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Technical Instructions
installation Guide System New Bora
MT-IS-GAI-NWB.01-E del 01/10/2013
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Technical Instructions installation Guide System New Bora
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Pag. 2 di 26
ID Technical Document: MT-IS-GAI-NWB.01-E
Rev. Date Review n. Issued by Reviewed/ Approved
0 19/03/2013 First Issue Technical office MT
Technical Manager R&S
1 01/10/2013 Second Issue Technical office MT
Technical Manager R&S
INTRODUCTION
This manual provides information about the installation of Zavoli S.r.l. gas systems. The process requires the support of specific equipment and specialized personnel. Our goal is to provide guidelines about the installation and fine-tuning of our injection systems. In particular, this manual is designed for anyone who:
installs or fine-tunes “Bora” gas systems,
needs a reference guide about the installation of these systems,
wishes to understand or improve their knowledge of the “Bora” gas system operating principles,
needs support to fine-tune the system or solve specific issues.
For more information about the “Bora” gas system, please refer to the other manuals published by Zavoli S.r.l.
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General Index Introduction ………………………………………………………… …2
1. ……………….. Installation of Mechanical Parts…………………………..……….. …4 1.1 ………… Component Location ……..………………………………………... …4 1.1.1……. Regulators ……………….…………………………………………. …4 1.1.2……. Gas Solenoid Valves………………………………………………… …5 1.1.3……. Installation of the Map……………………………………………… …7 1.1.4……. Filter and Sensor for temperature and gas pressure….…………. …7 1.1.5……. Injection Nozzles..…………………………………………………… …7 1.1.6……. Gas Injectors………………………………………………………… …10 2. ……………….. Complete Mechanical Installation Part Schemes ………………… …11 2.1 ………… Scheme the Mechanical GPL.…………….…...……………………. …11 2.2 ………… Scheme the Mechanical CNG.…………….……..…………………. …12 3. ………………. Electrical Wiring …...……………. ………………………………… …13 3.1 ………… Main Cables ……….……...……….………………………………… …13 3.2 ………… Injector Cut-Off Cables ...….…….…….…………………………… …14 3.3 …………. Connection of the Gas Injectors …………………………………... …14 3.4 …………. Wiring General Scheme…………………..………………………... …15 3.4.1……. Scheme 4 cylinders Bora Light LPG ……….……………………... …15 3.4.2……. Scheme 4 cylinders Bora LPG …....……….……………………….. …16 3.4.3……. Scheme 4 cylinders Bora Light CNG ……..……………………….. …17 3.4.4……. Scheme 4 cylinders Bora CNG …...……….……………………….. …18 4. ………………... Fine Tuning ……………………….………………………………… …19 4.1 …………. Main steps for setting up the unit...................................................... …20 4.2 …………. Initialization Ecu …..……………………………………………….. …20 4.3 …………. Parameters ………………………………………………………….. …21 4.4 …………. Sensores ……………………………………………………………... …21 4.5 …………. Save Calibration …………………………………………………... …22 4.6 …………. Self-Calibration ……...……………………………………………… …22 4.7 …………. Map ...………………………………………………………………... …23 5. ……………….. Bora Program Error Codes …..……………………………………. …24 6. ……………….. Table Sizing Jets For Injection Kit NEW BORA …...……………. …25 6.1 …………. Table Bora LPG injectors Pan-Jet .………………………………... …25 6.2 …………. Table Bora CNG injectors Pan-Jet ……..…………………………. …26
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1. Installation of Mechanical Parts
1.1 Component Location
Before installing your Bora or Bora Light (LPG) and Bora or Bora Light (CNG) system components, find a location inside the engine chamber which allows for the following operations to be easily completed:
1.1.1 Regulators - Maintenance and adjustments. - Inbound and outbound connections with the engine cooling liquid should be easily
accessible. Tubing should be kept as short as possible and should not be bent (fig. 1.1.1-2). - The tube connecting the gas outlet on the regulator and the gas inlet on the injectors should
be kept as short as possible (as indicated in the General Installation Manual, the maximum length is 700mm).
- The depressurization tube on the regulator should be kept as short as possible. The hole must be drilled right below the throttle valve, above the tubes branching off of the intake manifold and connecting to each individual cylinder (as indicated in the General Installation Manual, the maximum length of the tube is 700mm). See Fig. 1.1.1-2A for the Methane Regulator and Fig. 1.1.1-2B for the LPG Regulator.
- Do not use forks to connect the depressurization tube to the over-pressure valve. Connections for the LPG regulator should be separate. See Fig. 1.1.1-2B.
- The correct position of reducer during installation with gas exit (fig. 1.1.1-2B).
Fig. 1.1.1-1 Fig. 1.1.1-2
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Fig. 1.1.1-2A Fig. 1.1.1-2B
1.1.2 Gas Solenoid Valves; For the LPG (Bora or Bora Light) kit three different types of valves can be used. Choose the most appropriate model in accordance with the type of kit installed in the vehicle.
- In Fig. 1.1.2-1A, the solenoid valve has been installed right above the regulator. The regulator shown here is a basic model, and the valve is the kind commonly used for standard 4-cylinder vehicles. The connection with the regulator is established by means of a 6mm copper pipe, positioned in such a way as to allow for easy maintenance and replacement of the filters.
- When connecting the copper pipe, make sure to clean the pipe and check that shavings have not fallen inside it.
- The valve used in Fig. 1.1.2-1B is the kind designed for vehicles, and it has been connected directly to the regulator. For “super” versions of the regulator, the connection the feeding tube, which is a Ø 8mm (see Fig. 1.1.2-2C).
- Make sure not to tighten the joint too much, as this may cause its base to break.
For Methane (Bora or Bora Light) kits; - The solenoid valve must be installed above the regulator, model Apus (Fig 1.1.2-5). - The solenoid valve must be installed directly on the gearbox, model Benjo (Figure 1.1.2-6). - The fuel level sensor must be installed on the valve.
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Fig. 1.1.2-1 Fig. 1.1.2-2
Fig. 1.1.2-3 Fig. 1.1.2-4
Fig. 1.1.2-5 Fig. 1.1.2-6
Fig. 1.1.2-7 Fig. 1.1.2-8
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1.1.3 Installazione MAP
For versions of kit Bora Bora and Light LPG and CNG; - The sensor must be fixed in safety so provisional seen that serves only for the phase of self-mapping. - Connect the sensor Map using the "V" with the unit as shown in Figure 1.1.3-1.
Fig. 1.1.3-1
1.1.4 Filter and Sensor for temperature and gas pressure
For a correct installation of these components: - The gaseous-phase filter must be installed on the regulator output. As indicated in the
General Installation Manual, we recommend users to perform regular scheduled replacements of the filters.
- The temperature sensor and pressure sensor must be installed near the gas injectors, right after the gas filter by the regulator output.
1.1.5 Injection Nozzles
The position of nozzles (located on the intake manifold, fig. 1.1.5-1A) is a key element in the correct installation of sequential injection systems:
- We suggest that you clearly identify all the parts of the intake manifold that will have to be perforated.
- Drill your holes near the engine head, as shown in fig. 1.1.5-1B.
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Fig. 1.1.5-1A Fig. 1.1.5-1B
- Each nozzle must be installed at a 90 degree angle with the intake manifold – or at least at such an angle that jets are directed toward the engine rather than toward the throttle valve (fig. 1.1.5-2).
Fig. 1.1.5-2 - Before drilling any holes in the intake manifold, please make sure that nozzles are
positioned in a way which allows the tubes connected to the injectors not to exceed the maximum length of 150mm.
- Beside these standard injection nozzles (supplied with your kit) Zavoli s.r.l. manufactures two more types of nozzles. The one shown in fig. 1.1.5-3 features an extra opening, located on the side of the nozzle and marked by a spot in the hollow of its bottom part. The spot helps identify the direction of the hole, and represents a reference point for a correct installation of the nozzle jet. (Fig. 1.1.5-4A).
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Fig. 1.1.5-3 - The injection nozzle shown in fig. 1.1.5-5 can be fixed inside the intake manifold by means
of a Teflon tube. This type of installation can be particularly useful when drilling holes according to directions (near the engine head, etc.) is not an option. See fig. 1.1.5-4B.
Fig. 1.1.5-4A Fig. 1.1.5-4B
Fig. 1.1.5-5
Cod.491050
Cod.491COM052
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1.1.6 Gas Injectors
One of the main features which make our Pan-Jet injector (fig. 1.1.6-1) an extremely handy component is that it is a modular injector - i.e. it can be installed individually or in rails of two, three and so on (fig. 1.1.6-2). This characteristic makes it easier to keep the tube connecting the injection nozzle and the injector as short as possible.
- We suggest that careful attention be paid to any existing bends in the connecting tubing installed between the injectors and the intake manifold. Please make sure that bends are “soft” and flexible, and that enough room is allowed for the tubing. Make sure that the tubing does not get “crushed”, as this may prevent the system from working correctly.
- Use the metal bands supplied with the kit to tighten the connecting tube. - Tighten the injector. - Make sure that all jets are the right size and diameter.
Fig. 1.1.6-1
Fig. 1.1.6-2
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2. Complete Mechanical Installation Part schemes
2.1 Scheme the mechanical GPL
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2.2 Scheme the mechanical CNG
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3. Electrical Wiring
The following are general directions which should be considered valid for any type of vehicle. It is important to be fully aware of these directions, as they represent a key factor in understanding how the entire system works. Here are some of the most important points to remember for a correct installation: - All connections involving wires that are not joined to a connector must be soldered.
Connections must be watertight and properly insulated. - When installing electrical wiring for your Retrofit kit, please follow the original wiring
system of your vehicle. - Securely fix the wires with metal bands to prevent loose wires from rubbing together (or
against moving/fixed parts of the vehicle or the engine) and getting damaged. - Please make sure that wires are not too taut, as vibrations may damage these connections. - The gas tube should never be used as a support for an electrical wire or any other kit
component. 3.1 Main Cables
Main cables are a complex electrical component of the system, which includes a number of thin wires connected to stiff connectors. It is therefore recommended to handle it with great care during all phases of the installation process. In particular, pay careful attention to the following: - All cables must be installed at a safe distance from the fuses and their corresponding wires. - Connect all the ground wires at a point which ensures good electrical contact (battery
negative pole). - Do not force connectors into their sockets. Connectors are of a “polarized” kind – in other
words, they will only fit into their socket if inserted the proper way. Connections that do not have a connector (lambda signals, connection under the key slot, battery positive and negative poles) require soft brazing (watertight soldering).
- Install the fuse in a position which is easily accessible.
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3.2 Injector Cut-Off Cables
Fig. 3.2-3
The direction of your connections is very important. BLACK wires should be going to toward the petrol injection control unit, others toward the injectors. Important to follow the sequence of injection, starting with the blue / blue blacks to be connected with the gas injector labeled 1, the other in the order as shown in Figure 3.2-3.
3.3 Connection of the Gas Injectors
In order to install the gas injector cables correctly, please follow the order of the emulator cables very carefully. Gas injector outlets and cables are individually identified by letters (1, 2, 3, 4). For 5-6-8-cylinder vehicles, cables include two extra connectors and two extra sheaths (marked by two red bands) to allow for the second bench to be connected. The sheaths of the gas injector cables are identified by letters 5, 6, 7 and 8. To make sure that your connections are properly placed, please follow these directions: - 1-band sheath: it must be connected to the gas injector on the petrol injector (disconnected)
through the BLUE and BLUE/BLACK wires of the injector cut-off device. - 2-band sheath: it must be connected to the gas injector on the petrol injector (disconnected)
through the RED and RED/BLACK wires of the injector cut-off device. - 3-band sheath: it must be connected to the gas injector on the petrol injector (disconnected)
through the GREEN and GREEN/BLACK wires of the injector cut-off device. - 4-band sheath: it must be connected to the gas injector on the petrol injector (disconnected)
through the YELLOW and YELLOW/BLACK wires of the injector cut-off device.
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3.4 Wiring General Scheme 3.4.1 Scheme 4 cylinders Bora Light LPG
Fig. 3.4.1-1
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3.4.2 Scheme 4 cylinders Bora LPG
Fig. 3.4.2-1
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3.4.3 Scheme 4 cylinders Bora Light CNG
Fig. 3.4.3-1
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3.4.4 Scheme 4 cylinders Bora CNG
Fig. 3.4.4-1
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4. Fine Tuning The new software is characterised by a totally innovative approach and strongly aimed at the management of gas, as fuel for the most recent spark-ignition engines. The main innovation resides in the engine control software inside the control units that, thanks to the new management algorithms, allows for the optimisation of the gaseous fuel dosing in a simple and innovative way, allowing the installer to easily obtain the best results. In order to guarantee the greatest integration with the petrol engine control system and to satisfy the OBD requisites, the BORA software is equipped with advanced diagnostics of the gas system enabling communication with the original OBD system of the vehicle. The calibration Software has changed in both appearance and functionality, but also trying to help out installers as much as possible. The calibration software can be accessed without necessarily being directly connected to the control unit. To connect to the control unit instead, it will be necessary to have the pc and the control unit properly connected by means of an interface cable and a usb-serial adapter (if the PC is not equipped with a Serial port) that can be purchased from any retailer. Furthermore, the control unit must be connected to the +12V battery (Red wire) and to the ground wire (Black wire). This section will guide through the exact procedure to follow for a correct fine-tuning of your gas system. Please follow these directions:
- Always make sure to use the latest version of this software. Please contact the Zavoli Technical Support Center if you have any questions.
- Perform a vehicle configuration, as described in the Technical Manual - Calibration Software for the Bora Injection System.
Fig. 3.1-1
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4.1 Main steps for setting up the unit
4.2 Initialization Ecu After selecting the check box corresponding to the type of fuel LPG or CNG, simply press the button initializes. Automatically be sent to the control unit and a standard mapping software that will allow you to calibrate the car. At the end of the programming will pass to the next step.
Fig. 4.2-1
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4.3 Parameters t is the second step of the procedure, is used to specify additional information about the type of system installed and the car (see Fig. 4.3-1).
Fig. 4.3-1 4.4 Sensores It is the third step of the procedure, is used to specify additional information about the type of level sensor installed and to enable the reading of the oxygen sensor. (see fig. 4.4-1).
Fig. 4.4-1
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4.5 Save calibration Attention to a very important first save before running the self-mapping, otherwise it is impossible to perform the seve calibration.
Fig. 4.5-1 4.6 Self-Calibration
Fig. 4.6-1
Before starting self-mapping procedure for the Bora and Bora Light systems, the connection to the MAP sensor will be requested. Self-mapping consists in acquiring the values of the various parameters when idling on petrol and in their processing on the basis of the supplied data (engine displacement, number of cylinders,
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injection type, etc.). As soon as self-mapping starts, the key shown in fig. 4.6-1 will be enabled and will request to press start when the idling conditions with petrol have been reached. Please note: at the end of the self calibration procedure it is important that the off-set value is negative, otherwise repeat the procedure and check for any problems in the installation. On completion of a self-mapping is important to save again. At this point the car is already ready to be delivered to the customer. 4.7 Map This section allows having a numerical view of the multiplication coefficients used by the control unit in the calculation of the GAS injection time. The table displays on the Y-axis the petrol injection times, while on the X-axis we find the number of RPMs, (fig. 4.7-1).
Fig.4.7-1 The red-coloured selection displayed on the map identifies the RPMs and the petrol injection times at which the the engine is running. Increasing the value of the calculation coefficients (Off set) in the map, while maintaining the PETROL injection time constant, will increase the GAS injection time, while decreasing this value the exact opposite will take place, i.e. the system will be leaner. To change the values, select one or more check boxes on the map and press the "Enter" key; enter the value to be attributed to the cell and confirm the value with the “Enter” key.
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5. Bora Program Error Codes
Error Code
Cause
0 No error 1 Generic error 2 Framework.Net 4.0 Extended not installed 3 SQL Server Compact 4.0 not installed 4 The language set for the application is not valid (it does not exist in the DB, or it
exists but the resource file is missing) 5 License File error 6 Error in the chart settings File
100 Error in the Database Opening 101 Error in the retrieval of the SQL command 102 Error in the retrieval of the SQL parameter 103 Error in the retrieval of the languages 104 Error in the retrieval of the skin info (id_group and group code) 105 Error in the retrieval in the enabling of user functions 106 Error in the retrieval of the list of the variables based on the skin and language 107 Error in the retrieval of the info relating to the ecu and software (ECU and
ECU_DERIVATIVES and SOFTWARE and Enabling of Functions - GetEcuDetails)
108 ECU not present in the DB (GetEcuDetails) 109 ECU sw not present in the DB (GetEcuDetails) 200 Error in the initialisation of the communication library (oEcuLib.InitLibrary) 201 Error in the opening of the connection (oEcuLib.OpenConnection) 202 The request for info to the library returned FALSE 203 The control unit returned a negative reply to the request 205 The data that has returned from the control unit is not in the correct format
(DATA_KO) 206 Error in the procedure management of the info (OnGetEcuInfo) 207 There is no feature to read the Flag in RAM or failure in the read request
(SharedRamwithPC) 300 The Ecu has an ID that is not complete, and the user is not enabled to connect to
Ecu with an incomplete ID 301 The Ecu was programmed by a toll of a group different from the user's license 302 Ecu not associated to the SKIN group 303 File A2L does not exist 304 Error in the loading of the A2L file 305 Error in the reading of the calibration from the ECU
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Technical Instructions installation Guide System New Bora
MT-IS-GAI-NWB.01-E
del 01/10/2013
Pag. 25 di 26
6. Table Sizing Jets For Injection Kit NEW BORA 6.1 Table Bora LPG injectors Pan-Jet
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Technical Instructions installation Guide System New Bora
MT-IS-GAI-NWB.01-E
del 01/10/2013
Pag. 26 di 26
6.2 Table Bora CNG injectors Pan-Jet