LPG Installation Manuals
CHIP IT LPG INJECTION MANUAL
IMPORTANT: YOU SHOULD READ AND UNDERSTAND THESE INSTRUCTIONS IN THEIR ENTIRITY BEFORE BEGINNING TO INSTALL THIS DIESEL LPG ENHANCEMENT SYSTEM.
They should be read in conjunction with the accompanying wiring diagrams and pictures.
This LPG Enhancement System should be fitted to meet all relevant local standards that apply to the fitment of LPG delivery systems.
All safe working practices with regard to the use of power tools should be adhered to when fitting this system. Refer to the manufacturer’s instructions and wear appropriate protective equipment. This system should be installed by qualified persons that have a background of working with vehicles and LPG.
This system utilities liquid LPG from a tank. (LPG tank is not supplied with this under bonnet kit and vapour tanks can be used if necessary)
The liquid LPG is converted to gaseous form in the convertor utilizing hot water from the vehicles heater hoses, LP gas is then injected into the air intake tract of the engine. This makes the vehicle dual fuel in its operation when the LPG system is turned on. As with any aftermarket fuel system, the vehicle will require re-tuning for best results in both performance and economy.
First time installers should read the instructions and fully familiarize themselves with the installation before they begin. Time spent on a dynamometer would be the best way to re-tune any vehicle.
With the CHIP IT LPG System switched on, the vehicle with have more fuel at all points above on the “ON” LPG injection point. The LPG has a different burn characteristic to diesel. It burns rather than exploding. You will find that the effect this has, is to make the engine run quieter, as the normal knock produced as the diesel explodes is lessened by the burn of the LPG.
Install the converter into the engine compartment. The converter is supplied with the lock off fitted to the converter, but it may be necessary to remote fit the solenoid lock off in order to comply with local governing body guidelines in some regions. Two flare nuts are supplied with the kit for remote mounting of the lock off should this be necessary. Installers should ensure that they are familiar with and comply with all local relevant standards when fitting this under bonnet kit.
For reasons of transferred noise or vibration, it is not recommended that the convertor or solenoid lock off be mounted to the firewall. Install the converter in a place where it will be easiest to install the hoses, tubing and wiring required and keep it away from heat sources such as the turbocharger and exhaust. If limited space demands that the converter be placed near to a heat source, a heat shield of some type should be fitted. This applies to every part of the under-bonnet kit.
Connect the heater hose and “T” pieces to supply the vehicles heater hoses to the converter. Do this when the vehicle has cooled down and the water is not dangerously hot. Make sure that the “T” pieces are inserted into the heater hose lines in a position where they get constant flow when the engine is running and not only when the heater is turned on. Also make sure that the “T” pieces are in different hoses and not both in the same hose on the vehicle so as to have a circulating effect. The first thing to do is to establish where you should cut the heater hoses. Then the hoses should be clamped at either side of the proposed cuts in order to stop the fluid from draining. Once each hose is cut, slip a hose clamp over the hose and insert the brass “T” piece. Re-connect both ends in the same manner and the join the “T” pieces to the Convertor with the hose and clamps provided.
Connect the LPG line from the LPG tank to the converter via the Lock off Solenoid Valve. (Tank and line are not supplied) The tank, the filler and the line connecting the tank to the Lock off Solenoid Valve at the Converter must be sourced separately. They should be fitted by a qualified, competent person.
Fit the dash Change-over switch and Boost Controller ECU in an appropriate position in, under or on the vehicles dashboard and wire it up as shown in the accompanying wiring diagram. The position should be determined by the owner of the vehicle. A practical position for the wiring to be connected without dismantling the dashboard (instrument panel) is recommended.
Some wires are required to run from inside the vehicles cabin to the engine compartment and the reverse is also the case, with some wires required to be pulled through in opposite directions. A simple way of doing this is to attach the wire or wires required to a piece of stiff wire. Fencing wire or TIG welding wire work well. Bend the TIG wire around the wires to be pulled through after it has been inserted through the firewall and secure the wires to it with electrical tape. This can be pushed through an existing rubber bush in the vehicles firewall. A flat bladed screwdriver may be needed to open an appropriate sized hole in the first instance. Care should be taken not to damage the connectors on any wires during the pulling through process.
On turbocharged vehicles, fit the MAP sensor (brass 1/8” BSP- 3/16” hose barb) fitting to the engine air intake tract after the turbocharger (post butterfly valve where fitted) by using a drill and tapping the hole to suit. The convertor connects to this and is secured by the small hose clamps supplied. An 8.5mm drill and a 1/8” BSP tap are required. IMPORTANT: Care should be taken not to leave filings in the air intake tract. The boost sensor
Tee’s into this line at any convenient point along its length. (sample of fitting)
Fit the JET BOSS to the engine air intake tract in the same manner as the MAP air sensor fitting using the same technique applied to the MAP sensor. Fit the appropriate jet for your vehicle into the boss and then secure in place with the 1/8”BSP female – 3/16” hose barb supplied. Use sealant to ensure the joint is gas tight. (sample of jet boss)
NOTE: The jet boss should be fitted after the turbo and as far from the engine intake manifold as possible. This will allow for proper mixing of the gas and air before it reaches the combustion chamber.
Read the attached wiring diagrams. Wire the vehicle in accordance with the appropriate wiring diagram. Connectors are colour coded with red, yellow and green tape to pair the male to female connector halves.
The ORANGE wire is required to be connected to the ALTERNATOR “Exciter” wire. This feeds 12 volts, that switches on when the engine starts and switches off when the engine stops, to the safety relay. This signal can sometimes be found under the dashboard or elsewhere in the engine bay, but we recommend the alternator when fitting the system. This is critical to the operation of the safety relay.
CALIBRATING THE BOOST ECU.
Power up the Boost ECU and follow the instructions in the CHIP IT BOOST CONTROLLER SET UP GUIDE below: Remember, the system will not work until 40 degrees of engine temperature has been reached.
Chip It Boost Controlled LPG Injection System Setup
1. To be fitted by a Qualified and Experienced LPG Fitter
2. LPG quantity to be discussed and tuned by LPG Fitter using jets and LPG Regulator Pressure Settings.
3. Chip It Boost Setting: (default set to 6 psi on & 4.5 psi off) To adjust, if required, do the following
a. Press Set button, LED displays 0000. Use arrows keys select 0001 and press “SET”
b. Scroll through screen display to find AH1 (Relay trigger LPG Injector ON). Using arrows keys select desired LPG “ON” point (Minimum 2psi)(Min 4-5psi for Common Rail vehicles). Then press “SET” to confirm.
c. Scroll through Screen display using arrow key to find AL1 (Relay trigger Injector “OFF”. “OFF” point should be 0.5-2psi LESS then “ON” point (is 0.5 psi – 2psi).
d. Scroll through screen display to find “END” and then press “SET” to finish.
THE AH1 LED TRIGGER AT BOTTOM RIGHT CORNER OF BOOST ECU WILL ILLUMINATE WHEN LPG INJECTION ACTIVE COMMAND IS REACHED & OFF WHEN LPG TRIGGER AL1 HAS MET SET COMMAND.
Where there are instances where the gas delivery comes on too early to at idle simply set the boost ECU with a higher “ON” and “OFF” points.
All jets are identified by a number representing thousands of an inch, which is written on the side of the jet (silver bill type or brass fitting)
The Jetting Guide below is just that, a guide.
Tuning and LPG/Diesel ratios will vary from vehicle to vehicle.
Correct LPG ratios of circa 25% is the job of the installer/tuner.
The following Jetting Guide is a good starting point.
JET SIZE – ENGINE CAPACITY
020 1.0 – 1.5 LT
025 1.5 – 2.0 LT
030 2.0 – 2.5 LT
035 2.5 – 3.0 LT
040 3.0 – 3.5 LT
045 3.5 – 4.0 LT
050 4.0 – 4.5 LT
055 4.5 – 5.0 LT
060 5.0 – 6.0 LT
065 6.0 – 7.0 LT
070 7.5 – 9.0 LT
075 9.5 – 11 LT
080 11.5 – 13 LT
085 13.5 – 15 LT
090 15.5 – 17 LT
095 17.5 -19 LT
100 19.5 -22 LT
Note – LPG flow rates can and should also be adjusted with varying pressure from the Convertor.
Chip It does not accept responsibility for gas injection ratios or tunes used. This is the responsibility of the installer/tuner. By fitting the system you acknowledge this point.
For high LPG/Diesel ratios Chip It recommends the use of the super fast Chip It EGT monitor which can be programmed to interface with the Chip It PLATINUM. See the Chip It website or call for more details or orders.
CONNECT THE PETROL INJECTION MODULE TO YOUR LAPTOP TO CUSTOM TUNE IF DESIRED
THE VALUES SHOWN IN THE SOFTWARE REPRESENT BOOST PRESSURES.
ADJUST THE DESIRED INJECTION “ON” POINT BY INCREASING OR DECREASING THE “ON” POINT TRIGGER VALUE.
LOWER VALUES WILL REDUCE THE TIME NEEDED BEFORE THE PETROL INJECTION SYSTEM STARTS TO INJECT FUEL, HIGHER NUMBERS WILL DELAY THE ONSET OF INJECTION START.