BEFORE INSTALLATION, PLEASE REFER TO THEFLYING INJECTION OPERATING INSTRUCTIONS

AIR

CONDITIONER

1

R

3

24

INSTALLATION INSTRUCTIONS

FOR THE LPG FLYING INJECTION SYSTEM

ON THE VOLVO V40 1.8i 16V

ABS

• Year: from 1999 • kW: 90 • Engine code: B4184S2• Injection: electronic multipoint Siemens EMS 2000• Petrol injection ECU version: see the figures 1 and 2 on page 2• Ignition: electronic› Flying Injection single Smart basic kit code 08FJ00000001› Specific kit for Volvo V40 1.8i 16V code 08FJ00120005› N° 2 Modular Cab DX MM (R) packages code 06LB50030101 or N° 2 Modular Cab SX MM (L) packages code 06LB50030102 (to be checked)› Recommended tank: ring-shaped 30° E67R01 600x220 litres 47 code 27TE60022047Europa Multivalve for ring-shaped tank 30° 220x600 code 10MV32003220N.B. Depending on the anti-pollution regulation type (Euro 2 or Euro 3), choose the configurationand the wiring diagram specific for the vehicle type

MANUAL

TRANSMISS.

POWER

STEERING

DRIVER

SIDE

AIRBAG

LEFT-HAND

STEERING

1/11

23

6

Instruction FX00120005-1 dd. October 16th, 2001 in place of instr. n° 2 dd.: April 17th, 2001

CAPTION1 - LPG SOLENOID VALVE2 - GENIUS REDUCER3 - SMART DISTRIBUTOR4 - FLY GAS ECU (under the left front side member)5 - DISTRIBUTOR PRESSURE SENSOR

MAP SENSOR6 - MODULAR HI MM

SPARE PIPESdescription code length q.ty

(mm)from SMART tomanifolds 22TB01040260E 260 4from SMART to P1 22TB01040220E 220 1from SMART to P2 22TB01040300E 300 1from GENIUSto SMART 22TB02040300E 300 1from GENIUSto press. point 22TB04040600 600 1from MAPto press. point 22TB01040600 600 1

96/69/EC

Euro2

5

98/69/EC/A

Euro3

1

4

WARNING: VEHICLES WITH DIFFERENTCONFIGURATIONS AND WIRING DIAGRAMS

PETROL INJECTION

ECU VERSION

The petrol injection ECU (fig. 1) is situated in the

passenger compartment behind the central con-

sole.

The identifying codes of the injection types that

can be converted are the following ones:

- Euro 2 vehicles: Siemens EMS 2000 ECU,

code S110602002E (see figure 2).

- Euro 3 vehicles: Siemens EMS 2000 ECU,

code S110602006A (see figure 2).

Other possible codes that can be converted with

this kit are indicated on our web site

http://www.brc.it.

If there is no correspondence between this code

and the other codes indicated, do not convert

the vehicle and contact our after-sales service.

MECHANICAL INSTALLA TION

INSTALLA TION OF LPG SOLENOID VALVE

It is recommended to remove the air filter and

the battery and to attach the LPG solenoid valve

through a bracket on the right side of the left

front shock absorber, under the fuse-holder (see

figure 3).

Reposition the air filter and the battery as they

were originally.

INSTALLA TION OF GENIUS REDUCER

Secure the reducer through the hole “A” to the

bracket using the M8x14 screw supplied.

Make two holes with a ø 6,5 mm drill on the

exceeding part of the battery support on the right

side of the battery itself following the dimensions

indicated in the figure 5 on page 3.

Connect the rear of the reducer to the copper

pipe that has to be long enough to reach the

solenoid valve.

FX00120005-12/11

LEFT FRONTSHOCK ABSORBER

Fig. 3LPG SOLENOID VALVE

A

B

“GENIUS” REDUCER SECURING BRACKET

Fig. 4

B

FUSE-HOLDER

PETROL INJECTION ECU

EURO 2 PETROL INJECTION ECU VERSION

Fig. 2

Fig. 1

{ 90 Pin

INJECTIONCODE

EURO 3 PETROL INJECTION ECU VERSION

INJECTIONCODE

Through the two M6x16 hexagonal-head bolts

included in the kit and the holes “B” of the

bracket, attach the bracket/reducer assembly to

the two holes previously drilled (see the figure

6).

It is recommended to cut the two heater water

feed and return pipings near the bulkhead (see

figure 7) and, to prevent excessive loss of water,

to use BRC pliers code 90AV99004020. With the

two 16x16x16 Tees, realise the reducer water

circuit.

Secure the pipes with the supplied clamps.

Finally check the engine coolant level and top up

if necessary.

INSTALLA TION OF NOZZLES

Remove the injectors aluminium guard definitely.

By following the instructions of paragraph

4.F in the Flying Injection system operating

manual, drill the manifold with a ø 5 mm drill.

The holes should be drilled perpendicularly to

the manifold at a distance of about 15 mm from

the injectors connection (see figure 9).

Incline the hole on the first and on the second

FX00120005-13/11

BATTERY

Fig. 5

Fig. 8

+ -

Fig. 7

ENGINE

GENIUS

BULKHEAD

16x16x16 TEE

GENIUS

10 mm

Fig. 6

GENIUS

1° Man. 2° Man. 4° Man.3° Man.

LEFT FRONTSHOCK ABSORBER

B

BATTERY

21 mm

35 mm

BATTERYSUPPORT

BATTERY

B

GAS NOZZLES

A

manifold to approx. 15° towards the third

manifold and the hole on the third and fourth

manifold to approx. 15° towards the second

manifold (see figure 8 on page 3 and figure 10).

Screw the M6 nuts onto the 4 nozzles, which can

then be screwed into the tapped holes in the

manifold. The nozzles are then secured by tight-

ening the M6 nuts. You should insert the nozzles

using Loctite n° 83-21.

Without disturbing the nozzles (use two wrench-

es and/or the supplied wrench), connect the noz-

zles to the 4 pipes that will be connected to the

Smart distributor.

INSTALLA TION OF SMART DISTRIBUTOR

It is necessary to replace the four pipe-holder

flow distribution frame with the one of the boxer

type included in the specific kit by repositioning

the O-ring correctly.

Invert the position of the water pipe going from

the engine to the radiator.

Remove the pipe from its seat. Eliminate about

20 mm of pipe from the engine inlet side (see

figures 11 and 12).

Fit the inlet “M” on the connection “R” and vice

versa (see figure 11 and figure 13 on next page).

Installation:

Secure the Smart distributor to the holes “A” of

the bracket through the hexagonal-head M6x16

screws supplied.

Attach the bracket/Smart assembly through the

holes “B” to the injectors rack securing original

screws (see figures 15 and 16 on next page).

Connection of the pipes:

Screw the four lower fittings of the distributor to

FX00120005-14/11

GAS NOZZLE

15 mm

ENGINE

VIEW FROM “A” OF THE AIR-INTAKE MANIFOLD PROFILE

Fig. 9

M

Fig. 11RADIATOR

ENGINE

AIR-INTAKEMANIFOLD

Man. 1

GAS NOZZLES INCLINA TION

Fig. 10

15° 15° 15°15°

Man. 2 Man. 3 Man. 4

INJECTORSCONNECTION

PETROLINJECTOR

M

R

R

WATER PIPE IN ITS ORIGINAL POSITION

Fig. 12

M

R

TO ELIMINATE

20 m

m

P2

Fig. 15

SMART

the pipes coming from the nozzles previously

screwed on the manifolds.

Using Loctite n° 83-21, screw on the side fitting

P2 the 90° elbow included in the kit and orient it

in the same direction of the outlet P1.

Screw on the 90° elbow the pipe that should be

connected on the inlet P2 of the Distributor

Pressure Sensor.

Screw on the side fitting P1 the pipe that should

be screwed to the fitting P1 of the Distributor

Pressure Sensor.

Finally screw on the distributor the

Reducer/Distributor gas supply pipe that should

be screwed on the front of the reducer too by

using the 90° elbow supplied.

FX00120005-15/11

B

A

B

“SMART” DISTRIBUT OR SECURING BRACKET

Fig. 14

M

Fig. 13RADIATOR

ENGINE

M

R

R

TURNED WATERPIPE

A

B

B

P1

P2

Fig. 16

SMART

B

B

P1

INJECTORS RACK

VACUUM CONNECTIONS

It is necessary to make two vacuum connec-

tions, one to be connected to the front of the

reducer and one to be connected to the MAP

sensor.

To make the vacuum connection it is essential to

remove the PVC throttle body guard and to use

the “Y” pieces on the original vacuum pipe situa-

ted behind the throttle body going from the air-

intake manifold to the thermostatic device on the

air filter (see figure 17).

Finally reposition the throttle body guard as it

was originally.

DISTRIBUTOR PRESSURE SENSOR

MAP SENSOR

Remove the two original fittings in the lower part

of the Distributor Pressure Sensor and replace

them with the two 90° elbows supplied by

screwing them on the sensor with the shortest

thread and using Loctite n° 83-21 (see figure18).

Fit the MAP Sensor with the Distributor Pressure

Sensor in the sequence indicated in the figure

18.

Through the hexagonal-head M6x16 bolt sup-

plied, attach the sensors to the original through

hole present on the right side of the radiator (see

figure 19).

FX00120005-16/11

Fig. 17

FIXINGTONGUE

90° ELBOWS

MAP

BONNETOPENER

“Y”JUNCTIONS

Fig. 19

RADIATOR

DISTRIBUTOR PRESSURE SENSORMAP SENSOR

THROTTLEBODY

Fig. 18

INSTALLA TION of DISTRIBUT OR PRESSURE SENSOR andMAP SENSOR

P1

P2

ELECTRICAL INSTALLA TION

FLY GAS ECU INSTALLA TION

To secure the Fly Gas ECU it is necessary to

raise the vehicle.

Secure the Fly Gas ECU support bracket throu-

gh the hole “A” and the M8x20 hexagonal-head

screw supplied to the original threaded hole in

the lower part of the left front side member (see

figures 21 and 22).

Secure the Fly Gas ECU to the stud bolts “B” of

the bracket through the M5 nuts supplied (see

figure 23).

FX00120005-17/11

A

VEHICLE LEFT LOWER PART

Fig. 22

Fig. 21

LEFT FRONTSIDE MEMBER

B

B

A

“FLY GAS” ECU SECURING BRACKET

Fig. 20

B

B

A

VEHICLE LEFT LOWER PART

LEFT FRONTSIDE MEMBER

B

B

Fig. 23

VEHICLE LEFT LOWER PART

FLY GAS

BB

INSTALLA TION OF MODULAR HI

Secure the Modular HI support bracket through

the hole “A” to the power steering liquid cup

securing original screw in front of the right front

shock absorber (see figure 25).

Through the M5 nut secure the Modular HI,

through the special fixing tongue, to the stud bolt

“B” of the bracket (see figure 26).

INSTALLA TION OF CHANGEOVER SWITCH

The changeover switch assembly can be posi-

tioned at the installer’s discretion.

If you choose the position shown in the picture, it

is necessary to use the switch cut-out tool (code

90AV99000043).

To feed the 10-pole harness from the engine

compartment to the passenger compartment,

you are recommended to use the existing grom-

FX00120005-18/11

RIGHT FRONT SHOCK ABSORBER

Fig. 25

MODULAR HI SECURING BRACKET

A

Fig. 24

B

POWER STEERINGLIQUID CUP

POWER STEERING LIQUID CUP SECURING ORIGINAL SCREW

A

B

RIGHT FRONT SHOCK ABSORBER

Fig. 26

POWER STEERINGLIQUID CUP

MODULAR HI

Fig. 27

C/O SWITCH

met on the left side of the bulkhead connecting

the engine compartment with the drip moulding

and the passenger compartment.

ELECTRICAL CONNECTIONS

At this point, with reference to the specific wiring

diagram, carry out the connections both in the

engine and passenger compartments, by follow-

ing the assembly details contained in the operat-

ing instructions of the Flying Injection system.

After the installation and the wiring connections,

carefully follow the setting and starting proce-

dures described in the operating instructions for

the Flying Injection system.

FX00120005-19/11

Date:Diagram N°:

17.04.01

224.05.00In pl. of diagr. :

Draftsman: M.M.Signature:

WIRING DIAGRAM FOR THELPG FLYING INJECTION SYSTEM

ON THE VOLVO V40 1.8i 16V (V4184S2 - Euro 2) MULTIPOINT SIEMENS EMS 2000 ELECTRONIC INJECTION

90-pinInjection

ECU

LevelSensor

Connector

Yel

low

Ligh

t blu

e

Whi

te/V

iole

t (sh

ield

ed)

Gre

y

Bro

wn

FLY GAS

✂

Flying Injectionc/o switch

LPGS.V.

GR

EE

N

RED

"GENIUS" ReducerTemp. Sensor

Diagnostic point

+-BLACK

BLACK

RED

GREEN

Injector 1 Injector 2 Injector 3 Injector 4

"SMART"Distributor

4-wireConnector

BLACK 7.5A

BLACK

RED

P1 P2

DistributorPressure

Sensor

MAP

MAPSensor

3-wireConnector

Green/White

Connect to the Violet wire of the 1st Injector Modular Cab

Connect to the Violet wire of the 2nd Injector Modular Cab

Connect to the Violet wire of the 3rd Injector Modular Cab

Connect to the Violet wire of the 4th Injector Modular Cab

Violet/Black

Violet

Violet

Violet

Cut and Insulate

Cut and Insulate

Cut and Insulate

White/Red

White/Orange

White

Battery

Pin n° 29 Green (+12V after contact)

Pin n° 70 Pink (rpm signal)

Pin n° 43 Orange/White (TPS signal)

Pin n° 45 Yellow/Grey (lambda oxygen sensor signal)

NOTES:The injection ECU is situated in the passenger compartment, behind the central console.

1

31

61

15

45

75A

46

76

30

60

90B

16

Petrol injection ECU

CAUTION:Be careful with the cars for which the manufacturer prohibits or advises against disconnecting the battery, not to alter the antitheft devices or automatic adaptivity - Never use welders connected to the battery of the same car - Connect with suitably insulated soft solderings - Position the BRC electrical devices in a well ventilated area, protected from water seepages and heat sources - We recommend to insulate the BRC electronic control unit wires which are not connected - BRC reserves the right to modify this diagram without notice - We also recommend you to be sure to have the last revision of the diagram drawn up by BRC.

MM

Mod

ular

2

CANA

LI

HHII

MM

Mod

ular

2

CANA

LI

HHII

10/11 FX00120005-1

Date:Diagram N°:

16.10.02

317.04.01In pl. of Diagr.:

Draftsman: M.M.Signature:

WIRING DIAGRAM FOR THELPG FLYING INJECTION SYSTEM

ON THE VOLVO V40 1.8i 16V (V4184S2 - Euro 3)MULTIPOINT SIEMENS EMS 2000 ELECTRONIC INJECTION

LevelSensor

Connector

Whi

te/V

iole

t (sh

ield

ed)

Gre

y

Bro

wn

FLY GAS

Flying Injectionc/o switch

RED

Diagnostic Point

+-BLACK

BLACK

RED

GREEN

Injector 1 Injector 2 Injector 3 Injector 4

BLACK 7.5A

BLACK

RED

Connect to the Violet wire of the 1st Injector Modular Cab

Connect to the Violet wire of the 2nd Injector Modular Cab

Connect to the Violet wire of the 3rd Injector Modular Cab

Connect to the Violet wire of the 4th Injector Modular Cab

Violet/Black

Violet

Violet

Violet

Cut and Insulate

Cut and Insulate

Cut and Insulate

White/Red

White/Orange

White

BatteryNOTES:The injection ECU is situated in the passenger compartment, behind the central console.

1

31

61

15

45

75A

46

76

30

60

90B

16

Petrol Injection ECU

(#)

4-wireConnector

P1 P2

DistributorPressureSensor

MAP

MAPSensor

3-wireConnector

LPGS.V.

GR

EE

N

"GENIUS" ReducerTemp. Sensor

"SMART"Distributor

CAUTION:Be careful with the cars for which the manufacturer prohibits or advises against disconnecting the battery, not to alter the antitheft devices or automatic adaptivity - Never use welders connected to the battery of the same car - Connect with suitably insulated soft solderings - Position the BRC electrical devices in a well ventilated area, protected from water seepages and heat sources - We recommend to insulate the BRC electronic control unit wires which are not connected - BRC reserves the right to modify this diagram without notice - We also recommend you to be sure to have the last revision of the diagram drawn up by BRC.

90-pinInjection

ECU

Yellow

Light blue

Green/White

Pin n° 29 Green (+12V after contact)

Pin n° 70 Pink (rpm signal)

Pin n° 43 Orange/White (TPS signal)

MM

Mod

ular

2

CANA

LI

HHII

MM

Mod

ular

2

CANA

LI

HHII

Cut and insulate

Cut and insulate

11/11 FX00120005-1