The process of converting a car to run on LPG is fairly demanding and requires a good knowledge of automotive systems in general to accomplish.Raghav LPG offer kits having all required components of standard specification to perform the conversion. Retrofitment without the necessary know-how or spurious parts may lead to non optimum performance and safety hazard. Although LPG is very safe as an automotive fuel, if the system is not installed correctly, there can be safety problems. Raghav LPG also has a team of trained Retro fitters (mechanics) spreaded in many parts of India to help its ever increasing customer base.
Example dual-fuel conversion system
The first step is choosing a tank. Most conversions are dual-fuel conversions, meaning you won’t be replacing your old fuel system, you’ll simply be adding a second. As a result, the LPG tank will take up some of the storage space in your car, usually in the trunk.
Tanks come in “Torroidal” or “capsule” form. Capsule tanks generally have more capacity, but will take up more space in your car. Torroidal tanks are designed to fit in the spare tire well of your car. They are smaller tanks, and you’ll have to refuel AUTO LPG more frequently. A multi valve is used to cover the bunk of tank and to allow entry and exit of LPG from Tank.
Once the tank is bolted in, a filler valve is mounted to enable filling of auto LPG. The ideal location is one that requires minimal piping to connect to the tank. The fuel lines are made of copper tubes, which offer a certain amount of flexibility when the lines are routed. The tank must be connected to the fill point, and lines also have to run along the underside of the car up to the engine.
A solenoid valve (LPG valve in the above diagram) should be installed on the fuel line in between the tank and the engine. This valve cuts the flow of LP gas when the car is running on petrol and when the engine is shut off. It also has a filter built in that removes any dirt that may be in the fuel.
The next major component is called a regulator, also referred to as a vaporizer. This device performs one of the functions that a carburetor handles in a petrol engine — it uses heat from the car’s cooling fluids to vaporize the LPG into gas form. Another safety check occurs at the regulator. It includes an electronic circuit that cuts the flow of gas if the engine stops or stalls. The regulator is usually smaller than a regular carburetor, so finding space for it in the engine compartment is not a problem.
The other part of a carburetor’s function is handled by a mixer mounted in the intake manifold. The mixer takes air from air filter and vapours of LPG from vaporizer. It has vehicle specific design to ensure optimum mixer of LPG and air.
The system must then be wired into the car’s electrical system, allowing for a functioning fuel gauge, as well as proper automatic switching between LPG and petrol. (along with a dashboard-mounted manual switch). There must be connections to the car’s ECU so that the engine controller can adjust for different fuel settings.
Cars with MPFI (multi point fuel injection) will need an electronic emulator. When the car is operating on LP gas, the fuel injectors will not be sending any information to the other sensors in the car — this may light up the “check engine” light and give incorrect diagnostic readings. The emulator takes care of this situation and send proper signals so the ECU can operate properly.
Modern days cars (Euro IV and ahead) have stringent emission norms and require precision computer control supported by Electronic Control Unit (ECU) Raghav LPG's Sequential kit also have one Electronic Control Unit which work in synch with Electronic Control Module (ECM) of car as its slave. ECU helps to receive signals from various sensors, calculates and provides the LPG fuel specifications for gas operation of vehicle and ensure smooth running. It is also capable of 'Fault finding' by just connecting computer with ECU through proper socket.
Conversion kits come with more detailed instructions, but this is a basic overview of what needs to happen in a dual-fuel conversion.
This is not be used as a guide for an actual LPG conversion. It is intended as an overview of the process and not a set of instructions. Unless you are authorized in automotive fuel systems and electrical systems, you are strongly urged to have the conversion performed by a professional. All conversions should be done, tested and approved by a professional with experience and authorized for retrofitting by concerned RTO.