H I07

High Performance Injection system

LPG
CNG

INSTALLATION
EN
MANUAL
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INDEX

CHAPTER 1: FUNCTIONING PRINCIPLES

1.1 General Description
1.2 Input signals
1.3 Output signals
1.4 The components of the system

CHAPTER 2: INSTALLATION
2.1 Tools and Equipment for the conversion
2.2 Installer’s technical knowledge
2.3 Before proceeding with the installation
2.3.1 Procedure to calculate the correct nozzle diameter
2.4 Installation of the components
2.4.1 Pressure Regulator: ML04-XJ Lpg or NGV04-XJ Cng;
2.4.2 Lpg SV-06 Cut-Off valve
2.4.3 Cng Apus High Pressure valve
2.4.4 JMU injection Rail & Nozzles
2.4.5 Gaseous Filter FIL-05
2.4.6 Sequential control unit ECU07
2.4.7 Map sensor
2.4.8 Electric connections

2.5 Checks
2.5.1 Check in phase of acceptance of the vehicle
2.5.2 Check during the installation of the kit
2.5.3 Check at the end of the installation on the vehicle
2.5.4 Check at the end of the Autocalibration procedure

CHAPTER 3: TROUBLE SHOOTING

3.1 Installation
3.2 Petrol/Gas switch
3.3 Idle operation
3.4 Return to idle
3.5 Out-of-idle rpm through slow acceleration
3.6 Acceleration at medium/high RPM
3.7 Full load & low RPM
3.8 Power functioning of the engine
3.9 Various
3.10 Errors Diagnostic

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CHAPTER 1: FUNCTIONING PRINCIPLES OF EMMEGAS SEQUENTIAL HPI07
1.1 GENERAL DESCRIPTION
The Emmegas HPI07 is based on the latest generation of sequential injection technology for Petrol /
Lpg or Cng conversion of the vehicles and the functioning is based on the same principles used by
the gasoline ECU of the vehicle
The amount of required fuel is adjusted for each cylinder, independently and moment-to-moment:
the principle through which the ECU of gas determines the effective times of injection in the gas
injectors is based on the acquisition, during the running with gas, of the petrol injection times; this
means that the control of the engine is based on the petrol control unit while the gas control unit
simply converts the petrol signals into gas signals. This precise, synchronized injection strategy
optimizes performance, consumption, provides a stable response and eliminates the risk of backfiring
The HPI07 includes the latest technology, is easy to install and will not interfere with the OE settings
of the vehicle. Available in version for 3-4, 5-6-8, cylinders, the HPI07 is based on a simple and user-
friendly installation software with easy steps for configuration and diagnostics. The intelligent auto-
calibration function shows working parameters for gasoline under different conditions, mapping for
the highest efficiency in either Lpg – Cng.
The calculation of the gas injection times is based on a series of parameters, besides the times of
injection of gasoline, monitored by the Emmegas ECU07, such as:
gas pressure / gas temperature / water temperature / rpm / battery tension
Particularly, with the objective of maintaining a perfect coherence with the petrol system, the ECU07
Emmegas carries out the injection of the gas in the same cylinder where is registered the
corresponding petrol injection time.
During the maintenance of the vehicle, it is possible to monitor the functioning of the gas parameters
and to check the diagnostic connecting a computer with the EMMEGAS ECU-07 by the relevant USB
interface.

Fig.1: HPI07 Functioning Diagram

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1.2 INPUT SIGNALS:

- Petrol injection time

The system uses the petrol injection times as main parameters for the calculation of the amount of
Gas that should be injected into the engine: the Emmegas ECU07 converts the petrol injection times
into gas injection times.

- RPM
The RPM signal is one of the two basic parameters necessary to calculate the gas injection times. It
is also used to control if the engine is on or off. The RPM signal is detected through a cable
connected to the ignition coil of the vehicle.

- Engine Temperature
The temperature of the cooling liquid is necessary in order:
- to control the petrol – gas switch
- to correct the gas injection times

- Gas Temperature
The temperature of the gas is necessary in order to correct the gas injection time; this correction is
also essential to compensate for the variations of density during the running of the engine on the
basis of outside temperature variations.

- Gas Pressure
When the gas pressure increases, the density also increases so, it is necessary to have compensation
into the gas injection time on the basis of the pressure variations.
The signal of the gas pressure is also used in order to determine when to switch from gas to petrol
when the gas tank is empty or in case the pipes are obstructed.

- MAP
The MAP signal is necessary in order to continuously compensate the gas flow on the basis of the
gas pressure into the rail and vacuum into the engine

- Battery 12v
This 12V signal is necessary for the electric power of the system

1.3 OUTPUT SIGNALS

- Gas injection times

The Emmegas ECU07 generates the gas injection times on the basis of the petrol injection time in
order to determine the correct amount of gas to be injected in to the engine.

- Cut-Off Gas valve

The gas control unit controls the Cut-Off valve present before the pressure regulator.

By the switch / indicator the driver visualizes the following information:

- the type of fuel that is used during the running;
- the quantity of Gas available in the tank;
- the eventual check engine need in case of malfunctioning of the gas system
All the functions are accessible through a personal computer connected to the ECU07 with its
relevant interface, so that it will be possible to program the ECU07 and to diagnose eventual
functioning errors.
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1.4: THE COMPONENTS OF THE SYSTEM

LPG
Fig.2: HPI07 Lpg components

CNG
Fig. 3: HPI07 Cng components
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CHAPTER 2: INSTALLATION
2.1 TOOLS AND EQUIPMENT REQUIRED FOR THE CONVERSION
- Set of allen keys
- Set of screwdrivers
- Milling machine, diameter 30 mm
- Tap wrench & taps
- Meter
- Work bench with bench vice
- Digital Multimeter
- Air compressor
- Hydraulic pump, gauge and accessories for the hydraulic test of the gas pipes
- Exhaust Gas Analyzer
- Personal computer
- Wire stripper
- Lift
- Electric welder
- Gas detector, as alternative you can use a commercial fluid for the detection of leakages
(WITHOUT ammonia, corrosive or chemical agents)
- Oscilloscope
- Electric drill with a series of drills from 4 to 10 mm
- OBD scan tool (Emmegas code 117214)
- Various workshop materials (grease, radiator liquid, Adhesive tape, Sealer for threads)

2.2 TECHNICAL KNOWLEDGE OF THE INSTALLER

The installer should have attended an Emmegas technical training in order to have full knowledge of
the installation, calibration and diagnostic of the system

2.3 BEFORE PROCEEDING WITH THE INSTALLATION

Confirmation of correct operation of the following parts of the vehicle is required:
- Air filter
- Spark plugs, Cables, Coil (by the oscilloscope)
- Valves and Exhaust system
- The catalytic converter and lambda sensor should be under operational conditions
- Full diagnosis of the vehicle
If necessary, proceed with the replacement of the faulty components and start the installation only
when all the above parts are in good conditions

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2.3.1 PROCEDURE FOR THE CALCULATION OF THE CORRECT NOZZLE DIAMETER
The first step of fundamental importance in order to avoid troubles in the phase of autocalibration
and during the functioning of the vehicle is to choose the correct dimeter of nozzles of the
conversion kit; it is important to follow the procedure hereunder:

1) DIVIDE the displacement of the engine by the number of cylinders: this is the unitary cylinder
displacement to which corresponds a determined diameter of the nozzles
(example: 1.600 cc : 4 cylinders = 400 cc -->> Ǿ 2,25 mm)

2) DIVIDE the power of the engine by the number of cylinders: this is the unitary cylinder power to
which corresponds a determined diameter of the nozzles
(example: 120 hp : 4 cylinders = 30 hp -->> Ǿ 2,25 mm

3) If BOTH the results (unitary displacement and power) correspond to the same line, the
corresponding nozzle must be used

4) if both the results correspond to the same diameter but the values are very NEAR TO THE
SUPERIOR LIMITS, it is necessary to use the following nozzle with bigger diameter

5) if the results DO NOT CORRESPOND to the same line, it is always necessary to choose the bigger
diameter resulting from displacement or power calculations

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2.4 INSTALLATION OF THE COMPONENTS

- Install all the components into the engine compartment on the basis of the below indicated 4 (Fig.
4), 6 (Fig. 5) or 8 (Fig. 6) cylinder diagrams and relevant instructions

- Fix the components directly to the body of the vehicle or, indirectly, by means of the fixing
accessories present in the kit

- Set the components far from the ventilation system of the vehicle

- Do not install the components at a distance less than 20 cm from the exhaust system of
the engine. If it is not possible, it will be necessary to interpose a metal protection or equivalent
material, with a thickness not less than 1 mm.; anyway, the component has to be positioned at a
distance of at least 10 cm from the exhaust system.

- Be sure of not creating elbows or narrow curves in the connection of pipes and hoses
Fig. 4: 4 cylinder Installation Diagram

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 Fig. 6: 8 cylinder Installation Diagram Fig. 5: 6 cylinder Installation Diagram

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2.4.1 PRESSURE REGULATOR: ML04-XJ Lpg or NGV04-XJ Cng

For the installation of the pressure regulator, refer to the follwoing instructions:

Fig.7: Lpg Pressure Regulator ML04-XJ Fig.8: Cng Pressure Regulator NGV04-XJ
(w/o in-built valve version)

- Install the regulator in a position which allows easy maintenance

- Fix the regulator to the body of the vehicle (not to the engine, not to other components fixed to
the engine) and in a vertical position, if possible (nose pointing up)

- It is also advisable to position the regulator below the radiator level

- Clean carefully the gas pipes and tank before the installation, in order to avoid the storage of
dirt inside the regulator.

- Place the water hoses and fix them by the relevant fastener present in the kit; the other end of
the water hose should be connected in parallel with the heating system of the vehicle, by the ‘T’
connectors; it is important not to form elbows neither narrow curves in those connections

- Connect the gas pipe into the relevant gas inlet, using its nipple and bicone present in the kit

- Connect the gas hose into the relevant gas outlet, fixing the same by the fastener present in the
kit

- Connect the compensation hose (ø 4mm) to the compensation connection

- Only for the Cng installation, screw the Manometer in its seat by the relevant washer

- If necessary, adjust the pressure on the basis of the following parameters:

Lpg Pressure Regulator ML04-XJ Cng Pressure Regulator NGV04-XJ
between 1,1 ÷ 1,2 Bar between 1,8 ÷ 1,9 Bar

and consider the following intervals as correct tolerance pressure range:

Lpg between 0,6 ÷ 1,4 Bar Cng between 1,2 ÷ 2,4 Bar

To increase the pressure, turn clockwise the register on the front cover of the regulator

To decrease the pressure, turn anti-clockwise the above mentioned register

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2.4.2 LPG SV-06 CUT-OFF VALVE

The SV-06 Lpg Cut-Off valve is:

- incorporated to the ML04-XJ regulator version 4 cylinders, but it is

- separated (and it has to be installed separately) in the 6 and 8 cylinder versions of the regulator.

In the second case, to install the valve, the following indications should be observed:

- Install the valve before the reducer, in a position

which allows easy maintenance

- Fix the valve to the body of the vehicle by its

bracket; never fix it to the engine or to some
components fixed to the same

- Pay attention to the gas flow, as indicated by the

arrow printed on the valve

Fig.9: Lpg SV-06 Cut-Off Valve

2.4.3 CNG APUS HIGH PRESSURE VALVE

To install the Cng Apus High Pressure valve, refer to the following instructions:

- Install the valve between the reducer

and the filling valve, in such a way that
the maintenance will be facilitated.

- Fix the valve to the body of the vehicle

by its bracket; never fix it to the engine or to
some components fixed to the same

- Pay attention to the gas flow, as indicated

by the arrow printed on the valve

Fig.10: Cng Apus High Pressure Valve

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2.4.4 JMU INJECTION RAIL & NOZZLES
The JMU Injection rail is available in 2 / 3 / 4 cylinder versions; for the installation it is necessary to
follow the hereunder instructions:

Fig.11: JMU injection Rail

- Position the rail as close as possible to the intake manifold of the vehicle, so that the
connection hoses (ø internal 6 mm) will be the shortest possible and they can be easily connected to
the nozzles without making elbows.

- Install the rail by its brackets and, if possible, in vertical position (never put the coils upside-down)

- From the inlet gas side (position ‘E’) must be connected the hose coming from the the filter (ø
internal 12 mm); in the opposite side, where there is the pressure sensor (position ‘F’) it is necessary
to connect the compensation hose (ø 4 mm) to the Map Sensor (see Fig.11)

- Into the output side of the Rail (position ‘G’) it is necessary to connect the hoses (internal ø 6 mm)
up to the nozzles into the intake manifold: the distance of each hose must be less than 25 cm
and all 4, 6 or 8 hoses have to be of the same lenght

- The injection raíl and the nozzles should be perfectly fixed and connected by their relevant
fasteners

- Install the nozzles into the intake manifold as near as possible to the petrol injectors and
with the same inclination as represented hereunder (not at 90°):

Fig.12: nozzles positioning

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2.4.5 FILTER FIL-05

For the installation of the filter, follow the hereunder instructions:

- Position:
o as close as possible to the rail (no more than 25 cm
distance) and at the same time
o not too far from the regulator (no more than 70 cm
distance)
- Do not position the gas hoses too close to the hot parts
of the engine, so that the gas will not be heated
- Install the gas hoses as represented on page 8/9: the hose ø 12
mm from the reducer in the entrance of the filter (pos. ‘A’) Fig.13: Filter Fil-05
and the tube ø 12 mm to the raíl in the exit of the filter (pos. ‘B’)
- Inside the filter there is a paper cartridge which has to be periodically replaced (see User
Manual)

2.4.6 ECU07 CONTROL UNIT

For the installation of the Control Unit, follow the hereunder instructions:

- The ECU07 can be positioned into the engine

compartment or into the passenger compartment

- If installed into the engine compartment, it must be

fixed in vertical position and as far as possible
from sources of heat, as, for example, the exhaust
of the vehicle, the radiator, etc. and protected from
water infiltrations

- Position the ECU07 in such a way that it will be easy

to operate on the connectors

- Insert the connectors inside their lodgments on the

ECU07 (grey with grey and black with black) and with
their levers totally extracted; once inserted, lock the
connectors by pressing the levers

Fig.14: Emmegas ECU07 Control Unit

2.4.7 MAP SENSOR

For the Map Sensor installation, follow the hereunder instructions:

- Fix the Map Sensor to the body of the vehicle (not to the engine
or components fixed to the engine) and in an position higher than
the regulator

- To connect the entrance P (position B) directly to the pressure

sensor output of the rail

- To connect the entrance V (position A), to the compensation

connector of the reducer and to the vacuum of the intake
manifold (see diagrams page 8 and 9) Fig.15: Map Sensor
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2.4.8 ELECTRIC CONNECTIONS
All the necessary electric connections have to be done with the two different looms of the ECU07
control unit; in the following pages are presented the diagrams for the 4, 6 and 8 cylinder vehicles.

Fig.16: General Electric Diagram (black connector)

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Fig.17: 4 cylinder Electric Diagram (gray connector)
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Fig.18: 6 cylinder Electric Diagram (gray connector)

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Fig.19: 8 cylinder Electric Diagram (gray connector)

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2.5 CHECKS
Once the installation has been finished, the proper operation has to be checked on both petrol and
gas, to check if the petrol correctors work properly and according to the set parameters.

2.5.1 CHECK IN PHASE OF ACCEPTANCE OF THE VEHICLE

" Check the ignition system:
- correct resistance of the high tension cables
- check if there are any signs of current discharge in the ceramic insulator of the spark
plugs and if the electrodes are wornout
- Check the coils
" Check the air filter (if it is very dirty, replace it)
" Correct operation of the vehicle on petrol.
" Diagnostic control of the car pilot lights (on the dashboard, all the pilot lights have to be off)
" By the "scan tool" check the diagnostic of the vehicle and particularly the fast and the slow
petrol correctors (within +10% and -10%).

2.5.2 CHECK IN PHASE OF INSTALLATION OF THE KIT

" Check the positioning of the mechanical components of the kit to avoid they get in contact
with the moving elements of the engine.
" Check the heating water circuit of the reducer: the level of the cooling liquid has always to be
below the highest point (to avoid air bubbles).
" Check the installation of the electrical components is protected from any possible water
infiltrations and is far from ant heating sources (do not position the control unit close to the exhaust
manifold of the engine).
" Check the electrical connections are completely insulated and they cannot become sources
of false contacts or short circuits; check that all the connections have been carried out by a tin
welding.
" To place the nozzles, drill and tap the manifold into the point which is closest to the intake
valves and to the petrol injectors
" After having installed the injector nozzles into the intake manifold (plastic/aluminum), check
carefully that there aren’t any shavings or residuals inside them.

2.5.3 FINAL CHECK AT THE END OF THE CONVERSION OF THE VEHICLE

" Check the temperature of the reducer, just to be sure there is a good flow of hot water after
the engine has been running (and only after the thermostat has opened).
" Check the electrical connections are not sources of short circuits or contacts which can cause
damage to the wire.
" Check the high and the low pressure gas conduits of the installed system do not have any
leakages (check the connections and the bands by a Gas Analyzer).
" Verify the water circuit of the regulator is watertight.
" Carry out an accurate air purging of the cooling circuit of the engine.
" Check the resistance of the intake manifold, verifying that no suction nor any disconnections of
the vacuum pipes have occured.

2.5.4 CHECK AT THE END OF THE CALIBRATION

" At idle, check the gas operation of the engine: it is necessary there aren’t any vacuum, thrust nor
exhaust..
" Check the exhaust emissions by the gas analyzer (CO and HC)
" Check the Gas calibration map doesn’t affect the parameters of the carburetion on petrol (refer
to page no. 13 of the HPI07 programming Manual)
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CHAPTER 3: TROUBLE SHOOTING
3.1 INSTALLATION

MALFUNCTIONING REASON SOLUTION

The USB interface is not connected Connect the interface
to the ECU07 or to the Laptop

The RED or BLACK wires of the Connect the wires and / or

ECU07 are not connected to the replace the fuse
power or the fuse is out of order
Connection not possible The interface ‘drivers’ have not Download and install the ‘drivers’
with the ECU07 been downloaded into the laptop by the CD or from the web site
www.emmegas.net
The interface does not The interface could be damaged,
communicate with the ECU07 replace it

ECU07 damaged Replace the ECU07

During the auto-tuning the following Diameter of the rail nozzles Install the nozzles of adeguate
message is visualized: “Impossible too big or too small diameter, to be calculated on the
to continue, check installation” basis of table present on page 7

3.2 PETROL/GAS SWITCH

The functioning of the engine with gas is possible if the hereunder conditions are satisfied:
- achievement of RPM minimum limit for the change, page “Configuration”, window “Switch at
(RPM)” of HPI07 software
- achievement of Water Temperature minimum limit for the change, page “Configuration”,
window “Temperauture (°C)” of HPI07 software
- overcoming of “Forced petrol time (s)“ into page “Configuration”
MALFUNCTIONING REASON SOLUTION
Wrong Cut-injector connections Check the cut-injector
connections.

The ECU07 diagnostic found some Check the eventual signalizations

mistakes into the ‘ERROR’ page, solve the
trouble and cancel the error
The vehicle does not RPM limit for the change too high Check the value programmed and
switch to gas decrease the same

The ECU07 does not receive any Check the connection of brown
RPM signal wire; in case, install a RPM
amplifier
The gas injectors do not open Replace the rail

The tank or regulator cut-off valves Check the electric connection or

After the switch to gas, do not open replace the cut off valves
the engine turns off
The “Injector Delay” value into
Configuration page is too low Increase the value

After the switch to gas, Dirty Filter

the engine switch again Pressure of regulator too low
Adjust pressure of regulator
to petrol
Replace Map Sensor

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3.3 IDLE OPERATION

MALFUNCTIONING REASON SOLUTION

Unstable Idle, Too different values into the Map Conform the values of Map into
RPM increase and decrease the Idle operation area
At idle and with the air cond.
At idle and with the air conditioning turned on , increase the values
Too low values into the Gas Map
turned on, the carburation is lean of the Map until the correct
carburation is achieved
Pressure of the regulator too high At idle, adjust pressure at values
indicated on page 10
Rail damaged Replace the rail
At idle, the engine turns off
Rail replaced but then no new auto- Proceed with new auto-tuning
tuning
At idle, RPM is Air infiltration from vacuum circuit Check the compensation hoses
too high or too low and connections

3.4 RETURN TO IDLE

MALFUNCTIONING REASON SOLUTION

Engine turns off in acceleration Decrease the values of the Map
after running without accelerations The carburation is too rich into the return-to-idle area

Engine turns off when RPM Replace the nozzle

decrease from high values Too big diameter of nozzles
with adequate diameter
Check the installation, position
Too big distance between rail and again the Rail on the basis of
Unstable engine functioning nozzles into the intake manifold, instructions of page 12, in case,
wrong position of nozzles position again the nozzles into
the intake manifold in a position
closer to the valves

3.5 OUT-OF-IDLE RPM THROUGH SLOW ACCELERATION

MALFUNCTIONING REASON SOLUTION

Irregular engine functioning; Lean Carburation;

Gas injection time is around 3ms The Rail is functioning into a Map Increase the values of the Map
area with no correct values
Low pressure of gas in the tank,
low quantity of gas in the tank Fill the tank
The engine switch to Petrol,
the switch buzzer and flashes adjust pressure at values
Pressure of regulator too low indicated on page 10

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3.6 ACCELERATION AT MEDIUM/HIGH RPM

MALFUNCTIONING REASON SOLUTION

Carburation Map not correct Adjust the carburation, proceed

with a new auto-tuning
Check the installation, position
Too big distance between rail and again of the Rail on the basis of
Delay between the push of nozzles into the intake manifold, instructions of page 12, in case,
accelerator pedal and consequent wrong position of nozzles position again the nozzles into
acceleration of the vehicle the intake manifold in a closer
position to the valves
Response of the engine not Only for CNG application, check if
adeguate during the gas functioning is available a suitable Timing
Advance Processor

3.7 FULL LOAD & LOW RPM

MALFUNCTIONING REASON SOLUTION

Into “Configuration” page, adjust

Extra injections from petrol ECU. the ‘Sensibility’ value
At low RPM, the engine runs Only for CNG application and if Decrease the advance degrees of
irregularly, with jerking. installed, the Timing Advance Timing Advance Processor.
Processor is programmed with too
advance degrees

3.8 POWER FUNCTIONING OF THE ENGINE

MALFUNCTIONING REASON SOLUTION

Values of the Map into power area Increase the values of the Map
are too low into the power area and test the
The vehicle looses power, vehicle on the road
the carburation is lean
Too high gas pressure from the Repair / Replace the regulator
regulator

Proceed with following checks:

After a determined period of - gas filter,
functioning at full power, Too low gas pressure - pressure of regulator
the engine switches to petrol of the regulator - gas level into the tank
- possible elbow or narrow curves
into the low and high pipes and
hoses
Fuel consumption Decrease the values of the Map
out of usual values Some areas of the Map are too rich into the area of interest

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3.9 VARIOUS

MALFUNCTIONING REASON SOLUTION

The fuse of red/black wire is burnt Replace the fuse with another of
same capacity
Switch not illuminated Wire of the switch is damaged Repair the wire

The Switch is damaged Replace the Switch

One gas injector (or more) is not Check the rail and, if necessary,
working properly repair it or replace it
The vehicle runs in a irregular Replace the ECU07
way, sometimes the engine turn off Wrong electric connection between
and driving is not proper in all Cut-Injector wire and corresponden- Check the electric connection
conditions ting Gas Injector wire (1 with 1, 2 and the correspondance
with 2, etc)
The rail is damaged Replace the Rail
At all RPM level, the carburation
is too rich and there is no way to Too high gas pressure from the Adjust the pressure (see page
adjust it regulator 10) and, if not possible, replace
the regulator

3.10: ERRORS DIAGNOSTIC

The errors visualization of HPI07 sequential ECU is organized as follows:

- Error List: shows the list of all

the errors, pointing out if they
are current errors or memorized
(occurred during a previous running
with gas)

- Show Freeze Frame: the ECU07

pass to the Freeze Frame modality
showed aside;
In the Freeze Frame modality is
presented the list showing the
status of the vehicle during the last
error (instead of the list of errors)

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NOTES

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