KAC conversion kit installation manual

-Electrical Field Information- Engine type 14Bwith out TURBO Displacement 3,660 cc Cylinder bore 102.0 mm Piston stroke 112.0 mm Compression ratio 18:01 Cylinder block alloy cast-ir

-Electrical Field Information-

Engine type 14B(with out TURBO)

Displacement 3,660 cc

Cylinder bore 102.0 mm

Piston stroke 112.0 mm

Compression ratio 18:01

Cylinder block alloy cast-iron

Cylinder head alloy cast-iron

Cylinder liner dry liner

Injection type direct injection

Generator 24v / 30A (assumption)

Battery Capacity 65AH(2EA) CCA700A(assumption)

1 This Install Manual is contributed to workers in order for them to

understand rules and directions of converting diesel engine into

CNG(Compressed Natural Gas) engine

2 Matters that require attention

1) Workers ought to protect their own health during installation job

Be careful of safety accidents all the time

2) Vehicles are very sensitive to heat, vibration, moisture, and etc

more than general machines

3) This install manual recommends optimal installation, based on our

know-how for conversion into CNG engine If installation job is

followed by our recommendation, durability of engine and other parts can be extended However, installation job can be influenced by

worker’s idea in accordance with environment or condition of work However, workers have to consider content 2 2) all the time

Engine Checking

1 Idling state of the Engine (Cylinder dissonance)

2 Check all of the liquid condition flowing into the engine(rust, engine oil level) and check leak

- If you need, cleanse or exchange it

3 Visually inspect the exhausted gas if it emit different kind of gas, and expect the inside condition

of the engine

4 Check starting device

5 Check HVAC system

Over sized 14B 0.50mm piston

1 Remove carbon from the piston

2 Make the piston keep horizontal

3 Measure water volume by using a shot or electronic scale as like the picture

4 In the case of using an electronic scale, convert 1g into 1cc of water

5 The level of water should be the same as the level of the piston surface

BDC

H

D

Piston Water Measure Volume

Volume Cylinder

Total

, cc

80

Volume

M easure Water

Piston

If

(cc) 1640

(cc) 1639.911

Cm 14.5

12 4

π

V

, Cm 14.5

H Cm 12

D

If

H D

4

π

V

Voulme Cylinder

Calculate

3 2

Cyl

2 Cyl

 

  cc 26

80 106 V

olume easure

ater Piston

except

Volume Room

Cobustion

cc 106 106.17 16.2

1720 V

V : 1720 1

:

16.2

1, : 16.2 is

Ratio

n Compressio

If

Volume Room

Combustion Calculate

W

TDC

Piston Water measure Volume

Piston Cylinder

Head

TI-4 3/6

▣ Install Manual – Compression Ratio of Cylinder(1)

 

  cc 26

80 106 V

olume easure

ater Piston

except

Volume Room

Cobustion

cc 106 106.17 16.2

1720 V

V : 1720 1

:

16.2

1, : 16.2 is

Ratio

n Compressio

If

Volume Room

Combustion Calculate

W

TDC

Piston Water measure Volume

Piston Cylinder

Head

TI-4 3/6

▣ Install Manual – Compression Ratio of Cylinder(1)

h is Volume Measure

Water Piston

of depth

the

If

Volume Precessing

Piston using

Diameter Processing

Calculate

2



Attention : While processing piston, keep the depth of piston water measure volume

If the depth of it is adjusted, oil line gets damaged

▣ Install Manual – Compression Ratio of Cylinder(1)

Draw up and work on machining the piston based on the calculation you’ve done

1 Make the all edges be round (work for preventing hot spot)

2 Make the water chamber be finished with soft sand paper

3 Put some oil for preventing high temperature while machining

69.97cc

Piston placement  Piston machining  Photo of finished piston

Check the water volume of completed piston and remedy it delicately

Apply head inspection plug

1 Replace or reuse it after checking damage or deformation of the surface of head and the condition of valve and valve seal

2 Determine applied spark plug after checking diameter of diesel injection nozzle and the distance of valves

Tips for determination: machined plug tap should not be exceeded the range of the valve seat, and 14mm is

recommended –See the pictures-

Expand the bore for inserting the I/G cable  Check the size of machined M14-1.25P  The surface of finished cylinder head

1 While assembling spark plug, adjust the level of screw thread by using plug washer in order not to be exposed to combustion

Remove placed fuel pump and front case  Work on machining shaft taper based on fuel pump shaft (refer the sample) work on machining the front case in order to equip 6204ZZ(2EA) bearing

 Retainer standard (25-50-12)  work on machining the tap so that the shaft and the wheel sprocket could be fixed (M8-1.25P)  Check the condition of the taper which is assembled with genuine gear  Invent or purchase special tool in order to assemble the nuts inside of the genuine gear (nut size 17mm-diameter of the tool 22mm)

Assemble the machined wheel sprocket shaft and the bearing  Affix CPS sensor carefully and array it with the forth point of the engine TDC direction of rotation  the method of arraying the timing gear is followed TOYOTA method as usual except for the wheel sprocket gear

Disassemble the equipped T/B and air heater 

Produce a T/B flange by referring the picture on the left side and the sample 

Design the bore of T/B flange should be bigger or the same as the bore of T/B 

Place T/B flange by applying silicon outside of it 

1 ECU is recommended to be installed inside the car where it is not affected by

temperature, dust, and moisture

If it’s installed outside, cover should be installed for protection, and the place

should be well ventilated

2 Wiring harness should be placed where wires can not be directly affected by the engine part

or hot temperature location And tie the wires by using enclosed cable tie

3 When connecting the wires or using extension wires, use specified wires

Surely solder the connecting area, and insulate it(contraction tube is recommended)

4 While installing wiring harness ground and auxiliary ground, the grease and rust must be cleaned for the flows of electricity

5 When ECU is installed where grounding can not be practiced, make sure ECU case earths to chassis using ground ties

Normal : ECU is installed inside

Affix ECU and relay near fuse box of the car  Connect the wire of key box I/G key  Make a hole on the bottom of the vehicle and place wire harness through outside  Install engine room by using the structure of the vehicle  Protect from disconnection of wire which though the engine by differences in engine vibration  Connect wire harness to cylinder head

※ Electronics should be avoided moisture, source of heat and sharpened stuff ※

Make current flow of old vehicle be smooth by connecting engine part

and chassis part with ground cable

[Notice!]

1 Install the ground cable away from exhaust manifold

2 Install it after removing rust around installation area

3 Do not install at driver’s will

Connect Engine part and Chassis part with Ground Cable like the picture

Fix CPS and MAP connector  Connect regulator power switch to pressure gauge wire and solder them  Place switch indicator where driver can find easily  Fix O2 sensor connector and be aware of not contacting with exhaust manifold

※ Electronics should be avoided moisture, source of heat and sharpened stuff ※

1 Install level indicator & switch where it can be seen easily by driver

2 Connect the level indicator and wires of pressure gauge as shown

in the picture

[Notice!]

1 Avoid the place where malfunction can be caused by driver

24v wire should be prevented from exposing to moisture

 Check the battery and wire condition of an old vehicle, and replace or cleanse them as required

※ Electronics should be avoided moisture, source of heat and sharpened stuff ※

Fix MAP sensor to intake manifold 

Place WTS sensor where cooling water is always flowing 

Fix coil brocket to intake manifold (Equip it by using 4 holes) 

Place O2 sensor by using the sensor nuts that is supplied O2 sensor should be assembled from top to bottom

(To prevent sensor malfunction caused by moisture)

Assemble in the order of filter screen and then filter  Assemble pressure gauge and regulator  Place it where it is not affected by wind and rain drop (passenger seat)  Place nipple where cooling water is constantly flowing and connect hose (PT1/2-16Φ Nipple)  Make the bulk head to prevent influx of rain fall if you need

※ Santa Cruz downtown area may have 30~50 cm pools on rainy days so place regulator carefully ※

Cut the adjust bolt structure and equip it in order to secure flow rate of the valve, however there is not any improvement We worked on moving the valve outside because fuel setting

is uncomfortable  Use PT3/8-16Φ (ㄱ)Nipple, expand the bore to 11Φ  equip nipple to the valve for connecting hose  Place it where fuel controlling is convenient

The volume of equipped cylinder 100L (2EA), 60L (1EA)=260L

As like the picture above, place two 100L containers under the back seat and fix them on the floor by using band  Connect the valves with pipe  Place 60L container under the left side of the center  Let the pipe of the valve be in series  Place charging entrance

on the rear panel  connect pipe to regulator

※ Band 2-3 times on the CNG pipes in order to minimize the impact ※

Install Manual – Set up the fuel amount

– Before starting the engine

- Inspect gas leakage

- Check engine oil and coolant

- Set up TPS Output Voltage as a minimum of 0.7~0.8V

- Open Fuel Adjustment Bolt(MAS 2way, 3way) in the right amount

- Open the valve by over 1/3 of its total stroke(16mm)

- Exchange Air Filter with new one

(If the vehicle has dual filters, exchange all of them!)

- After starting the engine, keep the engine idling until the temperature of coolant of the engine

rises up by 60~80℃

- Inspect leakage of intake manifold

- Connect KSCAN-1000

– Set up the fuel amount at the medium and high speed

Open throttle valve slowly Maintain the engine RPM by 1,800~2,500rpm, which generates

maximum output (Refer to specification of the engine.)

While paying attention to the RPM data of SCANNER, open slowly fuel adjustment bolts

(MAS 2way, 3way) at the same time When the RPM arrives at the highest, it means the fuel

amount is adequate

– Adjust Idle RPM

- Adjust Idle RPM by changing TPS angles to meet the Target Idle RPM(600~700rpm)

(Normal TPS signal voltage varies depending on engine displacement, but mostly it should be 0.5~0.8V.)

– Adjust Idle AFR(Air & Fuel Ratio)

- If the state of idling is unstable or rpm is too high, change TPS angles and control Idle AFR

NI-20

The pictures above indicate that how air filter’s efficiency can be different in the same condition of valve

Picture No.1 : diesel air filter AFR 17.7:1, gasoline air filter 19.5:1, removal air filter 20.4:1

As shown, there is difference in AFR based on filter specification

Gasoline air filter should be used for 14B, 3B, 13B engine because the characteristic of mixer type of fuel system is that AFR is getting stronger as the resistance of air filter is getting higher In the case of diesel engine, it spray fuel to the combustion chamber directly by using nozzle, so we tell that there is not any specific problem

※ This part is directly related to fuel efficiency, so take notice ※

On the test driving after converting, output deficiency occurred Automatic transmission slipping problem happened in rapid acceleration situation The problem is solved after replacing clutch set

※ This part is directly related to fuel efficiency, so take notice ※

Thank you