicle to

operate on LPG. In this mode the LPG lamp will be

illuminated and the instrument cluster fuel gauge will

show the amount of LPG in the LPG tank.

The PCM c ontrols the f low of LPG, by sending a signal

to the smart unit via circuit 2531. On receiving this

signal the sm art unit energise s the solenoid valve. The

smart unit also energises the LPG lock-off valve via

circuit 5620.

To aid engine starting, a small amount of petrol is

injected during engine cranking.

NOTE: In the LPG mode, the following changes have

been made so the engine can operate on LPG. These

changes only effect the operation of the PCM when

operating in LPG mode.

Figure 8A2-30

INJECTOR PULSE WIDTH

The injector pulse width is set to zero in all LPG operating modes, except during engine cranking or, when the

vehicle runs in engine valve recession protection mode.

During engine crank ing the amount of petrol delivered is determ ined by the engine coolant tem perature and the

engine crank time. If the engine stalls, no petrol will be injected during cranking unless the ignition is cycled off

and on.

W hen operating in LPG mode under conditions of prolonged high speed / high load, a sm all amount of petrol is

injected into the engine to cool the valves and catalytic converter.

FUEL PUMP

To provide petrol when starting in the LPG mode, the fuel pump will run for two seconds when the ignition is

turned to the ON position and continue to run when the engine is being cranked, but will be turned off five

seconds after the engine starts.

The fuel pump will also operate under high load conditions. This allows for petrol to be injected into the engine

when the vehicle goes into the engine valve recession protection mode.

To protect the fuel pump, the PCM will switch off the fuel pump and disable the engine valve seat recession

protection mode, if ther e is less than s ix litres of f uel in the petr ol tank. T he PCM monitors the s er ial data normal

mode message to determine the amount of fuel in the petrol tank.

ELECTRONIC SPARK TIMING

The PCM has been programmed with a specific Electronic Spark Timing (EST ) map that provides optimal LPG

operation. If the engine speed drops below 300 RPM, the PCM prevents the spark plugs from firing by setting

the ignition dwell to zero.

FUEL USAGE SIGNAL OUTPUT

The PCM f uel us age output signal is us ed by the trip com puter to deter m ine the fuel c onsum ption display and is

re-calibrated to suit LPG.

ENGINE CRANKING

If the throttle opening is greater than 7% when operating in LPG mode, the PCM will prevent the engine from

cranking by not energising the starter relay.

3. SERVICE OPERATIONS

3.1 SERVICE LINE DRAINING

LT Section –

CAUTION: T he vehicle cannot be operated on LPG in the workshop, unless the workshop is a Specialist

Gas Workshop (in accordance with the current Australian Standards AS 2746-1985) and LPG is

specifically required for testing. Therefore, only at the completion of the following procedure, with the

manual service valve closed, all the LPG in the service lines exhausted and the vehicle running on

petrol, can the vehicle be driven into the workshop.

1. Park the vehicle in a well ventilated area, away from any ignition source when performing this operation.

2. For Sedan, open the rear compartment lid (A).

For Wagon, open the liftgate and raise the rear compartment floor carpet (B).

For Utility, open the access cover on the LPG tank cover (C).

Refer to Figure 8A2-31.

Figure 8A2-31

3. Remove or open the LPG tank valve box cover.

4. T urn the manual s ervice valve off in the dir ection shown (1), ref er to Figure 8A2-32, (A) Sedan, ( B) W agon,

CAUTION: If at any time the manual service valve becomes stuck, no service operations on the system

will be possible. Should for any reason the valve stick, the tank will have to be returned to the tank

manufacturer (APA) to arrange a replacement tank.

Contact: APA Industries, 190 Colchester Road, Kilsyth, Victoria 3137.

Phone - (03) 9720 2855, Fax - (03) 9761 4495, E-mail - [email protected].au

Figure 8A2-32

5. If required, press the f uel m ode switch (1) to place

the vehicle in LPG m ode. With the ignition on, the

LPG icon should be displayed on the instrument

cluster multi-function display.

6. Start the engine and allow to run on LPG until the

engine stalls, then crank the engine several times

to ensure the service lines are empty of LPG.

7. Press the fuel mode switch again to place the

vehicle in petrol mode. With the ignition on, the

LPG icon should not be displayed on the

instrument cluster multi-function display.

8. Disconnect the battery earth lead before

performing any service operations.

NOTE: If it is not possible to start and run the engine

out of LPG, the service lines should be cracked open

to allow them to be em ptied of LPG in accordance with

the current Australian Standards AS 2746 - 1985.

Figure 8A2-33

3.2 LPG TANK UNLOADING

LT Section –

1. Park the vehicle in a well ventilated area, away

from any ignition source.

2. Drain the LPG service lines, refer to

3.1 SERVICE LINE DRAINING.

3. Disconnect the battery earth lead and ensure the

manual service valve is turned off.

4. Disconnect the rear service line from the LPG

tank, refer to 3.15 REAR SERVICE LINE.

5. Connect an Apollo LPG pum p or equivalent to the

manual service valve assembly connection. Refer

to 10. SPECIAL TOOLS for further pump details.

6. Open the manual service valve and pump-out the

LPG tank, following the instructions provided by

the LPG pump manufacturer for the particular

pump you are using and in accordance with the

current Australian Standards AS 2746-1985.

CAUTION: The LPG tank must be pumped-out until

completely empty.

7. W hen the LPG tank is com pletely empty, close the

manual service valve and disconnect the pump.

8. Carefully open the manual service valve.

9. Remove the wiring connections from the tank fuel

gauge assembly.

10. Remove the smart unit and solenoid valve

from the manual service valve, refer to

3.8 SMART UNIT & SOLENOID VALVE.

11. Remove the filler line from the AFL valve, refer to

the 3.5 FILLER LINE.

Figure 8A2-34

12. Loosen the tank fuel gauge assembly retaining

screw (1), four places, one turn, Sedan shown,

Wagon and Utility similar.

13. Rock the tank fuel gauge assembly to relieve any

residual pressure in the LPG tank.

14. Continue to loosen the tank fuel gauge assembly

screws one turn at a time. Continue rocking the

tank fuel gauge assembly to ensure the LPG tank

has no residual pressure.

15. Completely remove the tank fuel gauge assembly

screws.

16. Remove the tank fuel gauge assembly (2), being

careful not to damage the float.

17. Purge the LPG tank with nitrogen to ensure there

is no residue of LPG in the tank.

CAUTION: After any valve or component has been

removed and reinstalled to the LPG tank, the LPG

tank must be pressure and leak tested in

accordance with the current Australian Standard

AS 2030-1 before the LPG tank is returned to

service.

18. If required, reinstall the tank fuel gauge assembly,

refer to 3.13 TANK FUEL GAUGE ASSEMBLY.

Figure 8A2-35

3.3 LEAK TESTING

LT Section – AA-650Q

The f ollowing leak test procedure is to be perf orm ed on the LPG s ystem high-pr essur e com ponents and is to be

performed at each normal maintenance service.

IMPORTANT: The leak test is to be perform ed in the open air in a well-ventilated area, away from any ignition

source and prior to bringing the vehicle into the workshop.

COMBUSTIBLE GAS DETECTORS

If a combustible gas detector is to be used for leak

testing of the LPG system, the combustible gas

detector should be capable of detecting 25 parts per

million (PPM) of LPG in air. A detector such as a LD-

9001 LP Gas Leak Detector or equivalent is

recommended.

Whichever leak detector is used, it is important to

follow the manufacturer's instructions in regard to

adjustment and setting the instrument prior to

conducting the leak test.

Care in interpretation is necess ary, as the detector can

respond to the pres ence of any of several vapours that

are com bus tible, som e of which m ay not be LPG, such

as oil smears, joining compounds, etc. It may also

detect residual LPG vapours that are present for

reasons other than leakage, and which must be

cleared before a valid test for leakage can be made.

If a leak is present, a detector will signal its existence

but not its size, and will indicate its general location,

but may not be able to locate it exactly. A proving or

follow up check with foam is often desirable.

Figure 8A2-36

FOAM

If foam is to be used, the foaming agent should be a

propriety leak test solution, formulated specifically for

the purpose, such as Gameco Leak Check TM or a

similar solution.

The solution should be fr esh and the whole of the ar ea

to be tested should be coated, and time allowed for

bubbles to form. All areas under test must be able to

be observed during the leak test.

Whichever foaming agent is used, it is important to

follow the manufacturer's instructions.

Foam testing is more effective for small leaks. Large

leaks tend to blow the solution away from the leak

without forming a bubble, so care in application is

necessary.

The leak test is performed by directing a spray of

solution at each of the pos sible leak points in the high-

pressure side of the system.

After applying the solution, look carefully for no less

than 15 seconds.

A leak is indicated by the presence of gas bubbles

(foaming) in the solution at the leak source

Figure 8A2-37

NOTE: LPG is heavier than air so test thoroughly below all components and fittings.

If a leak is detected at a joint, the relevant component/s must be removed as described in the appropriate service

operation in this Section. All mating threads must be thoroughly cleaned, then resealed using the specified

sealant and tightened to the specified torque. Once installed, thoroughly leak test the component/s again.

At the completion of each test, dry the leak test area of the foam ing agent with low-pressure com pressed air or

shop cloths and spray the immediate area with a water-dispersing agent such as WD40 or RP7, etc.

LEAK TEST PROCEDURE

With 3 litres of LPG in the LPG tank, leak test the complete LPG system following the instructions.

1. Park the vehicle in a dry, well ventilated area.

CAUTION: Do not smoke or allow naked flames or any ignition source near the vehicle during the testing

operations.

2. Ensure the vehicle is operating on LPG and run the engine for at least 30 seconds to fully pressurise the

system, then stop the engine.

3. Perform the following test sequence, referring to Figure 8A2-38 – Sedan, 8A2-39 – Wagon or 8A2-40 –

Utility:

View A

Remove the valve box cover and leak test at and around the:

• Pressure relief valve (1)

• AFL to LPG tank (2)

• AFL inlet elbow to the AFL (3)

• Filler line to the AFL inlet elbow connection (4)

• Tank fuel gauge assembly (5)

• Manual service valve assembly to the LPG tank (6)

• Manual service valve assembly (7)

• Rear service line to the manual service valve assembly elbow connection (8)

View B

Open the fuel filler door and leak test at and around the:

• Filler valve check ball (9)

Wagon & Utility only:

• Leak test at and around the filler valve to filler line connecting pipe (10)

Sedan: Remove the right-hand quarter inner rear side carpet, refer to 2.17 QUART ER INNER REAR SIDE

CARPET in Section 1A8.

W agon: Rem ove the right-hand r ear wheelhouse liner, refer to 3.2 REAR WHEELHOUSE LINER in Section

1A1.

Utility: Remove the lower vent hose clamp at the flange and pull back the hose to expose the filler line

connection.

• Leak test at and around the filler line connecting pipe to the filler line (11)

View C

Raise the rear of the vehicle and support on safety stands, refer to Section 0A GENERAL INFORM ATION

for the location of jacking points. Leak test at around the:

Utility: Remove the connection protector plate, refer to 3.15 REAR SERVICE LINE.

• Rear service line to rear service line joiner or elbow (12)

• Rear service line joiner or elbow to intermediate service line (13)

View D

Leak test in the engine compartment at and around the:

• Intermediate service line to front service line joiner (14)

• Front service line joiner to front service line (15)

View E

Leak test in the engine compartment at and around the:

• Front service line to lock-off inlet connection (16)

• Lock-off inlet connection to lock-off valve (17)

• Lock-off valve to lock-off outlet connection (18)

• Lock-off outlet connection to converter (19)

• Lock-off valve assembly (20, 21, 22)

• Converter mounting faces (23

Sub-compartment

The sub compartment including the vent hoses are incorporated into the system so that in the event any

LPG es c apes from the tank f ittings, press ure r elief valve or the s ervic e line c onnection the LPG is allowed to

vent to the atm osphere and not into the passenger compartm ent of the vehicle. It is im perative that the sub

compartment and hoses are checked at regular intervals in accordance with AS 1425-1999.

A compartment or sub compartment shall be tested to ensure that it is gastight to the vehicle interior by

blowing tracer gas into the compartment or sub compartment and testing the surrounding atmosphere for

gas leak age with a c ombustible gas detec tor. Passages between the compar tment and the outs ide air s uch

as ventilation provisions or an access hatch or door of a permanently inbuilt compartment, shall be sealed

during testing.

If any leakage is detected, the leak shall be rectified and the leak test is to be repeated.

If any leaks are detec ted, at the com pletion of the leak tes t close the m anual service valve, s tart the engine and

run the engine until all the LPG in the service line is exhausted. W ith the engine stopped, switch to petrol and

start the engine. The vehicle can now be driven into the workshop and any leaks rectified by referring to the

appropriate service procedures in 3. SERVICE OPERATIONS.

NOTE: The vehicle cannot be operated on LPG in the workshop unless the workshop is a Specialist Gas

Workshop, refer to Australian Standard AS 2746-1985.

SEDAN

Figure 8A2-38

Legend

1. Pressure Relief Valve 12. Rear Service Line Joiner to Intermediate Service Line

2. Automatic Fill Limiter (AFL) to LPG Tank 13. Intermediate Service Line to Front Service Line Joiner

3. AFL Inlet Elbow to AFL 14. Front Service Line Joiner to Front Service Line

4. Filler Line to AFL Inlet Elbow 15. Front Service Line to Lock-off Inlet Connection

5. LPG Tank Fuel Gauge Assembly 16. Lock-off Inlet Connection to Lock-off Valve

6. Manual Service Valve to LPG Tank 17. Lock-off Valve to Lock-off Outlet Connection

7. Manual Service Valve Assembly 18. Lock-off Outlet Connection to Converter

8. Rear Service Line to Manual Service Valve 19. Lock-off Valve Assembly

9. Filler Valve Check Ball 20. Lock-off Valve Assembly

10. Not Applicable for Sedan 21. Lock-off Valve Assembly

11. Filler Line to Filler Valve 22. Converter Mounting Faces

WAGON

Figure 8A2-39

Legend

1. Pressure Relief Valve 13. Rear Service Line Elbow to Intermediate Service Line

2. Automatic Fill Limiter (AFL) to LPG Tank 14. Intermediate Service Line to Front Service Line Joiner

3. AFL Inlet Elbow to AFL 15. Front Service Line Joiner to Front Service Line

4. Filler Line to AFL Inlet Elbow 16. Front Service Line to Lock-off Inlet Connection

5. LPG Tank Fuel Gauge Assembly 17. Lock-off Inlet Connection to Lock-off Valve

6. Manual Service Valve to LPG Tank 18. Lock-off Valve to Lock-off Outlet Connection

7. Manual Service Valve Assembly 19. Lock-off Outlet Connection to Converter

8. Rear Service Line to Manual Service Valve 20. Lock-off Valve Assembly

9. Filler Valve Check Ball 21. Lock-off Valve Assembly

10. Filler Valve to Filler Line Connecting Pipe 22. Lock-off Valve Assembly

11. Filler Line Connecting Pipe to Filler Line 23. Converter Mounting Faces

12. Rear Service Line to Rear Service Line Elbow

UTILITY

Figure 8A2-40

Legend

1. Pressure Relief Valve 13. Rear Service Line Elbow to Intermediate Service Line

2. Automatic Fill Limiter (AFL) to LPG Tank 14. Intermediate Service Line to Front Service Line Joiner

3. AFL Inlet Elbow to AFL 15. Front Service Line Joiner to Front Service Line

4. Filler Line to AFL Inlet Elbow 16. Front Service Line to Lock-off Inlet Connection

5. LPG Tank Fuel Gauge Assembly 17. Lock-off Inlet Connection to Lock-Off Valve

6. Manual Service Valve to LPG Tank 18. Lock-off Valve to Lock-off Outlet Connection

7. Manual Service Valve Assembly 19. Lock-off Outlet Connection to Converter

8. Rear Service Line to Manual Service Valve 20. Lock-off Valve Assembly

9. Filler Valve Check Ball 21. Lock-off Valve Assembly

10. Filler Valve to Filler Line Connecting Pipe 22. Lock-off Valve Assembly

11. Filler Line Connecting Pipe to Filler Line 23. Converter Mounting Faces

12. Rear Service Line to Rear Service Line Elbow

3.4 FILLER VALVE & CONNECTOR PIPE

LT Section – AA-650R

SEDAN

REMOVE

CAUTION: Ensure that there are no naked flames or other sources of ignition in the vicinity.

1. Drain the service lines of LPG and note all cautions, refer to 3.1 SERVICE LINE DRAINING.

2. Remove the r ight-hand quar ter inner rear s ide carpet, ref er to 2.17 QUARTER INNER REAR SIDE CARPET

in Section 1A8.

3. From within the rear c om partm ent, loosen the vent

tube clamp (1) and pull the vent tube (2) from the

filler valve flange (3).

4. Crack open the filler line connector (4) from the

filler valve (5) and allow any residual gas to

escape.

CAUTION: The filler line may contain LPG under

pressure.

5. Once the LPG in the line has dispersed, unscrew

the filler line connector completely and move the

filler line and vent tube away from the filler valve

flange.

6. Remove the two screws ( 6) and washers attac hing

the filler valve flange to the fuel filler housing.

7. Us ing a flat-blade screwdriver , prise the filler valve

flange from the fuel filler housing to break the

silicone sealer.

8. Remove the filler valve nut (7) and spacer (8) and

remove the filler valve.

Figure 8A2-41

REINSTALL

Installation if the filler valve is the reverse of the removal procedure, noting the following:

1. If new m ounting holes are r equired, use the tem plate supplied with the new part. Carefully drill the holes and

apply paint to any bare metal.

2. Clean the mating threads on the filler line and filler valve connector pipe.

3. Install the filler valve and tighten the retaining nut to the specified torque.

4. Apply silicone sealer to the mating surface of the filler valve flange.

5. Tighten the filler valve flange screws to the specified torque.

FILLER VALVE

RETAINING NUT

TORQUE SPECIFICATION 50.0 – 60.0 Nm

FILLER VALVE FLANGE

ATTACHING SCREW

TORQUE SPECIFICATION 7.0 – 9.0 Nm

6. Apply Loctite 577 sealant to the filler line and filler valve threads.

7. Tighten the filler line connector to the specified torque.

8. Leak test the LPG system, refer to 3.3 LEAK TESTING.

9. Reinstall the filler line vent tube and tighten the clamp to the specified torque.

WAGON

REMOVE

CAUTION: Ensure that there are no naked flames or other sources of ignition in the vicinity.

1. Drain the service lines of LPG and note all cautions, refer to 3.1 SERVICE LINE DRAINING.

2. Remove the right-hand quarter inner trim panel, refer to Section 1A8, 3.11 QUARTER INNER TRIM

PANEL.

3. Remove the right-hand rear wheelhouse liner, refer to Section 1A1, 3.2 REAR WHEELHOUSE LINER,

EXCEPT UTILITY.

4. From within the wheelhouse, crack open the filler

line connector ( 1) while holding the connector pipe

and allow residual LPG to escape.

CAUTION: The filler line may contain LPG under

pressure.

5. Once all the LPG in the line has dispersed,

unscrew the filler line connector completely.

6. From within the vehicle, remove the nut (2) and

spacer (3) retaining the filler valve (4).

7. Prise the grommet (5) from the filler pocket and

carefully manoeuvre the filler valve and connector

pipe into the fuel filler pocket and remove.

8. If required, disconnect the connector pipe (6) from

the filler valve.

Figure 8A2-42

REINSTALL

Installation if the filler valve and connector pipe is the reverse of the removal procedure, noting the following:

1. If new mounting holes are required, us e the tem plate supplied with the new part. Carefully drill the holes and

apply paint to any bare metal.

2. Clean the mating threads on the filler line, connector pipe and filler valve.

3. Apply Loctite 577 sealant to the filler line, connector pipe and filler valve threads.

4. Tighten the filler valve retaining nut to the specified torque.

5. Tighten the filler line connectors to the specified torque.

6. Leak test the LPG system, refer to 3.3 LEAK TESTING.

FILLER VALVE RETAINING NUT

TORQUE SPECIFICATION 50.0 – 60.0 Nm

CONNECTOR PIPE TO FILLER

LINE & FILLER VALVE

TORQUE SPECIFICATION 12.0 – 18.0 Nm

FILLER LINE TO FILLER VALVE

TORQUE SPECIFICATION 12.0 – 18.0 Nm

VENT TUBE HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

UTILITY

REMOVE

CAUTION: Ensure that there are no naked flames

or other sources of ignition in the vicinity.

1. Drain the service lines of LPG and note all

cautions, refer to 3.1 SERVICE LINE DRAINING.

2. Loosen the hose clamp (1) securing the filler line

vent tube (2) to the vent tube flange (3).

3. Crack open the filler line connector (4) while

holding the connector pipe (5) and allow residual

LPG to escape.

CAUTION: The filler line may contain LPG under

pressure.

4. Once all the LPG in the line has dispersed,

unscrew the filler line connector completely.

5. Remove the inner side panel front cover, refer to

Section 1B, 2.8 INNER SIDE PANEL FRONT

COVER.

NOTE: A right-angle screwdriver may be required to

access the front screws.

6. Remove the fuel filler door and the fuel filler pipe

seal retainer, refer to Section 1A1, 4.3 FUEL

FILLER DOOR ASSEMBLY, UTILITY.

Figure 8A2-43

7. From within the vehicle, remove the nut (1) and

washer (2) while an assistant holds the screw (3),

two places, retaining the filler valve (4).

9. As required, fold the fuel filler pipe seal out of the

way and prise the grommet (5) from the filler

pocket.

10. Carefully manoeuvre the filler valve and connector

pipe into the fuel filler pocket and remove.

8. If required, disconnect the connector pipe (6) from

the filler valve.

Figure 8A2-44

REINSTALL

Installation of the filler valve and connector pipe is the reverse of the removal procedure, noting the following:

1. If new m ounting holes are r equired, use the tem plate supplied with the new part. Carefully drill the holes and

apply paint to any bare metal

2. If the filler pocket has been replaced and new mounting holes are required, use the template provided with

the new filler valve assembly. Drill holes as required and coat any bare metal with primer.

3. Clean the mating threads on the filler line, connector pipe and filler valve.

4. Apply Loctite 577 sealant to the filler line, connector pipe and filler valve threads.

5. Tighten the filler valve retaining nut to the specified torque.

FILLER VALVE RETAINING NUT

TORQUE SPECIFICATION 12.0 – 15.0 Nm

6. Tighten the filler line connectors to the specified torque.

7. Leak test the LPG system, refer to 3.3 LEAK TESTING.

8. Reinstall the filler line vent tube and tighten the clamp to the specified torque.

CONNECTOR PIPE TO FILLER

VALVE & FILLER LINE

TORQUE SPECIFICATION 12.0 – 18.0 Nm

VENT TUBE HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

3.5 FILLER LINE

LT Section – AA-650R

SEDAN

REMOVE

CAUTION: Ensure that there are no naked flames

or other sources of ignition in the vicinity.

1. Drain the service lines of LPG and note all

cautions, refer to 3.1 SERVICE LINE DRAINING.

2. From within the LPG valve box, crack open the

filler line to AFL elbow connector (1) while holding

the AFL elbow and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure.

3. Once all the LPG in the line has dispersed,

unscrew the filler line connector completely from

the AFL elbow.

4. Disconnect the filler line from the AFL elbow

connector.

5. Remove the right-hand quarter inner rear side

carpet, refer to 2.17 QUARTER INNER REAR

SIDE CARPET in Section 1A8.

Figure 8A2-45

6. From within the rear c om partm ent, loosen the vent

tube clamp (1) and pull the vent tube (2) from the

filler valve flange (3).

7. Unscrew the filler line connector (4) from the filler

valve flange.

Figure 8A2-46

8. Loosen the vent tube clamp (1) and pull the vent

tube (2) from the vent tube joiner (3).

9. Withdraw the filler line through the vent tube and

remove.

Figure 8A2-47

REINSTALL

Reinstallation of the filler line is the reverse of the removal procedure, noting the following:

1. Clean the mating threads on the LPG tank AFL elbow, filler line and filler valve connector pipe.

2. Apply Loctite 577 sealant to the LPG tank AFL elbow and filler pipe connector threads, ensuring that the

flared surfaces are free of sealant and contaminants.

3. Tighten the filler line connections to the specified torque.

4. Leak test the LPG system, refer to 3.3 LEAK TESTING.

5. Reinstall the filler line vent tube and tighten the clamp to the specified torque.

6. Reinstall the LPG tank box cover.

WAGON

REMOVE

CAUTION: Ensure that there are no naked flames

or other sources of ignition in the vicinity.

1. Drain the service lines of LPG and note all

cautions, refer to 3.1 SERVICE LINE DRAINING.

2. De-pressurise the fuel (petrol) system, refer to

Section 6C1 POWERTRAIN MANAGEMENT.

3. Remove the fuel (petrol) tank assembly, refer to

Section 8A FUEL TANK.

4. From within the LPG tank valve box, crack open

the filler line hose to AFL elbow connector (1) while

holding the AFL elbow (2) and allow residual LPG

to escape.

CAUTION: The filler line will contain LPG under

pressure.

5. Once all the LPG in the line has dispersed, remove

the filler line hose connector completely from the

AFL elbow.

Figure 8A2-48

FILLER LINE CONNECTORS

TORQUE SPECIFICATION 12.0 – 18.0 Nm

VENT TUBE HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

6. From underneath the vehicle, while holding the

filler valve connecting pipe (1) from turning,

disconnect the filler line hose (2).

7. Us ing a suitable sized drill bit, drill into the head of

the two filler line hose retaining rivets (3) and

remove the filler line hose.

8. Using a suitable size pin-punch and hammer,

knock out remains of the rivets.

Figure 8A2-49

REINSTALL

Reinstallation of the filler line is the reverse of removal, noting the following:

1. Clean the mating threads of the LPG tank AFL elbow, filler line, and filler valve connecting pipe.

2. Apply Loctite 577 sealant to the LPG tank AFL elbow and filler pipe connector threads, ensuring that the

flared surfaces are free of sealant and contaminants.

3. Tighten the filler line connections to the specified torque.

4. Secure the filler line hose using a new rivets, before the fuel (petrol) tank is reinstalled.

5. Before starting the vehicle or opening the manual service valve, perform a fuel (petrol) system leak test,

refer to Section 6C1 POWERTRAIN MANAGEMENT - V6 ENGINE.

6. Leak test LPG system, refer to 3.3 LEAK TESTING.

7. Reinstall the LPG tank valve box cover.

FILLER LINE CONNECTORS

TORQUE SPECIFICATION 12.0 – 18.0 Nm

UTILITY

REMOVE

CAUTION: Ensure that there are no naked flames

or other sources of ignition in the vicinity.

1. Drain the service lines of LPG and note all

cautions, refer to 3.1 SERVICE LINE DRAINING.

2. Remove the LPG tank cover, refer to

3.6 LPG TANK, UTILITY.

3. From within the LPG valve box, crack open the

filler line to AFL elbow connector (1) while holding

AFL elbow and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure.

4. Once all the LPG in the line has dispersed, remove

the filler line connector completely from the AFL

elbow.

Figure 8A2-50

4. Loosen the hose clamp (1) securing the filler line

vent tube (2) to the vent tube flange (3).

5. Disconnect the filler line (4) from the filler pipe (5)

and remove the LPG filler line from within vent

tube.

Figure 8A2-51

REINSTALL

Reinstallation if the filler line is the reverse of the removal procedure, noting the following:

1. Clean the mating threads of the LPG tank AFL elbow, filler line and filler valve connecting pipe.

2. Apply Loctite 577 sealant to the LPG tank AFL elbow and filler pipe connector threads, ensuring that the

flared surfaces are free of sealant and contaminants.

3. Tighten the filler line connections to the specified torque.

4. Leak test the LPG system, refer to 3.3 LEAK TESTING.

5. Apply a commercially available silicone sealer to the vent tube mating surfaces.

6. Tighten the vent tube clamps to the specified torque.

7. Reinstall the LPG tank box cover.

FILLER LINE CONNECTOR

TORQUE SPECIFICATION 12.0 – 18.0 Nm

VENT TUBE HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

3.6 LPG TANK

LT Section – AA-650Q

SEDAN

REMOVE

CAUTION 1: After any valve or component has

been removed and reinstalled to the LPG tank, the

LPG tank must be pressure and leak tested in

accordance with current Australian Standard

AS 2030-1 and / or the laws of the State in which

the vehicle is registered, before the LPG tank is

refitted to the vehicle.

CAUT ION 2: Ensure th at there are no naked flames

or other sources of ignition in the vicinity.

1. Drain the service lines of LPG and note all

cautions, refer to 3.1 SERVICE LINE DRAINING.

2. Unload the LPG tank of LPG, refer to

3.2 LPG TANK UNLOADING.

3. Disconnect the LPG body harness connector (1)

from the LPG tank harness connector.

Figure 8A2-52

4. From within the LPG valve box, crack open the

filler line to AFL elbow connector (1) while holding

the AFL elbow and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure.

5. Once all the LPG in the line has dispersed, remove

the filler line connector completely from the AFL

elbow.

Figure 8A2-53

11. From within the LPG tank valve box, unscrew the

rear service line connector (1) from the manual

service valve assembly.

Figure 8A2-54

12. As required, rem ove the hose clamps (1) securing

the vent tubes ( 2) to the valve box , vent tube j oiner

(3) or floor flange (4).

13. W ithdr aw the filler and se rvice lines fr om the valve

box.

14. If required withdraw the vent tube from the

grommet (5) and remove.

Figure 8A2-55

15. Open the rear seat centre back and remove the

top two retaining screws (1) from the LPG tank

retaining bracket (2) on each side of the vehicle.

Figure 8A2-56

16. Fold the rear compartment carpet away from the

LPG tank rear mounting points.

17. With the aid of an assistant to hold the LPG tank

retaining scr ew (1), rem ove the LPG tank retaining

nut (2) and reinforcement plate (3) from beneath

the each side of the vehicle.

18. With help f r om the assis tant, remove the LPG tank

from the rear compartment.

Figure 8A2-57

19. If required, remove the LPG tank retaining bracket:

a. Remove the rear seat back assembly, refer to

Section 1A7, 6.3 REAR SEAT-BACK

ASSEMBLY.

b. Remove the two retaining screws (1) attaching

the rear seat back centre hinge and the LPG

tank retaining bracket (2) to the vehicle and

remove the bracket from behind the hinge.

c. Repeat for the opposite side if required.

Figure 8A2-58

REINSTALL

Installation of the LPG tank is the reverse of the removal procedure, noting the following:

1. If removed, install the front tank mounting brackets and rear seat-back hinges. Tighten the screws to the

specified torque.

2. If the floor panel, etc. has been replaced and new mounting holes are required, seat the tank to the front

mounting brackets and use the tank as a template. Drill holes as required and coat any bare metal with

primer.

3. Ensure the two LPG tank reinforcement plates are installed and all fasteners are tightened to the correct

specified torque.

4. Clean the mating threads on the manual service valve assembly, intermediate to rear service line joiner,

both rear service line connectors, AFL valve and filler line connector.

5. Apply Loctite 577 sealant to the intermediate to rear service line joiner threads, ensuring that the flared

surfaces are free of sealant and contaminants.

6. Assemble the rear service connector to intermediate to rear service line joiner and to the manual service

valve assembly.

7. Tighten both rear service line connectors to the specified torque.

8. Apply Loctite 577 sealant to the LPG tank AFL elbow threads, ensuring that flared surfaces are free of

sealant and contaminants.

9. Install the filler line c onnector to the LPG tank AF L elbow and tighten the filler line c onnector to the s pecif ied

torque.

10. Leak test the LPG system, refer to 3.3 LEAK TESTING.

11. Reinstall the vent tube(s) as required and tighten the clamp(s) to the specified torque.

12. Reinstall the LPG tank box cover

FRO NT LPG TANK R ETAINING

SCREW TORQUE SPECIFICATION 10.0 – 12.0 Nm

REAR LPG TANK RETAINING NUT

TORQUE SPECIFICATION 70.0 – 90.0 Nm

REAR SERVICE LINE CONNECTOR

TORQUE SPECIFICATION 12.0 – 18.0 Nm

FILLER LINE CONNECTOR TO AFL

ELBOW TORQUE SPECIFICATION 12.0 – 18.0 Nm

FRONT LPG TANK MOUNTING

BRACKET RETAINING SCREW

TORQUE SPECIFICATION 25.0 – 35.0 Nm

VENT TUBE HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

WAGON

REMOVE

CAUTION 1: After any valve or component has

been removed and reinstalled to the LPG tank, the

LPG tank must be pressure and leak tested in

accordance with current Australian Standard

AS 2030-1 and / or the laws of the State in which

the vehicle is registered, before the LPG tank is

refitted to the vehicle.

CAUT ION 2: Ensure th at there are no naked flames

or other sources of ignition in the vicinity.

1. Remove the rear compartment floor carpet, refer

to Section 1A8, 3.21 REAR COMPARTMENT

FLOOR CARPET ASSEMBLY AND SPARE

WHEEL COVER, WITH LPG.

2. Drain the service lines of LPG and note all

cautions, refer to 3.1 SERVICE LINE DRAINING.

3. Unload the LPG tank of LPG, refer to

3.2 LPG TANK UNLOADING.

NOTE: The service line will be disconnected at this

step.

4. Disconnect the LPG tank harness wiring connector

(1) from underneath the vehicle.

Figure 8A2-59

5. From within the LPG valve box, crack open the

filler line to AFL elbow connector (1) while holding

the AFL elbow and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure.

6. Once all the LPG in the line has dispersed, remove

the filler line connector completely from the AFL

elbow.

Figure 8A2-60

7. Remove the Torx screw (1), two places, attaching

the valve box flange (2) to the LPG tank.

8. Pull the valve box flange and seal (3) away from

the LPG tank so that there is sufficient clearance

to remove the LPG tank.

9. With the aid of an assistant, remove the left-hand

front LPG tank retaining bolt (1), washer (2) and

from underneath the vehicle the nut (3) and plate

(4), refer to Figure 8A2-62.

10. Loosen and remove the two lock-nuts, (5, 6 & 7),

three places, attaching the LPG tank to the LPG

tank brackets.

11. With the aid of an assistant, lift the LPG tank up

and remove from the vehicle.

12. Remove the isolator (8) and washer (9) and if

required the spacer (10).

Figure 8A2-61

Figure 8A2-62

13. As required, with the aid of an ass istant remove the nut, ( 1), plate (2), bolt (3) and washer (4) attaching the

LPG tank mounting brackets (A, B &/or C), refer to Figure 8A2-63.

NOTE: The mounting bracket (A) and its washer (A-4) are seated under the spare wheel carrier (5).

14. Once the bracket(s) are removed, remove the isolator (6), washer (7) and spacer (8) from the floor box-

section.

Figure 8A2-63

Legend

A. Right-hand Front LPG Tank Mounting Bracket 4. Washer

B. Right-hand Rear LPG Tank Mounting Bracket 5. Spare Wheel Carrier

C. Left-hand Rear LPG Tank Mounting Bracket 6. Isolator

1. Nut 7. Washer

2. Reinforcement Plate 8. Spacer

3. Bolt

REINSTALL

1. If the floor panel, etc . has been replac ed and new mounting holes are required, align the tank assem bly with

the spare wheel carrier at position A, refer to Figure 8A2-63, seat the tank centrally within the spare wheel-

well, use the tank as a template and ens ure the holes are central within the floor ribs. Drill holes as required

and coat any bare metal with primer.

• Position B, C and D – 12 mm hole through the floor panel and rear chassis rail followed by a 17 mm hole

in the floor panel only.

NOTE: For drilling details of position A and the spare wheel carrier refer to 3.25 SPARE WHEEL CARRIER.

2. If the mounting brackets have been removed, install them as required, referring to Figure 8A2-63. Hand

tighten the nuts at this stage.

3. If required, install the spacer for the left-hand front mount.

4. With the aid of an assistant, place the tank onto the LPG tank bracket studs, six places. Hand tighten the

nuts.

5. W ith the aid of an as sistant, install the lef t-hand f ront retaining bolt, and nut, ens uring the spac ers, is olators,

washers and reinforcement plates are installed correctly, refer to Figure 8A2-62.

6. While holding the retaining bolt, tighten all of the retaining nuts to the specified torque.

7. Install the valve box f lange, ensuring the valve box seal is s eated corr ectly. Tighten the two valve box flange

retaining screws to the specified torque.

8. Clean the mating threads on the manual service valve assembly, intermediate to rear service line joiner,

both rear service line connectors, AFL valve and filler line connector.

9. Apply Loctite 577 sealant to the intermediate to rear service line joiner threads, ensuring that the flared

surfaces are free of sealant and contaminants.

10. Assemble the rear service connectors to the intermediate service line joiner and the manual service valve

assembly.

11. Tighten both rear service line connectors to the specified torque.

12. Apply Loctite 577 sealant to the LPG tank AFL elbow threads, ensuring that flared surfaces are free of

sealant and contaminants.

13. Install the f iller line c onnector to the LPG tank AF L elbow and tighten the filler line c onnector to the s pecif ied

torque.

14. Leak test the LPG system, refer to 3.3 LEAK TESTING.

15. Reinstall the valve box cover.

16. Reinstall the luggage com par tm ent floor c over, ref er to Sect ion 1A8, 3.21 REAR COM PAR TM ENT FL OOR

COMPARTMENT ASSEMBLY & SPARE WHEEL COVER, WITH LPG.

UTILITY

REMOVE

CAUTION 1: After any valve or component has been removed and reinstalled to the LPG tank, the LPG

tank must b e pressure and leak test ed in accordance w ith curren t Au stralian Standard AS 2030-1 befo re

the LPG tank is refitted to the vehicl e.

CAUTION 2: Ensure that there are no naked flames or other sources of ignition in the vicinity.

LPG TANK RETAINING NUT

TORQUE SPECIFICATION 40.0 – 50.0 Nm

VALVE BOX ATTACHING SCREW

TORQUE SPECIFICATION 7.0 Nm

REAR SERVICE LINE CONNECTOR

TORQUE SPECIFICATION 12.0 – 18.0 Nm

FILLER LINE CONNECTOR

TO AFL ELBOW

TORQUE SPECIFICATION 12.0 – 18.0 Nm

1. Rem ove the Tor x sc rew (1), six places, attac hing the LPG tank c over (2) to the vehic le. Pull back the upper

edge of the tank cover slightly, refer to Figure 8A2-64.

2. Lift the tank cover upwards until the lower inner retainer grommet (3) disengages from ball stud (4) at four

places.

3. Remove the cover.

Figure 8A2-64

4. Drain the service lines of LPG and note all

cautions, refer to 3.1 SERVICE LINE DRAINING.

5. Unload the LPG tank of LPG, refer to

3.2 LPG TANK UNLOADING.

6. From within the LPG valve box, while holding the

AFL elbow, crack open the filler line to AFL elbow

connector (1) and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure.

7. Once all the LPG in the line has dispersed, remove

the filler line connector completely from the AFL

elbow.

Figure 8A2-65

8. From within the LPG valve box, disconnect the

service line connector (1) from the manual service

valve elbow.

Figure 8A2-66

9. Rem ove the hos e clam p (1) securing the vent tube

(2) to the tank valve box.

10. Withdraw the LPG service (3) and filler lines (4)

from the valve box.

11. Disconnect the LPG tank harness connector (5)

from the LPG body wiring harness connector.

Figure 8A2-67

12. Loosen the upper nut (1) and lower nut (2)

securing the LPG tank strap (3).

13. Completely remove the lower nut and washer (4).

14. Remove the upper nut, washer (5) and screw (6)

and remove the strap.

15. Repeat for each LPG tank strap.

16. With the aid of an ass istant, rem ove the LPG tank ,

manoeuvring the left-hand side rearward to

provide clearance for the vent tube.

Figure 8A2-68

17. If required, remove the nut (1) and washer (2)

attaching the upper connecting plate (3) to the

lower connecting bar (4).

18. Remove the load floor front panel assembly,

refer to 2.7 LOAD FLOOR FRONT PANEL

ASSEMBLY, UTILITY in Section 1B.

Figure 8A2-69

19. Rem ove the nut (1), washer (2) and screw (3), two

places, attaching the upper connecting plate (4) to

the load floor front panel assembly.

20. Remove the plate.

Figure 8A2-70

21. Rem ove the nut (1) , washer ( 2) and s c rew (3), four

places, attaching the tank support bracket (4) and

the backing bar (5), two places, to the load floor

front panel assembly.

22. Remove the support bracket and backing bar.

Repeat as required.

Figure 8A2-71

REINSTALL

Installation of the LPG tank and support assembly is the reverse of the removal procedure, noting the following:

1. If the floor panel, etc. has been replaced and new mounting holes are required, use the old floor as a

reference and the tank as a template. Drill holes as required and coat any bare metal with primer.

2. If removed, reins tall the tank cover ball s tuds (4) , r ef er to Figure 8A2-64. Tighten the nuts (5) to the specif ied

torque.

3. Install the support brackets and connecting plates in the reverse of removal.

4. Tighten the nuts to the specified torque.

5. Install the LPG tank into support brackets. Install the three LPG tank retaining straps, and all retaining

screws, washers and nuts.

6. Tighten to the nuts to the specified torque.

7. Clean the mating threads on the m anual servic e valve assem bly, rear service line connector, AFL valve and

filler line connector.

8. Apply Loctite 577 sealant to the rear service line connector threads, ensuring that the flared surfaces are

free of sealant and contaminants.

9. Assemble the rear service connector to the manual service valve assembly.

10. Tighten the rear service line connector to the specified torque.

11. Apply Loctite 577 sealant to the LPG tank AFL elbow threads, ensuring that flared surfaces are free of

sealant and contaminants.

12. Install the f iller line c onnector to the LPG tank AF L elbow and tighten the filler line c onnector to the s pecif ied

torque.

13. Reconnect the LPG body wiring harness connector to LPG tank connector.

14. Leak test LPG system, refer to 3.3 LEAK TESTING.

15. Apply a commercially available silicone sealant to the vent tube mating surface.

16. Tighten vent tube clamps to specified torque.

17. If required, install new Nutserts (6) with a commercially available Nutsert gun, refer to Figure 8A2-64.

18. Reinstall the LPG tank cover onto the locating studs.

19. Install the LPG tank cover upper retaining screws, six places and tighten to specified torque.

TANK SUPPORT BRACKET AND

UPPER CONNECTING

PLATE RETAINING NUT

TORQUE SPECIFICATION 40.0 – 50.0 Nm

LPG TANK STRAP RETAINING NUT

TORQUE SPECIFICATION 40.0 – 50.0 Nm

REAR SERVICE LINE CONNECTOR

TORQUE SPECIFICATION 12.0 – 18.0 Nm

VENT TUBE HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

FILLER LINE CONNECTOR

TORQUE SPECIFICATION 12.0 – 18.0 Nm

LPG TANK COVER UPPER

RETAINING SCREW

TORQUE SPECIFICATION 10.0 – 12.0 Nm

TANK COVER BALL STUD NUT

TORQUE SPECIFICATION 3.0 – 5.0 Nm

3.7 VENT TUBE FLANGE

LT Section –

SEDAN

REMOVE

1. Remove the LPG tank, refer to 3.6 LPG TANK –

SEDAN.

2. Using a suitable sized drill bit, remove the heads of

the rivet (1) attaching the vent tube flange (2) in

three places.

3. Prise the flange from the floor to break the

sealer (3).

NOTE: On later model vehicles, the vent tube flange

attaches to the floor in the same location but the rib in

the floor pan has been removed.

Figure 8A2-72

REINSTALL

1. If the floor panel has been replaced, align the vent tube flange in the position shown in Figure 8A2-72,

behind the floor join and on the floor rib.

2. Mark the holes and carefully drill three 5 mm holes for the rivets and a 51 mm hole. Clean up all drilling

swarf and prime any bare metal.

NOTE: If the rear side rail assembly has been replaced, also drill a 21 mm in the rail from the underside of the

vehicle, central to the flange hole.

3. Apply silicone sealer to the underside of the flange and install with three new rivets.

WAGON

REMOVE

CAUTION: Ensure that there are no naked flames

or other sources of ignition in the vicinity.

1. Remove the rear compartment floor carpet, refer

to Section 1A8, 3.21 REAR COMPARTMENT

FLOOR CARPET ASSEMBLY AND SPARE

WHEEL COVER, WITH LPG.

2. Drain the service lines of LPG and note all

cautions, refer to 3.1 SERVICE LINE DRAINING.

3. From within the LPG valve box, crack open the

filler line to AFL elbow connector (1) while holding

the AFL elbow and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure.

4. Once all the LPG in the line has dispersed, remove

the filler line connector completely from the AFL

elbow.

Figure 8A2-73

5. From within the LPG tank valve box, unscrew the

rear service line connector (1) from the manual

service valve assembly.

Figure 8A2-74

6. Disconnect the LPG tank harness wiring connector

(1) from underneath the vehicle.

7. Loosen the clamp (2) and prise the flange (3) from

the valve box and vehicle.

8. Withdraw the filler and service lines and remove

the flange.

Figure 8A2-75

REINSTALL

1. If the floor panel has been replaced, align the flange in position.

2. Mark the hole and carefully drill a 70 mm hole. Clean up all drilling swarf and prime any bare metal.

3. Apply silicone sealer to the floor around the flange opening and install the flange.

4. Clean the rear service line mating threads on the manual service valve assembly, the rear service line

connector, AFL valve mating threads and filler line connector.

5. Apply Loctite 577 sealant to the manual service valve assembly threads and AFL valve threads, ensuring

that the flared surfaces are free of sealant and contaminants.

6. Tighten the rear service line and filler line connections to the specified torque.

7. Tighten the vent flange clamp to the specified torque.

8. Leak test the LPG system, refer to 3.3 LEAK TESTING.

REAR SERVICE LINE CONNECTION

TORQUE SPECIFICATION 12.0 – 18.0 Nm

FILLER LINE TO AFL

VALVE CONNECTION

TORQUE SPECIFICATION 12.0 – 18.0 Nm

VENT FLANGE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

UTILITY

REMOVE

CAUTION: Ensure that there are no naked flames

or other sources of ignition in the vicinity.

NOTE: For r em oval of the s ervice line vent tube flange

(in the floor) refer to 3.14 REAR SERVICE LINE –

UTILITY.

1. Drain the service lines of LPG and note all

cautions, refer to 3.1 SERVICE LINE DRAINING.

2. Remove the LPG tank cover, refer to 3.6 LPG

TANK, UTILITY.

3. From within the LPG valve box, crack open the

filler line to AFL elbow connector (1) while holding

AFL elbow and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure.

4. Once all the LPG in the line has dispersed, remove

the filler line connector completely from the AFL

elbow.

Figure 8A2-76

6. Loosen the hose clamp (1) securing the filler line

vent tube (2) to the vent tube flange (3).

5. Crack open the filler line connector (4) while

holding the filler pipe and allow residual LPG to

escape.

CAUTION: The filler line will contain LPG under

pressure.

7. Once all the LPG in the line has dispersed,

disconnect the filler line from the filler pipe.

Figure 8A2-77

8. Using a suitable sized drill bit, remove the heads of

the rivet (1) attaching the vent tube flange (2) in

four places.

9. Prise the flange from the front inner side panel

cover to break the sealer (3).

Figure 8A2-78

REINSTALL

1. If the f ront inner s ide panel cover has been r eplac ed, seat the panel cover in position and note the filler valve

connector pipe position. Mark on the panel.

2. Seat the flange on the panel cover central to the mark.

3. Mark the f lange holes on the panel c over and c ar ef ully drill f our 5 m m holes f o r the r ivets and a 22 m m hole.

Clean up all drilling swarf and prime any bare metal.

4. If required, fit the panel cover, refer to Section 1B, 2.8 FRONT INNER SIDE PANEL COVER.

5. Apply silicone sealer to the underside of the flange and install with four new rivets.

6. Clean the mating threads of the filler line and filler valve connecting pipe.

7. Apply Loctite 577 sealant to the filler pipe connector threads, ensuring that the flared surfaces are free of

sealant and contaminants.

8. Tighten the filler line connection to the specified torque.

9. Leak test the LPG system, refer to 3.3 LEAK TESTING.

10. Apply silicone sealer to the vent tube mating surfaces.

11. Tighten the vent tube clamps to the specified torque.

12. Reinstall the LPG tank box cover.

FILLER LINE CONNECTOR

TORQUE SPECIFICATION 12.0 – 18.0 Nm

VENT TUBE HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

3.8 SMART UNIT & SOLENOID VALVE

LT Section – AA-650R

REMOVE

10. Park the vehicle in a well ventilated area, away

from any ignition source.

11. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

12. Disconnect the LPG harness connector (1) from

the LPG tank, refer to Figure 8A2-79 A – Sedan

and Utility or B – Wagon.

Figure 8A2-79

13. Remove the screw (1) attaching the smart unit (2)

to the solenoid sleeve (3). Sedan shown, Wagon

and Utility similar.

14. Remove the smart unit from the solenoid sleeve.

15. Remove the solenoid sleeve from the manual

service valve (4), ensuring that the solenoid valve

(5) is also removed.

16. Separate the solenoid valve from the sleeve and

discard the O-ring (6).

17. Disconnect the wiring connectors from the tank

gauge.

NOTE: To aid disconnection of the connectors,

remove the two screws attaching the contents gauge.

If required, refer to 3.13 TANK FUEL GAUGE

ASSEMBLY – CONTENTS GAUGE.

Figure 8A2-80

REINSTALL

Installation of the smart unit & solenoid valve to the manual service valve is the reverse of removal noting the

following:

1. Fit a new O-ring to the solenoid sleeve.

2. Tighten the solenoid sleeve to the specified torque.

3. Once installed, ensure that the smart unit retaining screw is tightened to the specified torque.

4. Leak test LPG system, refer to 3.3 LEAK TESTING.

SOLENOID SLEEVE

TORQUE SPECIFICATION 15.0 – 18.0 Nm

SMART UNIT RETAINING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

3.9 MANUAL SERVICE VALVE ASSEMBLY

LT Section – AA-650R

CAUTION: If at any time the manual service valve becomes stuck, no service operations on the system

will be possible. Should for any reason the valve stick, the tank should be returned to the tank

manufacturer (APA) to arrange a replacement tank.

Contact: APA Industries

190 Colchester Road

Kilsyth, Victoria. 3137

Phone - (03) 9720 2855

Fax - (03) 9761 4495

Email - [email protected].au

NOTE: The manual service valve is three valves in one. A manual shut off valve, an electrically operated

solenoid valve and an excess flow valve.

EXCESS-FLOW VALVE

TEST

CAUTION: Ensure there are no naked flames or

other sources of ignition in the vicinity.

Ensure all safety precautions listed at the front of

this manual are adhered to while performing this

test.

Do not perform this test on a vehicle with a hot

engine.

1. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

2. Remove the smart unit and solenoid valve

assembly, refer to 3.8 SMART UNIT &

SOLENOID VALVE.

3. Reinstall the solenoid sleeve (1) and O-ring (2),

without the solenoid valve (3), onto the manual

service valve (4).

4. Disconnect the front service line at the lock-off

valve to allow LPG to flow from this line when the

manual service valve is opened, refer to

3.14 FRONT SERVICE LINE.

5. Quickly open the manual service valve and listen

for the sound of the excess-flow valve operating.

6. If the excess flow valve is operating correctly, it

can be heard to click shut when the manual

service valve is opened quickly.

CAUTION: To ensure that the least amount of LPG

escapes into the atmosphere, only open the

manual serv ice v alve for th e minimal time po ssible

to perform this test.

7. Reins tall the front service line to the lock-o ff valve,

refer to the reins tallation pr oc edure in 3.14 FRONT

SERVICE LINE.

Figure 8A2-81

8. Remove the solenoid sleeve from the manual

service valve.

9. Reinstall the solenoid valve, solenoid sleeve and

smart unit, refer to 3.8 SMART UNIT &

SOLENOID VALVE.

10. Leak test the LPG system, refer to 3.3 LEAK

TESTING.

REMOVE

1. Park the vehicle in a well ventilated area, away from any ignition source.

2. Drain the service lines of LPG, refer to 3.1 SERVICE LINE DRAINING.

3. Unload the LPG tank of LPG, refer to 3.2 LPG TANK UNLOADING.

4. Disconnect the LPG harness connector (1) from the LPG tank, refer to Figure 8A2-82 (A) Sedan, Utility

similar or (B) Wagon.

Figure 8A2-82

5. Push the LPG tank harness back into the tank

valve box area.

6. Remove the solenoid assembly from the manual

valve, refer to 3.8 SMART UNIT & SOLENOID

VALVE.

7. Unscrew the four screws (1) attaching the m anual

service valve (2) to the tank and remove the

manual service valve.

NOTE: Typical manual service valve shown.

Figure 8A2-83

REINSTALL

1. Install the new manual service valve ensuring a new sealing ring (3) is fitted.

NOTE: Install the valve so that the service line connection elbow is correctly orientated.

2. Install the manual service valve attaching screws and tighten to the specified torque.

3. Reconnect the LPG body wiring harness connector to LPG tank harness connector and reinstall grommet.

4. Reinstall the rear service line, refer to 3.15 REAR SERVICE LINE.

5. Pressure and leak test the LPG tank in accordance with the current Australian Standard AS 2030-1.

6. Leak test the LPG system, refer to 3.3 LEAK TESTING.

MANUAL SERVICE VALVE

ATTACHING SCREW

TORQUE SPECIFICATION 5.0 – 7.0 Nm

3.10 PICK-UP PIPE & STRAINER

LT Section –

REMOVE

1. Remove the solenoid and manual service valve,

refer to 3.9 MANUAL SERVICE VALVE

ASSEMBLY.

2. Remove the two screws (1) retaining the LPG

pick -up pipe and strainer ( 2) to the m anual service

valve (3).

3. Twist the pick-up pipe out of manual service valve.

REINSTALL

Installation of the LPG pick-up pipe and strainer is the

reverse of removal. Ensure the O-ring on the end of

the pick-up pipe is correctly installed.

Figure 8A2-84

3.11 AUTOMATIC FILL LIMITER (AFL)

LT Section – AA-650Q

TEST

NOTE 1: When performing this test, the vehicle must

be on level ground.

NOTE 2: For Wagon vehicles remove the smart unit,

refer to 3.8 SMART UNIT & SOLENOID VALVE.

1. Fill the LPG tank until the autom atic fill limiter cuts

off.

2. Check the LPG contents gauge at the tank.

• If the gauge reads approximately 80% full ±

3% (A) the automatic fill limiter is operating

correctly.

• If the gauge is reading outside this

specification, the remaining part of this

procedure must be performed.

NOTE: Bounc e the vehicle a couple of tim es to ensur e

accuracy when checking the gauge reading.

3. If the gauge reading was out of specification, the

vehicle must be operated on LPG until the LPG

tank is completely empty.

NOTE 1: Advise the vehicle operator that the vehicle

should be operated on LPG until the LPG tank is

completely empty. Once emptied, the vehicle should

then be returned for inspection on petrol.

NOTE 2: It is not pos s ible to switch the f uel mode f r om

LPG to petrol while the vehicle is moving. Therefore,

the vehicle operator must select a location where

running out of LPG will not present a traffic hazard or

danger.

4. Check the fuel contents gauge on the LPG tank is

displaying empty and the engine will not start with

the vehicle in LPG mode.

5. Fill the LPG tank and note the number of litres

taken. The LPG tank fillable capacity is:

• Sedan – 74 litres ± 2 litres

• Wagon – 60 litres ± 2 litres

• Utility – 70 litres ± 2 litres

Any more indicates a faulty AFL.

Figure 8A2-85

NOTE 1: If the LPG tank is overfilled, the contents of the tank must be reduced to a safe level. This can be

achieved by either running the engine NON-STOP on LPG for sufficient time to consume the excess fuel, or

removing the excess fuel from the LPG tank, refer to 3.2 LPG TANK UNLOADING.

NOTE 2: If the LPG tank fillable capacity is within the specified limits, yet the initial test failed (the gauge was

reading outside the specified parameters), check the calibration of the contents gauge. Refer to 3.13 TANK

FUEL GAUGE ASSEMBLY.

REMOVE

NOTE: The automatic fill limiter should only be replaced if it proves to be faulty.

1. Park the vehicle in a well ventilated area, away from any ignition source.

2. Drain the service lines of LPG, refer to 3.1 SERVICE LINE DRAINING.

3. Unload the LPG tank of LPG, refer to 3.2 LPG TANK UNLOADING.

4. From within the LPG valve box, while holding the

AFL elbow, crack open the filler line to AFL elbow

connector (1) and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure. Once all the LPG in the line has

dispersed, unscrew the filler line connector

completely from the AFL elbow.

Figure 8A2-86

5. Remove the four screws (1) attaching the AFL (2)

to the tank. Sedan shown, Wagon and Utility

similar.

6. Remove the AFL from the LPG tank.

Figure 8A2-87

REINSTALL

1. Install a new sealing ring (1) onto the AFL (2).

2. Fit the AFL into the tank, ensuring it is correctly

orientated.

3. Install the four screws (3) and tighten to the

specified torque.

4. Reconnect LPG body wiring harness connector to

the LPG tank harness connector and reinstall the

grommet.

5. Reinstall the rear service line, refer to

3.15 REAR SERVICE LINE.

6. Apply Loctite 577 sealant to the f iller line connector

threads, ensuring that the flared surfaces are free

of sealant and c ontam inants. Connec t the filler line

to AFL elbow and tighten to the specified torque.

Figure 8A2-88

7. Pressure and leak test LPG tank in accordance

with the current Australian Standard AS 2030-1.

8. Perform system leak testing, refer to

3.3 LEAK TESTING.

AUTOMATIC FILL LIMITER ATTACHING

SCREW TORQUE SPECIFICATION 5.0 – 7.0 Nm

FILLER LINE CONNECTOR TO AFL

ELBOW TORQUE SPECIFICATION 12.0 – 18.0 Nm

3.12 PRESSURE RELIEF VALVE

LT Section –

REMOVE

NOTE: The pr essure relief valve fitted to Utility vehic les is part of the m anual service valve assem bly and is not

serviced.

1. Park the vehicle in a well ventilated area, away from any ignition source.

2. Drain the service lines of LPG, refer to 3.1 SERVICE LINE DRAINING.

3. Unload the LPG tank of LPG, refer to 3.2 LPG TANK UNLOADING.

4. Remo ve the pres s ure r elief valve ( 1) from the LPG tank valve box, refer to Figure 8A2- 89, A – Sedan, or B –

Wagon.

Figure 8A2-89

REINSTALL

1. Ensure that new relief valve and LPG tank mating threads are clean.

2. Apply an anaerobic s ealant, suc h as Permabond A129 or equivalent to the valve thr ead and a sm all am ount

to the tank mating thread.

3. Tighten the pressure relief valve to the specified torque.

4. Pressure and leak test the LPG tank in accordance with the current Australian Standard AS 2030-1.

5. Leak test the LPG system, refer to 3.3 LEAK TESTING.

PRESSURE RELIEF VALVE

TORQUE SPECIFICATION 60.0 – 65.0 Nm

3.13 TANK FUEL GAUGE ASSEMBLY

LT Section – AA-650R

REMOVE

1. Park the vehicle in a well ventilated area, away

from any ignition source.

2. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

3. Unload the LPG tank of LPG, refer to

3.2 LPG TANK UNLOADING.

NOTE: T he tank fuel gauge as sembly will be removed

during this procedure.

REINSTALL

1. Fit a new tank fuel gauge sealing ring (1) and

reinstall the tank fuel gauge assembly (2).

NOTE: Ensure the gauge assembly is correctly

orientated.

2. Connect the wiring harness connectors to gauge

terminals.

3. Install the gauge assembly attaching screws and

tighten to the specified torque.

4. Pressure and leak test the LPG tank in

accordance with the current Australian Standard

AS 2030-1.

5. Leak test the LPG system, refer to

3.3 LEAK TESTING.

Figure 8A2-90

CONTENTS GAUGE

REMOVE

1. Park the vehicle in a well ventilated area, away

from any ignition source.

2. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

3. Remove the smart unit and solenoid valve from

the manual service valve, refer to

3.8 SMART UNIT & SOLENOID VALVE.

4. Disconnect the wiring harnes s c onnec tors f r om the

contents gauge terminals.

5. Remove the two screws attaching the contents

gauge and remove the contents gauge from the

LPG tank gauge assembly.

CAUTION: Do not remove the four screws

retaining the tank fuel gauge assembly to LPG

tank.

Figure 8A2-91

TANK FUEL GAUGE ATTACHING

SCREW TORQUE SPECIFICATION 5.0 – 7.0 Nm

TEST

1. Connect an ohmmeter to the contents gauge

sender unit terminals (1).

2. Place a magnet (2) behind the contents gauge and

rotate the magnet to change the position of the

gauge needle and test for the specified resistance.

3. If the needle does not move in relation to the

movement of the magnet or the resistance does

not meet specification, the contents gauge must

be replaced.

Figure 8A2-92

REINSTALL

1. Install the contents gauge onto the tank fuel gauge assembly and tighten the screws.

2. Connect the wiring harness connectors to the contents gauge terminals.

3. Reinstall the smart unit and solenoid valve on the manual service valve, refer to 3.8 SMART UNIT AND

SOLENOID VALVE.

4. Reconnect the battery earth lead.

TANK CONTENTS GAUGE

RESISTANCE (APPROX.)

EMPTY: 40 OHMS

FULL: 255 OHMS

3.14 FRONT SERVICE LINE

LT Section – AA-650Q

REMOVE

1. Park the vehicle in a well ventilated area, away

from any ignition source.

2. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

3. Disconnect the front service line (1) connector

from the LPG lock-off connection (2).

4. W hile holding the front to intermediate service line

joiner (3), disconnect the front service line

connector and remove the front service line.

Figure 8A2-93

REINSTALL

1. Clean the m ating threads of the f ront service line, LPG loc k-off connection and interm ediate to fr ont s ervice

line connector.

2. Apply Loctite 577 sealant or equivalent to the LPG lock-off connection and to the intermediate service line

front connector threads, ensuring that flared surfaces are free of sealant and contaminants.

3. Assemble the front service line connectors to the LPG lock-off connection and intermediate service line

connector and tighten to the specified torque.

NOTE: Ensure the front service line does not chafe or come in contact with the body or other components.

4. Leak test the LPG system, refer to 3.3 LEAK TESTING.

FRONT SERVICE LINE TO LOCK-OFF AND

INTERMEDIATE L I NE CONNECTOR

TORQUE SPECIFICATION 12.0 – 18.0 Nm

3.15 RE AR SERVICE LINE

LT Section – AA-650Q

SEDAN

REMOVE

1. Park the vehicle in a well ventilated area, away

from any ignition source.

2. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

3. From within the LPG valve box, (while holding the

AFL elbow) crack open the filler line to AFL elbow

connector (1) and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure. Once all the LPG in the line has

dispersed, unscrew the filler line connector

completely from the AFL elbow.

Figure 8A2-94

4. From within the LPG tank valve box, unscrew the

rear service line connector (1) from the manual

service valve assembly.

5. Jack up rear of the vehicle and support on safety

stands, refer to Section 0A, GENERAL

INFORMATION for jacking point locations.

Figure 8A2-95

6. From underneath the vehicle, remove the rear

service line grommet (1) from the body.

7. W hile holding the intermediate to rear service line

joiner (2) from turning, unscrew the rear service

line connector (3).

8. Remove the rear service line by withdrawing it

through the body.

Figure 8A2-96

REINSTALL

Installation of the rear service line is the reverse of removal noting the following:

1. Clean the rear service line mating threads on the manual service valve assembly, intermediate to rear

service line joiner, both rear service line connectors, AFL valve mating threads and filler line connector.

2. Reinstall the grommet into the body before installing the vent tubes.

3. Apply Loctite 577 sealant to the intermediate to rear service line joiner threads, manual service valve

assembly threads, and AFL valve threads, ensuring that the flared surfaces are free of sealant and

contaminants.

4. Tighten rear service line and filler line connections to the specified torque.

NOTE: Ensure the rear service line and filler lines do not chafe or come in contact with the body or other

components.

5. Leak test the system, refer to 3.3 LEAK TESTING.

WAGON

REMOVE

9. Park the vehicle in a well ventilated area, away

from any ignition source.

10. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

11. From within the LPG valve box, crack open the

filler line (1) while holding the AFL elbow (2) and

allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure.

12. Once all the LPG in the line has dispersed, remove

the filler line connector completely from the AFL

elbow.

Figure 8A2-97

13. From within the LPG tank valve box, unscrew the

rear service line connector (1) from the manual

service valve assembly.

14. Jack up the rear of vehicle and support on safety

stands, refer to Section 0A, GENERAL

INFORMATION for the jacking point locations.

15. Remove the fuel (petrol) tank, refer to

Section 8A1, 2.1 FUEL TANK – SEDAN &

WAGON.

Figure 8A2-98

REAR SERVICE LINE CONNECTION

TORQUE SPECIFICATION 12.0 – 18.0 Nm

FILLER LINE TO

AFL VALVE CONNECTION

TORQUE SPECIFICATION 12.0 – 18.0 Nm

16. W hile holding the intermediate to rear service line

elbow (1) from turning, unscrew the rear service

line connector (2) from the service line joiner.

17. Using a suitable sized drill bit, remove the heads of

the rivets (3) attaching the rear service line retainer

(4) in three places.

18. Remove the rear service line.

19. Using a suitable size pin-punch and hammer,

knock out the remaining rivets from the chassis

rail.

Figure 8A2-99

REINSTALL

Installation of the rear service line is the reverse of removal noting the following:

18. Clean the rear service line mating threads on the manual service valve assembly, intermediate to rear

service line joiner, both rear service line connectors, AFL valve mating threads and filler line connector.

19. Apply Loctite 577 sealant to the intermediate to rear service line joiner threads, manual service valve

assembly threads, and AFL valve threads, ensuring that the flared surfaces are free of sealant and

contaminants.

20. Tighten the rear service line and filler line connections to the specified torque.

21. Secure the rear service line to the chassis rails with the three clamps and new rivets.

22. Before starting the vehicle or opening the manual service valve, perform a fuel (petrol) system leak test,

refer to Section 6C1 POWERTRAIN MANAGEMENT - V6 ENGINE.

23. Leak test the LPG system, refer to 3.3 LEAK TESTING.

REAR SERVICE LINE CONNECTION

TORQUE SPECIFICATION 12.0 – 18.0 Nm

FILLER LINE TO AFL

VALVE CONNECTION

TORQUE SPECIFICATION 12.0 – 18.0 Nm

UTILITY

REMOVE

1. Park the vehicle in a well ventilated area, away

from any ignition source.

2. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

3. From within the LPG valve box, while holding the

AFL elbow, crack open the filler line to AFL elbow

connector (1) and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure.

4. Once all the LPG in the line has dispersed, remove

the filler line connector completely from the AFL

elbow.

Figure 8A2-100

5. From within the LPG tank valve box, unscrew the

rear service line connector (1) from the manual

service valve assembly.

6. Jack up the vehicle and support on safety stands,

refer to Section 0A, GENERAL INFORMATION

for the jacking point locations.

Figure 8A2-101

7. Drill-out the rivets (1) securing the service line

connection protector plate (2) and remove the

plate.

8. W hile holding the intermediate to rear service line

elbow (3) from turning, disconnec t the rear service

line connector (4).

9. Disconnect the vent tube at the valve box and

remove the rear service line by pulling up through

the vent tube.

10. If required, remove the lower clamp (5) from the

vent tube (6) within the lower vehicle cavity and

remove the tube.

11. Drill-out the four rivets (7) attaching the vent tube

flange (8) to the vehicle and remove the flange.

Figure 8A2-102

REINSTALL

Installation of the rear service line is the reverse of removal noting the following as required.

1. Install the vent tube flange with new rivets.

2. Apply a commercially available silicone sealant to the vent tube to flange mating surfaces.

3. Tighten the clamp to the specified torque.

4. Clean the rear service line mating threads on the manual service valve assembly, intermediate to rear

service line elbow, both rear service line connectors, AFL valve mating threads and filler line connector.

5. Apply Loctite 577 sealant to the intermediate to rear service line joiner threads, manual service valve

assembly threads, and AFL valve threads, ensuring that the flared surfaces are free of sealant and

contaminants.

6. Tighten the rear service line and filler line connections to the specified torque.

NOTE: Ensure the rear service line and filler lines do not chafe or come in contact with the body or other

components.

7. Leak test the LPG system, refer to 3.3 LEAK TESTING.

8. Fit the protector plate with new rivets.

VENT TUBE HOSE CLAMP

TORQUE SPECIFICATION 2.0 – 3.0 Nm

REAR SERVICE LINE CONNECTION

TORQUE SPECIFICATION 12.0 – 18.0 Nm

FILLER LINE TO AFL

VALVE CONNECTION

TORQUE SPECIFICATION 12.0 – 18.0 Nm

3.16 INTERMEDIATE SERVICE LINE

LT Section – AA-650Q

REMOVE

1. Park the vehicle in a well ventilated area, away

from any ignition source.

2. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

3. From within the LPG valve box, while holding the

AFL elbow, crack open the filler line to AFL elbow

connector (1) and allow residual LPG to escape.

CAUTION: The filler line will contain LPG under

pressure. Once all the LPG in the line has

dispersed, unscrew the filler line connector

completely from the AFL elbow.

4. Disconnect the front and rear service lines as

required, ref er to 3.14 FRONT SERVICE LINE and

3.15 REAR SERVICE LINE.

Figure 8A2-103

5. Remove the screw (1) attaching the fuel line

retainer (2), two places, to the dash panel.

Figure 8A2-104

6. Remove the five rivets (1) attaching the fuel

harness heat shield (2) to the vehicle.

7. Depressurise the fuel (petrol) system, refer to

Section 6C1-3 SERVICE OPERATIONS – V6

ENGINE.

8. Remove the fuel pipe assembly, refer to

Section 8A1, 2.12 FUEL PIPE ARRANGEMENT.

9. Open the retainers and unattach the intermediate

service line (1) from the fuel pipe assembly; A –

Sedan, B – Wagon, C – Utility, refer to Figure

8A2-106.

Figure 8A2-105

Figure 8A2-106

REINSTALL

Installation of the intermediate service line is the reverse of removal noting the following:

1. Ensure the service line does not chafe or come in contact with the body or other components.

2. Connect the intermediate service line connections to the front and rear service lines, refer to

3.14 FRONT SERVICE LINE and 3.15 REAR SERVICE LINE.

3. Leak test the LPG system, refer to 3.3 LEAK TESTING.

4. Fit the heat shield plate with new rivets.

5. Tighten the retaining clamp screws to the specified torque.

SERVICE LINE RETAINING

CLAMP SCREW

TORQUE SPECIFICATION 12.0 – 15.0 Nm

3.17 LPG LOCK-OFF

LT Section –

REMOVE

1. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

2. Disconnect the LPG lock-of f harnes s connec tor (1)

from the LPG lock-off.

Figure 8A2-107

3. Disconnect the front service line (1) from the LPG

lock-off connection (2).

Figure 8A2-108

4. Remove the two screws ( 1) securing the c onverter

heat shield (2) to the c onverter (3) and remove the

heat shield.

Figure 8A2-109

5. Remove the two screws (1) attaching the lock-off

bracket (2) to the converter (3).

6. Remove the two screws and nuts (4) securing the

lock-off bracket to the lock-off (5) and remove the

lock-off bracket.

Figure 8A2-110

7. Loosen the LPG lock-off outlet connection at the

converter.

8. Remove the two heat shield support posts (1) and

the converter retaining screw (2).

9. Lift the converter (3) up as far as possible and

unscrew the LPG lock-off assembly from the

converter.

10. Lower the converter down into its mounting

position and tem porally seat the converter onto the

converter support bracket (4).

Figure 8A2-111

FILTER ELEMENT REPLACEMENT

The following filter element replacement procedure can

be perfor med with or without the LPG lock -off installed

to the converter.

CAUTION: If performing the following procedure

with the LPG lock-off installed, the service

lines must first be drained of LPG, refer to

3.1 SERVICE LINE DRAINING.

1. As required, disconnect the front service line

connector from the LPG lock-off and disconnect

the LPG lock-off wiring connector, refer to

3.17 LPG LOCK-OFF – REMOVE.

2. Rem ove the screw (1) attaching the cup assem bly

(2) to the valve body (3).

3. Separate the cup assembly from the valve body.

4. Remove the cup lid (4) from the cup (5) and

gasket (6), and remove the filter element (7).

5. Remove and discard the cup lid to valve body O-

ring (8) and the cup assembly screw O-ring (9).

6. Replace the filter, O-rings and cup gasket with new

parts.

7. As semble the parts , ensuring that the m agnet ( 10)

is cleaned and located in the cup.

8. Tighten the cup assembly screw to the specified

torque.

NOTE: A filter element replacement kit is available and

contains the following components:

• LPG lock-off cup assembly screw O-ring (9)

• LPG lock-off to valve body gasket (6)

• Filter element (7)

• Cup lid to valve body O-ring (8)

• Bobbin (11) to valve body O-ring (12)

• Coil plunger (13)

Figure 8A2-112

9. Connect the inlet of the LPG lock-off to

pressurised nitrogen (1).

10. Check for any flow of nitrogen from the LPG lock-

off outlet fitting (2).

11. The LPG lock-off should completely stop the flow

of nitrogen up to the specified pressure rating.

12. If the LPG lock-off allows any amount of the

nitrogen to flow, the LPG lock-off should be

replaced.

Figure 8A2-113

LPG LOCK-OFF CUP ASSEMBLY

ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

LPG LOCK-OFF PRESSURE

RATING SPECIFICATION 1200 kPa

TEST

1. Connect an ohmmeter to the two LPG lock-off

term inals and check for continuity or a short circ uit

of the solenoid coil winding.

2. If the measured resistance is not to specification,

the LPG lock-off should be replaced.

Figure 8A2-114

REINSTALL

Installation of the LPG lock-off is the reverse of removal noting the following:

1. Clean the mating threads of LPG lock-off inlet and outlet connections and the front service line connector.

2. Apply Loctite 577 sealant to the LPG lock-off inlet thread and install the LPG lock-off to the converter and

tighten securely. If necessary, further tighten the lock-off to the converter to align it to the lock-off bracket.

3. Tighten all fasteners to the specified torque.

4. Apply Loctite 577 to the lock-off connector and tighten the connector to the specified torque.

5. Leak test the LPG system, refer to 3.3 LEAK TESTING.

LPG LOCK-OFF

COIL RESISTANCE 17 – 27 OHMS

@ 20° C

LPG LOCK-OFF BRACKET TO

CONVERTOR ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

CONVERTOR TO SUPPORT

BRACKET ATTACHING SCREW

TORQUE SPECIFICATION 10.0 – 12.0 Nm

HEAT SHIELD SUPPORT

POST ATTACHING SCREW

TORQUE SPECIFICATION 10.0 – 12.0 Nm

HEAT SHIELD

ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

FRONT SERVICE LINE TO LPG

LOCK-OFF CONNECTOR

TORQUE SPECIFICATION 12.0 – 18.0 Nm

3.18 CONVERTER

LT Section – AA-650Q

CONVERTER ON VEHICLE TEST PROCEDURE

1. Drain the service lines of LPG, refer to 3.1 SERVICE LINE DRAINING.

2. Remove the converter from the vehicle while keeping all lines connected, refer to the procedure in this

Section.

NOTE: To aid accessing the ports, remove the front service line retainers from the dash panel, refer to

3.14 FRONT SERVICE LINE.

Referring to Figure 8A2-115:

3. Remove the plug from the converter primary test port (5) and install a straight test nipple (6) into the

converter primary test port.

4. Connec t the press ure gauge hose to the str aight nipple and to the HI connec tion of the 0 – 5 PSID pr essur e

gauge (3) from the LPG test kit, refer to 10. SPECIAL TOOLS.

5. Remove the plug f rom the conver ter sec ondar y test port (12) and install the test elbow (8) into the sec ondary

test port.

6. Connect the vacuum gauge hose to the secondary test elbow and the LO connection of a 0 – 10 inches

W.C. vacuum gauge (1) from the LPG test kit.

7. Turn the manual service valve on and check the test connections for leaks.

8. With the fuel mode switch in LPG position, start the engine and allow to idle.

NOTE: If the engine will not start, crank the engine and record pressures.

9. Converter primary pressure should be 7 – 10 kPa.

10. Disconnect the FCV to converter balance lines at the converter (10, 11).

11. Secondary converter pressure should be negative 1 – 1.5 inches W.C.

12. Reconnect the balance line and the secondary pressure gauge should fluctuate from 1 – 5 inches W.C.

13. Turn the engine off. The gauges should hold pressure for at least five minutes.

Figure 8A2-115

Legend

1. Inches W.C. Gauge (secondary pressure) 5. Primary Pressure Port 9. Water Drain

2. Low Port 6. Straight Test Nipple 10. Balance Hose (to mixer)

3. PSID Gauge (primary pressure) 7. Vapour Hose 11. Balance Hose (to FCV)

4. High Port 8. Test Elbow 12. Secondary Pressure Port

REMOVE

1. Drain the service lines of LPG, refer to 3.1 SERVICE LINE DRAINING.

2. Depressurise the engine cooling system by removing the radiator cap in two stages.

CAUTION: Do not remove radiator cap while the engine coolant is hot as personal injury may result.

3. Plac e a drain tray beneath the vehicle. Loosen the

clamps (1) securing the engine coolant hoses (2)

to the converter coolant inlet and outlet elbows.

Remove the coolant hoses f rom the converter and

lay back away from the converter.

Figure 8A2-116

4. Disconnect the LPG-off harness connector (1)

from the LPG lock-off (2).

Figure 8A2-117

5. Disconnect the front service line (1) from the LPG

lock-off inlet connection (2).

Figure 8A2-118

6. Remove the two screws ( 1) securing the c onverter

heat shield (2) to the c onverter (3) and remove the

heat shield.

Figure 8A2-119

7. Remove the FCV balance hose (1) and vacuum

hose (4) from the converter connections.

8. Loosen the mixer to converter vapour hose clamp

(2) at the converter vapour outlet and disconnect

the vapour hose (3) from the converter.

Figure 8A2-120

9. Loosen and remove the two heat shield support

bolts (1), two places, and the converter retaining

bolt (2).

10. Remove the converter assembly (3).

11. Remove the engine coolant inlet and outlet elbows,

vapour outlet, FCV balance hose connection and

lock-off assembly if required.

12. If performing the following overhaul procedure on

the converter assembly, loosen and unscrew the

LPG lock-off to converter connection, remove the

connection and the LPG lock-off from the

converter.

Figure 8A2-121

OVERHAUL

Under normal operating conditions, installation of a complete converter repair kit should only be necessary:

• at the time or distance intervals specified in the vehicle owners handbook LPG leaflet, or

• if the converter has been out of service for some time causing the gaskets and diaphragms to deteriorate, or

• after the converter has been stored after being used.

The c onverter repair kit c ontains the components shown in the following diagram m arked # in the Legend, ref er

to Figure 8A2-122.

All other converter components are available separately, refer to spare parts information for details.

Figure 8A2-122

Legend

1. Primer Button 10. Screw 19. Sponge #

2. Screw # 11. Screw # 20. Primary Seat #

3. Diaphragm Cover 12. Primary Diaphragm Cover 21. Heat Exchanger Body

4. Secondary Diaphragm # 13. Primary Diaphragm Spring 22. Plug

5. Hand Primer Washer # 14. Primary Diaphragm # 23. Gasket #

6. Secondary Diaphragm Lever Fulcrum Pin 15. Primary Valve Pin 24. Plug

7. Secondary Diaphragm Lever 16. Regulator Body 25. Heat Exchanger Cover

8. Secondary Seat # 17. Gasket # 26. Screw #

9. Secondary Diaphragm Lever Spring 18. Plug

DISASSEMBLE

1. Remove the eight diaphragm cover to regulator

body attaching screws.

Figure 8A2-123

2. Lift up the diaphragm cover and diaphragm from

the regulator body.

3. Move the diaphragm cover and diaphragm away

from the low-pressure outlet by approximately 25

mm to disengage the two prongs of the diaphr agm

link from the secondary diaphragm lever.

4. Remove the diaphragm cover and diaphragm f rom

the regulator body.

Figure 8A2-124

5. Loosen and remove the primary diaphragm cover

to regulator body screw that retains the secondary

diaphragm lever fulcrum pin.

Figure 8A2-125

6. Slide the secondary diaphragm lever fulcrum pin

from the primary diaphragm cover and remove.

Figure 8A2-126

7. Remove the secondary diaphragm lever and

spring from the primary diaphragm cover.

Figure 8A2-127

8. Remove the remaining six primary diaphragm

cover to regulator body retaining screws (1 – 6).

NOTE: Rem oval of these screws releases the primary

diaphragm cover from the regulator body, thereby

allowing the primary diaphragm springs to be released.

Figure 8A2-128

9. Remove the primary diaphragm cover with the

diaphragm (1) and primary diaphragm springs (2)

from the regulator body.

10. Remove the primary valve pin (3) from the

regulator body.

Figure 8A2-129

11. Remove the two remaining regulator body to heat

exchanger body attaching screws.

Figure 8A2-130

12. Loosen and separate the regulator body from the

heat exchanger body. Discard the gasket.

Figure 8A2-131

13. Remove and discard the primary valve seat (1)

and sponge (2) from the heat exchanger body.

Figure 8A2-132

14. Remove the heat exchanger cover to heat

exchanger body attaching screws.

Figure 8A2-133

15. Separate the heat exchanger cover (1) from the

heat exchanger body (2) and discard the gasket

(3).

Figure 8A2-134

REASSEMBLE

1. Clean all parts in a suitable cleaning solution and

thoroughly dry and inspect all components.

2. Car e should be tak en to clean all depos its (1) from

the heat exchanger body and cover.

Figure 8A2-135

3. Us ing a new gask et, assem ble the heat exchanger

cover to the heat exchanger body, matching the

mounting bosses (A) in the cover with those on the

exchanger body.

4. Ins tall and tighten the attaching screws s ecurely in

the sequence shown.

Figure 8A2-136

5. Place the sponge in the recess in the heat

exchanger body.

NOTE: The sponge must be accurately positioned.

Figure 8A2-137

6. Install a new primary valve seat (1) into the heat

exchanger body.

Figure 8A2-138

7. Plac e the regulator body to heat exchanger gask et

on the primary pin boss and two locating pins on

the underside of the regulator body .

8. Use the two screws to locate the regulator body

and gasket on the heat exchanger as shown.

9. T ighten the scr ews just until the head engages the

regulator body.

Figure 8A2-139

10. Place the prim ary valve pin into the regulator body

hole.

Figure 8A2-140

11. Install the primary diaphragm (1) over the locating

pins (2) and the screw bosses in the regulator

body. This is essential to ensure proper alignment

and assembly of the primary diaphragm springs

and primary diaphragm cover.

Figure 8A2-141

12. Place the two primary diaphragm springs upon

their locating bosses on the backing plate of the

primary diaphragm assembly.

Figure 8A2-142

13. Place the primary diaphragm cover over the

primary diaphragm springs and push the cover

down on the springs until it contacts the regulator

body.

NOTE: The springs must locate in the cups in the

primary diaphragm cover.

14. While holding down the primary diaphragm cover,

insert the six c over attaching s crews, ens uring that

the two shallow headed sc rews are installed in the

correct locations, screws (2) and (4) in Figure

8A2-144.

NOTE: Do not install the attaching screw used to

retain the secondary diaphragm lever fulcrum pin at

this stage.

Figure 8A2-143

15. Tighten the primary diaphragm cover screws until

they contact the cover.

16. Tighten the screws securely in the order shown.

Figure 8A2-144

17. Remove the old secondary seat from the

secondary diaphragm lever and r eplac e with a new

seat.

Figure 8A2-145

18. Install the secondary diaphragm lever to the

primary diaphragm cover.

19. Insert the fulcrum pin whilst holding the lever in

place.

Figure 8A2-146

20. Install the remaining primary diaphragm cover

screw also used to retain the fulcrum pin. Tighten

the screw securely.

Figure 8A2-149

21. Install the secondary diaphragm lever spring by

slipping it under the secondary diaphragm lever.

22. Ensure that the s pring is correctly located between

the retaining tabs (1) on the lever and the r etaining

area (2) in the primary diaphragm cover.

Figure 8A2-150

23. Using the secondary diaphragm lever adjustment

gauge, part of LPG Test Kit ITK-1, refer to

10. SPECIAL TOOLS and ensure that the resting

position of the s econdary diaphragm lever is within

specification as shown. The height of the

secondary lever link pin (2) should correspond to

the slot in the measuring gauge.

24. If the height of the secondary diaphragm lever link

pin is not to specification, gently bend the

secondary diaphragm lever at point (3) until the

specified height is achieved.

Figure 8A2-151

25. Assemble the new secondary diaphragm by

attaching the secondary diaphragm slots to the

secondary diaphragm lever link pin.

Figure 8A2-152

26. Ensure of the c or rec t r elationship of the diaphragm

on the lever link pin.

Figure 8A2-153

27. Install the diaphragm cover onto the regulator

body, ensuring that the secondary diaphragm is

correctly located between the cover and regulator

body.

28. Install the attaching screws and tighten until all

screws contact the cover.

29. Continue to tighten the attaching screws in the

sequence shown until all are seated, then tighten

to the specified torque.

Figure 8A2-154

CONVERTER OFF VEHICLE TEST

1. Remove the converter from the vehicle, refer to REMOVE within this Section.

2. Referring to Figure 8A2-153:

A. Remove the plug from the converter primary test point and install the straight test nipple (1) into the

converter primary test point (2).

B. Connect the pressure gauge hose (3) to the straight test nipple and to the high connection of the

0 - 5 PSID pressure gauge (4), part of the LPG test kit ITK-1.

C. Remove the plug from the converter secondary test point and install the test elbow (5) into the

secondary test point (6).

D. Connect the vacuum gauge hose (7) to the test elbow and the LOW connection of the 0 - 10 inches

W.C. vacuum gauge (8), part of the LPG test kit ITK-1.

E. Remove the converter to LPG lock-off connector (9) from the LPG lock-off and reinstall into the

converter. Tighten the connector securely.

F. Connect an air supply (10) into the converter to LPG lock-off connector and adjust the air supply

pressure to 875 kPa.

G. Note the pressur e reading on the primary pressur e gauge. Primary converter press ure should be 7 - 10

kPa.

H. Disconnect the air supply. The converter should hold primary pressure for at least five minutes.

NOTE: The following step involves the use of a domestic vacuum cleaner as a vacuum source.

I. Reconnect regulated air supply to the converter to LPG lock-off connector. W hile watching the primary

pressur e gauge, bring the vac uum nozzle of the vacuum c leaner ( 11) to the converter vapour outlet (12).

When the primary pressure gauge needle moves (indicating start point of vapour supply out of

secondary), note and record the secondary vacuum gauge reading.

J. The secondary converter pressure should be negative 1 - 1.5 inches W.C.

3. If during this tes t the specified prim ary and/or secondary pressures cannot be ac hieved, the converter m ust

be overhauled.

DIAPHRAGM COVER TO REGULATOR

BODY ATTA CHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

Figure 8A2-155

REINSTALL

Installation of the converter is the reverse of the removal procedure, noting the following points:

1. If removed, ensure that the engine coolant inlet and outlet elbows, vapour outlet, FCV balance hose

connection threads and converter mating threads are clean.

2. Apply Loctite 577 sealant to coolant and vapour elbow threads and tighten these elbows to the positions

shown in Figure 8A2-154.

3. Ensure that the LPG lock-off to converter connector and the front service line to lock-off connector mating

threads are clean.

4. If removed, also clean the LPG lock-off connector and the LPG lock-off mating threads.

5. Apply Loctite 577 sealant to the LPG lock -of f connec tor ensur ing that flared s urf aces ar e free of sealant and

contaminants. Install the LPG lock-off connector to the LPG lock-off and tighten securely.

6. Install the LPG lock-off on to the converter and tighten securely. If necessary, further tighten the lock-off to

align it with the retaining bracket.

Figure 8A2-156

Legend

1. Converter 5. Coolant Elbow A. Front of Vehicle

2. Vapour Outlet Elbow 6. LPG Lock-off

3. FCV Balance Hose Connector 7. Connector

4. Nipple 8. Coolant Elbow

7. Tighten the fasteners to the specified torque.

8. Apply Loctite 577 to the lock -off connector and tighten the f ront servic e line to LPG lock-of f connector to the

specified torque.

9. Leak test the LPG system, refer to 3.3 LEAK TESTING.

10. Refill the cooling system with coolant to the cor rec t c onc entration level and pr es sur e test the system , ref er to

Section 6B1 ENGINE COOLING – V6 ENGINE.

LOCK-OFF BRACKET TO CONVERTER

ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

CONVERTER TO SUPPORT BRACKET

ATTACHING SCREW

TORQUE SPECIFICATION 10.0 – 12.0 Nm

HEAT SHIELD SUPPORT

POST SCREW

TORQUE SPECIFICATION 10.0 – 12.0 Nm

HEAT SHIELD ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

FRONT SERVICE LINE CONNECTOR

TO LPG LOCK-OFF

TORQUE SPECIFICATION 12.0 – 15.0 Nm

3.19 REGULATOR CHECK VALVE

LT Section –

TEST

1. Connect TECH 2 (4) to the DLC (1) with the cable

(3) and adapter (2).

NOTE: For additional information on connecting and

operating TECH 2, refer to Section 0C TECH 2.

2. Select: Diagnostics / (3) 2003 / VY Commodore /

Engine / V6 / Turn the ignition as instructed by

TECH 2 and confirm the System Identification /

Data Display / All Data.

3. Scroll to Fuel Control Valve.

4. Start the engine and take note of the duty cycles

displayed on the TECH 2 screen for the FCV (%).

Figure 8A2-157

5. Place a finger over the regulator check valve

(RCV) (1) atmospheric port (large opening) and

take note of the FCV duty cycles.

There should be little or no change in the duty

cycle.

6. Place a 3/8” inside diameter hose over the RCV

atmospheric port (large opening). Apply a small

amount of air press ur e to the open end of the hose

(physically blow through hose) and take note of the

duty cycles displayed for the FCV.

7. If duty cycles do not change, it indicates the RCV

is not opening as required and should be replaced.

Figure 8A2-158

REMOVE

1. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

2. If required, remove the two screws securing the

heat shield to the converter heat shield support

bolts and remove heat shield.

3. Unscrew the RCV (1) from the converter.

Figure 8A2-159

REINSTALL

Reinstallation of the RCV is the reverse of the removal procedure, noting the following:

Apply Loctite 577 sealant to RCV threads, install RCV to the converter and tighten securely. If required, further

tighten the RCV to correctly align it.

3.20 FUEL CONTROL VALVE

LT Section – AA-650Q

REMOVE

1. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

2. Using a flat bladed screwdriver, gently lever the

retaining tang on the fuel control valve (FCV)

retaining bracket (1) towards the rear of the vehicle

and slide the FCV (2) outwards.

3. W ith the FCV rem oved from the retaining brack et,

disconnect the wiring harness connector, remove

the balance and vacuum hoses and remove the

FCV from the vehicle.

Figure 8A2-160

TEST

1. Connect an ohmmeter to the coil terminals of the

FCV (1) and check the coil resistance.

2. If the res ist ance is not as s pecified, the fuel c ontrol

valve should be replaced.

Figure 8A2-161

3. Connect a vacuum pump (1) such as Tool No.

J23738 A, to the vacuum connector of the FCV

(2).

4. Operate the vacuum pum p until 15 inches Hg. (50

kPa) of vacuum is applied to the FCV

Figure 8A2-162

FUEL CONTROL VALVE COIL

RESISTANCE 19 – 21 ohms

@ 20° C

5. Note the time taken for the vacuum to bleed off

through the FCV.

If 15 inches Hg. (50 kPa) of vacuum cannot be

created, or the bleed off time is less than three to

five seconds, then the FCV should be replaced.

Figure 8A2-163

6. Using appropriate test leads (2), such as those

found in KM-609, c onnec t 12 volts ( vehicle batter y)

to the FCV coil terminals (1).

The valve should open (audible click) when 12

volts is applied. Chec k that the valve can be blown

through while open. If the valve does not open and

cannot be blown through, replace the FCV.

Figure 8A2-164

REINSTALL

Installation of the FCV is the reverse of the removal procedure noting the following and referring to Figure

8A2-165:

1. Ensure the FCV balance and vacuum hoses are routed correctly.

2. Connect the LPG wiring harness connector to the FCV, ensuring that it is routed correctly.

Figure 8A2-165

Legend

1. Balance Hose (Atmospheric) 2. Vacuum Hose 4. Breather Hose

1A. Balance Hose (Vacuum) 3. FCV Wiring Harness Connector

3.21 MIXER

LT Section – AA-650Q

TEST

1. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

2. Disconnect the Mass Air Flow sensor connector.

3. With petrol mode selected via the fuel mode

switch, start the engine and allow to idle until the

Malfunction Indicator Lamp is illuminated, then turn

the engine OFF.

NOTE: Running the engine with the Mass Air Flow

Sensor connec tor disconnected will cause DTC P0101

to set. Setting DT C P0101 will allow the engine to s tart

with the air duct rem oved as des c ribed in Step 6 of this

procedure.

4. Loosen the clamps (1) on either end of air duct

boot (2), between the mixer and the mass air flow

(MAF) sensor. Remove the air duct boot.

Figure 8A2-166

5. Loosen and remove the bell housing to air valve

cover attaching bolt (1) and separate the bell

housing (2) and gasket (3) from the mixer body

(4).

Figure 8A2-167

6. With petrol mode selected via the fuel mode

switch, start the engine and allow to idle.

7. Observe the mixer diaphragm position. The

diaphragm should lift slightly (A) as the engine is

cranked. Also, the diaphragm lift should increase

as engine RPM is increased.

8. If the diaphragm does not lift as RPM increases,

check for vacuum leaks between the mixer and

throttle body. If no vacuum leaks are found,

overhaul the mixer, refer to OVERHAUL in this

Section.

Figure 8A2-168

9. Install the bell housing gasket (3), bell housing (2)

and the bell housing to air valve cover attaching

bolt (1) and tighten to the specified torque.

10. Install the air duct and tighten the air duct clamps

to the specified torque.

11. Connect the MAF sensor.

12. Clear all DTCs using Tech 2.

Figure 8A2-169

REMOVE

1. Drain the service lines of LPG, refer to

3.1 SERVICE LINE DRAINING.

2. Remove the FCV vacuum supply hose (1) from the

mixer (2).

3. Disconnect the crankcase breather hose (3) from

the mixer.

Figure 8A2-170

MIXER BELL HOUSING

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

AIR DUCT CLAMP

TORQUE SPECIFICATION 1.5 – 2.5 Nm

4. Remove the fuel control valve (FCV) from the

mixer, refer to 3.20 FUEL CONTROL VALVE.

5. Loosen the clamps (1) on either end of air duct

boot (2), between the mixer and MAF sensor and

remove the air duct boot.

Figure 8A2-171

6. Loosen the adapter hose clamp (1) at the mixer

end (2).

7. Pull the mixer from the adapter hose (3).

8. Loosen the vapour hose to mixer inlet clamp (4),

disconnect the vapour hose (5) and remove the

mixer.

Figure 8A2-172

OVERHAUL

For identification of the various parts within the mixer assembly refer to Figure 8A2-173.

NOTE: There is no repair kit available for the mixer overhaul procedure; all mixer components are available

separately.

Figure 8A2-173

Legend

1. Screw 7. Diaphragm Assembly 13. Mixer Body

2. Bell Housing 8. Diaphragm 14. Plug

3. Gasket 9. Air Valve 15. Gasket

4. Screw 10. Idle Screw 16. Adapter

5. Air Valve Cover 11. Spring 17. Screw

6. Spring 12. Screw

1. Remove the bell housing screw (1) and the

separate the bell housing (2) and gasket (3) from

the mixer body.

Figure 8A2-174

2. Remove the five air valve cover attaching screws

(1) and remove the air valve cover (2) from the

mixer body.

3. Remove the spring (3) and the diaphragm and air

valve assembly (4) from the mixer body.

4. Check the condition of the diaphragm and spring

for wear or damage and replace as required.

5. Clean all parts in a suitable cleaning solution and

inspect their condition.

6. If the air valve was removed from the diaphragm,

or a new part is being installed, fit the air valve on

to the diaphragm ensuring the air valve ring is in

position between the air valve and the diaphragm.

Tighten the screws to the specified torque.

Figure 8A2-175

7. Place the diaphragm and air valve assembly (1)

into the mixer body ensuring that the diaphragm

and mixer body square locating lugs (2) are

aligned.

Figure 8A2-176

AIR VALVE TO DIAPHRAGM

ATTACHING SCREW

TORQUE SPECIFICATION 2.0 – 2.5 Nm

8. Locate the spring onto the diaphragm and install

the air valve cover assembly on to the mixer body.

9. Install the five air valve c over attac hing s c rews and

tighten in the sequence shown to the specified

torque.

Figure 8A2-177

10. Ins tall a new bell housing gas ket (1) onto the m ixer

body (2).

11. Locate the bell housing (3) onto the mixer body

and install the attaching screw (4) and to the

specified torque.

Figure 8A2-178

AIR VALVE COVER

ATTACHING SCREW

TORQUE SPECIFICATION 7.5 – 9.0 Nm

MIXER BELL HOUSING

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

REINSTALL

Installation of the mixer is the reverse of removal noting the following:

1. Ensure the FCV balance and vacuum hoses are routed correctly, refer to Figure 8A2-179.

2. Connect the LPG wiring harness connector to the FCV, ensuring that it is routed correctly, refer to Figure

8A2-179.

Figure 8A2-179

Legend

1. Balance Hose (atmospheric) 2. Vacuum Hose 4. Breather Hose

1A. Balance Hose (vacuum) 3. FCV Wiring Harness Connector

3.22 FUEL MODE SWITCH

LT Section – AA-650Q

REMOVE

1. Remove the floor console front compartment liner

(1) by lifting upwards to disengage the retaining

lugs.

Figure 8A2-180

2. Remove the screw (1) attaching the floor console

cover assembly (2) slightly to the right of centre.

3. Prise the cover assembly from the floor console,

six places (3).

4. Lift the cover assembly up from the rear,

disconnect the wiring connector (4) from the side

window switch assembly and auxiliary switches as

required, and remove the cover assembly.

Figure 8A2-181

5. Depr ess the four tabs s ecuring the auxiliary switch

bezel to the cover assembly and remove.

6. Depress the two tabs securing the fuel mode

switch to the cover assembly and remove the

switch.

Figure 8A2-182

TEST

Connect an ohmmeter to the fuel mode switch

terminals as shown and test for continuity. If the tests

are not as specified, replace the switch or bulb as

required.

NOTE: For further information, refer to

Section 12B, 3.19 SWITCH ILLUMINATION.

Figure 8A2-183

REINSTALL

Installation is the reverse of removal, noting the

following:

1. The fuel mode switch can only fit in the one

location.

2. Tighten the f loor console cover assem bly screw to

the specified torque.

SWITCH POSITION TERMINALS RESULT

ON (A) 3 – 5 Continuit y

OFF (B) 3 – 5 No Continuity

ON or OFF (BULB) 2 – 6 Approx. 30Ω

FLOOR CONSOLE COVER

ASSEMBLY ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

3.23 COOLANT HOSES

LT Section – AA-650Q

The converter is incorporated into the coolant circuit to aid vaporisation of the LPG. The converter is routed

between the heater water valve and the engine, refer to Figure 8A2-184. Note the operation of the water valve

when the heater is in the OFF position (A) or ON position (B).

Figure 8A2-184

Legend

1. Engine 4. Heater Core A. Heater Valve Closed

2. Converter 5. Vacuum Source to Heater Control B. Heater Valve Open

3. Water Valve 6. Vacuum Source from Heater Control

The coolant hoses are installed as shown in the following illustration.

Ensure that the hose connections are thoroughly cleaned before installing any new or existing hoses. When

securing a hose with a retaining clamp, ensure that the vent tube is correctly fitted.

After the hos es are f itted, ref ill the cooling system with the cor rect c oncentration of coolant and pressure test the

cooling system, refer to Section 6B1 ENGINE COOLING - V6 EN GINE.

CAUTION: Always wear pro tect iv e safet y glasses w hen w o rking with sprin g t ype hose clamps. F ailure to

do so could result in eye injury.

Figure 8A2-185

Legend

1. Water Valve 7. Screw 13. Coolant Hose Retaining Clamp

2. Hose Clamp 8. Nut 14. Screw

3. Engine Coolant Inlet 9. Converter 15. Vent Tube

4. Hose Clamp 10. Hose Clamp 16. Coolant Hose Retaining Clamp (2 places)

5. Vent Tube 11. Hose Clamp 17. Screw (2 places)

6. Coolant Hose Retaining Bracket 12. Vent Tube 18. Nut (2 places)

3.24 AIR CLE ANER ASSEMBLY

LT Section – 03-250

REMOVE

1. Loosen the hose clamp (1) attaching air duct

adapter (2) to the air cleaner upper housing (3).

2. Disconnect the air duct from the air cleaner upper

housing.

3. Unclip the clips securing the air cleaner upper

housing in place.

4. Remove the air cleaner upper housing and air

cleaner element (4).

5. Remove the two retainers ( 5) attaching the c old air

intake duct (6) to the front panel. Disengage the

cold air intake duct from the air cleaner lower

housing (7) and remove the cold air intake duct.

6. Remove the three nuts (8) attaching the air cleaner

lower housing to the air cleaner support bracket (9)

and remove the lower housing.

REINSTALL

Installation of the air cleaner assembly is the reverse

of the removal. Tighten the nuts to the specified

torque.

Figure 8A2-186

AIR CLEANER LOWER

HOUSING ATTACHING NUT

TORQUE SPECIFICATION 5.0 – 7.0 Nm

3.25 SPARE WHEEL CARRIER, WAGON

LT Section –

REMOVE

1. Remove the spare wheel cover and the spare

wheel from the carrier.

2. Remove the rear compartment carpet, refer to

Section 1A8, 3.21 REAR COMPARTMENT

FLOOR CARPET ASSEMBLY AND SPARE

WHEEL COVER, WITH LPG.

3. Remove the rear bolt (1) attaching the carrier (2)

to the rear reinforcement bracket (3).

4. With the aid of an assistant, remove the nut (4)

and reinfor cement (5) f rom under neath the vehicle

and remove the bolt (6) attaching the carrier and

tank bracket (7). Slide the washer (8) out from

under the carrier.

5. With the aid of an assistant, remove the nut (9),

reinforcement (10) and fuel filter brack et (11) from

underneath the vehicle and remove the bolt (12)

attaching the carrier.

6. With the aid of an assistant, remove the nut (13)

and remove the bolt (14) and reinforcement (15)

from underneath the vehicle.

7. Remove the carrier from the vehicle.

8. If required, remove the reinforcement plate (16)

and two spacers (17) from the chassis rail cavity.

9. If required, partially remove the tank bracket and

remove the spacer, washer and insulator (18).

10. If required, remove the two screws (19)

securing the reinforcement bracket to the chassis

rail. Remove the right-hand rear shock

absorber mounting plate, refer to

Section 4A REAR SUSPENSION. Manoeuvre the

bracket out of the chassis rail, through the shock

absorber mount plate opening.

Figure 8A2-187

REINSTALL

Installation of the spare wheel carrier is the reverse of removal noting the following:

NOTE: If the f loor panel, chass is rail, etc. has been r eplaced and new mounting holes ar e required, position the

spare wheel carrier ensuring the front edge aligns 50 mm rearward of the floor joint (1) and the rear hole (2)

aligns centrally within the rib in the side to side direction. Use the carrier as a template for the other holes and

mark the floor with their positions. Drill as follows:

• For position (2), drill a 12 mm hole only through the floor panel. If required, drill a 12 mm hole (3) through

each side of the chassis rail for the reinforcement bracket attaching screws.

• For position (4), drill a 12 m m hole com pletely through the floor and rear crossm ember. Drill the hole in the

floor panel only out to 17 mm.

• For position (5), drill a 12 mm hole completely through the floor and rear chassis rail. Drill the hole in the

floor panel only out to 17 mm.

• For position (6) , drill a 12 m m hole c ompletely through the floor and rear chass is rail. T his hole is also us ed

as the right-hand front tank bracket mount.

Figure 8A2-188

1. Install all of the components and hand tighten the nuts and bolts. Ensure the spacers and reinforcement

plates, etc. are assembled in their correct positions.

2. Tighten the bolts and nuts to the specified torque.

SPARE WHEEL CARRIER

ATTACHING NUT AND BOLT

TORQUE SPECIFICATION 40.0 – 50.0 Nm

4. TECH 2 PROCEDURES

4.1 LPG SE TUP PROCEDURE

NOTE: The following procedure must be performed

when any LPG system component (mixer, converter,

FCV or PCM) has been replaced, overhauled,

reprogrammed, or when the engine assembly has

been replaced or overhauled.

The LPG Setup proc edure allows the idle mixtur e to be

adjusted under the following controlled conditions:

• Short and Long-Term Fuel Trim Cells set to zero.

• Fixed Spark advance.

• Fixed idle air control valve steps.

• Fuel control valve duty cycle fixed at 40%.

1. Connect TECH 2 (4) to the DLC (1) with the

adapter (2) and cable (3).

NOTE: For further information on Tech 2

connection and operation procedures refer to

Section 0C TECH 2.

2. With the vehicle in LPG mode, start the engine.

3. With no load on the engine, air conditioning off (if

fitted), all electrical consum ers turned off and park

position selected, allow the engine and oxygen

sensor to reach operating temperature.

Figure 8A2-189

4. On TECH 2 select:

F0: Diagnostics / (3) 2003 / VY Series / F0: Engine

/ V6 / F5: Function Tests / F5: LPG Setup.

5. During the setup procedure, Tech 2 ensures the

follow engine operating conditions are met and

maintained:

• Engine Coolant Temperature greater than

91°C,

• Operating in closed loop mode,

• Right hand oxygen sensor is ready,

• The engine cooling fan is off, (engine coolant

temperature less than 104°C).

6. Once all the preconditions have been met, T ech 2

will display the right-hand oxygen sensor voltage

and status.

Engine

LPG Setup

Right O2 Sensor

Right O2 Status 500 mV

Rich

VXLPG001

Confirm

Figure 8A2-190

Techline

7. Adjust the idle mixture screw until the right-hand

oxygen sensor voltage is as close to 500 mV as

possible and the status of the right oxygen sensor

is constantly toggling between rich and lean.

• An oxygen sensor voltage greater than 500

mV indicates a rich mixture. Turn the idle

mixture screw anti-clockwise to lean-off the

mixture.

• An oxygen s ensor voltage of less than 500 mV

indicates a lean mixture. Turn the idle mixture

screw clockwise to richen the mixture.

NOTE: If the engine coolant temperature exceeds

104°C, the engine cooling fan will operate and Tech 2

will suspend the setup procedure. When the engine

cools, the cooling fan will cease operation and Tech 2

will continue with the setup procedure.

Figure 8A2-191

4.2 LPG FUEL CONTROL VALVE TEST

The LPG fuel control valve test is used to command

the LPG fuel control valve from 10% to 90% in

increments of 10%.

1. Connect TECH 2 (4) to the DLC (1) with the

adapter (2) and cable (3).

Figure 8A2-192

2. On TECH 2 select:

F0: Diagnostics / (3) 2003 / VY Series / F0: Engine

/ V6 / F4: Miscellaneous Tests/ F6: LPG Fuel

Control Valve Test.

Miscellaneous Tests

VXLPG005

F0: Output T ests

F1: IAC System

F2: EGR Control

F3: Reset Cells

F4: Bypass Spark

F5: Air Fuel Ratio

F 6: LPG F u el C o n t rol Valve Test

F7: LPG Enable

Figure 8A2-193

3. With the LPG mode select ed, start the engine and

allow the engine to idle.

4. The FCV duty cycle can be increased and

decreased using the decrease or increase soft

keys. Increasing the duty cycle will cause a leaner

air f uel r atio, dec reas ing the duty cycle will cause a

richer air fuel ratio.

NOTE: The F CV c an only be commanded if the engine

is running in the LPG mode.

Figure 8A2-194

4.3 LPG ENABLE TEST

The LPG enable test is used to enable the vehicle to be plac ed in LPG operating mode. W hen com manded ON,

the PCM will switch to the LPG operating mode.

When commanded OFF, the PCM will switch to petrol operating mode.

NOTE: The PCM will only toggle between the petrol and LPG mode if the ignition is on and the engine is not

running, or if the engine speed is greater that 1300 RPM.

1. Connect TECH 2 (4) to the DLC (1) with the cable

(2) and adapter (3).

Figure 8A2-195

2. On TECH 2 select:

F0: Diagnostics / (3) 2003 / VY Series / F0: Engine

/ V6 / F4: Miscellaneous Tests/ F7: LPG Enable

Test.

Miscellaneous Tests

VXLPG006

F0 : Ou tp ut Tests

F1: IAC System

F2: EGR Control

F3 : Re set C el ls

F4: Bypass Spark

F5: Air Fuel Ratio

F6: LPG Fuel Co n tro l Valve Test

F7: LPG Enable

Figure 8A2-196

3. With the ignition on and the engine not operating

or with the engine operating above 1500 RPM, the

LPG mode can be commanded ON or OFF using

the ON and OFF soft keys.

4. When comm anded ON, the PCM will switch to the

LPG m ode. W hen c omm anded OFF, the PCM will

switch to the petrol mode.

Figure 8A2-197

5. AFTER INSTALLATION CHECK

5.1 GENERAL INFORMATION

At the 1,500 km (or 1 month) service it is a requirement that the following after installation check be performed.

All items in this checklist must be performed to ensure they have been adjusted or installed as outlined in this

Section.

5.2 UNDE RBODY

(Tick the appropriate boxes)

CHECK OK REPAIR

1. The rear service line and interm ediate service line

connectors (under vehicle) are tightened to the

correct torque specification.

! ! !

2. Service lines are correctly routed and retaining

clips installed. ! ! !

3. LPG tank correctly installed and attaching nuts

tightened to the correct torque specification. ! ! !

5.3 REAR COMPARTMENT

(Tick the appropriate boxes)

CHECK OK REPAIR

1. Vent tube flange installed and silicone sealer

applied. Sedan and Utility. ! ! !

2. Service line vent tube installed to vent tube flange

and retaining clamps tightened. Sedan and Utility.

Vent tube grommet installed correctly. Wagon only

! ! !

3. Service line vent tube installed to joiner and

retaining clamp tightened. Utility only. ! ! !

4. Filler line connected to joiner and LPG tank high-

pressure inlet elbow and filler line connectors

tightened to the correct torque specification.

! ! !

5. Filler valve installed correctly and retaining nut

tightened to the correct torque specification. ! ! !

6. Filler door operates without binding and shuts

flush, AFL sticker is affixed to inside of filler door. ! ! !

7. Rear service line connected to manual service

valve assembly and connector tightened to the

correct torque specification.

! ! !

8. LPG tank level sender and smart unit harness

connector is connected to LPG body harness

connector.

! ! !

9. Rear compartment carpet and quarter trim carpet

have been reinstalled and are pos itioned correctly.

Sedan and Wagon

! ! !

10. Check the s pare wheel carrier is correctly installed

and the nuts are tightened to the specified torque.

Wagon only

! ! !

11. Check the spare wheel is correctly fitted and the

retainer is tightened securely by hand. Wagon only ! ! !

5.4 UNDER HOOD

(Tick the appropriate boxes)

CHECK OK REPAIR

1. The vapour line to mixer and vapour line to

converter retaining clamps are installed and

tightened.

! ! !

2. T he vapour line and vacuum hos es are connected

and routed correctly. ! ! !

3. The converter and converter bracket is installed

and retaining bolts are tightened to the correct

torque specification.

! ! !

4. The coolant pipe hose clamps are fitted and

tightened. Coolant and vapour hoses are correctly

routed to avoid contact with engine or body parts.

! ! !

5. The fuel control valve (FCV) is installed and the

retaining bolt tightened to the correct torque

specification.

! ! !

6. The air intake tube is installed, clamps and

mounting screw tightened to the correct torque

specification.

! ! !

7. Air cleaner assembly and MAF sensor installed. ! ! !

8. Intermediate LPG line P-clamps installed on the

dash panel and tightened to the correct torque

specification.

! ! !

5.5 LEAK CHECK

With at least 3 litres of LPG in the tank, leak test the

complete LPG system, refer to 3.3 LEAK TESTING.

The following points must be tested. (Tick the appropriate boxes)

CHECK OK REPAIR

1. Pressure relief valve. ! ! !

2. Manual service valve assembly to LPG tank. ! ! !

3. Solenoid and manual service valve assembly. ! ! !

4. Rear service line to solenoid and manual service

valve assembly connector. ! ! !

5. LPG tank fuel gauge assembly. ! ! !

6. AFL inlet elbow to LPG tank. ! ! !

7. Rear service line to AFL inlet elbow connector. ! ! !

8. AFL to LPG tank. ! ! !

9. Filler valve to filler valve connecting pipe and filler

line. ! ! !

10. Filler valve check ball. ! ! !

11. Rear servic e line to intermediate s ervice line joiner

connection. ! ! !

12. Intermediate service line to rear service line joiner

connection. ! ! !

13. Intermediate s ervice line to front ser vice line joiner

connection. ! ! !

14. F r ont ser vic e line to intermediate ser vice line joiner

connection. ! ! !

15. Front service line to LPG lock-off inlet connection. ! ! !

16. LPG lock-off inlet connection to LPG lock-off. ! ! !

17. LPG lock-off. ! ! !

18. LPG lock-off to LPG lock-off outlet connection. ! ! !

19. LPG lock-off outlet connection to converter. ! ! !

6. DIAGNOSIS

6.1 PREREQUISITES TO DIAGNOSIS AND TROUBLESHOOTING

PRELIMINARY SYSTEM REQUIREMENTS

• Ensure that sound earth connections are provided for all functioning components, particularly at the body

earth connection (fender panel inner stud, adjacent to the battery).

• Ensure the battery is in good condition and adequately charged (above 12.5 volts) before carrying out any

electrical checks.

SAFETY REQUIREMENTS

• Disconnect the battery when carrying out work which involves the risk of an electrical short circuit.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00, 5. BATTERY DISCONNECTION PROCEDURES before disconnecting the battery.

• Do not touc h mechanic al c omponents during function chec ks, to avoid the risk of a hand being caught in the

mechanism.

• All Safety Standards and Regulations pertaining to LPG must be followed at all times.

CHECKING EQUIPMENT

• Tech 2 scan tool.

NOTE: For information on Tech 2 connection and operation procedures refer to Section 0C TECH 2.

• A digital multimeter, with a minimum 10 Mega-ohm impedance must be used when undertaking any

electrical checks on these systems.

• Exercise care when taking readings from wiring harness connectors. It is preferred that the back probing

method with individual connectors is employed wherever possible, to avoid terminal damage and

subsequent connection failure.

• When carrying out wiring checks as directed to by the diagnostic charts, rather than probe terminals and

connectors with incorrect sized multimeter connections, use the adapters contained in connector test

adapter kit KM-609. This will prevent any possibility of spreading or damaging wiring harness terminals.

IMPORTANT: Ensure that the ignition is turned off and the battery earth lead is disconnected before any test

that requires the disconnection or connection of any control module connectors.

• When checking the complete sy stem, the exact order of the test steps should be observed.

• If the required nominal value is not achieved in any stage, then the problem must be rectified before

proceeding further.

• Unless the multim eter being us ed has an auto r anging f unc tion, chec k that the corr ec t range, as specified, is

selected before the test is carried out.

• Testing of the system will involve gaining access to specific wiring harness connectors. For the location of

connectors not detailed in this Section, refer to Section 12O FUSES AND WIRING HARNESSES.

6.2 GENERAL INFORMATION

The procedures outlined in the LPG vehicle preliminary diagnostic chart must be carried out first whenever

diagnosing a problem in a LPG vehicle.

The LPG system is designed to operate in LPG mode when LPG has been selected via the fuel mode switch.

W hen diagnosing the LPG system, unless otherwise directed, ensure that LPG mode has been selected, there is

LPG in the LPG tank and the manual service valve is turned ON.

When LPG has been selected via the fuel mode switch, the PCM will operate in LPG mode if the operating

parameters sensed by the PCM permit the switching to the LPG mode.

Before any diagnostic procedures are carried out on the LPG system you must first confirm that the vehicle

operates on petrol without any problems.

NOTE: For diagnosis of the LPG fuel gauge and the LPG instrument cluster display icons, refer to

Section 12C INSTRUMENT CLUSTER.

6.3 LPG VEHICLE PRELIMINARY DIAGNOSIS

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

1. Ensures Tech 2 is functioning correctly.

2. Checks if Tech 2 can communicate with the PCM.

3. Checks if any PCM DTCs are present.

4. Checks if the PCM can operate in the LPG mode.

5. Checks if the LPG switch is operating correctly.

6. Checks the operation of the LPG icon.

7. Checks if the engine will operate on petrol.

8. Checks if the engine will crank when LPG has been selected.

9. Checks if the engine will run when LPG has been selected.

STEP ACTION YES NO

1. 1. Turn ignition off, connect Tech 2 to DLC, turn ignition on and

Tech 2 on.

2. Does Tech 2 power-up (screen will illuminate and display

Tech 2)?

Go to Step 2. Refer to Tech 2

DIAGNOSIS in,

Section 0C.

2. 1. With Tech 2 still connected and ignition on, press the ENTER

key then select F0: Diagnostics / (3) 2003 / VY Commodore / F0:

Engine / V6 and then follow the screen instructions.

2. Does Tech 2 display PCM identification information?

Go to Step 3. Refer to ON-

BOARD

DIAGNOSTIC

SYSTEM CHECK

in Section 6C1.

3. 1. At the Tech 2 PCM Identification screen, press the Confirm soft

key. From the Engine menu select F1: Diagnostic Trouble Codes

/ F0: Read Current DTC.

2. Are any DTCs present?

Refer to ON-

BOARD

DIAGNOSTIC

SYSTEM CHECK

in Section 6C1.

Go to Step 4.

4. 1. Return to the Tech 2 Engine menu and select F2: Data Display /

F0: All Data / Scroll to LPG Fuel Enabled.

2. Does Tech 2 display LPG Fuel Enabled YES?

Go to Step 5. Refer to 6.4

DOES NOT

OPERATE ON

LPG.

5. 1. With Tech 2 still connected, scroll to Fuel.

2. Select LPG via the fuel mode switch.

3. Does Tech 2 Data parameter Fuel change from Petrol to LPG?

Go to Step 6. Refer to 6.5 FUEL

MODE SWITCH

DOES NOT

OPERATE.

6. 1. With the LPG Mode selected.

(Tech 2 Data parameter Fuel displaying LPG).

2. Is the LPG icon illuminated in the instrument cluster?

Go to Step 7. Refer to Section

12C

INSTRUMENTS.

7. 1. Select Petrol via the fuel mode switch.

2. Will the engine crank and start immediately the ignition key is

turned from off to start (no delay)?

Go to Step 8. Refer to ON-

BOARD

DIAGNOSTIC

SYSTEM CHECK

in Section 6C1.

8. 1. Select LPG via the fuel mode switch.

2. Will the engine crank immediately the key is turned from off to

start (no delay)?

Go to Step 9. Refer to 6.6

ENGINE DOES

NOT CRANK.

9. 1. Does the engine start and run on LPG? Go to Step 10. Refer to 6.7

ENGINE

CRANKS BUT

WILL NOT

START ON LPG.

10. 1. Does the engine backfire when operated on LPG? Refer to 6.8

ENGINE

BACKFIRES ON

LPG.

Go to Step 11.

STEP ACTION YES NO

11. 1. Does engine lack power, sluggish or have poor performance

when operating on LPG? Refer to 6.9

POOR

PERFORMANCE,

FLAT SPOTTI NG,

SLUGGISH OR

POOR FUEL

CONSUMPTION

WHEN

OPERATING ON

LPG.

Go to step 12.

12. 1. Does fuel gauge operate correctly? LPG Diagnostic

Check completed. Refer to

Section 12C

INSTRUMENTS.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

6.4 DOES NOT OPERATE ON LPG

Figure 8A2-198

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

1. The LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK must be the first step when diagnosing any LPG

system problem.

2. The PCM will not operate in the LPG mode if the PCM has not been programm ed to operate on LPG. Refer

to the latest technical publications for the correct PROM application.

3. W hen the ignition is turned on, battery voltage is applied to terminal X3_F16 of the PCM. This enables the

PCM to operate in either the Petrol or LPG mode. If battery voltage is not applied to PCM terminal X3_F16

the PCM will only operate in the Petrol mode.

4. This test confirms that the PCM connector terminal retention is not causing the problem. The terminal

retention should always be checked before a PCM is replaced.

STEP ACTION YES NO

1. 1. Has the LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK

been performed. Go to step 2 Perform

LPG VEHICLE

PRELIMINARY

DIAGNOSIS

CHECK.

2. 1. Has the PCM been programmed for LPG operation?

Go to step 3. Perform SPS to

program the PCM

for LPG operation.

Refer to SPS in

Section 0C

Tech 2.

3. 1. Ignition on.

2. Measure the voltage at PCM connector A84 terminal X3_F16

circuit 300 (orange/green wire).

3. Is battery voltage present?

Go to step 4. Repair open in

circuit 300.

Verify repair.

4. 1. Check PCM connector terminal retention.

If retention OK replace PCM.

2. Is terminal retention OK?

Replace PCM.

Verify repair. Repair terminals.

Verify repair.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

6.5 FUEL MODE SWITCH DOES NOT OPERATE

Figure 8A2-199

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

1. The LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK must be the first step when diagnosing any LPG

system problem.

2. Checks for battery voltage when the fuel mode switch is activated.

3. Tests operation of fuel mode switch.

4. Checks for voltage at the fuel mode switch. If voltage is not present, circuit 300 is open between the fuel

mode switch and the ignition switch. If voltage is present there is an open circuit between the fuel mode

switch and PCM terminal X3_F4.

5. This test checks for an open in the fuel mode switch circuit 5606 between the fuel mode switch and PCM

terminal X3_F4.

6. This test confirms that the PCM connector terminal retention is not causing the problem. The terminal

retention should always be checked before a PCM is replaced.

STEP ACTION YES NO

1. 1. Has the LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK been

performed. Go to step 2 Perform

LPG VEHICLE

PRELIMINARY

DIAGNOSIS

CHECK.

2. 1. Ignition On

2. Measure the voltage at PCM terminal X3_F4.

3. Is battery voltage present when the fuel mode switch is

depressed?

Go to step 6. Go to step 3.

3. 1. Test the fuel mode switch, refer to 3.22 FUEL MODE SWITCH.

2. Is the fuel mode switch OK? Go to step 4. Replace fuel

mode switch.

Verify repair.

4. 1. Ignition on.

2. Measure the voltage at the fuel mode switch connector S118

circuit 300 (orange wire).

3. Is battery voltage present?

Go to step 5. Repair open in

circuit 300.

Verify repair.

5. 1. Check for open in circuit 5606 (Blue/Orange wire) between fuel

mode switch and PCM terminal X3_F4.

2. Is circuit open?

Repair open in

circuit 5606.

Verify repair.

Go to step 6.

6. 1. Check PCM connector terminal retention.

2. Is terminal retention OK? Replace PCM.

Verify repair. Repair terminals.

Verify repair.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

6.6 ENGINE DOE S NOT CRANK

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

1. The LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK must be the first step when diagnosing any LPG

system problem.

2. The theft deterrent system must be disarmed before the engine will crank. If the Theft Deterrent System

cannot be disarmed, refer to Theft Deterrent Diagnostics in Section 12J BCM.

3. When PETROL is selected, the engine should crank immediately the ignition switch is turned from off to

start. If the engine does not crank immediately, then refer to Section 6C1 ON-BOARD DIAGNOSTIC

SYSTEM CHECK.

4. When LPG is selected, the engine should cr ank imm ediately the ignition switch is turned f rom of f to start. If

the engine cranks immediately system is operating correctly.

5. When LPG is s elected, the PCM will prevent the engine from cranking if the PCM determines the throttle is

open more than 7%. This tests uses Tech 2 to monitor the Throttle Position sensor operation.

STEP ACTION YES NO

1. 1. Has the LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK been

performed. Go to step 2 Perform the

LPG VEHICLE

PRELIMINARY

DIAGNOSIS

CHECK.

2. 1. Ignition on.

2. Is theft deterrent system disarmed?

(Theft deterrent status indicator in the instrument cluster not

flashing or illuminated).

Go to Step 3. Refer to

Section 12J BCM.

3. 1. Ignition on.

2. Select Petrol via the fuel mode switch.

2. Turn ignition switch from OFF to START for a maximum of five

seconds or until engine starts to crank.

3. Does engine crank immediately (less than one second)?

Go to Step 4. Refer to

ON-BOARD

DIAGNOSTIC

SYSTEM CHECK,

Section 6C1.

4. 1. Ignition on.

2. Select LPG via the fuel mode switch.

3. Turn ignition switch from OFF to START for a maximum of five

seconds or until engine starts to crank.

4. Does engine crank immediately (less than one second)?

System operating

correctly.

Check for

intermittent

connections.

Go to Step 5.

5. 1. Turn ignition off.

2. Connect Tech 2 to the DLC.

3. Turn ignition on and then turn Tech 2 on.

4. At the ENGINE menu select F2: Data Display / F0: All Data.

5. Scroll to Throttle Position Sensor.

6. Is Throttle Position sensor displaying 0%?

Refer to

ON-BOARD

DIAGNOSTIC

SYSTEM CHECK,

Section 6C1.

Refer to

TP SENSOR

OUTPUT CHECK

Section 6C1-2A.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

6.7 ENGINE CRANKS BUT WILL NOT START ON LPG

TEST 1

Figure 8A2-200

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

1. The LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK must be the first step when diagnosing any LPG

system problem.

2. These initial checks are designed to verify that the engine is capable of operating on LPG.

3. Voltage is supplied to the LPG lock-off from the smart unit when the ignition is first turned on and when the

engine is cranking or running. If voltage is not present at these times, the lock-off will not be energised and

LPG will not flow to the converter.

4. This test confirms correct converter operation. Incorrect converter pressures can cause the engine not to

start.

5. This test determines if the PCM is causing the no start condition.

6. Vacuum leaks or blockages can cause a variety of system operating problems. All hoses and vacuum lines

should be checked.

7. This tests confirms correct mixer operation.

8. This tests co nfirms correct PCM LPG set up.

STEP ACTION YES NO

1. 1. Has the LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK been

performed. Go to step 2. Perform the

LPG VEHICLE

PRELIMINARY

DIAGNOSIS

CHECK.

2. INITIAL CHECKS:

1. Has LPG been selected via the fuel mode switch?

2. Has the PCM been programmed to operate on LPG?

3. Is the manual service valve open?

4. Is there any LPG present in the LPG tank, check contents gauge?

If yes to all, go to

Step 3. Repair any faults.

Recheck starting

on LPG.

3. 1. Measure the voltage at LPG lock-off connector Y143 circuit 5620

(Blue/Yellow wire).

2. Is voltage above nine volts for three seconds when the ignition is

first turned on or while the engine is cranking?

Go to Step 4. Go to Diagnostic

Chart ENGINE

CRANKS BUT

WILL NOT

START ON LPG

(Test 2).

4. 1. Test for presence of LPG in the system by checking converter

pressures, refer to 3.18 CONVERTER in this Section.

2. Are converter pressures OK?

Go to Step 5. Go to Diagnostic

Chart ENGINE

CRANKS BUT

WILL NOT

START ON LPG

(Test 3).

5. 1. Ignition on, select Petrol via the fuel mode switch.

2. Start engine and bring to 2000 RPM.

3. Select the LPG mode vi a the fuel mode switch.

4. Does the engine continue to run?

Setup LPG

System. Refer to

4.1 LPG SETUP

PROCEDURE.

Recheck starting

on LPG.

Go to Step 6.

6. 1. Check for vacuum leaks or incorrect routing in the vacuum or

vapour feed lines between the mixer and converter, or a blocked

balance line, FCV or RCV.

2. Are there any leaks, incorrect routing or blockages?

Repair vacuum

leaks or

blockages.

Recheck starting

on LPG.

Go to Step 7.

7. 1. Test mixer operation, refer to 3.21 MIXER in this Section.

2. Is mixer operating correctly? Go to Step 8. Check and repair

any air leaks

between mixer

and throttle body,

if there are no

leaks, overhaul

mixer. Refer to

3.21 MIXER.

Recheck starting

on LPG.

8. 1. Perform the LPG setup procedure, refer to 4.1 LPG SETUP

PROCEDURE and recheck starting on LPG.

2. Does engine start on LPG?

System OK. Go to Diagnostic

Chart ENGINE

CRANKS BUT

WILL NOT

START ON LPG

(Test 2).

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

TEST 2 – ENGINE CRANKS BUT WILL NOT START ON LPG

Figure 8A2-201

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

1. This test checks that the smart unit is supplying voltage to circuit 5620.

2. This test checks if circuit 5620 is shorted to earth.

NOTE: T he sm art unit has a current pr otection device on this c ircuit, if cir cuit 5620 is shorted to ear th the sm art

unit will shutdown. The ignition must be cycled from on to off to reset the smart unit.

3. This test checks continuity of the smart unit earth circuit 450.

4. This test checks that voltage is being applied to the smart unit from fuse F33.

5. Ignition voltage should be present at PCM terminal X3_F16 circuit 300 whenever the ignition is on.

6. When oper ating in LPG mode, the PCM puls es the 12 volt pull-up in the s mart unit to earth via c irc uit 2531 at

a 50% duty cycle. Therefor e the voltage at PCM term inal X1_A3 should be approxim ately five volts when the

ignition is first turned on or when the engine is cranking.

7. This test checks the continuity of circuit 2531 (White/Green wire).

8. This test checks if circuit 2531 (White/Green wire) is shorted to earth.

STEP ACTION YES NO

1. 1. Ignition ON, LPG selected.

2. Measure the voltage at the fuel sender & pump control module

(smart unit) connector A55, circuit 5620 (Blue/Yellow wire).

3. Is voltage above nine volts for three seconds when the ignition is

first turned on or while the engine is being cranked?

Repair open in

LPG lock-off

circuit 5620

between smart

unit and lock-off.

Recheck starting

on LPG.

Go to Step 2.

2. 1. Check for short to earth in LPG lock-off circuit 5620 between the

Smart Unit and lock-off.

2. Is circuit 5620 shorted to earth?

Repair short to

earth in LPG lock-

off circuit 5620

between smart

unit and lock-off.

Recheck starting

on LPG.

Go to step 3.

3. 1. Check continuity of smart unit earth circuit 450 (Black/Red wire)

between smart unit connector A55 and a known good earth.

2. Is there continuity?

Go to step 4. Repair open in

circuit 450

(Black/Red wire).

Recheck starting

on LPG.

4. 1. Ignition ON.

2. Measure the voltage at smart unit connector A55 circuit 439 (Pink

wire).

3. Is battery voltage present?

Go to Step 5. Repair open in

circuit 439 (Pink

wire) between

fuse F33 and the

smart unit.

5. 1. Ignition ON.

2. Measure the voltage at PCM connector A84_X3 terminal F16

circuit 300 (Orange wire).

3. Is battery voltage present?

Go to step 6. Repair open in

circuit 300

(Orange wire)

Ignition switch

and PCM.

Recheck starting

on LPG.

6. 1. With LPG selected via the fuel mode switch.

2. Disconnect smart unit connector A55.

3. Measure the voltage at smart unit connector A55 circuit 2531 PCM

side (White/Green wire).

4. Turn the ignition from OFF to ON, is voltage approximately five

volts for three seconds when the ignition is first turned on or when

the engine is cranking?

Check smart unit

connector

terminal retention.

If OK, replace

smart unit.

Verify repair.

Go to step 7.

7. 1. With LPG selected via the fuel mode switch.

2. Measure the voltage at PCM connector A84_X1 terminal A3 circuit

2531 (White/Green wire).

3. Turn the ignition from OFF to ON, is voltage approximately five

volts for three seconds when the ignition is first turned from off to

on or when the engine is cranking?

Go to step 8. Check PCM

connector

terminal retention.

If OK,

replace PCM.

Recheck starting

on LPG.

8. 1. Check continuity of circuit 2531 (White/Green wire) between smart

unit connector A55 and PCM connector A84_X3 terminal A3.

2. Is there continuity?

Go to step 9. Repair open in

circuit 2531

(White/Green

wire).

Verify repair.

9. 1. Check for a short to earth in circuit 2531 (White/Green wire)

between smart unit connector A55 and PCM connector A84_X1

terminal A3.

2. Is there a short to earth?

Repair short to

earth in circuit

2531

(White/Green

wire).

Verify repair.

Check PCM

connector

terminal retention.

If OK,

replace PCM.

Recheck starting

on LPG.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

TEST 3 – ENGINE CRANKS BUT WILL NOT START ON LPG

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

1. Low primary converter pressure can be caused by low supply pressure or a faulty converter.

2. If the primary converter pressure is too high the converter will have to be overhauled.

3. If the primary converter pressure is within specification but the secondary converter pressure is out of

specification the converter will have to be overhauled.

4. This test checks if the solenoid valve is restricting the flow of LPG.

5. This test checks the flow of LPG from the LPG tank to the LPG lock-off.

6. This test determines if the LPG lock-off or the converter is causing the problem.

7. This test chec ks if the servic e line is block ed. If the s ervice line is not bloc ked then the m anual servic e valve

or the LPG cylinder pick up must be blocked.

STEP ACTION YES NO

1. 1. Is primary converter pressure below specification? Go to Step 4. Got to Step 2.

2. 1. Is primary converter pressure above specification? Repair the

converter, refer to

3.18

CONVERTER.

Recheck starting

on LPG.

Go to Step 3.

3. 1. If primary converter pressure is within specification, is the

secondary converter pressure out of specification? Repair converter,

refer to 3.18

CONVERTER.

Recheck starting

on LPG.

Go to step 4.

4. 1. Ignition OFF.

2. Close manual service valve.

3. Remove the solenoid valve from the manual service valve

assembly and reinstall solenoid sleeve, refer to 3.8 SMART UNIT

AND SOLENOID VALVE.

4. Does engine start and run on LPG?

Replace the smart

unit and solenoid

valve.

Recheck starting

on LPG.

Go to Step 5.

5. 1. Ignition OFF.

2. Close manual service valve.

3. With the solenoid valve still removed from the manual service

valve assembly.

4. Disconnect the front service line at the LPG lock-off.

5. In accordance with AS-1425, have a second technician slowly

open the manual service valve so that the excess flow valve

doesn’t shut LPG flow off (if a click is herd at the manual service

valve, the excess flow valve has closed).

6. Does LPG flow from the front service line?

Go to Step 6. Go to Step 7.

6. 1. Test LPG lock-off, refer to 3.17 LPG LOCK-OFF.

2. Is LPG lock-off OK? Repair converter,

refer to 3.18

CONVERTER.

Recheck starting

on LPG.

Repair LPG lock-

off, refer to 3.17

LPG LOCK-OFF.

Recheck starting

on LPG.

7. 1. Disconnect the rear service line at the manual service valve.

2. With front service line still disconnected, blow air through service

line to check for blockages

3. Does air flow through service line?

Check for manual

service valve or

LPG tank fuel

pick-up blockage

or fault. Repair or

replace blocked or

damaged

components.

Recheck starting

on LPG.

Check for

damaged or

blocked service

lines. Repair or

replace blocked or

damaged

components.

Recheck starting

on LPG.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

6.8 ENGINE BACKFIRES ON LPG

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

NOTE: Whenever an engine backfire has occurred, the complete intake system including the mixer should be

checked for damage.

1. The LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK must be the first step when diagnosing any LPG

system problem.

2. An ON BOARD DIAGNOSTIC SYSTEM CHECK should be performed to confirm that a problem with the

powertrain management system is not causing the engine to backfire when operating on LPG?

3-7. An ignition system that is not operating at it’s full potential can cause an engine to backfire when operating

on LPG. Ignition leads that operate quite well when operating on petrol, c an cause problem s when operating

on LPG. Therefore, all ignition system components must be at here optimum when operating on LPG.

8. Vacuum leaks or blocked vacuum lines can cause incorrect system operation, causing engine backfire.

9. Incorrect mixer operation can cause incorrect air/fuel ratios. Incorrect air/fuel ratios can cause engine

backfire.

10. Incorrect LPG set-up can cause incorrect system operation, causing engine backfire.

11. Incorrect converter operation can cause incorrect air/fuel ratios. Incorrect air/fuel ratios can cause engine

backfire.

12. This test confirm correct regulator check valve (RCV) operation, incorrect RCV operation can cause slow

converter response causing engine backfire.

13. Engine mechanical condition can cause engine operating problems that do not effect the engine when

operating on petrol. The engine must be in optimum operating condition to prevent the engine backfiring

when operating on LPG.

STEP ACTION YES NO

1. 1. Has the LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK been

performed. Go to step 2 Perform the

LPG VEHICLE

PRELIMINARY

DIAGNOSIS

CHECK.

2. 1. Has an ON BOARD DIAGNOSTIC SYSTEM CHECK been

performed? Go to Step 3. Perform

ON-BOARD

DIAGNOSTIC

SYSTEM CHECK.

Refer to Section

6C1.

Recheck for

engine backfire.

3. 1. Check spark plug leads for tracking or cracks in insulation and

check their resistance, refer to Section 6D1-3 IGNITION SYSTEM

- V6.

2. Are the spark plugs leads OK?

Go to Step 4. Replace spark

plug leads.

Recheck for

engine backfire.

4. 1. Remove and inspect spark plugs for fouling.

2. Are the spark plugs OK? Go to Step 5. Replace spark

plugs. Recheck

for engine

backfire.

5. 1. Re-gap spark plugs to minimum specification.

2. Have spark plugs been re-gaped to minimum specification? Go to Step 6. Re-gap spark

plugs to minimum

specification

Recheck for

engine backfire.

6. 1. Check ignition coil resistance, refer to Section 6D1-3 IGNITION

SYSTEM - V6.

2. Is the ignition coil resistance within specification?

Go to Step 7. Replace faulty

ignition coil.

Recheck for

engine backfire.

7. 1. Check PCM, DIS and crank angle sensor wiring harness terminal

retention.

2. Is terminal retention OK?

Go to Step 8. Resize terminals.

Recheck for

engine backfire.

STEP ACTION YES NO

8. 1. Check for vacuum leaks in vacuum or vapour feed lines between

mixer and converter, or a blocked balance line, FCV or RCV.

2. Are there any leaks or blockages?

Repair vacuum

leaks or

blockages.

Recheck for

engine backfire.

Go to Step 9.

9. 1. Test mixer operation, refer to 3.21 MIXER.

2. Is the mixer operating correctly? Go to Step 10. Overhaul mixer,

refer to 3.21

MIXER.

Recheck for

engine backfire.

10. 1. Is the LPG setup correct? Go to Step 11. Perform the LPG

setup procedure

refer to 4.1 LPG

SETUP

PROCEDURE.

Recheck for

engine backfire.

11. 1. Test converter pressures.

2. Are the converter pressures OK? Go to Step 12. Overhaul the

converter, refer to

3.18

CONVERTER.

12. 1. Test regulator check valve operation, refer to 3.19 REGULATOR

CHECK VALVE.

2. Is Regulator Check Valve operating correctly?

Go to Step 13. Replace the

regulator check

valve, refer to

3.19

REGULATOR

CHECK VALVE.

Recheck for

engine backfire.

13. 1. Check the engine mechanical condition by checking

compression, valve timing, intake and exhaust valves and manifolds

for casting flash.

2. Is the engine mechanical condition OK?

Check for

incorrectly routed

harnesses,

ignition leads

or non genuine

accessories.

Repair any faults.

Recheck for

engine backfire.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

6.9 POOR PERFORMANCE, FLAT SPOTTING, SLUGGISH OR POOR

FUEL CONSUMPTION WHEN OPERATING ON LPG

NOTE: Due to the nature of LPG , a m inim al loss of power m ay be experienced under heavy acceleration, this is

expected and quite normal.

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

1. The LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK must be the first step when diagnosing any LPG

system problem.

2. An ON BOARD DIAGNOSTIC SYSTEM CHECK should be performed to confirm that a problem with the

powertrain management system is not causing the engine to backfire when operating on LPG?

3. This checks for common causes of engine drivability problems.

4. Incorrect LPG setup can cause incorrect air/fuel ratios.

5. Incorrectly tensioned air valve to diaphragm attaching screws can cause incorrect mixer operation.

6. Correct mixer operation is required so that the correct air/fuel ratio is achieved.

7. A regulator check valve that is blocked or opening at the wrong vacuum can cause incorrect converter

operation.

8. The converter is one of the key components in the control of the delivery of LPG. Incorrect converter

operation can cause rich or lean mixtures.

STEP ACTION YES NO

1. 1. Has the LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK been

performed. Go to step 2 Perform the

LPG VEHICLE

PRELIMINARY

DIAGNOSIS

CHECK.

2. 1. Has an ON BOARD DIAGNOSTIC SYSTEM CHECK been

performed? Go to Step 3. Perform

ON-BOARD

DIAGNOSTIC

SYSTEM CHECK,

refer to

Section 6C1.

Recheck

performance.

3. 1. Perform SYMPTOMS CHECK, refer to Section, 6C1.

2. Are all checks OK? Go to Step 4. Repair any faults.

Recheck

performance.

4. 1. Has the LPG setup procedure been performed? Go to Step 5. Perform the LPG

setup procedure,

refer to

4.1 LPG SETUP

PROCEDURE.

Recheck

performance.

5. 1. Check air valve to diaphragm attaching screws for correct torque.

Refer to 3.21 MIXER.

2. Are the screws tightened to the correct torque?

Go to Step 6. Tighten the

screws to the

correct torque

specification.

Recheck

performance.

6. 1. Test mixer operation, refer to 3.21 MIXER.

2. Is mixer operating correctly? Go to Step 7. Overhaul mixer,

refer to

3.21 MIXER.

Recheck

performance.

7. 1. Test the regulator check valve (RCV) operation, refer to 3.19

REGULATOR CHECK VALVE.

2. Is the RCV operating correctly?

Go to Step 8. Replace the

regulator check

valve.

Recheck

performance.

8. 1. Test converter operation, refer to 3.18 CONVERTER.

2. Is converter operating correctly? Repair the

converter, refer to

3.18

CONVERTER.

Recheck

performance.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

6.10 FUEL CONTROL VALVE DOES NOT OPERATE

Figure 8A2-202

TEST DESCRIPTION

The numbers below refer to step numbers in the following diagnostic chart.

1. The LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK must be the first step when diagnosing any LPG

system problem.

2. This test confirms if the FCV is operating correctly.

3. This test confirms the continuity of the FCV circuit 439 and 5623.

4. This test confirms that the PCM is pulsing the FCV circuit to earth.

5. This test confirms that voltage is being applied to the FCV from fuse F33.

6. This test confirms that circuit 5623 is not open or shorted to battery voltage.

7. This test confirms that circuit 5623 is not shorted to earth.

8. This test checks the operation of the FCV.

9. This test confirms the retention of the PCM terminals. If the terminal retention is OK, the PCM should be

replaced.

STEP ACTION YES NO

1. 1. Has the LPG VEHICLE PRELIMINARY DIAGNOSIS CHECK been

performed? Go to step 2. Perform the

LPG VEHICLE

PRELIMINARY

DIAGNOSIS

CHECK.

2. 1. Perform a fuel control valve test, refer to 3.20 FUEL CONTROL

VALVE.

2. Is the fuel control valve operating correctly?

Fuel control valve

operation is

intermittent.

Check retention of

all FCV circuit

terminals.

Go to Step 3.

3. 1. Ignition OFF, disconnect PCM Connector A84_X3.

2. Ignition ON.

3. Measure the voltage between the PCM connector A84_X3

terminal E16 and earth.

4. Is battery voltage present?

Reconnect PCM

Connector A84

Go to Step 5.

Reconnect PCM

Connector A84

Go to Step 4.

4. 1. Ignition ON, LPG selected.

2. Measure the voltage at PCM connector A84_X3 terminal E16

circuit 5623 (Black/Blue wire) and earth.

3. Turn the ignition from off to on. Is there at least nine volts present

for three seconds when the ignition is first turned on or when the

engine is cranking?

Go to step 8. Go to Step 5.

STEP ACTION YES NO

5. 1. Ignition off.

2. Disconnect FCV connector Y143_FCSV.

3. Ignition on.

4. Measure the voltage at the FCV connector Y143_FCSV circuit 439

(Pink wire) and earth.

5. Is battery voltage present?

Go to step 6. Repair open in

circuit 439 (Pink

wire) between

fuse F33 and

connector

Y143_FCSV.

6. 1. Check for open or short to voltage in circuit 5623 (Black/Blue wire)

between FCV connector Y143_FCSV and the PCM.

2. Is circuit open or shorted to voltage?

Repair open or

short to voltage

circuit 5623

(Black/Blue wire).

Verify repair.

Go to Step 7.

7. 1. Check for a short to earth in circuit 5623 (Black/Blue wire).

2. Is circuit 5623 (Black/Blue wi re) shorted to earth? Repair short to

earth in circuit

5623

(Black/Blue wire).

Verify repair.

Go to step 8.

8. 1. Test operation of the FCV, refer to 3.20 FUEL CONTROL VALVE

in this Section.

2. Is the FCV operating correctly?

Fuel control valve

operation is

intermittent.

Check all FCV

circuit terminal

retention.

Replace FCV.

Verify repair.

9. 1. Check the PCM connector terminal retention.

2. Is PCM terminal retention OK? Replace PCM.

Recheck starting

on LPG.

Repair PCM

terminals.

WHEN ALL DIAGNOSIS AND REPAIRS ARE COMPLETE, VERIFY CORRECT OPERATION.

6.11 TECH 2 SCAN TOOL: ENGINE DATA

The T ECH 2 scan tool engine data listed in the f ollowing table may be used for com paris on when diagnosing faults

on MY 2003 VY Series vehicles operating on LPG:

• After completing the 6.3 LPG VEHICLE PRELIMINARY DIAGNOSIS and the ON-BOARD DIAGNOSTIC

SYSTEM CHECK in Section 6C1.

• Finding the on-board diagnostics are functioning properly and

• No diagnostic DTCs are displayed.

IMPORTANT: The data in the f ollowing table is TYPICAL and as m any of the param eters are var iable according to

operating conditions, should be used as a guide only. For descriptions of the data parameters refer to

Section 6C1-2 DIAGNOSIS – V6 ENGINE.

A Tech 2 scan tool that displays faulty data should not be used, and the problem should be reported to the

manufacturer. The use of a faulty Tech 2 Scan Tool can result in misdiagnosis and unnecessary parts replacement.

TEST DESCRIPTION

The numbers below refer to the bracketed numbers on the diagnostic chart.

1. Scan Position refers to the data that will be displayed when from the Engine menu, F2: Data Display then F0: All

Data is selected. The down arrow can be used to scroll through the data one parameter at a time. After Time

From Start parameter is displayed, pressing the down arrow again w ill display the top of the list again.

2. Units Displayed are the available ways of displaying what each parameter is currently operating in, or a value

that is being sensed or being outputted by the PCM.

3. Typical Data Value is separated into two parts: ignition on and engine running. These displayed values are

typical of a normally operating vehicle. The Ignition ON com parison should be performed first as this may lead

to a quick identification of a f ailure. The engine running data should be compared to the Ignition ON data as a

diagnostic check to make sure the component or system is operating properly.

4. Ignition ON values are the typical values that should be seen on the T ech 2 scan tool with the ignition ON, the

engine stopped and at normal operating temperature.

5. Engine Running values are the typical values that should be seen on the Tech 2 scan tool with the engine

running at normal operating temperature.

NOTE: When operating in the LPG m ode all of the left hand oxygen sensor inf orm ation will be f rozen or invalid, this

is because the PCM only monitors the right hand oxygen sensor when operating on LPG. The values that are frozen

or invalid are shaded in the following table.

TYPICAL DATA VALUE (3)

SCAN POSITION (1) UNITS DISPLAYED

(2) IGNITION ON

(4) ENGINE RUNNING (5)

ENGINE SPEED (IN PARK) RPM 0 RPM ± 100 RPM FROM DESI RED IDLE SPEED

ENGINE SPEED (IN DRIVE) RPM 0 RPM ± 50 RPM FROM DESIRED IDLE SPEED

DESIRED IDLE SPEED

(IN PARK) RPM 0 RPM 737 RPM

(VARIES WITH TEMPERATURE)

DESIRED IDLE SPEED

(IN DRIV E ) RPM 0 RPM 662 RPM

(VARIES WITH TEMPERATURE)

ENG. COOLANT TEMP (ECT) VOLTS VARIES VARIES

COOLANT TEMPERATURE DEGREES C VARIES VARIES

IAT VOLTS VARIES VARIES

INTAKE AIR TEMPERATURE DEGREES C VARIES VARIES

MAF SENSOR FREQUENCY Hz 0 Hz 2200-2500 Hz

MASS AIR FLOW GRAM /SEC 0 g/s 5 - 10 g/s

MASS AIR FLW / CY L Mg/s 0.0 Mg/s 140 to 150 Mg/s

TPS SI GNA L VOLTS 0.51 V 0.51 V

THROTTLE ANGLE 0-100 % 0 % 0 %

RH 02 SENSOR READY YES / NO NO YES

LH 02 SENSOR READY YES / NO NO NO

RH 02 SENSOR Mv 451 Mv 100-1000 Mv AND V A RY ING

LH 02 SENSOR Mv 451 Mv 100-1000 Mv AND VARYING

RH ST FUEL TRIM + 100% TO –100% 0 % +10 % TO –10 %

LH ST FUEL TRIM + 100% TO –100% 0 % +10 % TO –10 %

RIGHT LT FUEL TRIM + 100% to – 100 % 0 % + 10 % to – 10 %

LEFT LT FUEL TRIM + 100% to – 100 % 0 % + 10 % t o – 10 %

LTFT ENABLE YES / NO NO YES

FUELING MODE OP E N / CLOS ED LOOP OPEN LOOP CLOSED LOOP

LTFT CELL CELL # 0 16

RH O2 STAT US RICH / LE AN LEAN RICH

LH O2 STATUS RICH / LEAN LEAN LEAN

RH O2 CROSS CNTS COUNTS 0 1

LH O2 CROSS CNTS COUNTS 0 0

STFT DELTA 0 – 100 % 7 % 7 %

LTFT DELTA 0 – 100 % 2 % 2 %

DECEL FUEL CUTOF F NO / Y ES NO NO

INJ. P ULS E TIME Ms 0.00 Ms 3.55 Ms

INJECTOR V OLTA G E VOLTS 11.9 V 13.8 V

AIR / FUE L RATIO % 14.7 : 1 14.7 : 1

PURGE PWM % 0 % 7 %

EGR POS . COMMANDED % 0% 0 %

EGR POS. FEEDBACK % 0% 0 %

EGR PINTLE SENSOR VOLTS VOLTS 0.8 V 0.8 V

BATTERY VOLTAGE VOLTS 11.9 V 13.4 V

REFERENCE V O LTS VOLTS 5.0 V 5.0 V

3X SIGNAL MISSING / PRESENT MISSING PRESENT

18X SIGNAL MISSING / PRESENT MISSING PRESENT

CAM SIGNAL MISSING / PRESENT MISSING PRESENT

IAC POSITION STEPS 51 STEPS 43 STEPS

LITERS P ER HOUR L/hour 0.00 1 – 2 L/Hour

IDLE RPM VA RIATION RPM 0 RPM 200-268 RPM

SPARK MODE BYPASS / EST BYPASS ELEC. SPARK. TIM.

SPARK ADVANCE DEGREES BTDC 0 ° CA + 20° CA

KNOCK SIGNAL CYLINDER 1 NONE / KNOCK

DETECTED NONE NONE

TYPICAL DATA VALUE (3)

SCAN POSITION (1) UNITS DISPLAYED

(2) IGNITION ON

(4) ENGINE RUNNING (5)

KNOCK SIGNAL CYLINDER 2 NONE / KNOCK

DETECTED NONE NONE

KNOCK SIGNAL CYLINDER 3 NONE / KNOCK

DETECTED NONE NONE

KNOCK SIGNAL CYLINDER 4 NONE / KNOCK

DETECTED NONE NONE

KNOCK SIGNAL CYLINDER 5 NONE / KNOCK

DETECTED NONE NONE

KNOCK SIGNAL CYLINDER 6 NONE / KNOCK

DETECTED NONE NONE

KNOCK SIGNAL ANY

CYLINDER KNOCK / NONE NONE NONE

KNOCK RETARD # OF DEGREES NO NO

KNOCK RET A RD CYLINDER 1 # OF DEGREE S 0 ° CA 0 ° CA

KNOCK RET A RD CYLINDER 2 # OF DEGREE S 0 ° CA 0 ° CA

KNOCK RET A RD CYLINDER 3 # OF DEGREE S 0 ° CA 0 ° CA

KNOCK RET A RD CYLINDER 4 # OF DEGREE S 0 ° CA 0 ° CA

KNOCK RET A RD CYLINDER 5 # OF DEGREE S 0 ° CA 0 ° CA

KNOCK RET A RD CYLINDER 6 # OF DEGREE S 0 ° CA 0 ° CA

TCC SOLENOID ON / OFF OFF OFF

VEHICLE SPEED KM / H 0 KM/H 0 KM/H

A/C REQUEST ON / OFF OFF OFF

A/C CLUTCH ON / OFF OFF OFF

A/C PRESSURE SENSOR VOLTS 1 - 2 V 1 - 2.5 V

A/C PRE S SURE SENS OR kPa 832 kPa 600 - 700 kPa A/C OFF

800 - 1200 kPa A/C ON

HIGH SPEED FAN ON / OFF OFF OFF

LOW SPEED FAN REQUEST ON / OFF OFF OFF

THEFT STATUS NO START/START START START

STARTER RELAY OFF / ON ON OFF

FUEL PUMP RELAY ON / OFF OFF OFF

CRANK TIME SEC 0.0 SEC 0.4 SEC

DTC STA T US NO DTC(s )/ DTC(s) SE T NO DT C NO DT C

TIME FROM START TIME 0:00:00 VARIES

CHECK P OWERTRAIN

LAMP OFF / ON ON OFF

REQUEST E D TORQUE Nm 476 Nm 476 Nm

(Nm will vary depending on the ABS/TCS

control module request ed torque)

ACTUAL TO RQUE Nm 0 Nm 11 Nm

(Nm will closely follow requested torque

during tract i on control)

LOW OIL PRESSURE NO / YES YES NO

LPG SWI TCH " OFF / ON OFF OFF

LPG FUEL ENABLE NO / YES YES YES

FUEL # P E T ROL / LPG LPG LPG

LPG FUEL CONTROL VA LV E 0-100 % 0% 36 %

LPG MODE ENABLED NO / YES YES YES

LPG LOW PET ROL CUT OUT NO / YES NO NO

LPG SMART SOLENOID ON / OFF OFF ON

" Momentary contact switch. Depressing the switch will change the value to ON and revert to OFF when released.

# Fuel ref ers to the mode the vehic le is currently operating in. The m ode can only be switched with the ignition on

and engine not running, or at an engine speed greater than 1500 rpm.

7. WIRI NG & CONNECTORS

Figure 8A2-203

Figure 8A2-204

8. SPECIFICATIONS

LPG tank fillable capacity:

- Sedan......................................................................................... 74 litres ± 2 litres

- Wagon ....................................................................................... 60 litres ± 2 litres

- Utility.......................................................................................... 70 litres ± 2 litres

Converter primary pressure .......................................................... 1 - 1.5 psi (7 - 10 kPa)

Converter secondary pressure ..................................................... Negative 1 - 1.5 inches W.C

(Negative 24 - 38 mm W.C.)

Contents gauge sender unit resistance:

- Empty......................................................................................... 40 Ohms

- Full............................................................................................. 255 Ohms

Fuel Control Valve (FCV) resistance ............................................ 19 - 21 ohms @ 20°C

LPG lock-off coil resistance ......................................................... 17 - 27 ohms @ 20°C

LPG lock-off pressure rating......................................................... 1200 kPa

Spark plug gap.............................................................................. 1.4mm

9. TORQUE WRENCH SPECIFI CATIONS

Air cleaner lower housing nut................................................ 5.0 – 7.0

Air duct clamp....................................................................... 1.5 – 2.5

Air valve cover screw............................................................ 7.5 – 9.0

Air valve to diaphragm screw................................................ 2.0 – 2.5

Automatic fill limiter screw..................................................... 5.0 – 7.0

Converter to support bracket screw...................................... 10.0 – 12.0

Coolant hose clamp nut........................................................ 10.0 – 12.0

Coolant hose clamp screw.................................................... 3.0 – 4.0

Tank fuel gauge screw.......................................................... 5.0 – 7.0

Diaphragm cover to regulator body screw............................ 3.0 – 5.0

Filler line & connector pipe connectors................................. 12.0 – 18.0

Filler valve nut, Sedan........................................................... 50.0 – 60.0

Filler valve nut, Wagon ......................................................... 50.0 – 60.0

Filler valve nut, Utility............................................................ 12.0 – 15.0

Filler valve flange screw, Sedan ........................................... 7.0 – 9.0

Floor console cover assembly screw.................................... 1.0 – 3.0

Heat shield screw.................................................................. 3.0 –5.0

Heat shield support post screw............................................. 10.0 – 12.0

Lock-off bracket to converter screw...................................... 3.0 – 5.0

Lock-off cup assembly screw................................................ 3.0 – 5.0

Manual service valve screw.................................................. 5.0 – 7.0

Mixer bell housing screw....................................................... 1.0 – 3.0

Pressure relief valve to LPG tank ......................................... 60.0 – 65.0

Service line connectors......................................................... 12.0 – 18.0

Service line retaining clamp screw........................................ 12.0 – 15.0

Smart unit screw................................................................... 1.0 – 3.0

Solenoid sleeve to manual service valve.............................. 15.0 – 18.0

Spare wheel carrier nut and bolt........................................... 40.0 – 50.0

Tank cover ball stud nut, Utility............................................. 3.0 – 5.0

Tank cover upper screw, Utility............................................. 10.0 –12.0

Tank front mounting bracket screw, Sedan.......................... 25.0 – 35.0

Tank screw, front Sedan....................................................... 10.0 – 12.0

Tank nut, rear Sedan............................................................ 70.0 – 90.0

Tank nut, Wagon .................................................................. 40.0 – 50.0

Tank strap nut, Utility............................................................ 40.0 – 50.0

Tank support bracket nut, Utility ........................................... 40.0 – 50.0

Tank support upper connecting plate nut, Utility................... 40.0 – 50.0

Valve box screw, Wagon ...................................................... 7.0

Vent tube hose clamp........................................................... 2.0 – 3.0

10. SPECIAL TOOLS

TOOL NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

N/A

LPG TANK UNLOADING PUMP

Commercially available.

COMMERCIALLY

AVAILABLE

J39200

DIGITAL MULTIMETER

Tool No. J39200 previously

released, or use commercially

available equivalent. Must have 10

meg ohm input impedance.

Available

J35616-A

(KM609)

CONNECTOR TEST ADAPTOR

KIT

Used when carrying out electrical

diagnostic circuit checks.

Previously released.

Desirable

7000086I

TECH 2 DIAGNOSTIC SCAN

TOOL

Used for diagnosis of vehicle

electrical system.

Previously released.

Mandatory

J23738-A

HAND VACUUM PUMP

(20 IN. HG MINIMUM)

Used for applications where a

controlled vacuum is required to be

applied.

Previously released and also

commercially available.

Mandatory

N/A

ELECTRONIC GAS LEAK

DETECT OR

Commercially available

Available

TOOL NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

N/A

LEAK TEST FOAMING AGENT

Commercially available

(such as Gameco Leak Checktm)

Available

ITK-1

LPG TEST KIT

AVAILABLE FROM:

IMPCO TECHNOLOGIES

1 - 3 TAUNTON DRIVE

CHELTENHAM VIC. 3192

ALL CORRESPONDENCE TO:

P.O. BOX 45, CHELTENHAM VIC.

3192

TELEPHONE: (03) 9584 5644

FAX: (03) 9583 0696

The LPG test kit contains the

following tools.

Previously released.

Available

ITK-1

(c)

PRESSURE GAUGE HOSE

Part of LPG test kit ITK-1.

Available

ITK-1

(e)

PRESSURE GAUGE HOSE

CONNECTOR FOR INCHES W.C.

PRESSURE GAUGE

Part of LPG test kit ITK-1.

Available

ITK-1

(d)

PRESSURE GAUGE HOSE

CONNECTOR FOR PSID

PRESSURE GAUGE

Part of LPG test kit ITK-1.

Available

ITK-1

(b)

PRESSURE GAUGE INCHES

W.C.

Part of LPG test kit ITK-1.

Available

TOOL NUMBER ILLUSTRATION DESCRIPTION CLASSIFICATION

ITK-1

(a)

PSID PRESSURE GAUGE

Part of LPG test kit ITK-1.

Available

ITK-1

(f)

SECONDARY DIAPHRAGM

LEVER ADJUSTMENT GAUGE

Part of LPG test kit ITK-1.

Available