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Vialle LPi LPE-7 Assembly Manual

Made by: Vialle
Type: Assembly Manual
Category: Laboratory Equipment
Pages: 15
Size: 0.78 MB

 

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HZ

221838.0

-1-

Set-instruction:

220714.0

Assembly manual

221838.0

First release: 29-01-09

DC/name

D09 008

RD

Release

29-01-09

RD

Assembly manual for a 

Multipoint Liquid Propane Injection (LPi) System

Make of vehicle

:

Citroën

Type

:

Berlingo 1.6i 16V

Cubic capacity

:

1587 cc

Engine type

:

NFR

Transmission

:

Manual

Model year

:

2008

Tank situation

:

Under floor 67 ltr. ring tank

 


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HZ

221838.0

-2-

Page:

Code:

Date:

Content

1

221838.0

29-01-09

Cover sheet

2

221838.0

29-01-09

Contents table, general guidelines

3

221838.0

29-01-09

Summary of components engine room, interior

4

221838.0

29-01-09

Manifold assembly/disassembly
(Injector assembly by Vialle)

5

221838.0

29-01-09

Pressure regulator assembly

6

221838.0

29-01-09

LPE-7 assembly (LPi control unit)

7

221838.0

29-01-09

LPE-7 assembly (LPi control unit)

8

221838.0

29-01-09

Wiring harness, Fuel Switch, Stickers

9

221838.0

29-01-09

Wiring harness connections

10

221838.0

29-01-09

Wiring harness connections

11

221838.0

29-01-09

Tank assembly

12

221838.0

29-01-09

Tank assembly

13

221838.0

29-01-09

Tank assembly

14

221838.0

29-01-09

Tank assembly

15

221838.0

29-01-09

Electrical diagram LPE-7

*

Consult the workshop manual before
components are disassembled

*

All instructions provided in this
manual are from the perspective of
the driver’s position behind the stee-
ring wheel

*

Cylinder 1, as described in the con-
nection of wiring harnesses is loca-
ted on the distribution side of the
engine!

*

Undo the earth cable from the batte-
ry before starting to build in the LPG
installation (unless otherwise speci-
fied in the workshop instructions).
Note: the memories of any radios
and/or telephone may be wiped, the
central door locking may engage and

the alarm may go off. If necessary
the battery may be connected tem-
porarily

*

Deburr the drilled holes, remove any
chippings from the vehicle and treat
the edges with an anti-rust agent

*

Lay the wiring harness such that no
water can get into the interior
Seal any open splits after the
assembly of the wiring harness with
silicon rubber to prevent noise and
water leakage

*

The LPG installation should be built
in in accordance with the National
Instructions for the fitting of a LPG
Installation

Failure to comply with the instructions in
this manual may result in a poor or
inoperative gas installation or may
cause a hazardous situation

The illustrations, technical information,
data and text were correct at the time of
printing. In spite of the care taken in the
composition of this publication, no liabili-
ty can be accepted on the grounds of
any fault or error which might occur in
this publication

published by Vialle Alternative  Fuel

Systems BV

General guidelines

Contents table

English

- Contents table
- General guidelines

 


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- Summary of components 
- Wiring harness route
- Line bundle route

HZ

221838.0

-3-

9

L

B

3a

5

6

6

6

6

Z

H

7

M

1

+

3b

2

K

Fig 1

L

LPE-7 (LPi control unit)

Z

Fuse holder

K

Pressure regulator

B

Fuel Switch

H

Main relay

R

Resistor box

M

Engine running module

1

Battery+

2

Ground engine

3

Engine running safety conn.

4

Won’t be used

5

Petrol injector interrupt

6

LPG injector conn.

7

λ

-probe connection

8

Won’t be used

9

Petrol gauge reset

Wiring harness route

Line bundle route

Engine running harness route

 


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- Manifold assembly/disassembly

(Injector assembly by Vialle)

HZ

221838.0

-4-

Manifold assembly/disassembly

-

Disassemble the inlet manifold in accordance with
the workshop manual.

-

NOTE:

the disassembled manifold must be sent to

Vialle with the consignment note and will be retur-
ned with the fitted LPi-injectors.

-

Assemble the inlet manifold in accordance with the
workshop manual

Fig 2

 


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- Pressure regulator assembly

HZ

221838.0

-5-

Pressure regulator assembly

-

Assemble the pressure regulator with the bracket
at the bolt of the engine bracket

-

Lay the LPG-lines in a curl

Fig 5a

Fig 5b

Fig 3

Pressure regulator assembly

-

Adjust the bracket in accordance with the fig.

Fig 4

Pressure regulator assembly

-

Assemble the bracket to the pressure regulator,
see insert.

-

Assemble the LPG lines from the manifold to the
pressure regulator.

1

3

4

2

1
2
3
4

Spacer

Bracket

Rubber

Washer

1

90º

30

 


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HZ

221838.0

-6-

Fig 6

Fig 7

Fig 8

- LPE-7 assembly (LPi control unit)

LPE-7 assembly

-

Adjust the LPE-bracket in accordance with the fig.

LPE-7 assembly

-

Assemble the LPE to the bracket

-

Assemble the 70-pole connector to the LPE

LPE-7 assembly

-

Stick a 12cm piece of rubber next to the
fuse/relaybox in accordance with the fig.

 


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- LPE-7 assembly (LPi control unit)

HZ

221838.0

-7-

Fig 9

LPE-7 assembly

-

Position the LPE next to the fuse/relaybox in
accordance with the fig.

-

Drill a hole Ø3mm and assemble the bracket with
a sheet metal screw (6,3x19)

Fig 10

LPE-7 assembly

-

Assemble main relay 

H

and fuse holder 

Z

in accordance with the fig.

Ø3mm

Fig 11

LPE-7 assembly

-

Assemble engine running module 

M

in accordance with the fig.

H

Z

M

 


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- Fitting the wiring harness
- Fuel Switch assembly

-

Positioning the stickes

HZ

221838.0

-8-

Fig 14

Positioning of the fuses sticker

-

Stick the yellow sticker “Fuses of the Autogas sys-
tem” on the cover of the LPi-fuse holder

-

On the other sticker enter the amperages of the
fuses (see the electrical diagram) and stick it in the
cover of the fuse holder.

Fitting the combi-switch

-

Drill a hole of Ø8 mm at the position indicated and
press the switch into the hole (glue if necessary).

Fig 12

Fitting the wiring harness

-

Lay the wiring harness in the vehicle in accordance
with fig.1 on page 3..

NOTE:

For 5 or 6 cyl, solder the provided wiring har-

ness connectors for the LPG injectors, (5-6 cyl) to
the main wiring harness. See diagram, note the
colour of the label.

Ø10mm

25

30

Fig 13

!

40

Sup

rT

yr

e

s

165

/4

5/1

5

X

X

X

P

S

I

Fitting the wiring harness

-

Drill a hole Ø10mm at the position indicated, see fig.
(double layered sheet)

!

NOTE!!!  Drill max. 40mm deep!

-

Feed the wiring harness through.

-

Assemble isolation-tube.

-

Make sure there is a good seal to prevent leakage
and engine noise.

 


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HZ

221838.0

-9-

LPi wiring harnesses connection

Stick the connectors in the associated female plugs.

Connections to the original electrical system

1

Red wire with eye

Connection : Battery+
Position

: At the plus clamp of the fuse/relaybox

Joint

: Clip off the red wire 

as short as possible

NOTE

: Solder the provided eye Ø8.5

2

Eye with black wire

Connection : Ground engine
Position

: Left front of the engine, at the lifting ring

Joint

: M6 nut

3

Green/red wire + engine safety module

Connection : Engine running safety, see drawing:
Position

: Connect to the 

green/red

wire from the 

engine running module provided

Joint

: Solder and insulate

3a

Pink/yellow wire from Engine running module

Connection :

Alternator (see fig.)

Position

: The two-pole connector at the alternator, 

pos.1

, see fig.

Joint

: Solder and insulate

3b

Red wire from the Engine running module

Connection : Constant+

(see fig.)

Position

: The 

not-spliced red wire

in the LPI wiring har-

ness, just underneath the fuse box, see fig.

Joint

: Solder and insulate

- LPi wiring harnesses connection

Overview of connection points, see fig.1 on page 3
Electrical diagram, see last page

The wires without connector can be clipped off at 

the right length. DO NOT ROLL UP any excess 

length of the wires with connector because of 

faults but tidy them away using a ‘detour’

Alternator pos.1 (warning light) 

black (ground)

pink/yellow (signal)

red (positive)

blue wire

DONʼt

 cut

green/red

green/red

LPE

1x red

2x red

!

3b

3a

Engine running

module

LPi Fuse box 

!

Don’t use the spliced wires!

Use this wire to give the

Engine running

module a constant+

Pos.1

Route engine running module-alternator

3a

3b

 


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Grey/black en grey/white wire

Connection :

λ

-Probe-2  signal and ground

Position

: Not used

Connection : Clip off and insulate

8

Brown/black and brown/white wire

Connection :

λ

-Probe-1  signal and ground

Position

: Not used

Connection : Clip off and insulate

Orange/black and orange/white wire

Connection :

λ

-Probe-2  signal and ground

Position

: Not used

Connection : Clip off and insulate

9

Relay with resistor 

A

Connection : Reset of the petrol gauge
Position 

: 6-pole connector at the petrol pump

pos.3:

12Volt

pos.4:

ground

pos.6:

signal wire petrol gauge

measure!

(resistance to ground = 10-300

)

Connection : Solder and Insulate

Main relay

7-pole black connector

Connection

:

Fit the relay in the black 7-pole connector

Fuses

Black fusebox

Connection :

Insert the 4 fuses into the fusebox
see electrical diagragram on the last page

Fuel switch

3-pole black connectors

Connection:

3 wires of switch and wiring harness

Connection:

Fit the contacts in the 3-pin connector as follows:

Tank

3 Connectors

Connection

:

Fit the connectors to the tap, the fueltronic
and the pump control

Eye with black wire

Connection

:

Earth multivalve

Connection

:

M5 bolt

HZ

221838.0

-10-

LPi wiring harnesses connection

Stick the connectors in the associated female plugs.

Connections to the original electrical system

4

Pink and grey/red wire

Connection : Optional
Position 

: Won’t be used

Connection : Clip off and insulate

5

Interrupt relay (internal LPe-7)

Connection : Petrol Injector interrupt
Position

: Injectors will be interrupted at the middelmost 

48-pole grey/black ECU-connector 

B

Connection : Solder and insulate

6

Connectors with coloured labels

Connection : LPi injectors
Postion

: Stick the connector 

at the right injector

7

Purple/white and yellow/white wire

Connection :

λ

-Probe-1  signal and ground 

Position 

: 4-pole green connector, at the left bof the engine

Connection : Solder and insulate

- LPi wiring harnesses connection

Overview of connection points, see fig.1 on page 3
Electrical diagram, see last page

The wires without connector can be clipped off at 

the right length. DO NOT ROLL UP any excess 

length of the wires with connector because of 

faults but tidy them away using a ‘detour’

WHITE

WHITE

GREY

BLACK

heating

heating

ground

signal

PURPLE/WHITE

YELLOW/WHITE

If not extant, attach
yellow/white to
ground engine

4

-p

in

c

o

n

n

e

c

to

r

position

to ECU

to injector

Cyl 1

M3

white

white/green

Cyl 2

J4

brown

brown/green

Cyl 3

K4

blue

blue/green

Cyl 4

L4

grey

grey/green

interrrupt relay

6

5

4 3

2 1

B

9

A

Cyl.1 RED

Cyl.2 BLUE

Cyl.3 YELLOW

Cyl.4 WHITE

L

A

B

E

L

S

Connector switch

Connector wiring harness

pos.

wire colour

wire colour

1

blue/red

blue/red

2

yellow

yellow

3

white

white

 


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Sunken filler assembly

-

Assemble the sunken filler by means of 
manual 221725.

-

Adjust the 2 washers in accordance with the drawing:

Assembly manual Case Side

Make/Type:

Citroen Berlingo

Tank situation:

Under floor  67 ltr. ring tank

HZ

221838.0

-11-

External filler assembly

-

Assemble the sunken filler with the spacers
provided and M5x35 bolts. 
(use the adjusted washers)

External filler assembly

-

Assemble the dust cap by means of a sheet metal
screw in accordance with the fig.

adjusted washers

M5 nuts

M5x35

bolts

spacers

Fig 15

Fig 16

Fig 17

 


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HZ

221838.0

-12-

Fig 20

Assembly manual Case Side

Make/Type:

Citroen Berlingo

Tank situation:

Under floor  67 ltr. ring tank

Filler hose assembly

-

Filler hose route

LPG line assembly

-

Fit the line bundle under the vehicle in accordance
with fig.1 on page 3 (begin at the pressure regulator)

Filler hose assembly

-

Assemble the helper springs provided

-

Remove the floor matt, spare wheel, and spare
wheel bracket

-

Disassemble the plastic spare wheel stoppers 

A

Filler hose assembly

-

Assemble the short reduce nipple 
(with the bonded seal!) and filler hose

Fig 18

Fig 19

A

A

 


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HZ

221838.0

-13-

Assembly manual Case Side

Make/Type:

Citroen Berlingo

Tank situation:

Under floor  67 ltr. ring tank

Tank assembly

-

Remove threaded rod 

B

Tank assembly

-

Disassemble the plastic rear sill protection plate

-

Mark center 

M

-

Lay the graduated jig with the center at 

M

-

Mark and drill holes 

1

Ø14 at 

45

º, 

135

º, 

208

º, and

300

º

Fig 21

Fig 22

Fig 23

AA

AA

AA

AA

AA

AA

AA

B

B

1

Strap fastening

Ø14 mm

1

1

1

1

240

60 25

M

M

60

25

45

º

300

º

13

2

0

8

º

 


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HZ

221838.0

-14-

Fig 26

Assembly manual Case Side

Make/Type:

Citroen Berlingo

Tank situation:

Under floor  67 ltr. ring tank

Tank assembly

-

Attach the straps and supports with the plates 

A

under the floor in accordance with manual 59338.

Tank assembly

-

Drill the 2 holes 

B

Ø8mm through plate 

A

and

assemble 2 M8x15 bolts

-

Drill hole 

C

Ø8mm because of the plastic rear sill

protection plate

-

Stick rubber on top and underneath hole 

D

of the

spare wheel bracket in accordance with the dra-
wing

Tank assembly

-

Position the ring tank underneath the vehicle wit
the hearth of the accessory cabinet at  ±

255

º

-

Fit line bundle and filler hose. 
(assemble all parts of the accessoiry cabinet)

-

Raise up the tank and fit it into the straps

NOTE:

Resize the four M10 threaded ends 

-

Assemble heat foil 

E

, see fig.

Fig 24

Fig 25

D

E

C

B

B

Ø8mm

D

A

 


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- Electrical diagram (LPE-7)

HZ

221838.0

-15-

L

P

G

 i

n

je

c

to

3

e

n

g

in

e

 r

u

n

n

in

g

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a

fe

ty

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e

la

y

g

ro

u

n

d

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P

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g

ro

u

n

d

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P

G

 p

re

s

s

u

re

+

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a

tt

e

ry

(c

la

m

p

 3

0

)

g

ro

u

n

d

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P

G

L

P

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a

lv

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s

L

-

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p

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1

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o

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it

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 (

tr

a

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m

it

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rx

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 (

re

c

e

iv

e

)

p

o

w

e

s

u

p

p

ly

 5

V

P

u

m

p

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o

n

tr

o

l

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e

t

r

o

l

-

i

n

j

e

c

t

o

r

s

C

il 

4

C

il 

3

C

il 

2

C

il 

1

 

C

il 

6

C

il 

5

g

r

o

u

n

d

 

e

n

g

i

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e

lin

e

 b

u

n

d

le

1

2

c

o

v

e

r

1

2

3

1

2

3

valve

pump

ground

2  1  3  4

2

1

2

1

3

1

2

3

1

2

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2

3

4

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u

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p

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p

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:

1

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p

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:

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LPi injector

C

il

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2

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3

5

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4

5

1

2

7

5

5

2

2

8

6

5

3

2

9

7

5

4

3

0

8

5

5

3

1

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5

6

3

2

1

0

5

7

3

3

1

1

5

8

3

4

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2

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3

5

1

3

6

0

3

6

1

4

6

1

3

7

1

5

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3

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6

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4

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2

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6

4

7

LPi injector

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LPi injector

LPi injector

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