sequent p&d installation - IMPCO
Contents
1. Org L 22 Org From Bank 1 HEGO Sensor 1 Heat Shrink Cap Over 5 LINA 8 1112135115116 OEM OBD II 31962 Data Link Connector CNG Manometer LPG L EV REAR Reg Lockoff 2 Conv Tan BIk Wht Not Used From OEM ECM e x 1 Yel faj e a 9 ROO Yel BIk Tan Brn Yel Bik Lt Blu Bik Lt Grn Blk Rev B INJ 1 Fuse 20A Underhood Fuse Box Connector X1 Engine Firing Order 1 2 3 4 5 6 OEM Fuel Rails OEM Fuel Rail Bank 2 Pnk BIk OEM Fuel Rail Bank 1 To OEM Injectors Passenger Side of Vehicle Pur Wht L 1111 Yel L 2222 Yel End of Pigtail Wires Hidden Not Used L 666666 Vio Wht Grn L 55555 Org L 4444 Vio L 22 Vio Not Used L 1111 Blu L 2222 Blu Underhood Fuse Box Connector X1 5 Not Used From CKP Sensor NOTES 1 Wire LASER imprints are indicated adjacent to wire with an L and wire color in apprenthesis Example L 666666 Org a Technician installed splice 2009 GM 3 5 3 9L ECM Connectors View From Wire Side L 333 Org L 1 Org L 55555 Vio L 333 Vio L 1 Vio ECM Connector X2 N Pnk BIk A o Tan Wht zech o OEM ECM Connector X2 ECM Connector X1 Yel Bik 00 052 O72 Lt Blu Bik jr oe 3 7 Lt Grn Bl2. 344 3555 or go to www nfpa org There are state standards and regulations enforced by the state fire marshal in most states In Texas the Texas State Railroad Commission sets standards There may be other local standards set by counties cities and municipalities Be sure to consult all regulatory agencies to assure adherence to all standards in enforcement Safety in the workplace is everyone s responsibility Regardless of the type work you do it is very important that you pay attention to what you are doing for your safety and the safety of those around you 2009 IMPCO Technologies Inc 1 2009 3 5 3 9L Impala CNG The following points are things to keep in mind when working on internal combustion engines and gaseous fuel systems Y Before working on any fuel system study the NFPA standard for the fuel in use v Before working on any fuel system read and understand all manufacturers recommended procedures Y Before working on any fuel system make sure you have local code approved safety goggles face shields gloves and clothing v Before working on any fuel system make sure there is adequate ventilation Y Before working on any fuel system turn OFF the fuel system supply valve and slowly bleed the fuel from all lines before working on the fuel system or engine 2009 IMPCO Technologies Inc 2 2009 3 5 3 9L Impala CNG INTRODUCTION A Important Vehicle Owner Advisories e At the time of this writing
3. IMPCO Technologies Inc 16 2009 3 5 3 9L Impala CNG H Sequent OEM Electrical Connections Proper Wire Splicing Terminal Crimping Types There are two types of terminals used in the installation of the Sequent P amp D wiring harness To ensure a good crimp use the appropriate style crimping tool including correct gauge as illustrated below NOTE Not all crimping tools are made exactly the same Experiment with different tools to achieve the best crimps possible before working on the vehicle s wiring harness The first is the U style splice crimp used to splice the Sequent P amp D harness circuits to the OEM harness circuits U Style Crimping Tool U Style Crimp Before amp After Crimping 18 16 Gauge 2 0mm The second is the Barrel style non insulated lug terminal used to connect the Sequent P amp D harness to the battery post terminals Barrel Style Non Insulated Crimping Tool Barrel Style Crimp Before amp After Crimping 12 10 Gauge 5 5mm IMPORTANT NOTE After crimping either style terminal be sure to solder the connection as illustrated on the next page before shrink wrapping 2009 IMPCO Technologies Inc 17 2009 3 5 3 9L Impala CNG Soldering Crimps amp Terminals Solder all terminals after crimping as illustrated using an electronic grade rosin core solder 0 7 to 1 0mm diameter works best Make sure all wires in the terminal receive adeq
4. 32 Phone H Sa a 89 E 3 E aH dues ald i k installers Name r m Address State Prov Choose y elephone Phone Odometer Reading at Time of Installation Date of Completed Installation tate Prov Choose EiilASdais E elephone Deen To be Completed and Mailed by the Installer red mm dd yyvy PPI 108 Rev B 37773 Enter Secunty Code Submit All fields are mandatory Log Out e 2 Fill out the Emissions Label completely and attach it where illustrated 2009 IMPCO Technologies Inc 25 2009 3 5 3 9L Impala CNG 3 Install the Fuel Door E85 Notice label on the inside of the fuel door 4 Put the Sequent P amp D Owner s Guide in the a prominent location on the dash or center console where the customer can easily locate it It is strongly recommended to go over some of the highlights of the Owner s Guide with the customer Owner s Guide Supplement for SEQUENT Plug amp Drive Equipped Bi Fueled Vehicles Sequent 2009 IMPCO Technologies Inc 26 2009 3 5 3 9L Impala CNG T Maintenance Maintenance consists of e Periodic visual inspection of all vacuum lines and fittings Periodic visual inspection of all fuel lines and fittings Periodically check entire intake system for vacuum leaks Periodically check condition of all wiring Periodic CNG lockoff fuel filter replacement Delta P fuel pressure manual inspection adjustment Except for the Delta P p
5. ENGINES 52 FOR CNG VEHICULAR FUEL SYSTEMS OR 58 FOR LPG SYSTEMS INSTALLERS LPG INSTALLATIONS IN THE UNITED STATES MUST BE DONE IN ACCORDANCE WITH FEDERAL STATE OR LOCAL LAW WHICHEVER IS APPLICABLE AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET 58 STANDARD FOR STORAGE AND HANDLING OF LIQUIFIED PETROLEUM GASES TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATON WITH FEDERAL STATE OR LOCAL LAW IN CANADA REFER TO CAN CGA PROPANE INSTALLATION CODES CNG INSTALLATIONS IN THE UNITED STATES MUST BE DONE IN ACCORDANCE WITH FEDERAL STATE OR LOCAL LAW AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET 52 COMPRESSED NATURAL GAS CNG VEHICULAR FUEL SYSTEMS TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION WITH FEDERAL STATE OR LOCAL LAW IN CANADA REFER TO CAN CGA CNG INSTALLATION CODES LPG AND OR NATURAL GAS INSTALLATIONS ON STATIONARY ENGINES MUST RE DONE IN ACCORDANCE WITH FEDERAL STATE OR LOCAL LAW AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET 37 STATIONARY COMBUSTION ENGINES AND GAS TURBINE ENGINES TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION WITH FEDERAL STATE OR LOCAL LAW FAILURE TO ABIDE BY THE ABOVE WILL VOID ANY IMPCO WARRANTY ON THE PRODUCTS AND MAY CAUSE SERIUS INJURY OR PROPERTY DAMAGE DUE TO THE INHERENT DANGER OF GASEOUS FUELS THE IMPCO PRODUCTS SHOULD NOT BE INSTALLED OR USED BY PERSONS NOT KNOWLABLE OF THE HAZARDS ASSOCIATED WITH THE USE OF GASEOUS FUELS To order these documents call the NFPA 800
6. NG C Required Tools Equipment amp Supplies Sequent Installer s Tool Kit part 90AV99004048 Software Installation Kit part 90AV99002055 SAE and metric mechanic s hand tools Electric or cordless drill and assorted drill bits Large hose clamp pliers Heat gun Soldering iron Solder 60 40 electronic rosin core 0 7 to 1mm diameter works best DVOM and assorted test leads Wire Terminal crimper s capable of handling 10 12 gauge 5 5mm non insulated barrel terminals and 18 16 gauge 2 0mm U style splices Wire stripper Electrical tape PC or laptop with Sequent P amp D software installed Leakdown tester Standard mechanic s diagnostic tools OBD II compliant scan tool CAN enabled OEM Upper Intake Manifold Gasket Set OEM Factory Service Manual NFPA approved CNG high pressure tubing and fittings as necessary OEM touchup paint to match vehicle D Torque Specifications e CNG high pressure filter mounting banjo bolt 15 22 ft lbs 20 30 Nm e CNG high pressure filter blocking Screw 37 52 ft lbs 50 70 Nm e NEESS 15 30 ft lbs 20 40 Nm e CNG pressure temperature sensor 20 5 23 5 ft lbs 28 32 Nm e Regulator Temperature Sensor ss 89 in lb 10 Nm e MAP sensor mounting mut 20 5 23 5 ft lbs 28 32 Nm e TR SS zzz ezen eze esze ed s os Hand tight turn e BRC Injector mounting nuts cence eseceeecestc usec enecenceuseceneren
7. S Gas Inj Gnd 1 19 Bik I AII AA PS SE ll lU III EE cen E a A E UK CO Rk E SRA AA a WC _ NO OOO 7 S IN HENEM li UQ EA OEM Inj 5 LS Input Org KR DES ER DEE i i ef fe F GE dle E Cc o E 4 E all _ LI KKK EE CA uel Supply Hoses AE AAA dnd dl Gm H 5 HEGO 1 Bnk 2 Output Blu Z 2f Wht E o BIk a Red Spark Advance Grn Yel if Grn A e EE EE RNC mG E EE E Le Gnd BIk AAA SES EE e Ge e Re H sh See N El MASA ELA P Lockoff 2 Ctrl Grn Blk OEM Inj 1 LS Input Org sss Grn A ma ee ue ch 1 Bees OEM Inj 2 LS Input Org are eu me 7 e OEM Inj 3 LS Input Org ns 138188 Pnk BIk D nn E J1962 Connector OEM Inj 4 LS Output Vio al GE RE ATT x alioishi OEM Inj 6 LS Output Vio a 9 hozhat JE Les a e I INJ 1 Fuse E Gi Yel Blk Tan Wht Underhood Fuse Box Connector X1 Not Used Grn 56 Cavity Blk Lt Blu BIk Pnk BIk L 666666 Org Lt Grn Blk Tan Lf H L 4444 Org L 22 Org Passenger Side of vehicle DIT TEE O a 1 E EN eee A eee ee p o Pnk Bik WR L 333 Vio L 4 55555 Org Lt Blu Bik L 4444 Vio Tan Wht 2 L 55555 Vio Yel Bik L 666666 Vio L 1 Yel MR Pur wht aj ay oa gt ECM IGN Fuse O L 22 Yel Not Used Pnk 3 Pur Wht_ L 1 Blu l 15A Not Used L 22 Blu Kee ge SES t ane Wht BIk l Position CKP Sensor 56 Cavity Bik OEM ECM Brn Conn X1 19 Pnk L
8. Tees and the Regulator coolant hose nipples Slide hose clamps onto the two hoses and install them onto the Tees Tighten the six clamps on the Tees and remove the hose pliers Slide two more hose clamps onto the Regulator Coolant Hoses install the hoses onto the Regulator and tighten the clamps Install the Regulator onto the engine compartment rear bulkhead studs Locate the Lockoff bracket and mark it for modification as illustrated Cut off the end of the bracket drill two diameter holes as indicated and bend the bracket 90 where indicated Round off any sharp corners with a file or grinder 2009 3 5 3 9L Impala CNG Bend the bracket to fit the vehicle shock tower along this surface 4 Bend Line Driver Side Shock Tower 02009 IMPCO Technologies Inc 2 The bracket will be mounted on the driver s side shock tower close to the top Bend the bracket as illustrated to approximate the mounting surface of the shock tower 3 Install the Lockoff onto the bracket as illustrated Using the bracket as a template drill two Y diameter holes in the shock tower Mount the Lockoff and bracket to the shock tower IMPORTANT If the vehicle has ABS be sure to allow for clearance between the Lockoff and the ABS Unit lines 4 Using code approved fuel line and fittings fabricate a fuel line to connect between the lockoff and the regulator 1 Wrap each of the six fuel hoses with cor
9. _ IMPCO AUTOMOTIVE 2009 CHEVROLET 3 9L IMPALA SYSTEM INSTALLER S GUIDE TABLE OF CONTENTS SAFETY READ FIRST EE 1 INTRODUCTION WE 3 A Important Vehicle Owner Achvisortes nono nono nononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nan nenen 3 B SEQUENT P amp D Installation Kit Contents ooocccinccicncccnnoccnnnnnnncnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnninn 3 C Required Tools amp Eoupment nn non non nn nn nono nnnnnnnnnnnnnnnnnnnnnnnnnennininiis 5 D Torque Specifications seen 5 E Installation Note corrosion protection se 5 INSPECT FOR CORRECT VEHICLE INFORMATION amp THE OPERATIONAL INTEGRITY OF THE o e 6 Preliminary Inspection EE 6 B Scan Tool Ee e EE 6 C High Mileage Vehicle Inspection 75k sise 7 SEQUENT P amp D INSTAELA TON ui iii 8 A Pre lnstallation Bench ASS momo rt dt lan to illa 8 B Intake Manifold Ignition Coil Pack and Air Filter Housing Removal 11 C Intake Manifold Modifications occcccccccnnccnnncnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnninnnnos 11 D Zenith Regulator and Coolant Hose Installation 13 E Lockoff and High Pressure Tubing Installation ooonnnnnnnnnnnccnnnnnnnnnnononccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 14 Fa Fuel Rall Installations ins men geet Ee 15 G CNG Low Pressure Hose Connections occocccccnncnnncnnncnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnn
10. crow s foot tool or 10mm wrench tighten each fuel hose nozzle assembly approximately turn past hand tight 2009 3 5 3 9L Impala CNG 2009 IMPCO Technologies Inc 13 7 Apply some clean engine oil to the OEM injector o rings and install the OEM fuel injector rails torqueing the bolts to OEM specifications Intake manifold with OEM fuel injector rails installed and Sequent fuel hoses routed correctly Drill and tap the upper intake manifold for the brass vacuum port adapter using the 5mm drill and the 6mm tap Clean all traces of metal chips from the manifold Apply a light coat of Loxeal to the adapter threads before installing Set the upper manifold aside in a clean area protected from dirt and debris Cover the lower manifold to keep dirt and debris from entering the intake runners The Zenith Regulator will be installed in the center of the bulkhead utilizing three existing studs 2009 3 5 3 9L Impala CNG 2 3 4 5 6 Heater hoses with Tees and Regulator Hoses installed 7 8 1 Cut S gra 2009 IMPCO Technologies Inc 14 Begin modifying the heater hoses by pinching them with four hose pliers to make room for the two plastic Tees Cut the heater hoses between the clamps install four hose clamps onto the hoses and install the two plastic Tees Temporarily install the Regulator and cut two lengths of the Regulator Coolant Hose to fit between the two
11. ctor holes except for those on the runner you will be drilling amp tapping Using a rubber tipped blow gun blow air into the runner being drilled and tapped so all metal chips will be carried out of the runner through the intake runner opening Also incorporating a wet dry vacuum on the intake runner opening will help evacuate metal chips from the runner IMPORTANT Make sure the intake valve for the cylinder you are working on is completely closed If not rotate the engine by hand until it is CAUTION BE SURE to wear goggles and a face mask to protect your eyes from flying particles 3 While blowing air through one of the runners and using one of the 5mm drills in the Sequent Installer s Tool Kit drill through the top intake manifold runner wall keeping the drill perpendicular to the runner face DO NOT drill into the bottom wall of the runner 2009 3 5 3 9L Impala CNG 2009 IMPCO Technologies Inc 12 4 5 6 Attach the long tap handle to the combination 6x1mm tap amp drill Apply a light coat of tapping oil to the tap threads and tap the nozzle hole keeping the tap perpendicular to the runner face Repeat steps 3 5 for the remaining five intake runners When finished clean all traces of metal chips from the intake runners Apply a light coat of Loxeal to each of the fuel hose nozzle threads Thread the fuel hose nozzle assemblies into the tapped holes Using the nozzle
12. d assembled wrap one of the maximum fuel working pressure labels around EACH hose 10 Wrap the label around the hose Towards one end of the hose as illustrated DO NOT affix the label along a bend in the hose as it may cause a kink in the hose restricting fuel flow 11 One of these labels must be affixed to every fuel hose between the regulator outlet and the intake manifold to comply with government regulations 2009 3 5 3 9L Impala CNG B Intake Manifold Ignition Coil Pack and Air Filter Housing Removal Prior to any disassembly clean the engine and engine compartment with engine degreaser where necessary Disconnect the negative battery cable followed by the positive battery cable and remove the battery from the vehicle Following the manufacturer s service manual instructions remove the upper intake manifold then the ignition coil pack Remove the air filter housing to expose the ECM C Intake Manifold Modifications 2009 IMPCO Technologies Inc 11 1 Using a straight edge draw two lines along the intake manifold keeping the straight edge just inboard of the runner numbers Using a center punch make a small dimple where the lines intersect in the photo arrows NOTE Lower intake manifold has been removed from the engine for clarification DO NOT remove the lower intake manifold from the engine 2 Before drilling amp tapping the runners cover all of the intake ports and OEM inje
13. eceseresecesecete 71 in lbs 8 Nm e Fuel hose amp manifold vacuum hose adapter nuts 89mm 62 in lbs 7 Nm e Zenith regulator mounting bolts 8mm 15 ft lbs 20 Nm E Installation Notes e Anytime the OEM painted surface is broken by drilling component removal etc the exposed metal surfaces must be protected from corrosion This is especially important in areas where salt is used on the roads during the winter months GM recommends their Super Lube with PTFE part 12371287 GM bulletin 03 00 89 008D Follow the instructions in the bulletin to ensure a positive outcome e DO NOT use Teflon tape on any fittings Teflon tape may get into the regulator primary and secondary seats and the fuel injector seats causing fuel pressure problems Any warranty returned item found contaminated with Teflon tape will be returned 2009 IMPCO Technologies Inc 5 2009 3 5 3 9L Impala CNG INSPECT FOR CORRECT VEHICLE INFORMATION AND THE OPERATIONAL INTEGRITY OF THE ENGINE Installing an alternative fuel system into a vehicle with an engine or ignition system that is in poor condition will produce less than desirable results and may lead to exhaust emissions beyond acceptable levels It is strongly advised that all of the following inspections be done BEFORE installing the Sequent P amp D system A Preliminary Inspection The preliminary inspection should consist of a vi
14. ernator generator e The B connection can be made directly to the battery or engine chassis ground DO NOT connect to ground near the alternator generator due to electrical noise 2009 IMPCO Technologies Inc 20 2009 3 5 3 9L Impala CNG K Re install the Ignition Coil Pack and the Upper Intake Manifold 1 Following the OEM installation procedures re install the ignition coil pack and using new gaskets the upper intake manifold with the Sequent injector rail brackets Manifolds removed from engine for clarification purposes only 2 Fabricate the MAP Sensor bracket as illustrated Mount the MAP sensor in the bracket torqueing the nut to 20 5 23 5 ft Ibs 28 32 Nm MAP Sensor Bracket match the illustration 4 Remove the right upper Throttle Body mounting bolt and secure the assembly to the Throttle Body 5 Connect the short hose to the vacuum nipple on the upper intake manifold and the long hose to the vacuum nipple on the regulator 14 3 Cut the MAP sensor vacuum hose to 02009 IMPCO Technologies Inc 21 2009 3 5 3 9L Impala CNG M OBD II Connections and Changeover Switch Buzzer Installation 1 Remove the grommet on the passenger side of the bulkhead Split the grommet with a razor blade just enough to push the Changeover Switch and OBD II pigtails through Push the changeover switch connectors through the hole re install the grommet and seal it with a little black RTV Sealan
15. gulator temperature sensor Sequent P amp D 4 Connect lockoff Fuel Rails 5 Connect the Sequent ECM O Final Connections 1 Connect the high pressure CNG line to the lockoff Leak test the entire Sequent and OEM fuel systems with applicable code approved equipment before starting the engine 2 Reconnect all OEM components except for the engine cover 3 Reinstall the battery If the installation requires the Sequent B and B connections be made at the battery connect them now 1 Perform the fuel level calibration as Gen described in the Sequent P amp D Display el es Se Software User Manual 2009 IMPCO Technologies Inc 23 2009 3 5 3 9L Impala CNG Q Initial Engine Start 1 After making all fuel system leaks and installation inspections e Switch the changeover switch to Gasoline operation red FOIL e Connect an OBD II scan tool to the OEM DLC connector e Connect the Sequent DLC cable to the vehicle and the laptop e Open the Sequent P amp D software and start the engine e With the OBD II scan tool verify there are no pending or hard codes If any codes appear diagnose the cause and repair before continuing 2 Let the engine warm up to operating temperature then depress the changeover switch for gaseous operation position When the system begins changing over to CNG operation the engine should continue running without hesitation or stumbling If the engine begins running rough during t
16. he changeover cycle then 2 or more of the injector connectors are misplaced Perform the Injector Changeover Test Diagnostics section of the Sequent P amp D Display Software User Manual Cert 1 With the engine idling running on CNG and at operating temperature open the display software and select the Delta P pressure for graphing see the Diagnostics section in the Sequent P amp D Display Software User Manual for graphing instructions The Delta P pressure should be averaging at approximately 2000 mbar If it is not make adjustments with a 4 mm allen wrench at the regulator 2009 IMPCO Technologies Inc 24 2009 3 5 3 9L Impala CNG S Warranty Card Emissions Label amp Owner s Guide 1 Warranty registration is available on IMPCO Technologies Website IMPCO i Dedicated to a better world through cleaner air http www impco ws sequent tools asp O E me LE requires login EE If Internet registration is not possible fill weem out the warranty card completely and IN IR drop it in the mail or fax it to bal i 714 656 1414 _ SEQUENT Installation Registration P amp D 56 IMPCO Vehicle Identification Number VIN Dedicated toa better world through cleaner air Our Company Markets Product Environment Technical Support ontacts Services License Plate State 2838 AE e Owner s Name 25n5 Hi Address o gt S F o ro gta SE 8 2
17. k 88838888 i Pur Wht 8848883889308938 3888888 86 E S A Wht BIk Wht BIk 56 Cavity BIk 8 K y by og ji Pnk 1 1 1 1 ua ar 1 Je aigle 4 4 4 4 5 3 5 5 5 61 41 6 6 4 6 Pnk 7 7 7 7 a LS E ae T E JB CD PH Je U Underhood Fuse Box Connector X1 Sequent P amp D ECM OEM ECM Connector X2 Coolant Battery 25A Fuse 5A Fuse Diagnostic Change Over Sequent MAP Fuel Level Lockoff Lockoff Temp Sensor Connector Switch Buzzer Sensor al 1 2 kee eng Manometer Sequent P amp D Coolant Temp Sen Input 1 Yel 23 2 L Wiring Schematic SV Ref Output 2 Red gt XXX D D X X X X E ee DO 1c Em D D Ox x E Xx E Fuel Press Sen Input 3 Grn D mmm F e e no O Or A m a 5 a 5 2009 3 5 3 9L 4 S Ea 6 6 Chevy Impala HEGO 1 Bnk 1 Input 5 Yel a Kee yon H HEGO 1 Bnk 2 Input 6 Yel ee i prs tp E E E EEN LE Sh a PP ae ence Ee We ht GE eg Pe eles ee 0007 SE ary A O IM VBatt Red Deeg Er E REES EE or hy A ee ae AA AAA AA AA AA E A DS eee ay E Er EA ions WC KEE 4 Gas Inj Ctrl Wht Grn SR SSE
18. nnnnnnnnnnnnnnennness 16 H Sequent OEM ECM Electrical CGonnechons nono nono nono nono nono nnnnnnnn nono nnnnnnnnnnnas 17 6 Proper Split A AA One iter ae Rs 17 I Sequent ECM Relay 8 Fuse Locations sise 20 Js Battery Connections aa ae 20 K Re install the Ignition Coil Pack and Upper Intake Manifold annneeeneeeeeeeeeeenn eenn eeene nsen nen rnsnrnne een 21 L Sequent MAP Sensor Installation 21 M OBD II Connections and Changeover Switch Buzzer Installation 22 N Sequent Component Electrical Connections o occocccncnnncccnnncnnnennneninnnnnennnnnnnnnnnnnnnnnnnnnnnnnnneninininins 23 O Final Connections EE 23 P Fuel Level Calibration sers 23 e TER Engine SUN se E Cat saa ia 24 R Sequent Delta P Pressure Adjustment ses 24 S Warranty Card Labels and Owner s Guide oocccccccccnnccnccnnnononnnnnnnnnononnnnnnnnnnnonnnnnnnnnnnnnennnnnnnininoss 25 Tia MAINTE MANGC ET 27 SAFETY WARNING READ BEFORE PERFORMING ANY INSTALLATION SERVICE MAINTANENCE OR REPAIR ON THE FUEL SYSTEM There are safety regulations and standards that must be followed when installing or servicing gaseous fuel equipment It is highly recommended you obtain and read the following National Fire Protection Association NFPA guidelines SERVICE TECHNICIANS AND USERS CAREFULLY READ AND ABIDE BY THE PROVISIONS SET FORTH IN NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET 37 FOR STATIONARY
19. ressure check all other maintenance items are in the MPCO Owner s Guide Supplement Consult the guide for maintenance schedules 1 The Lockoff fuel filter replacement requires the following parts O ring Filter _ Cartridge Part Description Qty idsi 02BM03990001 Kit Filter 1 ae EE INM Filter Spring PPI A 021 Rev B August 09 Copyright O 2009 IMPCO Technologies Inc All rights reserved Reproduction by any means electronic or mechanical including photocopying recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from IMPCO Technologies Inc Created and published by IMPCO Automotive Technical Publications 2009 IMPCO Technologies Inc 27 2009 3 5 3 9L Impala CNG gt E c o s o j lt m IMPCO TECHNOLOGIES INC 3030 South Susan Street Samba na C A Smears Di 4 mer 14 656 12 A 656 14 Email autoinguires impcotechnologies com 0 0 00 Sequent P amp D ECM Diagnostic Connecor Fuel Supply Hoses Fuel Temp amp Press Sensor sel L 666666 L 4444 MS Sequent P amp D Fuel Rails Gray Heat Shrink Tube L EV FRONT E a Fuel Tank Level Sensor Changeover Switch Buzzer Sequent MAP Sensor Reducer Temp Sensor 2009 3 5 3 9L Chevy Impala Sequent P amp D Installer s Wiring Diagram L 4444 Org L 666666
20. retaping 4 Locate both injector pigtails on the Sequent P amp D harness labeled Inj 1 2 3 4 BENZ and nj 5 6 7 8 BENZ Cut the connectors off of both pigtails 5 Cut the adhesive lined shrink wrap into 1 to 1 strips Install one of the strips over the first wire to be reworked 6 Steps 6 through 9 should be done on the wires one at a time Referring to the 2009 3 5L Impala P amp D Installer s Wiring Diagram cut each wire at the ECM indicated on the diagram Strip the ends of the wires in preparation for crimping and soldering Important Make sure to cut the wires so there is adequate space between the splice and the ECM connector to allow for repacking the wires into the harness conduit 7 Position the wire ends in one of the U shaped crimps and securely crimp the wires together parallel splice illustrated 8 Solder the connection 9 Apply the shrink wrap to the splice 10 Repeat until all circuits have been reworked NOTE The OBD II connections cannot be made until the interior harness pigtail has been installed 2009 3 5 3 9L Impala CNG Sequent ECM Relay amp Fuse Locations 1 Install the Sequent ECM with spacers relay and fuses where indicated J Battery Connections Crimp and solder the terminals onto the red and black battery wires NOTES e The B connection can be made directly to the battery or fuse box DO NOT connect to any circuit directly connected to the alt
21. rugated conduit make sure the max wp labels are installed first 2 Mount the 1 3 fuel rail onto its bracket Attach fuel hoses 1 3 to the appropriate injector routing the hoses as indicated in the photo 3 Tie wrap 2 amp 3 hoses to the OEM fuel rails where indicated in the photo 1 3 Fuel Rail Bracket 2009 3 5 3 9L Impala CNG 4 Mount the 4 6 fuel rail onto its bracket Attach fuel hoses 4 6 to the appropriate injector routing the hoses as indicated in the photo Tie wrap 4 amp 5 hoses to the OEM fuel rails where indicated in the photo 4 6 Fuel Rail Bracket 1 Locate the two preformed low pressure fuel hoses the length of bulk fuel hose and the fuel splitter Y 2 Install the short preformed hose onto the Regulator fuel nipple slide two fuel hose clamps onto the hose and install the other end onto the single Y inlet nipple 5 Slide two fuel hose clamps onto the other preformed hose and install the end with the sharp bend onto one of the Y outlet nipples and the other onto the 4 6 fuel rail inlet nipple 6 Position the two fuel rails approximately in their installed locations and cut the bulk fuel hose to length to fit between the other Y outlet nipple and the 1 3 fuel rail Install two fuel hose clamps onto the hose and install it 7 Secure all fuel hose clamps with the hose clamp pliers in the Sequent Installer s Tool Kit 8 Re install the ignition coil pack 2009
22. sual inspection of the following items Emissions Label for correct Model Year Engine Group Evaporative Emissions Family and Engine Type o Model Year 2009 ONLY o Engine Group 9GMXV03 9052 ONLY o Evaporative Emissions Family 9GMXR0133810 ONLY hg VEHICLE EMISSION CONTROL CORPORATION INFORMATION Conforms to regulations 2009 FFV Fuel Gasoline Ethanol U S EPA class stds LDV TIER2 California class stds PC ULEV2 qualified Group 9GMXV03 9052 3 9L Evap 9GMXR0133810 SFI HO2S TWC OBD Il Jl kd mM KA Y Ds gt E o ES til Correct MY Engine Group amp Evaporative Emissions Family NOTE If the Emissions label identification information does not match exactly you CANNOT install the system in the vehicle Installation in a non certified vehicle may be punishable by a fine and or imprisonment Air filter and intake plumbing condition Engine gaskets and seals for leaks Exhaust system condition Cooling system for leaks Under hood wiring and hose condition Inspect the secondary ignition wires ignition coils and suppressor caps for any signs of damage or wear Repair or replace any faulty items B Scan Tool Inspection Connect an OBD II compliant scan tool to the vehicle DLC connector and check the following Active or Historic fault codes follow the OEM s diagnostic recommendations for any codes found and make necessary repairs OBD monitors for completion and passed
23. t 2 Make the OBD II connections illustrated in the 2009 3 5L Impala P amp D Installer s Wiring Diagram 3 The Changeover Switch can be installed in either a 9 16 diameter hole or a 7 8 diameter hole The 7 8 hole is preferable if the location surface is textured and less than 3 32 thick If the 9 16 hole is to be used attach the double sided tape onto the back of the switch If the 7 8 hole is to be used remove the outer bezel from the switch 4 The Changeover Switch installation location is a somewhat a matter of customer preference However make sure the Changeover Switch pigtail is long enough for the customers preference If not make suggestions for alternative locations 5 The Buzzer is installed by installing the double sided tape to the back of the buzzer and sticking to a clean smooth surface on the back of the dash panel 2009 IMPCO Technologies Inc 22 2009 3 5 3 9L Impala CNG N Sequent Component Electrical Connections Fuel Supply Hoses 1 Connect the Sequent injector connectors Match the number on the injector wiring to the CNG injector as illustrated Fuel Temp amp Press Sensor Failure to follow this order will result in a rough fuel change over and reduced performance on CNG Refer to the 2009 3 5L Impala P amp D Installer s Wiring Diagram for additional information L 1111 2 Connect the fuel temperature pressure sensor a 3 Connect the re
24. tests o Ifall applicable monitors have not completed drive the vehicle until they have completed and passed o lIfany monitors have failed a test follow the OEM s diagnostic recommendations and make any necessary repairs 02009 IMPCO Technologies Inc 6 2009 3 5 3 9L Impala CNG C High Mileage Vehicle Inspection 75k or scan tool not available High mileage vehicles require further inspection The following items require physical inspection e Start the engine and inspect the exhaust for signs of excessive smoke e Remove the engine dip stick and inspect the oil condition Change oil and filter if necessary e Remove and inspect spark plugs Replace the plugs if any are found to be worn show signs of gas fouling or oil contamination e Perform a leak down test MAKE ANY NECESSARY REPAIRS BEFORE INSTALLING THE SEQUENT SYSTEM 2009 IMPCO Technologies Inc D 2009 3 5 3 9L Impala CNG SEQUENT P amp D INSTALLATION A Pre Installation Bench Assembly O Rings l l Washer Concave Side Against Rail Wen ap oD j i MAP Hose Connection High Pressure Filter 2009 IMPCO Technologies Inc 1 2 3 Locate the six fuel injectors and both fuel rails The injectors will be installed into the rails as illustrated Install three Sequent injectors into each of the fuel rails and torque the injector nuts to 71 in lb 8 Nm Install the Fuel Temperature Pressure Sensor into the longer of the t
25. the Sequent P amp D system has not been certified by the California Air Resources Board CARB If the vehicle is moved to California it may not be registered without returning the vehicle to as close as possible to original condition Please inform the customer that emissions standards vary state to state and to check with the emissions enforcement agency or DMV prior to moving the vehicle into another state IMPCO is pursuing a CARB certification Contact IMPCO for certification status and updates e The EPA certification on the 2009 GM 3 5 3 9L Impala covers vehicles with the E85 fuel option It is important that the vehicle be run on gasoline with a maximum of 10 alcohol content with the Plug amp Drive system Operation on E85 fuel may cause rough engine running and possible check engine light illumination during or shortly after the changeover to CNG operation Please advise your customers before installing the system B SEQUENT P amp D 2009 3 5 3 9L Impala Installation Kit Contents Remove all kit package contents and verify all parts are included and undamaged Do not attempt to repair any damaged parts Contact IMPCO Technologies for replacement of damaged or missing parts Part Number Description Quantity 2009 IMPCO Technologies Inc 3 2009 3 5 3 9L Impala CNG ESA O 6 8 EE Part Number Description Quantity 7 Ria NIN CH A et 2009 IMPCO Technologies Inc 4 2009 3 5 3 9L Impala C
26. uate solder to ensure a permanent connection Barrel Style Lug Terminals U Style Splice Crimps Heat the terminal and apply the solder from the Heat the terminal and apply the solder in the lug side of the crimp to minimize wicking solder Center of the crimp fold allowing it to wick into Securing the wires to the battery cables will help into the wires as they will be secured by the wiring minimize this risk loom Shrink Wrapping Connections Shrink wrap all splices and the positive battery lug Cut the adhesive lined shrink tubing into 1 to 1 72 25 38mm pieces Use a heat gun with a U shaped nozzle to heat the shrink tubing uniformly as illustrated IMPORTANT Familiarize yourself with ALL schematics and electrical diagrams BEFORE splicing wires Some of the modules and Sequent ECU share the same electrical connections splices 2009 IMPCO Technologies Inc 18 2009 3 5 3 9L Impala CNG 2009 3 5L Chevy Impala Seque Installer s Wiring Diagrar 2009 IMPCO Technologies Inc 19 1 Disconnect both connectors from the OEM ECM Layout the Sequent wiring harness with all pigtails approximately where they will be installed 2 Carefully remove the wiring cover from the back of the OEM ECM connectors X1 8 X2 3 Remove the harness tape and conduit to expose the ECM connector wiring OEM ECM harness with modifications completed and ready for
27. wo rails and torque the sensor to 20 5 23 5 ft lbs 28 32 Nm NOTE Numbering the fuel rail as illustrated will help when connecting the harness to the injectors Install the Regulator Temperature Sensor onto the Zenith Regulator and torque it to 89 in lb 10 Nm 2009 3 5 3 9L Impala CNG 4 Insert the aluminum sealing washer into the CNG manometer receiver on the high pressure filter and install the manometer Tighten the manometer so it is in the approximate position keeping the torque between 15 30 ft lbs 20 40 Nm 5 Install the High Pressure Filter onto the regulator Rotate the filter to the position shown and torque the banjo bolt to 15 22 ft lbs 20 30 Nm DO NOT over tighten 6 Lightly apply Loxeal to the two regulator bolt threads and install the regulator onto the bracket 2009 IMPCO Technologies Inc 9 2009 3 5 3 9L Impala CNG A Labels A Sample Illustration 02009 IMPCO Technologies Inc st Regulator Outlet 10 7 Assemble the fuel hoses by inserting the barbed hose fittings through the 8mm special nuts and into the ends of the fuel hoses Install two clamps over the hoses centering them over the barbed fittings and clamping them with the hose clamp pliers Thread the fuel nozzles into one end of the fuel hoses and torque them to 62 in lbs 7 Nm NOTE Hose illustrated not actual length 9 After all fuel hoses have been cut to length an
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