MAKE OF AUTOMOBILE: OPEL TYPE: INSIGNIA Sports Tourer / Sedan TANK CAPACITY: 65 Liter Stako toroidal TANK LOCATION SPARE WHEEL ROOM MODEL YEAR: 2009> SYSTEM APPROVAL NUMBER ( R115 ) E4-115R-000012 DLM-LPG 05 BOOT SET NUMBER 957/070001/A / 957/070002/A MANUAL NUMBER 076/1707965 DATE 2011-06-14
Copyright © Prins Autogassystemen B.V. 2013
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Index
General ................................................................................................................................................ 2 Tank Fuel Module ................................................................................................................................ 3 Preparation ........................................................................................................................................... 4 Tank 1 .................................................................................................................................................. 5 Tank 2 .................................................................................................................................................. 6 Filler Break, Sedan ............................................................................................................................... 7 Filler hose ............................................................................................................................................. 8 Tank wiring ........................................................................................................................................... 9 Cover plate break ................................................................................................................................. 9 Cover plate Sedan ............................................................................................................................. 11
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General
Tools needed for installing the LPG tank : - Soldering iron - Drilling machine - Drilling kit - Drill size 22 / 30mm / 55mm / 70 mm
- Workshop tools. - Gas leak detection device - Vacuum cleaner - Anti-corrosion agent / black body coating - Car lift
Note the jack supporting points and moveable parts when mounting the LPG line.
It is not permitted to have LPG lines routed through the passenger compartment or a closed cargo space. Place a rubber socket on the back of the outer filler. Seal the socket gastight on both sides.
After having drilled holes ( use safety glasses ) for the mounting of a tank frame, floor ventilation, etc., always treat the holes against corrosion after having removed the grindings.
Provide a thorough frame mounting on vehicles with a thin metal or wooden floor panel (vehicles with commercial registration). Secure the mountings to the vehicle frame and not to the floor.
Treat the LPG tank when mounted under the car with a black body coating.
Failure to follow the instructions in this manual can result in a poor or non-working gas installation or a dangerous situation.
No component of the LPG-system shall be located within 100 mm of the exhaust or similar heat source, unless such components are adequately shielded against heat.
Prins Autogassystemen is not responsible for any damages to people or objects as a result of changes to Prins products.
Mount the LPG tank according to the local LPG regulations. The LPG installer is responsible for that. This manual is based on Dutch regulations.
After having completed the installation, check the whole system for gas leakage; use a gas leak detection device. Beware of moving, hot and rotating parts.
This manual is based on Dutch regulations, always install the system in accordance to the local regulations.
Check the Prins site for tank certificates and wiring diagrams.
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Tank Fuel Module
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Preparation
Break
Sedan
Remove spare wheel and boot cover and the spare wheel support.
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Tank 1
Break Sedan
Mark tank mountings and remove tank. Mark holes for the tank and drill Ø11mm.
Treat anti-rust.
Bleeders Filler and fuel line hoses Ø30mm
Bleeder
Bleeder filler hose
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Tank 2
Break / Sedan
Screw the tank using M10 bolts and mounting plates.
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Filler Break, Sedan
Hole filler connection is Ø22mm. (it is an oval hole). The filler bracket drill holes Ø5.5mm.
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Filler hose
With a drawstring pull the filler hoses down to the fuel filler neck.
Place the filler hoses behind the bumper to the bleeder hole on the back side.
Break Sedan
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Tank wiring
Lpg tank housing
Wire number / code Wire colour Connection
3-pole tank level connector 40 Ground tank gauge 12 Tank level in 11 + tank level supply
Brown Blue Red
Connect the 3-pole connector to the tank level sensor.
1. 2-pole connector tank lock-off
Green-yellow Brown
From tank pump driver From tank pump driver
2. 3-pole connector tank pump
Red 2.5mm2
Brown 2.5mm2
From tank pump driver From tank pump driver
3. 2-pole connector driver
Red 2.5mm2
Brown 2.5mm2
From tank pump relay 87 From main ground
4. 2-pole connector driver
Green Grey
From AFC pin 22 pwm From AFC pin 64 diagnose
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Cover plate Tourer
Cut the foam block into 4 parts.
Adhesive foam sealant blocks in the parts of the trunk (see photo).
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Cover plate Sedan
